9852 2321 01 Maintenance Schedules ROC D65s

Atlas Copco
ROC D65s
Maintenance schedules
PM No. 9852 2321 01

2010-01
SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.
Special attention must be paid

to information alongside
this symbol.
Only use genuine Atlas Copco parts.
1250 0071 04
© Copyright 2010, Atlas Copco Rock Drills AB, Sweden

All product names in this publication are trademarks of Atlas Copco. Any unauthorized use or copying of the
contents or any part thereof is prohibited. Illustrations and photos may show equipment with optional extras. No
warranty is made regarding specifications or otherwise. Specifications and equipment are subject to change
without notice. Consult your Atlas Copco Customer Center for specific information.
Translation of original instructions.
Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
Safety
Safety
Reference................................................................................................................. 5
3
Safety
4
Safety
Reference
Note
Always read the information in the Safety document before starting to use the rig or
starting maintenance work.
1250 0099 89
5
Safety
6
1. Maintenance intervals .............................................................................................. 9
Foreword.................................................................................................................. 9
Every 10th engine hour ......................................................................................... 10
Breakout table/Rod guide - every 10th engine hour ......................................... 10
Compressor tank - every 10th engine hour....................................................... 11
Engine package - every 10th engine hour......................................................... 12
Electrical system - every 10th engine hour....................................................... 13
Every 50th engine hour ......................................................................................... 14
Feeder - every 50th engine hour ....................................................................... 14
Hydraulic hoses - every 50th engine hour ........................................................ 15
Rod handling (RHS 140) - every 50th engine hour .......................................... 16
Boom C14 - every 50th engine hour................................................................. 17
Boom C20 - every 50th engine hour................................................................. 18
Track frames - every 50th engine hour ............................................................. 19
Rig frame/track frame - every 50th engine hour .............................................. 20
Compressor components - every 50th engine hour .......................................... 21
Radiator - every 50th engine hour .................................................................... 22
Hydraulic oil reservoir - every 50th engine hour.............................................. 23
Cab - every 50th engine hour............................................................................ 24
Fire extinguisher - every 50th engine hour....................................................... 25
Every 250th engine hour ....................................................................................... 26
Feeder - every 250th engine hour ..................................................................... 26
Breakout table/Rod guide - every 250th engine hour ....................................... 27
Boom C14 - every 250th engine hour............................................................... 28
Boom C20 - every 250th engine hour............................................................... 29
Air conditioning - Every 250th engine hour..................................................... 30
Electrical system - every 250th engine hour..................................................... 31
Track frames - every 250th engine hour ........................................................... 32
Dust collector (DCT) - every 250th engine hour.............................................. 33
Cab - every 250th engine hour.......................................................................... 34
Power pack - every 250th engine hour ............................................................. 35
Air, coolant and intercooler systems - every 250th engine hour ...................... 36
Hydraulic system - every 250th engine hour .................................................... 36
Every 500th engine hour ....................................................................................... 37
Pipe guide - every 500th engine hour ............................................................... 37
Track frames - every 500th engine hour ........................................................... 38
Diesel engine - every 500th engine hour .......................................................... 39
Cab - every 500th engine hour.......................................................................... 40
Air filter for engine and compressor - 500 engine hours.................................. 41
Every 1000th engine hour ..................................................................................... 42
Feeder - 1000 engine hours............................................................................... 42
Air conditioning - 1000 engine hours ............................................................... 43
Air filter for engine and compressor - 1000 engine hours................................ 44
Air system - 1000 engine hours ........................................................................ 45
Compressor - 1000 engine hours ...................................................................... 46
7
Pressure tank, separator - 1000 engine hours ................................................... 47

Every 1500th engine hour...................................................................................... 48
Track frames - every 1500th engine hour ......................................................... 48
Hydraulic oil reservoir - every 1500th engine hour.......................................... 49
Every 2000 engine hours ....................................................................................... 50
Dust collector filter - 2000 engine hours .......................................................... 50
Engine heater - every 2000th engine hour ........................................................ 51
Every 20000th Engine hour................................................................................... 52
Boom - Every 20000th engine hour.................................................................. 52
8
1. Maintenance intervals
Foreword
This instruction manual is part of the complete delivery of the hydraulic drill rig. It
provides information on the design and operation of the drill rig and contains advice
and the measures necessary to keep the rig operational. This instruction manual is no
replacement for thorough training on the drill rig. The documentation consists of the
following:
• Maintenance intervals. Engine hours.

- Every 10th hour
- Every 50th hour
- Every 250th hour
- Every 500th hour
- Every 1000th hour
- Every 1500th hour
- Every 2000th hour
- Every 10000th hour
- Every 20000th hour
This instruction manual should be read in advance by all persons who are to operate
or repair the drill rig or carry out maintenance on it.
Note
The intervals specified in the engine manufacturer's documentation apply for the die-
sel engine.
How to use these maintenance instructions
• We recommend that you make copies of all maintenance intervals and keep a
record of each point checked.
• The owner of the equipment is recommended to compile a filing system for each
maintenance interval.
• Carefully read all the instructions and study the drawings of the machine so that
maintenance work will be performed safely and correctly.
Genuine Atlas Copco spare parts
• To ensure the safety and functionality of the drill rig, always use genuine Atlas
Copco spare parts.
Environmental aspects
9
• Avoid the use of detergents and other cleaning agents containing solvents (e.g.
carbon tetrachloride). Use alternative agents that are less harmful to health and the
environment. Be sure to dispose of waste oil from the machine.
Note
The illustrations only show examples of grease nipples; check all mountings and
bearings appurtenant to relevant systems so you can find the existing grease nipples.
Every 10th engine hour
Breakout table/Rod guide - every 10th engine hour
C
1250 0201 40
Figure: Breakout table/Rod guide
Table: Breakout table/Rod guide

Check point Control object Action
- Grease nipples Fill grease into the grease nipples
A Cylinder bracket, breakout table Check the torque, 600 Nm
B Cylinder bracket, pipe guide Check the torque, 120 Nm
10

C Lock nut for adjusting screw, pipe Check the torque, 185 Nm
guide
Note
If central lubrication is installed then the function and connections must be checked.
Compressor tank - every 10th engine hour
A B
1250 0201 24
Table: Compressor tank

A Tank, draining Open drain plug (A). Drain the water. The drill
rig must have been standing still for one hour
before the water can be drained.
B Tank, oil level Check the oil level. The gauge must be in the
green zone. The drill rig must be level and
must have been standing still for 10 minutes
before checking.
11
Engine package - every 10th engine hour
A
1250 0201 51
Figure: Engine package
Table: Engine package

- Engine/Compressor Check for leakage around the engine and
compressor
A Hydraulic pumps Check for signs of leakage
B Fuel prefilter Drain off water
C Oil level in diesel engine The oil must be between the two marks on the
dipstick
D Coolant Check the level
E Hydraulic oil Check the level
F Lubricating oil HECL/ECL/ECG Check the level
- Grease for central lubrication Check the level
(extra equipment)
- Grease for thread lubrication Check the level
(extra equipment)
12
Electrical system - every 10th engine hour
A A
1250 0189 44
B
Figure: Electrical system
Table: Electrical system

A Working lights Front, rear and on feeder. Function
B Emergency stop buttons/Wire Attachment. Check each emergency stop
button individually. The engine must stop.
Before checking the next emergency stop
button the previous one must be reset before
restarting.
13
Feeder - every 50th engine hour

C
1250 0169 15
A
B
F
E
D
Figure: Feeder
Table: Feeder
A Ropes Lubrication, check tension
B Water-hose drum Lubrication
C Pipe guide halves Check for wear, adjust
D Cradles Check the clearance (2-4 mm). See
maintenance instructions for adjustment.
E Feed beam Inspect for damage and wear.
F Calibration sensors Attaching, function.
Adjust the distance, approx. 5 mm.
Rotation unit/Rock drill Attachment, check tightness of bolted joints.
Hydraulic hoses Check for wear.
14
Hydraulic hoses - every 50th engine hour
A
1250 0201 22
Figure: Hoses over hose drum
Table: Hoses over hose drum

A Hoses over hose drum Lubrication
15
Rod handling (RHS 140) - every 50th engine hour

A
1250 0094 78
Figure: Rod handling (RHS 140)
Table: Rod handling (RHS 140)

A Grease nipples Pump grease into 17 grease nipples
Note
16
Boom C14 - every 50th engine hour

A
A
1250 0203 20
A A
B
A A
A A
A A
A
A
A
Figure: Boom
Table: Boom
A Grease nipples Fill with grease
B Feed holder Check the clearance (2-4 mm). See
Note
17

A
A
1250 0207 89
A
A
A A
B
A
A A
A
A
A

A Grease nipples Fill with grease
B Feed holder Check the clearance (2-4 mm). See
Note
18
Track frames - every 50th engine hour

A
1250 0089 28
B
C
Figure: Track frames
Table: Track frames

A Traction motors Check for signs of leakage
B Grease nipples Pump grease into 2 grease nipples.
C Traction gears Check for leaks. First oil change after 150
engine hours , clean the gears with flushing
oil before filling with new. The level plug must
be placed just above the centre of the
tramming gear.
D Support roller Check wear, leakage
E Mountings Retighten all mountings after 100 engine
hours as per Track frame - Every 250 engine
hours . Then every 250 engine hours.
Note
19
Rig frame/track frame - every 50th engine hour

A
A
1250 0000 00
Figure: Rig frame/track frame
Table: Rig frame/track frame

A Track frame/rig frame Lubrication
Note
20
Compressor components - every 50th engine hour
A
1250 0189 54
Figure: Compressor parts
Table: Compressor parts

- Compressor Signs of leakage. Air/Oil
- Air filter Compressor/Diesel Check connections and couplings on inlet
engine manifold
A Oil filter Change filter after the first 50 hours
21
Radiator - every 50th engine hour

A
B
1250 0186 25
Figure: Radiator
Table: Radiator
A Radiator Check coolant level
B Radiator Check to see whether the radiators are clogged.
Clean with compressed air.
22
Hydraulic oil reservoir - every 50th engine hour

1250 0201 25
A
Figure: Draining point
Table: Draining
A Hydraulic oil reservoir Drain off the water. The drill rig must have
been standing still for one hour before the
water can be drained.
23
Cab - every 50th engine hour
A
D
1250 0182 93
A
C
E B
b
B b
Figure: Cab
Table: Cab
A Circulation filter Clean or change the filter element if necessary.
B Circulation filter Clean or change the filter element if necessary.
C Primary filter Clean or change if necessary.
D Prefilter Clean or change if necessary.
E Fire extinguisher Check the legibility of the instructions
F Steps to door Check mounting, cracks and damage
- Air conditioning Run the cooling system for 5 minutes (winter
and summer)
- Condenser element Clean with compressed air
- Handle Check mounting, cracks and damage
- Roof Protective members. Mounting and damage
- Horn Check that the horn is in working order
- Reversing warning signal and Check functionality
warning light
- Plates and decals for warning, Check legibility and attachment
safety and information.
24
Fire extinguisher - every 50th engine hour
Figure: Fire extinguisher
Table:
A Hand-held fire extinguisher Check the legibility of instructions and the condition
(rear) of the fire extinguisher.
B Hand-held fire extinguisher (cab) Check the legibility of instructions and the condition
of the fire extinguisher.
Note
The variant of the fire extinguisher that is supplied depends on the different national
regulations. It is therefore essential to follow the instructions printed on the fire extin-
guisher.
The fire extinguishers supplied with the drill rig should be considered as “Delivery
fire extinguishers”. If the fire extinguishers are not approved in accordance with pro-
visions in force for the worksite then they must be replaced with approved ones. In
which case, the manufacturer's instructions for maintenance must be followed.
25
Feeder - every 250th engine hour
A
1250 0169 14
DE
DE
EFG
C
Figure: Feeder
Table: Feeder
A Cradles Check the slide pieces, play, mounting, damage
and tightening torque. Play 2 - 4 mm. See also
maintenance instructions for adjustment
instructions
B Slide rails Check for wear.
C Sensors Check mounting and function
Adjust the distance, approx. 5 mm.
D Bush halves Check for wear and cracks
26

E Hydraulic cylinders Check mounting
F Ball bearings in cylinder lugs Check clearance, Max. 0.5 mm
G Drill-steel support halves Check adjustment, wear and cracks
Feed cylinder Check mounting and damage.
Breakout table/Rod guide - every 250th engine hour

1250 0204 44
A
C
Table: Breakout table/Rod guide

A Ball bearings in cylinder lugs Check clearance, Max. 0.5 mm
B Drill-steel support halves Check adjustment, and for wear and cracks.
C Breaker jaws Check adjustment, and for wear and cracks.
- Bolted joints, general Check tightening: M10 41 Nm, M12 73 Nm,
M16 185 Nm.
27

1250 0186 63
Figure: Boom
Table: Boom
A Boom head/Feed holder Check mounting
B Feed bracket Check the play between feeder and feed
bracket, 2 - 4 mm. Check mounting
- All bushings and bearings Check play between bushes, shaft and holder.
Change bushes and shaft as necessary. Max
play 1 mm
28
1250 0186 63
Figure: Boom
Table: Boom
A Boom head/Feed holder Check mounting
B Feed bracket Check the play between feeder and feed
bracket, 2 - 4 mm. Check mounting
- All bushings and bearings Check play between bushes, shaft and holder.
Change bushes and shaft as necessary. Max
play 1 mm
29
Air conditioning - Every 250th engine hour
A
1250 0205 30
Figure: Air conditioning.
Table: Air conditioning.

A Circulation filter Changing
B Primary filter Changing
C Prefilter Changing
30
Electrical system - every 250th engine hour

1250 0187 52
Figure: Electrical system
Table: Electrical system

A Electric cabinet Check sealing strip damage
- Connection blocks Corrosion, tightening.
31

I
F
E,G
A,B
D
1250 0116 51
H
Table: Track frames

A Traction gear Check for leaks
B Traction gear Check oil level. Level plug and filler plug must
be in horizontal position.
C Traction motors Check mounting. Tightening torque 315 Nm
D Track wheels Check mounting. Tightening torque 315 Nm
E Support rollers Check leakage, wear. Mounting 73 Nm
F Crawler track Tensioning, 25-50 mm, see maintenance
instructions. Do not overtension!
G Track control Check mounting. Tightening torque 210 Nm
H Track frames Check mounting. Tightening torque 73 Nm 2x3
bolts
I Support roller Check level. The rollers should be half full.
Check through the level plug.
32
Dust collector (DCT) - every 250th engine hour
A
B
I
H J
G
C
F
1250 0201 21
D
L
M
Figure: DCT
Table: DCT
A Engine Mounting, 2 bolts M12 73 Nm
B Engine plate Mounting, 12 lock nuts M10 41 Nm
C Diaphragm valves Check for leaks
D Dust collector Mounting, 4 bolts M16 185 Nm
E Inlet connector piece Check for wear
F Wear rubber Check wear and attachment
G Filter Visual check
H Inlet connector piece Check for wear
I Centre hose Check the wear. Replace or rotate if
necessary.
J Wear rubber Check wear and attachment
K Hose Check wear and attachment
L Suction hoses Check for wear and sealing integrity
M Dust gasket Check for wear and sealing integrity
33
1250 0183 18
Figure: Cab
Table: Cab
- Door hinges Lubricate
- Cab Check mounting, damage. Tightening torque
185 Nm
34
Power pack - every 250th engine hour
A
1250 0201 56
C D
B
Figure: Power pack
Table: Power pack

A Motor oil Change engine oil. Drain at A.
See the instructions for the diesel engine.
B Engine oil filter Change filter
C Fuel filter Change filter
D Fuel prefilter Change filter
Battery Check electrolyte level
V-belts generator/air Check wear and tension (see maintenance
conditioning instructions)
35
Air, coolant and intercooler systems - every 250th engine

hour
A B
1250 0186 33
Figure: Exhaust system.
Table: Exhaust system.

- Clamps Check/retighten clamps. Tightening torque type A:
5 - 6 Nm, type B: 10-12 Nm
Hydraulic system - every 250th engine hour
A
1250 0197 42
Figure: Hydraulic system
Table: Hydraulic systems

A Breather filter Change if clogged
36
Pipe guide - every 500th engine hour

1250 0186 67
Table: Rod guide

A Slide pieces Check thickness, min. 4 mm
37
1250 0093 34
A
C
B
Table: Track frames

A Track frames Check mounting, Tightening torque 73 Nm (57
lbf.ft). 2 x 3 bolts
B Track wheels Check mounting. Tightening torque 185 Nm
(136 lbf.ft)
C Support roller Level check. The rollers should be half full.
Check via oil level plug.
38
Diesel engine - every 500th engine hour

1250 0191 21
Figure: Diesel engine
Table: Diesel engine

A Engine Check mounting and tightening torque
B Engine frame Check mounting and tightening torque
C Hydraulic pumps Check mounting and tightening torque
D Rubber coupling between diesel Check for cracks and wear
engine and hydraulic pump
39
1250 0179 23
Figure: Cab
Table: Cab
A Fire extinguisher Check the legibility of instructions and the
condition of the fire extinguisher
- Warning/safety signs Warning and safety labels plus labels with
information symbols. Legibility, affixation
40
Air filter for engine and compressor - 500 engine hours

1
2
3
4
1250 0194 87
Figure: Air filter
Table: Air filter

3 Air filter Replace the safety cartridge (3). See
maintenance instructions
Note
This only applies if replacement must, for some reason, be made at determined inter-
vals, which is not normally recommended.
Normally filter components should be replaced when indicated on the display for
engine and directional instruments.
See maintenance instructions.
41
Feeder - 1000 engine hours
A
1250 0201 34
A
A
A B
C C
C > 50 mm > 50 mm
B
Figure: Feeder
Table: Feeder
A Grease nipples on feed beam Fill grease, see maintenance instructions.
B Grease nipples on the sheave Fill with grease.
C Guides Check the wear. Must be at least 50 mm thick.
42
Air conditioning - 1000 engine hours
A
1250 0205 27
Figure: Air conditioning
Table: Air conditioning

Aa Circulation filter Changing
43
Air filter for engine and compressor - 1000 engine hours

1250 01206 21
Figure: Air filter
Table: Air filter

A Air filter Check the indicator.
See maintenance instructions.
44
Air system - 1000 engine hours
A
1250 0202 05
B C
Figure: Pressure tank's top side

A Valve plate Clean the restriction where hose AD19 is
connected.
B Start protection contact breaker Check. Max. pressure 1.5 bar.
B336 See maintenance instructions
C Minimum pressure contact Check. Min. pressure 4 bar.
breaker B337 See maintenance instructions
- Control valves for percussion Check
pressure
- Compressor Check intermediate stage pressure
0.5 to 2 bar for unloaded compressor
5 to 6.5 bar for loaded compressor
45
Compressor - 1000 engine hours

C
A
1250 0206 19

A Compressor Changing oil
Only Atlas Copco PAROIL S or PAROIL S68
may be used.
See maintenance instructions
B Oil filter Change filter
C Safety valve Pressure test
32 bar for L6(25)/L8(25)
35 bar for L6(30)/L8(30)
See maintenance instructions
46
Pressure tank, separator - 1000 engine hours

1250 0207 35
Figure: Pressure tank, separator
Table: Pressure tank, separator

A Pressure tank separator filter Replace separator filter
Note
Check that the washer (1) under the filter remains in place and is not discarded with
the old filter during filter replacement.
47

1250 0093 35
A
Table: Track frames

A Traction gear Change oil
48
Hydraulic oil reservoir - every 1500th engine hour

1250 0202 73
A
B
Figure: Drainage points for hydraulic oil
Table: Hydraulic oil reservoir

Hydraulic oil reservoir Oil change and filter change. See maintenance
instructions. The machine must be horizontal
49
Every 2000 engine hours
Dust collector filter - 2000 engine hours

1250 0001 94
a
Figure: Dust collector, filter
Table: Dust collector, filter

A Dust collector filter Filter replacement
50
Engine heater - every 2000th engine hour
4
3
1250 0168 82
Figure: Engine heater

1 Engine heater
2 Dosage pump
3 Fuel prefilter
4 Fuel tank
Table: Engine heater

3 Fuel prefilter Changing
51
Every 20000th Engine hour
Boom - Every 20000th engine hour

1250 0248 36
Figure: Boom
Table: Boom
A Boom head Changing
52

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Atlas Copco

PM No. 9852 2321 01

Special attention must be paid

Only use genuine Atlas Copco parts.

© Copyright 2010, Atlas Copco Rock Drills AB, Sweden

Translation of original instructions.

Atlas Copco Rock Drills AB

Pressure tank, separator - 1000 engine hours ................................................... 47

• Maintenance intervals. Engine hours.

How to use these maintenance instructions

Genuine Atlas Copco spare parts

Every 10th engine hour

Breakout table/Rod guide - every 10th engine hour

Figure: Breakout table/Rod guide

Table: Breakout table/Rod guide

Check point Control object Action

Compressor tank - every 10th engine hour

Table: Compressor tank

Engine package - every 10th engine hour

Figure: Engine package

Table: Engine package

Electrical system - every 10th engine hour

Table: Electrical system

Every 50th engine hour

Feeder - every 50th engine hour

Hydraulic hoses - every 50th engine hour

Figure: Hoses over hose drum

Table: Hoses over hose drum

Rod handling (RHS 140) - every 50th engine hour

Figure: Rod handling (RHS 140)

Table: Rod handling (RHS 140)

Boom C14 - every 50th engine hour

Boom C20 - every 50th engine hour

Check point Control object Action

Track frames - every 50th engine hour

Table: Track frames

Rig frame/track frame - every 50th engine hour

Figure: Rig frame/track frame

Table: Rig frame/track frame

Compressor components - every 50th engine hour

Figure: Compressor parts

Table: Compressor parts

Radiator - every 50th engine hour

Hydraulic oil reservoir - every 50th engine hour

Cab - every 50th engine hour

Fire extinguisher - every 50th engine hour

Figure: Fire extinguisher

Every 250th engine hour

Feeder - every 250th engine hour

Check point Control object Action

Breakout table/Rod guide - every 250th engine hour

Figure: Breakout table/Rod guide

Table: Breakout table/Rod guide

Boom C14 - every 250th engine hour

Boom C20 - every 250th engine hour

Air conditioning - Every 250th engine hour

Figure: Air conditioning.

Table: Air conditioning.