CAUTION

Before each shift commences, carry out the “Daily checks” incl.“Extra safety check” as described in the Operating InstructionsNo. AIB 181 00 10For rock drills see Maintenance Schedule

CAUTION

Repairs to the crawler shall only be carried out by experiencedservice personnel which is familiar with the rig design. Also, anywelding work necessary may only be carried out by approvedwelders (authorized acc. to EN 287 part 1). After repair, thecrawler is to be inspected and approved by qualified engineersbefore being put back into service.

NOTEl = Check points and maintenance measuresm = Lubrication, oil change etc.

Reg. codeASB ROC 203PC2000-05

Service Schedule forPneumatic Crawler Drills

ROC 203PC

No. ASB 181 00 10

ATLAS COPCO ROCK DRILLS ABÖREBRO l SWEDEN

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PM No. 9853 1108 01© Copyright 2005, Atlas Copco Rock Drills AB, SwedenAny unauthorized use or copying of the contents or any part thereof is prohibited.This applies in particular to trademarks, model denominations, part numbers and drawings.

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Sr. No. Check Point Check Procedure Delivery Interval in hrs of operation Instructions

check 40 125 500 1500

1 Frame Cracks, Damage l l l l l -

2 Tow Hook Cracks, Damage l l l l l Lubricate Pawl bearing

& Function with thin oil

3 Grease Nipple Fill with Grease m m m m See Table, Page 12

4 Lock Plates Attachment, damage l l l l l -

5 Track Frame Cracks, Destortion l l l Avoid Excessive

@ Idler Guide Track Tightening

6 Warning Plates Legibility, l l l l -

Attachment

WAGON FRAME WITH TRACK FRAME

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Sr. No. Check Point Check Procedure Delivery Interval in hrs of operation Instructions

check 40 125 500 1500

1 Boom, Boomhead Cracks, Damage l l l l l -

Boom support

2 Feed holder Cracks, Damage l l l l l -

3 Grease Nipple Fill with Grease m m m m See Table, Page 12

4 Lock Plates Attachment, damage l l l l l -

5 Boomhead Attachment l l l l l -

6 Warning Plates Legibility, l l l l -

Attachment

BOOM SYSTEM

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Sr. No. Check Point Check Procedure Delivery Interval in hrs of operation Instructions

check 40 125 500 1500

1 Grease Nipple Fill with Grease m m m m m See Table, Page 12

2 Track tensioning Track tension l l l l l Check as shown in

Cylinder illustration (A).

Force in grease so

that the clearances

is between 25-50 mm

3 Crawler track Wear l l l Check that the

track plates are in

good condition

4 Front wheel Attachment, leakage l l l -

5 Track rollers Attachment, leakage l l l -

6 Drive wheel Attachment l l l -

7 Traction unit Leakage l l l l l -

8 Gear box Oil level m m m m Level should reach the

plug. Rig should

stand horizontal.

See table, page 12

9 Gear box Oil change m See table, page 12

First change after

125 hours

Before tapping up

with new oil, rinse

out the gear with

flushing oil

TRACK FRAME WITH TRACTION UNIT

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Sr. No. Check Point Check Procedure Delivery Interval in hrs. of operation Instructions

check 40 125 500 1500

1 Feed beam Damage, cracks, l l l l l Make sure the beam

bending, scoring is not bent nor has

deformed sliding surfaces

2 Cradle Movement function l l l l l Forward and return

movements should be

without friction & without

too much play between

the feed and cradle

(both when drill feeding

and rapid feeding)

3 Drill steel support Attachment, wear l l l l l -

4 Jockey Attachment l l l l l -

5 Chain Lubrication m m m m Clean and oil as necessary

see table, page 12

6 Chain tensioner Tension l l l l l Check chain tension with

the cradle in rearmost

end position.

Slack should be between

25-50 mm. (1"-2")

Adjust suitable tension.

Coat tension screw

with grease

7 Sliding pieces, Attachment, play l l l l l Tightening torque

cradle 210 Nm (155 lbf.ft.)

CHAIN FEED

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WORM GEAR & PISTON MOTOR COMPLETE 3162 1663 81 SINGLE START FEED UNIT

Sr. No. Check Point Check Procedure Delivery Interval in hrs of operation Instructions

check 40 125 500 1500

1 Worm gear Wear l -

2 Sprocket Wear l l -

3 Worm gear Oil level m m m m See table, page 12

4 Worm gear Oil changel m m See table, page 12

First oil change after

40 hours.

5 Air motor Overhaul l -

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WORM GEAR, PLANETARY & PISTON MOTOR COMPLETE 9718 4259 78FIVE START FEED UNIT

Sr. No. Check Point Check Procedure Delivery Interval in hrs of operation Instructions

check 40 125 500 1500

1 Worm gear Wear l -

2 Sprocket Wear l l -

3 Worm gear Oil level m m m m See table, last page

4 Worm gear Oil change m m See table, last page

First oil change after

40 hours.

5 Planetary gearing Wear l -

6 Air motor Overhaul l -

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ROTATION UNIT - BBR 4 (DTH VERSION) 8032 0101 03

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Sr. No. Check Point Check Procedure Delivery Interval in hrs of operation Instructions

check 40 125 500 1500

1 Rotation unit Attachment l l l l l Tightening torque 210 Nm

(155 lbf.ft.)

2 Grease nipples Four strokes with a m m m m See table, page 12

(2 pcs.) grease gun

3 Planet gear Attachment l l l Tightening torque 85 Nm

(63 lbf.ft.)

4 Motor Attachment l l l Tightening torque 50 Nm

(37 lbf.ft.)

5 Gear housing Attachment l l l Tightening torque 85 Nm

(63 lbf.ft.)

6 Connection pipe Attachment l l l Tightening torque 200 Nm

(148 lbf.ft.)

7 Cover Attachment l l l Tightening torque 75 Nm

(55 lbf.ft.)

8 Adapter Attachment l l l Tightening torque 85 Nm

(63 lbf.ft.)

9 Rear bearings, Fill with grease m During overhaul and

service, min. once per year

10 Main gear Fill with grease m m m m Open this plug of cover for

degreasing / greasing

main gear

11, 12 Grease nipples Four strokes with a m m m m Open grease nipple 12,

grease gun fill grease from 11.

See table, page 12

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BBC 120F 8311 0603 08

Sr. No. Check Point Check Procedure Delivery Interval in hrs of operation Instructions

check 40 125 500 1500

1 Side bolts Attachment, function l l l l l Tightening torque 196 Nm

(145 lbf.ft.)

2 Connection pipe Damage, Leakage l l l l l -

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AIR SYSTEM

Sr. No. Check Point Check Procedure Delivery Interval in hrs of operation Instructions

check 40 125 500 1500

1 Hoses, pipes and Leakage, damage l l l l l -

couplings

2 Operating controls Function, leakage l l l l l -

3 Water separator Auto-valve function l l l l l Separator shall

Drift filter automatically release

water in regular

intervals during operation

4 wire mesh hose Attachment, damage l l l l l -

chain

5 Lubricating valves Function, setting l l l l l Check that the exhaust air

from the air motors and

rock drill (BBR-4 and

BBC 120F rotation only)

contains oil

6 Lubricating oil tanks Oil level / refill m m m m m See table, page 12

7 Pressure regulator Setting l l l Correct pressure 6 bar

8 Lubricating oil tanks Drain off condensate l l -

9 Lubricating oil tanks Clean tanks l -

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HYDRAULIC SYSTEM

Sr. No. Check Point Check Procedure Delivery Interval in hrs of operation Instructions

check 40 125 500 1500

1 Hydraulic oil tank Oil level m m m m m See table, page 12

2 Hydr. oil return filter Clogging l l l l Check pressure gauge

while hydraulic pump is

running (oil temperature0should be at least 20 C

0(68 F)).

Immediately replace filter if

the needle is in the red

field. Replace filter at the

latest after 1500 hrs.

3 Hose, pipes and Damage, leakage l l l l l -

couplings

4 Hydraulic cylinders Function, leakage l l l l l -

double check valves

5 Operating controls Function, leakage l l l -

6 Ventilation filters Renew l l -

7 Pump unit Attachment l l -

8 Hydr. oil tank Oil change m See table, page 12

0 0 01 6 1 09 1 7

0 1 7 21 6 09 3 1

M x.a

aM x.

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Volumes

Lubricating oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 l 2.69 Imp.gal 3.17 US.gal

Hydraulic oil system, total . . . . . . . . . . . . . . . . . . . . . . 85 l 18.7 Imp.gal 22.5 US.gal

Hydraulic oil tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 l 18 Imp.gal 21 US.gal

Traction unit, planetary gear (each) . . . . . . . . . . . . . . 0.25 l 0.055 Imp.gal 0.066 US.gal

Feed gear (single boom version) . . . . . . . . . . . . . . . . 1 l 0.22 Imp.gal 0.26 US.gal

Air motor power pack. . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 l 0.26 Imp.gal 0.31 US.gal

Tightening torques

Size Wrench size Tightening torque in Nm (lbf.ft.)

8.8 12.9

M 10 17 mm 49 (36) 69 (51)

M 12 19 mm 86 (63) 120 (89)

M 16 24 mm 210 (156) 295 (218)

M 20 30 mm 410 (303) 580 (428)

Recommended hydraulic oils and lubricants

Lubricating point Recommendation

Hydraulic oil tank l Use mineral-based hydraulic oils with good anti-wear, anti-rust, anti-oxidation and foam inhibitingproperties and with good air and water separation characteristics. Choose an oil with viscositygrade (VG) and viscosity index (VI) in accordance with the table below. An oil with a high viscosityindex is less sensitive to the effects of temperature:

Hydraulic oil temperature in tank °C (°F) Viscosity ViscosityNormal operating temp. Min. starting temp. Max. temp grade VG index VI

2(viscosity 25-50 mm (cST)) (viscosity min. (ISO 3448)/s21000 mm /s (cST))

+ 45 to + 60 (113 to 140) -5 (23) 75 (167) ISO VG 68 min. 100+ 35 to + 50 (95 to 122) -10 (14) 65 (149) ISO VG 46 min. 100+ 25 to + 40 (77 to 104) -15 (5) 55 (131) ISO VG 32 min. 100+ 10 to + 25 (50 to 77) -25 (13) 45 (113) ISO VG 15 min. 100NB: When operating in extremely low temperature, installation of additional heating equipment is

recommended. If the oil temperature exceeds +60 °C (140 °F) during long periods, a tropicaloil cooler should be installed.

Lubricating oil tank l Mineral-based air-tool oilsFeed chains Viscosity grade Ambient temperature °C (°F) (ISO 3448)

-30 to ± 0 (22 to 32) VG 32 - 68-10 to + 20 (14 to 68) VG 68 - 100+ 10 to + 50 (50 to 122) VG 100 - 150

orl Transmission oils of hypoid type SAE HD 80W/90

Valid for ambient temperatures -30 to + 50 °C (22 to 122 °F)Specification: MIL-L-2105C, EP tests L27 and L42

Grease nipples Operating temp. °C (°F)Feed beam l Universal grease NLGI 2 lithium/molybdenum additive Max. 100 (212)

l Synthetic sodium or calcium grease Max. 140 (284)

Traction gears l Use mineral-based transmission oils (for cars) that conform to quality SAE HD 80W/90 and to theFeed gear norm MIL-L-2105C

Air motro l Use mineral-based engine oils that conform to quality SAE20 W / 40(Power pack)

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