Boom

Component Removal and

Installation Instructions
SmartROC D65

Original Instructions
2018-02-12 | No: 5588060811.1 en-US
Boom Table of Contents

Table of Contents
1 Introduction ........................................................................................................... 5
1.1 Safety First! ................................................................................................................................ 5
1.2 Terms and Abbreviations .......................................................................................................... 5

2 Preparations and Prerequisites ........................................................................... 7

2.1 Technical Data............................................................................................................................ 7
2.1.1 Machine Technical Data ........................................................................................................... 7
2.1.2 Technical Data.......................................................................................................................... 7
2.2 Spare Parts ................................................................................................................................. 7
2.3 Reference Documentation......................................................................................................... 7
2.4 Job Safety and Environmental Analysis (JSEA) ..................................................................... 8

3 Before Starting the Task....................................................................................... 9

3.1 Safety Precautions Before and During the Work .................................................................... 9
3.2 Machine Start Isolation............................................................................................................ 10
3.3 Releasing Stored Energy......................................................................................................... 10

4 Removing Boom.................................................................................................. 13

5 Installing Boom ................................................................................................... 21

6 After the Installation ........................................................................................... 29

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Boom Table of Contents

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Boom 1 Introduction

1 Introduction

This instruction has been developed with the intention of providing the step-by-step se-
quence to remove and install the component that is mentioned on the front cover, on the
machine/s also mentioned on the front cover.
Where applicable, safety warnings and messages are used in the instruction to point out
potential hazards however, this instruction must be used in conjunction with a local Job
Safety and Environmental Analysis (or equivalent) in order to identify and manage hazards
and risks.

1.1 Safety First!

The person or persons performing work according to instructions in this manual must be
qualified for the work according to local regulations and requirements. It is the duty of all
personnel that are involved in performing the tasks to read and understand the machine-
specific Safety, Operation, and Maintenance manuals before commencing any work on the
machine.
The instructions include specific safety messages that are marked with Danger, Warning,
Caution, or Notice. Pay extra attention to these messages as they are additional to in-
struction text. Comply with any local safety rules specific to the work location.

1.2 Terms and Abbreviations

Term Definition

Job Safety and Environmental Analysis Local job risk observation tool, used for job hazard
identification and determination of how to manage
the risk through appropriate control measures.

Technician A person who is qualified to perform the work ac-

cording to local regulations and requirements.

Machine operator A person who is qualified and approved to operate

the machine according to local regulations and re-
quirements.

Spotter A person who oversees machine operation within

the surrounding environment, and assist and com-
municates with the machine operator to ensure
safe and precise movement and maneuvering of
the machine.

Crane / Lifting device operator A person who is qualified and approved for oper-
ating the crane or lifting device according to local
regulations and requirements.

Approved lifting device A device that is connected to, or applied on, a

component for the purpose of lifting it. The device
must fulfil local regulations and requirements for

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Boom 1 Introduction

Term Definition

the lifting operation. The illustrations in this in-

struction show principal examples for information
purpose only.

Machine The complete Atlas Copco machine that the com-

ponent is located within.

Equipment Auxiliary equipment to assist task operations, in-

cluding but not limited to Lifting Devices, Com-
pressors, Tooling.

Work environment The main location where the work is performed,

for example a workshop, field workshop, under-
ground, open pit.

Work area The specific area within the work environment

where the job is performed.

Local regulation Regulation, specification, or instruction that is

valid for the local site and that can complement or
override the instructions in this document.

Abbreviation Definition

JSEA Job Safety and Environmental Analysis

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Boom 2 Preparations and Prerequisites

2 Preparations and Prerequisites

2.1 Technical Data

To select the correct lifting device, stands, tools and so forth, this section provides general
technical specifications.

! NOTE: Due to the variation of machine options and components, actual values can dif-
fer from data. Data is for reference only.

2.1.1 Machine Technical Data

See machine-specific manuals for weight, dimensions, and other data relevant to bringing
the machine to the work area and performing the task.

2.1.2 Technical Data

Description Data Remarks

Boom Weight 599 kg (1321 lbs)

Feed Dump Cylinder Weight 135 kg (298 lbs) Each Cylinder

Boom Lift Cylinder Weight 196 kg (432 lbs)

Boom Attachment Pin Weight 58 kg (128 lbs)

2.2 Spare Parts

! NOTE: To create an order list request for the spare parts, refer to the Spare Parts Cat-
alog for your specific machine model and serial number.

2.3 Reference Documentation

! NOTE: The listed documentation must be available in valid version at the location
where the job is being performed.

Manual Reference

Safety Manual Machine Specific (per serial number)

Operation Manual Machine Specific (per serial number)

Service/Maintenance Manual Machine Specific (per serial number)

Mining and Rock Excavation Torque Specification No 1185028747

Atlas Copco Spare Parts Catalog Machine Specific (per serial number)

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Boom 2 Preparations and Prerequisites

Manual Reference

SmartROC D65 - CRI - Boom Head (Knuckle) Document ID 5526327051.1 en.US

2.4 Job Safety and Environmental Analysis (JSEA)

! NOTE: Refer to local regulation and JSEA or equivalent type of job risk assessment
documentation.

Job Safety and Environmental Analysis provides job hazard identification, potential risk as-
sessment, and suggested controls for the tasks that are described within this instruction.
The technician must create a JSEA for the job or task on the physical objects in front of
them, and consider any local conditions, environmental hazards, and risks.

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Boom 3 Before Starting the Task

3 Before Starting the Task

3.1 Safety Precautions Before and During the Work

WARNING
High System Pressure
There is a risk of personal injury when working with pressurized systems.
u Do not perform maintenance work while the machine is running.
u Check that the hydraulic, water, and air systems are depressurized before starting to
work on these systems.

WARNING
Heavy Objects That Require Approved Lifting Device
Can cause crushing injury or death.
u Never lift heavy objects above your personal capability.
u Use approved lifting devices.
u Do not stand under the heavy object being lifted.

WARNING
Mounting surfaces
Risk of pinch points during installation.
u Keep hands clear of mounting surfaces while positioning the parts.

WARNING
Uncontrolled Release of Stored Energy
Can result in death or serious injury.
u Always remain out of the line of fire (impact zone of released stored energy).
2. Always use approved lifting devices to support the weight of the machine components.
3. Inspect all tooling and equipment before use.

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Boom 3 Before Starting the Task

CAUTION
Heavy Objects Lifted by Hand
Can cause body or muscle strains.
u Position the body accordingly to take the weight.

WARNING
Loud Noise
Risk of hearing damage.
u Use hearing protection when working with impact wrenches.
u Use hearing protection when starting diesel engine.

3.2 Machine Start Isolation

The engine must be switched off (key switch) and the battery isolation switch must be iso-
lated during service and maintenance work on the machine.

Shutting off the Engine

a. Follow all instructions in the Operation manual of the machine when shutting off
the engine.

Battery Isolation Switch

a. Refer to the machine Operation manual to locate the battery isolation point for
the machine.

b. Switch the isolation point so that it is in the lockable position.

c. Verify the lockout by trying to start the engine from the cab.

d. It is highly recommended to disconnect all battery cables and place all fuses and
circuit breakers in the open position when doing any extensive electrical work on
the machine.

3.3 Releasing Stored Energy

Stored energy is a common term for forces that remain in the machine systems when
power supply and functions are turned off. Stored energy forces are potentially dangerous
when working on the machine. Especially when unplugging hoses or cables, opening up
system connections, or loosening load-bearing joints.
Present in surface drill rigs are different forms of stored energy.
Determine the appropriate stored energy to be released or controlled in the relevant sys-
tem for the task about to be performed, some examples follows.
• Rock drill accumulators (percussion and damper accumulator) - Verify that accumula-
tor nitrogen pressure has been dissipated before removing the accumulator from the
rock drill.

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Boom 3 Before Starting the Task

• Weight of booms and feeds - Any work done on or near the booms lift cylinders or po-
sitioning cylinders should consider that if the circuit is broken there is a potential for the
Boom to fall or swing. Support the weight of the boom and feed as required to prevent
hazards.
• Hydraulic tank pressure - Relieve residual pressure in hydraulic tank.
• Water mist system pressure - Relieve residual pressure in water tank.
• SAHR brake assemblies - SAHR Brake assemblies are an internal component of the
final drives. It is mandatory that adequate training competence is achieved before
working on SAHR brake assemblies, follow SAHR maintenance procedures.
• Batteries - They contain an electrolyte which contains dilute sulfuric acid. Sulfuric acid
may cause severe chemical burns. During the charging process or during operation,
they might develop hydrogen gas and oxygen, which under certain circumstances may
result in an explosive mixture. They can contain a considerable amount of energy,
which may be a source of high electrical current and a severe electric shock in the
event of a short circuit.
• Engine coolant tank pressure - Relieve header pressure in coolant tank. Be aware of
potential high temperature of fluid.
• Compressed air receiver tank - Relieve pressure from compressor reservoir.
• Compressed air circuit - Relieve residual pressure in air circuit.

! NOTE: Refer to machine maintenance and service manual for specific methods to iso-
late the stored energy on the specific machine you are working with.

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Boom 3 Before Starting the Task

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Boom 4 Removing Boom

4 Removing Boom

First read: Before Starting the Task [} 9]

Precondition p The boom head (knuckle) is removed according to procedure.

1. Position the machine for the task.

a. Perform a stored energy release for the hydraulic tank and system.

! NOTE: Verify that there is no pressure that is left in the sys-

tem.

b. Isolate the machine using the battery isolation switch. Apply the necessary Lock-
out-Tagout procedure.

c. Refer to local regulations, extra requirements can apply.

2. Remove the rod end pin retainer plate (A Figure 1) and grease line (B Figure 1) from
the boom swing cylinder.

Figure 1

3. Remove the rod end pin (C Figure 1) and withdraw cylinder away from boom.

4. Place a suitable receptacle under the boom lift cylinder hoses.

5. Clean, label, and disconnect the two hydraulic hoses (A Figure 2) from the cylinder.

! NOTE: Immediately plug and cap the hoses and ports.

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Boom 4 Removing Boom

WARNING
Excess Oil and Disconnected Hoses
Slipping hazard.
u Wipe up the excess oil.
u Attach the disconnected hoses to the side.

Figure 2

6. Disconnect and remove the grease block from the boom (A Figure 3).

Figure 3

7. Remove the boom angle sensor (A Figure 4).

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Boom 4 Removing Boom

Figure 4

8. Remove the earth leads from both sides of the boom (A Figure 5A) and (A Figure 5B).

Figure 5A

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Boom 4 Removing Boom

Figure 5B

9. Remove the protection cover (A Figure 6).

CAUTION
Heavy Objects Lifted by Hand
Can cause body or muscle strains.
u Position the body accordingly to take the weight.

Figure 6

10. Remove the boom swing sensor (A Figure 7).

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Boom 4 Removing Boom

Figure 7

11. Remove the boom swing sensor bottom plate (A Figure 8).

Figure 8

12. Attach an approved lifting device to the boom and support the weight (Figure 9).

WARNING
Heavy Objects That Require Approved Lifting Device
Can cause crushing injury or death.
u Never lift heavy objects above your personal capability.
u Use approved lifting devices.
u Do not stand under the heavy object being lifted.

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Boom 4 Removing Boom

Figure 9

13. Remove the boom attachment pin retainer plate (A Figure 10).

Figure 10

14. Attach lifting eye to boom attachment pin (B Figure 10).

15. Attach an approved lifting device to the lifting eye at the boom attachment pin (A Fig-
ure 11).

WARNING
Heavy Objects That Require Approved Lifting Device
Can cause crushing injury or death.
u Never lift heavy objects above your personal capability.
u Use approved lifting devices.
u Do not stand under the heavy object being lifted.

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Boom 4 Removing Boom

Figure 11

16. Lift the boom attachment pin (A Figure 11) away from the boom and place in a safe
and suitable location. Remove lifting device and lifting eye

17. Lift the boom away from the machine (Figure 12) and place in a safe and suitable lo-
cation. Remove lifting device

Figure 12

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Boom 4 Removing Boom

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Boom 5 Installing Boom

5 Installing Boom

First read: Before Starting the Task [} 9]

1. Verify that the machine is isolated and if necessary isolate the machine using the bat-
tery isolation switch. Apply the necessary Lockout-Tagout procedure.

2. Attach an approved lifting device to the boom.

WARNING
Heavy Objects That Require Approved Lifting Device
Can cause crushing injury or death.
u Never lift heavy objects above your personal capability.
u Use approved lifting devices.
u Do not stand under the heavy object being lifted.

3. Lift and align the boom onto the machine for attachment pin installation (Figure 1).

Figure 1

4. Attach an approved lifting eye and lifting device to the boom attachment pin.

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Boom 5 Installing Boom

WARNING
Heavy Objects That Require Approved Lifting Device
Can cause crushing injury or death.
u Never lift heavy objects above your personal capability.
u Use approved lifting devices.
u Do not stand under the heavy object being lifted.

5. Lift and align the pin over the boom attachment and slowly lower through the machine
and boom (A Figure 2).

Figure 2

6. Make sure that the boom attachment pin is correctly installed (B Figure 3).

Figure 3

7. Install the boom attachment pin retainer plate (A Figure 3).

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Boom 5 Installing Boom

8. Install the boom swing sensor bottom plate (A Figure 4).

Figure 4

9. Install the boom swing sensor (A Figure 5).

Figure 5

10. Install the protection cover (A Figure 6).

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Boom 5 Installing Boom

Figure 6

11. Install the earth leads to both sides of the boom (A Figure 7A) and (A Figure 7B).

Figure 7A

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Boom 5 Installing Boom

Figure 7B

12. Install the boom angle sensor (A Figure 8).

Figure 8

13. Install and connect the grease block to the boom (A Figure 9).

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Boom 5 Installing Boom

Figure 9

14. Connect the two hydraulic hoses (A Figure 10) to the boom lift cylinder according to
labels.

Figure 10

15. Insert the boom swing cylinder into the boom and install the pin (C Figure 11).

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Boom 5 Installing Boom

Figure 11

16. Install the rod end pin retainer plate (A Figure 11) and grease line (B Figure 11).

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Boom 5 Installing Boom

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Boom 6 After the Installation

6 After the Installation

After completing the Installation section of this instruction, the component is installed but
possibly not ready to operate.
A trained machine specialist must proceed with a commissioning start-up procedure to en-
sure that the machine system status is correct for start-up and all machine safety and func-
tional requirements are met.
Refer to the machine-specific manuals for information about machine start-up require-
ments.

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Boom 6 After the Installation

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 6 After the Installation

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