9852 2730 01 Maintenance Schedules FlexiROC T35, T40 PDF

Atlas Copco
FlexiROC T35 and FlexiROC T40

Maintenance schedules
PM No. 9852 2730 01

2011-05
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 2011, 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 4th impact hour ........................................................................................... 10
Drill-steel support - Every 4th percussion hour................................................ 10
Every 20th impact hour ......................................................................................... 11
Feeder - Every 20th percussion hour ................................................................ 11
Every 100th impact hour ....................................................................................... 12
Feeder - Every 100th percussion hour .............................................................. 12
Rod handling - every 100th percussion hour .................................................... 13
Dust collector - Every 100th percussion hour .................................................. 14
Every 200th impact hour ....................................................................................... 15
Drill-steel support - Every 200th percussion hour............................................ 15
Every 10th engine hour ......................................................................................... 16
Power pack - every 10th engine hour ............................................................... 16
Hydraulic system - Every 10th engine hour ..................................................... 17
Diesel filter - Every 10th engine hour .............................................................. 18
Electrical system/Winch - every 10th engine hour ........................................... 19
Every 50th engine hour ......................................................................................... 20
Boom/Feeder - every 50th engine hour ............................................................ 20
Track frames - every 50th engine hour ............................................................. 21
Rig frame/track frame - every 50th engine hour .............................................. 22
Power pack - every 50th engine hour ............................................................... 23
Radiator - every 50th engine hour .................................................................... 24
Compressor tank - every 50th engine hour....................................................... 25
Hydraulic oil reservoir - every 50th engine hour.............................................. 26
Cabin - every 50th engine hour ........................................................................ 27
Winch - every 50th engine hour........................................................................ 28
Remote-control box - every 50th engine hour .................................................. 29
Every 250th engine hour ....................................................................................... 30
Boom/Feeder - every 250th engine hour .......................................................... 30
Air conditioning - Every 250th engine hour..................................................... 31
Electrical system - every 250th engine hour..................................................... 32
Track frames - Every 250th engine hour .......................................................... 33
Dust collector (DCT) - Every 250th engine hour ............................................. 34
Cabin - every 250th engine hour ...................................................................... 35
Battery - Every 250th engine hour.................................................................... 36
Diesel engine - every 250th engine hour .......................................................... 36
Hydraulic system - every 250th engine hour .................................................... 37
Every 500th engine hour ....................................................................................... 38
Track frames - every 500th engine hour ........................................................... 38
Diesel engine - every 500th engine hour .......................................................... 39
Winch - every 500th engine hour...................................................................... 40
Cabin - every 500th engine hour ...................................................................... 41
Terminal blocks - every 500th engine hour ...................................................... 42
Terminal blocks - every 500th engine hour ...................................................... 43
7
Every 1000th engine hour...................................................................................... 44

Hydraulic system - every 1000th engine hour .................................................. 44
Compressor - every 1000th engine hour........................................................... 45
Air filter - every 1000th engine hour ................................................................ 46
Pressure tank, separator - 1000 engine hours ................................................... 47
Track frames - every 1500th engine hour ......................................................... 48
Winch - Every 1500th engine hour ................................................................... 49
Dust collector filter - Every 2000th engine hour .............................................. 50
Engine heater - every 2000th engine hour ........................................................ 51
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:
• Part 1 - Maintenance intervals Percussion hours (feeder and rock drill).

- 4th hour
- 20th hour
- 100th hour
- 200th hour
• Part 2 - Maintenance intervals Engine hours.
- Every 10th hour
- Every 50th hour
- Every 250 Hours
- Every 500 Hours
- Every 1000 Hours
- (Every 1500th 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.
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
• 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.
9
Note
The illustrations only show examples of grease nipples; check all attachments and
bearings appurtenant to relevant systems so you can find the existing grease nipples.
Every 4th impact hour
Drill-steel support - Every 4th percussion hour

1250 0043 02
Figure: Drill support
Table: Drill support

Check point Control object Action
A Grease nipples Pump grease into 12 grease nipples
10
Feeder - Every 20th percussion hour

G A
E I
H
F C
B
J C
1250 0198 51
C
L
K
C
Figure: Feeder
Table: Feeder
A Feed cylinder Check for leaks
B Pull and return rope Adjusting voltage, check lubrication and leakage.
C Limit switches Check attachment and function.
D Intermediate drill-steel support Lubrication. Check for wear on the intermediate
drill-steel support bearing and change as
necessary.
E Feed beam Inspect for damage and wear
F Rock drill Check attachment, tightening bolted joints
G Hydraulic hoses Check wear and tension
H Water-hose drum Check lubrication and wear on hose drum bearing.
11

I Rock drill cradle Check attachment, play, leaks and damage
J Grease nipples Pump grease into 14 grease nipples (RHS)
K Drill-steel support halves Check for wear.
L Bolted joints Tightening
Feeder - Every 100th percussion hour

A
B
H
F C
G D
E
E
1250 0116 80
E
F
E
G
F A
Figure: Feeder
Table: Feeder
A Cradles Check clearance, mounting, damage tightening
torque 185 Nm (185 Nm (136 lbf ft)). Max
clearance 2 - 4 mm. See also maintenance
instructions for adjustment directions.
B Feed cylinder Check attachment and damage.
12

C Hydraulic cylinders Check mounting
D Bushing halves Check for wear and cracks
E Sensor Check mounting and function
F Drill-steel support halves Check adjustment, wear and cracks
G Ball bearings in cylinder lugs Check clearance, Max. 0.5 mm
H Slide pieces Check wear. Min. thickness 4 mm
Rod handling - every 100th percussion hour

A
1250 0137 11
B
E
Figure: Rod handling equipment
Table: Rod handling equipment

A (Applies only to Hydraulic motor Check mounting
rigs equipped with
RHS)
B Bushing halves Check for wear, cracks
C Hydraulic cylinders Check mounting
D (Applies only to Sensor Check mounting, functionality
rigs equipped with
RHS)
13

E (Applies only to Bracket Check attachment, cracks
rigs equipped with
RHS)
Dust collector - Every 100th percussion hour
A
B
C
E D
1250 0002 68
C
E
Figure: Dust collector.
Table: Dust collector.

A Suction hoses The hoses must be intact and sealed. Replace
if necessary.
B Dust gasket The gasket must be intact and seal around the
pipe. Replace if necessary.
C Inlet connector pieces The connector pieces must not be worn
through. Change if necessary.
D Centre hose The hose must be intact. Rotate or replace as
necessary.
E Wear protection The wear protectors must be fitted securely
and not be worn. Replace if necessary.
14
Drill-steel support - Every 200th percussion hour
Figure: Drill support
Table: Drill support

A Attachment Check mounting, direction. Tightening torque 185
Nm (136 lbf.ft)
B Bolted joints Tightening
Slide pieces Check for wear.
15
Every 10th engine hour
Power pack - every 10th engine hour

D
A
1250 0116 82
Figure: Power pack
Table: Power pack

A Compressor oil level Look at the compressor sight glass. Check that the
pressure gauge needle is in the green zone.
B Hydraulic oil pumps Check for signs of leakage
C Diesel engine oil level The oil must be between the two marks on the
dipstick
D Diesel engine Check for leaks
16
Hydraulic system - Every 10th engine hour
A:1
A
B
C
D
1250 0183 74
Figure: Hydraulic system
Table: Hydraulic oil reservoir

A Hydraulic oil filter Change the filters if the return oil filter pressure
gauge needle (A:1) is in the red sector. The oil
temperature should be 40 °C
B Hydraulic oil tank Connections, signs and leakage
C Oil level The oil should cover the bottom sight glass
completely and half the upper. The rig must be
standing horizontally before a correct reading
can be obtained.
D Fill up to the high level mark. If all the oil in the
lubricating system has been used up, bleeding
of the system will be necessary
17
Diesel filter - Every 10th engine hour

1250 0163 43
A
Figure: Primary filter element
Table: Diesel engine/compressor

A Primary filter element Drain off water
18
Electrical system/Winch - every 10th engine hour
1250 0279 33
B A C
D
Table: Electrical system/Winch

A 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.
B Working lights Front and rear, functionality.
D Winch wire rope Check for damage, unwinding, wear and
corrosion.
E Hook Check damage, cracks, wear and mounting.
19
Boom/Feeder - every 50th engine hour
A
A
1250 0195 25
A
A
A
Figure: Boom/Feed
Table: Boom/Feed
A Grease nipples Pump grease into 21 grease nipples
20
Track frames - every 50th engine hour
Figure: Track frames
Table: Track frames

A Traction motors Check for signs of leakage
B 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.
C Support roller Check for wear and leaks.
D Grease nipples Pump grease into two grease nipples.
E Mountings Retighten all mountings after 100 engine hours as
per Track frame - Every 250 engine hours . Then
every 250 engine hours.
21
Rig frame/track frame - every 50th engine hour
A
1250 0000 00
Figure: Rig frame/track frame
Table: Rig frame/track frame

A Track frame/rig frame Lubrication
22
Power pack - every 50th engine hour
1250 0137 33
B
C
Table: Power pack
A Compressor/Diesel engine Signs of leakage. Air/Oil
B Air filter Compressor/Diesel Check connections and couplings on inlet
engine manifold
23
Radiator - every 50th engine hour
Figure: Radiator
Table: Radiators
A Primary fuel filter moisture trap Drain off the water
B Radiators and coolers Check coolant level, antifreeze. See
maintenance instructions
Radiators and coolers Check to see whether the radiators are
clogged. Clean with compressed air.
24
Compressor tank - every 50th engine hour
1250 0116 56
A
Figure: Compressor tank
Table: Compressor tank

A Air tank Open drain plug (A). Drain the water. The drill
rig must have been standing still for eight
hours before the water can be drained.
25
Hydraulic oil reservoir - every 50th engine hour
Figure: Hydraulic oil reservoir
Table: Hydraulic oil reservoir

A Hydraulic oil reservoir Drain off the water. The drill rig must have
been standing still for eight hours before the
water can be drained.
26
Cabin - every 50th engine hour
A
D
1250 0182 93
A
C
E B
b
B b
Figure: Cabin
Table: Cabin
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.
- Air conditioning Run the cooling system for 5 minutes (winter
and summer)
- Condenser element Clean with compressed air
E Fire extinguisher Check the legibility of the instructions
F Steps to door Check mounting, cracks and damage
- Handle Check mounting, cracks and damage
- Roof Protective members. Mounting and damage
- Air conditioning Clean the condenser element with
compressed air.
- Signal Horn Check that the horn is in working order
- Reversing warning signal and Check function
warning light
- Warning/safety signs Warning and safety labels plus labels with
information symbols. Legibility, affixation
27
Winch - every 50th engine hour
Figure: Winch
Table: Winch
A Winch Mounting in the frame, tightening torque 350
Nm. 8 bolts.
28
Remote-control box - every 50th engine hour
a a
Figure: Remote control box.
Table: Remote control box.

A Rubber bellows on levers and Make sure none of the rubber bellows on
switches switches/levers is damaged
29
Boom/Feeder - every 250th engine hour
E
D
A
F
1250 0195 23
D
E
B,C
Figure: Boom/Feed
Table: Boom/Feed
A Boom head Check mounting, tightening torque 73 Nm (54
lbf.ft)
B Feed bracket Check the clearance between feed and feed
attachment 2 - 4 mm
C Feed bracket Mounting, tightening torque 185 Nm (136 lbf.ft)
D Bushes in boom and boom head Check for play between bushes, shaft and
holder. Replace with new bushes as necessary
and change the shaft if needed.
E Bearings in cylinder lugs/ Max. clearance 1 mm
E Attachment of feed extension Check mounting. Tightening torque 90 Nm.
cylinder
F Locking plates Check mounting, damage. 9 plates. Tightening
torque 73 Nm (54 lbf.ft)
30
Air conditioning - Every 250th engine hour
A
D
1250 0182 93
A
C
E B
b
B b
Figure: Air conditioning.
Table: Air conditioning.

A Circulation filter Change as necessary
B Circulation filter Change as necessary
C Primary filter Change
D Prefilter Change
31
Electrical system - every 250th engine hour
C1
S456
S457
S458
S459
C4 C2
C5 C3
A1 B1 15
t2
K542
t1
16 18 A2
2489.9870
Figure: Electrical system
Table: Electrical system

A Electric cabinet Check sealing strip damage.
32
Track frames - Every 250th engine hour

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, 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.
33
Dust collector (DCT) - Every 250th engine hour
B:2
B:1
B
1250 0091 26
A
Figure: DCT
Table: DCT
A Lubricating oil tanks Drain off water
B Dust collector Mounting 8 bolts (B:1): Tightening torque 73
Nm (54 lbf.ft) Mounting 8 bolts (B:2) Tightening
torque 20 Nm (15 lbf.ft)
34
1250 0183 18
Figure: Cabin
Table: Cabin
A Door hinges Lubricate
B Cabin Check mounting, damage. Tightening torque
185 Nm
35
Battery - Every 250th engine hour
Figure: Battery
Table: Battery
A Batteries Check electrolyte level
Diesel engine - every 250th engine hour

4
9
5
7
1250 0183 75
2 10 6
8 1
Figure: Diesel engine
36
Table: Diesel engine

1 Engine oil filter Replace the filter
2 Secondary filter Replace the filter
3 Primary filter element Replace the filter
- Engine Oil change, drain plug, rear oil pan
5-7 V-belts, generator, water pump, air Check wear, tension, max. play 10 mm.
conditioning
- Grounding bolt Check/clean/tighten. See separate instructions
for diesel engine.
Hydraulic system - every 250th engine hour
A
1250 0116 57
Figure: Hydraulic systems
Table: Hydraulic systems

A Breather filter Change if clogged
37

B
D
1250 0116 58
A
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).
D Support roller Level check. The rollers should be half full.
Check via oil level plug.
38
Diesel engine - every 500th engine hour
1250 0051 31
Figure: Engine
Table: Engine
A Hydraulic pumps Mounting pump 1: 86 Nm (62 lbf ft) Pumps 2
and 4: 49 Nm (36 lbf ft)
- Poly-V-belt Water pump and generator. Wear, voltage,
max play 10 mm (see maintenance
instructions; Maintenance of diesel engine
components)
- Rubber coupling between diesel Check for cracks and wear
engine and hydraulic pump
- Engine Mounting 8 bolts tightening torque 73 Nm (54
lbf ft) 4 bolts 185 Nm (136 lbf ft)
- Valves Check valve clearance. (See separate
instructions for diesel engine.)
39
Winch - every 500th engine hour
A
B
C
1250 0116 60
Figure: Winch
Table: Winch
A Winch gearing The gearing is permanently lubricated.
Remove the plug in the bottom of the gear
housing once a year for draining.
B Disengagement of the drum brake Lubricate with oil if it does not rotate freely.
C Drum brake The brake acts on the cable drum only when
the cable is wound manually.
40
Figure: Cabin 1250 0179 23
Table: Cabin
A The fire extinguisher Check legibility of instructions
41
Terminal blocks - every 500th engine hour

A
0
1
1250 0003 94
Figure: Connection blocks
Table: Connection blocks

A Connection blocks Tightening, corrosion
42
Terminal blocks - every 500th engine hour
C1
S456
S457
S458
S459
C4 C2
C5 C3
A1 B1 15
t2
K542
t1
16 18 A2
2489.9870
Figure: Connection blocks
Table: Connection blocks

- Connection blocks Tightening, corrosion
43
Hydraulic system - every 1000th engine hour
A
1250 0098 00
Figure: Hydraulic systems
Table: Hydraulic systems

A Hydraulic oil reservoir Oil change see maintenance instructions. The
machine must be positioned horizontally
44
Compressor - every 1000th engine hour
A
C
Figure: Compressor
Table: Compressor
A Compressor Changing oil
B Oil filter Change cartridge
C Safety valve 15 bar pressure test
45
Air filter - every 1000th engine hour

1250 0195 22
Figure: Safety cartridge
Table: Safety cartridge

A Indicator Check function
See maintenance instructions
46
Pressure tank, separator - 1000 engine hours
1250 0253 13
1
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
Winch - Every 1500th engine hour
B A
1250 0182 01
Figure: Winch
Table: Winch
A Winch Mounting in the frame, tightening torque 350 Nm.
B,C Winch Side bolts, tightening torque 140 Nm.
D Winch Mounting, disengagement, tightening torque 350 Nm.
E Winch Mounting, hydraulic motor, tightening torque 29 Nm.
49
Dust collector filter - Every 2000th engine hour

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 Replacement
51

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Atlas Copco

FlexiROC T35 and FlexiROC T40

PM No. 9852 2730 01

Special attention must be paid

Only use genuine Atlas Copco parts.

© Copyright 2011, Atlas Copco Rock Drills AB, Sweden

Translation of original instructions.

Atlas Copco Rock Drills AB

Every 1000th engine hour...................................................................................... 44

• Part 1 - Maintenance intervals Percussion hours (feeder and rock drill).

How to use these maintenance instructions

Genuine Atlas Copco spare parts

Every 4th impact hour

Drill-steel support - Every 4th percussion hour

Figure: Drill support

Table: Drill support

Every 20th impact hour

Feeder - Every 20th percussion hour

Check point Control object Action

Every 100th impact hour

Feeder - Every 100th percussion hour

Check point Control object Action

Rod handling - every 100th percussion hour

Table: Rod handling equipment

Check point Control object Action

Dust collector - Every 100th percussion hour

Figure: Dust collector.

Table: Dust collector.

Every 200th impact hour

Drill-steel support - Every 200th percussion hour

Figure: Drill support

Table: Drill support

Every 10th engine hour

Power pack - every 10th engine hour

Figure: Power pack

Table: Power pack

Hydraulic system - Every 10th engine hour

Figure: Hydraulic system

Table: Hydraulic oil reservoir

Diesel filter - Every 10th engine hour

Table: Diesel engine/compressor

Electrical system/Winch - every 10th engine hour

Table: Electrical system/Winch

Every 50th engine hour

Boom/Feeder - every 50th engine hour

Track frames - every 50th engine hour

Figure: Track frames

Table: Track frames

Rig frame/track frame - every 50th engine hour

Figure: Rig frame/track frame

Table: Rig frame/track frame

Power pack - every 50th engine hour

Radiator - every 50th engine hour

Compressor tank - every 50th engine hour

Table: Compressor tank

Hydraulic oil reservoir - every 50th engine hour

Figure: Hydraulic oil reservoir

Table: Hydraulic oil reservoir

Cabin - every 50th engine hour