Tophammer

Safety, Maintenance & Troubleshooting

Safety, Maintenance & Troubleshooting

This booklet is designed to help you handle your Epiroc rock drilling tools. The safety section
offers a range of special warning signs for use at your workplace.
The maintenance section covers routines for the maintenance of Integrals, Extension and
COPROD equipment.
In the cases where premature faults in Epiroc equipment can occur, we have created a
special troubleshooting system. The main causes of faults are classified by using individual
codes. Each code describes probable causes of the fault as well as relevant remedies. This
enables you to rectify the fault quickly and efficiently.
By then reporting these fault codes to Epiroc, we are enable to rectify the faults and improve
product reliability.

3
4
Contents

Safety

Safety instructions 6–13

Maintenance

Routine checks – drill rig and rock drill 14–15

Troubleshooting

Inserts and bit body 16–33

Integral and taper rods 34–35

Button bits 36–43

Rods and tubes 44–49

Couplings 50–51

Shank adapters 52–55

COPROD system 56–69

• Tube driver 58–59

• Rods 60–63

• Tubes 64–67

• Heads and bits 68–69

COPROD bits 70–75

5
Safety instructions

To reduce risk of serious or mortal injury to yourself or others,

read these safety instructions before using rock drilling tools.
Post these safety instructions at the work place, provide copies
for employees – and make sure that everyone reads
the safety instructions before using rock drilling tools.
Comply with all safety regulations.

Symbols

The indications DANGER, WARNING and CAUTION have the following meanings:

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in serious or
mortal injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in serious or
mortal injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.

6
 Safety instructions
Silica/dust hazard

WARNING

Exposure to crystalline silica (sometimes called “silica dust”) as a result of rock drilling
may cause silicosis (a serious lung disease), silicosis related illnesses, cancer, or death.
Silica is a major component of rock, sand, and mineral ores. To reduce silica exposure:
• Use proper engineering controls to reduce the amount of silica in the air and the
build-up of dust on equipment and surfaces. Examples of such controls include:
exhaust ventilation and dust collection systems, water sprays, and wet drilling. Make
sure that controls are properly installed and maintained;
• Wear, maintain, and correctly use approved particulate respirators when engineering
controls alone are not adequate to reduce exposure below permissible levels;
• Participate in air monitoring, medical exams, and training programs offered by your
employer and when required by law;
• Wear washable or disposable protective clothes at the worksite; shower and change
into clean clothes before leaving the worksite to reduce exposure of silica to your-
self, other persons, cars, homes, and other areas;
• Work with your employer to reduce silica exposure at your worksite.

WARNING

Some dusts, vapors, or mists created during rock drilling may contain materials or
chemicals known to the state of California to cause cancer and birth defects or other
reproductive harm.

7
Safety instructions

Vibration hazard

WARNING

Exposure to vibrations during drilling may cause injury to your fingers, hands, arms,
and other body parts. If numbness, tingling, pain, whitening of the skin, or reduction
in feeling occurs when operating drilling equipment, or even when not operating the
equipment, do not resume operating the equipment and promptly contact a physician.

Noise hazard

WARNING

High sound levels may cause permanent hearing loss. Use hearing protection in
accordance with occupational health and safety regulations.

Projectile hazard

WARNING

During rock drilling, splinters or other particles of rock may become projectiles and
cause bodily injury by striking the drilling operator or other persons. Use approved
personal protective equipment, including impact resistant eye protection, to reduce the
risk of being injured by a projectile.

Rock drilling tools modification hazard

WARNING

Rock drilling tools must not be modified. Modification may result in bodily injuries to
yourself or others.

8
 Safety instructions
Electrical hazard

DANGER

Rock drilling tools are not electrically insulated. If a tool comes into contact with electri-
city, it may result in serious or mortal injuries. To reduce the risk of such injury or death,
never drill near any electric wire or other source of electricity. Make sure that there are
no concealed wires or other sources of electricity.

Explosion hazard

DANGER

If a rock drilling tool comes into contact with an explosive, an explosion may occur.
Explosions may cause serious or mortal injuries. To reduce such risk of explosion,
never drill near any explosive, including dynamite or other explosives in the rock. Make
sure that there are no explosives in the rock. Never drill in an old hole.

DANGER

Drilling can cause sparks, which may ignite explosive gases and cause explosions.
Explosions may cause serious or mortal injuries. To reduce such risk of explosion, never
drill in any explosive environment. Make sure that there are no undetected sources of
gas.

9
Safety instructions

Operating hazards

WARNING

Avoid coming in contact with operating tools. Rock drilling tools in operation move
with significant force. If you come in contact with an operating tool, you may be
seriously injured.

WARNING

Never grab or touch an operating tool. There is a risk of getting dragged into or caught
by an operating rock drilling tool, which may cause serious injury. Avoid loose clothing
and other items that may get caught. If you have long hair, cover it in a hair net.

WARNING

Make sure that the rod is fully inserted and the retainer is in a locked position before
the rock drill is started. If the drill rod retainer on the rock drill is not in a locked position,
the drill rod can be ejected with great force, which may cause serious injury.

CAUTION

Rock drilling tools may become hot during operation, and remain hot for a period of
time even after drilling has stopped. To avoid burns or other injuries, avoid direct skin
contact with hot drilling rods.

10
 Safety instructions
WARNING

To reduce the risk of a rod breaking, always maintain proper alignment between the
rock drill, drill rod, and rock face. Rock drilling tools may occasionally and without any
prior indication break during operation, regardless of how new or used the tools are. For
example, if a drill rod breaks, there may be sudden, erratic, or unexpected movement
of the rock drill and/or drill rod, which may cause bodily injury.

To reduce the risk of bodily injury in the

event that a drill rod breaks:
• Never stand in front of or next to an
operating rock drill
• Never reach in front of or next to an
operating rock drill
• Always maintain balanced and secure
footing
• Never “ride” or lean on the drilling
machine or other equipment while in
operation
• Always wear proper safety helmet,
eye protection, and safety boots.

11
Safety instructions

Safety regulations

Note! Only qualified and trained operators should operate drilling equipment.
• Always use your common sense and good judgment
• Do not operate or handle any drilling equipment or rods if you are under the influence of
alcohol, drugs, or medication
• Participate in safety and training courses
• Never hit a rock drilling tool
• Do not use rock drilling tools for any purpose other than for drilling
• Make sure that the rod is properly attached to the rock drill before you start to drill
• Always inspect the rock drilling tool prior to use. Never use a damaged rock drilling tool
• Make sure that the rock drill is properly serviced prior to attaching the rock drilling tool
onto the rock drill

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 Safety instructions
Protective equipment

Always use approved personal protective equipment, according to local Health and Safety
regulations. We recommend that operators and other persons in the work place wear the
following protective equipment:
• Protective helmet
• Hearing protection
• Eye protection
• Respiratory protection, when appropriate
• Protective gloves
• Protective boots

13
Maintenance

Check the following parameters on the drilling rig and rock drill, which is fundamental
to understanding and preventing damage to rock drilling tools.

Routine checks – drill rig

• Gaps and wear on feed beam and cradle

• Gaps and wear in the cylinders
• Worn out drilling support
• Worn out drill guides
• Grippers in breakout table
• Lubrication

Note! Check all settings in accordance with the rig supplier’s recommendations.

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 Routine checks – drill rig and rock drill
Routine checks – rock drill

• Percussion pressure
• Feed pressure
• Rotation pressure and speed
• Damping pressure
• Water or air pressure
• Driver and bushings
• Piston (anvil for COPROD)
• Flushing tube
• Lubrication

Note! Check all settings in accordance with the drill supplier’s recommendations.

15
Troubleshooting

Damage classification

Inserts

S Damage to the insert

L Brazing-joint damage with loss of the whole or part of the insert

Bit body

A4 The bit is squared

A10 The solid centre is worn

A11 The solid centre plugged (riveted)

B4 Piece missing from the skirt of the bit

C1 Riveted threads

F Steel damage near the insert

K20u Skirt broken, starting from outside and 20 mm from bottom of insert

Side joint 2

Top

Base

Side joint 1
Bottom joint

Flushing hole

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Inserts and bit body

17
Troubleshooting

S1 Transversal crack

Cause Remedy

• Bad grinding (e.g deep grinding scratches • Change to the correct grinding wheel, for
due to use of wrong grinding wheel) soft wheel use air and for hard wheel use
water as cooling media

• Edge too sharp after grinding • Always chamfer the edge of the carbide
after grinding and leave no sharp corners

• Wrong insert angle after grinding (too • Use grinding templates to control the
acute) grinding result. Check the draft angle

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 Inserts and bit body
S2 Crushed insert corner

Cause Remedy

• Edge too sharp on the corners after • Check grinding procedure

grinding • Always chamfer the edge of the carbide
after grinding and leave no sharp corners
• Inserts must be reground when anti-taper
exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

• Snakeskin • Shorter intervals between regrinding

• Anti-taper • Use grinding templates to control the

grinding result

• Careless collaring • Collaring with reduced effect

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Troubleshooting

S3 Crushed insert edge

Cause Remedy

• Small edge angel • Use grinding templates to control the

• Poor chamfering after grinding
grinding result
• Always chamfer the edge on the carbide
after grinding and leave no sharp corners
• Inserts must be reground when anti-taper
exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

• Snakeskin • Shorter intervals between regrinding

• Careless collaring • Collaring with reduced effect

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 Inserts and bit body
S4 Entire cutting edge crushed

Cause Remedy

• Small edge angel • Always chamfer the edge on the carbide

after grinding and leave no sharp corners
• Inserts must be reground when anti-taper
exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

• Bad grinding (e.g deep grinding scratches • Change to the correct grinding wheel, for
due to use of wrong grinding wheel) soft wheel use air and for hard wheel use
water as cooling media

• Snakeskin • Shorter intervals between regrinding

• Careless collaring • Collaring with reduced effect

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Troubleshooting

S5 Longitudinal crack

Cause Remedy

• Overheating of the insert during grinding • Avoid overheating

• Avoid rapid cooling (water or snow)
• Change to the correct grinding wheel, for
soft wheel use air and for hard wheel use
water as cooling media

• Snakeskin • Shorter intervals between regrinding

S6 Corner crushed,
longitudinal cracks

Cause Remedy

• Anti-taper • Use grinding templates to control the

grinding result
• Inserts must be reground when anti-taper
exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

• Snakeskin • Shorter intervals between regrinding

• Careless collaring • Collaring with reduced effect

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 Inserts and bit body
S7 Ridge shaped fracture surface

Cause Remedy
• Anti-taper • Use grinding templates to control the
grinding result
• Always chamfer the edge of the carbide
after grinding and leave no sharp corners
• Inserts must be reground when anti-taper
exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

• Snakeskin • Shorter intervals between regrinding

• Careless collaring • Collaring with reduced effect

• A result from S3 and S4 damages • See Remedy for damage S3 and S4

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Troubleshooting

S8 Crack across edge of insert

Cause Remedy

• Anti-taper (when the crack is located high
up on the insert)
• Use grinding templates to control the
grinding result
• Always chamfer the edge of the carbide
after grinding and leave no sharp corners
• Inserts must be reground when anti-taper
exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

• Snakeskin • Shorter intervals between regrinding

• Careless collaring • Collaring with reduced effect

• When a crack has developed close to the • Avoid overheating

base of the insert • Avoid rapid cooling (water or snow)

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 Inserts and bit body
L1 Whole insert vanished

Cause Remedy

• The insert can vanish after a long drilling • Regrind the drill steel even if the insert
cycle in non abrasive rock formation. This is not worn, as fatigue in the brazing often
is not due to a manufacturing defect, but starts from the tip of the insert, thereby
fatigue of the brazing joint causing the possibility of failure

L2 Part of insert vanished

Cause Remedy

• Bad grinding (e.g deep grinding scratches • Check and adjust your grinding proce-
due to use of wrong grinding wheel) dure, change to correct grinding wheel

• Too sharp edge after grinding • Always chamfer the edge of the carbide
after grinding and leave no sharp corners

• Wrong insert angle after grinding (too • Use grinding templates to control the
acute) grinding result. Check the draft angle

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Troubleshooting

L3 Insert chipped at base

Cause Remedy

• Anti-taper (when the crack is located at
the base of the insert)
• Use grinding templates to control the
grinding result
• Always chamfer the edge of the carbide
after grinding and leave no sharp corners
• Inserts must be reground when anti-taper
exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

• Snakeskin • Shorter intervals between regrinding

• Careless collaring • Reduce impact force when collaring

• When a crack has developed close to the • Avoid overheating

base of the insert • Avoid rapid cooling (water or snow)

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 Inserts and bit body
L4 Front completely damaged

Cause Remedy

• Small edge angle • Always chamfer the edge of the carbide

after grinding and leave no sharp corners
• Use grinding templates to control the
grinding result
• Inserts must be reground when anti-taper
exceeds 8 mm

• Bad grinding (e.g deep grinding scratches • Check and adjust your grinding proce-
due to use of wrong grinding wheel) dure, change to correct grinding wheel

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Troubleshooting

Insert crushed close to solid centre.

L11 Slot partly stripped of carbide

Cause Remedy

• Small edge angle • Always chamfer the edge of the carbide

after grinding and leave no sharp corners

• Anti-taper • Use grinding templates to control the

grinding result
• Inserts must be reground when anti-taper
exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

• Bad grinding (e.g deep grinding scratches • Check and adjust your grinding proce-
due to use of wrong grinding wheel) dure, change to correct grinding wheel

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Inserts and bit body

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Troubleshooting

F1 Part of flank missing F2 Part of insert and flank missing

F3 One flank missing F4 One flank and whole insert missing

F5 Both flanks and F6 Longitudunal breakage

whole insert missing of insert and one flank missing

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 Inserts and bit body
F1-F6
Cause Remedy

• Bad grinding (e.g deep grinding scratches • Check and adjust your grinding proce-
due to use of wrong grinding wheel) dure, change to correct grinding wheel

• Edge too sharp after grinding • Always chamfer the edge of the carbide
after grinding and leave no sharp corners

• Wrong insert angle after grinding (too • Use grinding templates to control the
acute) grinding result. Check the draft angle

• Anti-taper (when a crack is located up on • Use grinding templates to control the

the insert) grinding result
• Chisel bits must be reground when anti-
taper exceeds recommendations:
–Cross bits/X-bits max 6 mm
–Integrals max 8 mm

• Snakeskin • Shorter intervals between regrinding

• Careless collaring • Collaring with reduced effect

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Troubleshooting

A4 B4

A10 A11 C1
K

A4 Squared bit

Cause Remedy

• Wrong rotation speed • Change rotation speed

• Specific rock formation, e.g. iron ore • Change to X-bit or button bit

A10 Worn out center flushing hole

Cause Remedy

• Rock formation will not break in centre of • Change bit design

the bit as it’s suppose to do

A11 Plugged center flushing hole

Cause Remedy

• Rock is stuck in the centre flushing hole • Increase the flushing pressure
caused by size of the crushed rock • Change bit design

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 Inserts and bit body
A4 B4

A10 A11 C1
K

B4 Piece missing from the skirt of the bit

Cause Remedy

• Connection between rod and bit is not • Make sure that rod and bit are connected
tightened before drilling

C1 Upset threads

Cause Remedy

• Upset thread • Avoid empty hammering

• Worn out thread • Change the bit

K20u Broken skirt, starting 20 mm from bottom of insert

Cause Remedy

• Low flushing pressure • Increase flushing pressure

• Check pressure settings and rotation
speed

• Worn out threads • Check the condition of the threads

(A2-A3)

• Marks from using sledge hammer • Avoid using sledge hammer

• Use knock-off tools on tapered bits
• Avoid empty hammering

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Troubleshooting

Damage classification

Integral and taper rods

N Location of breakage measured from the shank end

K Location of breakage measured from the bit end

u Breakage starting from flat section of the rod

h Breakage starting from corner

i Breakage starting from flushing hole

x Starting point of breakage unable to be determined

Examples

N160u Breakage initiated by outside forces, 160 mm from shank striking face

Starting point of breakage in the wall of the flushing hole, 30 mm from shank
N30i
striking face

Starting point of breakage at a corner, 70 mm from base of carbide insert or

K70h
tapered end

N K

N K

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 Integral and taper rods
i Always indicate the point of crack initiation,
if this can be determined.
u
If not, mark with x (for example: N370x).

Knock-off tool

K20 Tapered end breakage

Cause Remedy

• Spinning bits • Make sure that the bits are connected to

the rod before you start to drill

• Hitting the bit skirt with sledge hammer • Use knock-off tools
to remove bit

For more damage examples, see chapters Rods and tubes and Shank adapters.

35
Troubleshooting

Damage classification

GB CB

S4
S3
S1 S7

S7u

Button bits

S1 Button cracked

S3 Button crushed

S4 Top of button crushed on same level as surrounding steel

S7 Top of button torn loose on same level as surrounding steel

S7u Button broken-off inside the bit body

GB Gauge button

CB Center button

S1 Button cracked

S7 Top of button torn loose on same level as surrounding steel

Cause Remedy

• Overdrilled GB and CB • Reduce intervals between regrinding

• Snakeskin • Shorter intervals between regrinding

• Wrong regrinding method or equipment
• Use proper equipment and technique for
regrinding
• Regrind despite the button not being
worn. Microscopic cracks in the carbide will
develop into failures

36
 Button bits
S3 Button crushed

S7u Button broken-off inside the bit body

Cause Remedy

• Overdrilled GB and CB • Reduce intervals between regrinding

• Snakeskin • Shorter intervals between regrinding

• Wrong regrinding method or equipment
• Use proper equipment and technique for
regrinding
• Regrind despite the button not being
worn. Microscopic cracks in the carbide will
develop into failures

• Anti-taper (when gauge buttons are
crushed )
• Use grinding templates to control the
grinding result
• Buttons must be reground when anti-
taper exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

S4 Top of button crushed on same level as surrounding steel

Cause Remedy

• The button protrudes too far due to high • Regrind the button to normal height,
wear of the surrounding steel according to the bit size. Make sure the
height of the buttons are even

37
Troubleshooting

Damage classification

CB GB
L1

F5
F1

F3
F1b

F4

Button bits

F1 Crack close to gauge button

F1b Crack in the flank starting from bottom of button hole

F3 Button undamaged but surrounding flank partly missing

F4 Button and part of surrounding flank missing

F5 Button and whole surrounding flank missing

L1 Button loose

GB Gauge button

CB Center button

F1 Crack close to gauge button

Cause Remedy

• Overdrilled GB • Shorten grinding intervals

• Take out the bit for re-sharpening when
the wear diameter is 1/3 of the button
diameter

38
 Button bits
Crack in the flank starting
F1b from bottom of button hole

Cause Remedy

• Overdrilled gauge button. Repeated
overdrilling, which causes excessive wear
of bit head diameter
• Shorten grinding intervals and make sure
that the clearance angle is correct
• Take out the bit for re-sharpening when
the wear diameter is 1/3 of the button
diameter

Button undamaged but surrounding

F3 flank partly missing

Cause Remedy

• Damage caused by external object • Avoid drilling into ground support, e.g.
roof bolts

F4 Button and part of surrounding flank missing

Cause Remedy

• Diameter too small in combination with
overdrilling of GB
• Shorten grinding intervals and make sure
that the clearance angle is correct
• Take out the bit for re-sharpening when
the wear diameter is 1/3 of the button
diameter
• Check the bit diameter

39
Troubleshooting

F5 Button and whole surrounding flank missing

Cause Remedy

• A result from F4 damage • Shorten grinding intervals and make sure

that the clearance angle is correct
• Take out the bit for re-sharpening when
the wear diameter is 1/3 of the button
diameter
• Check the bit diameter

L1 Button loose

Cause Remedy

• Empty hammering • Make sure that the front of the bit has full
contact with the rock when loosening the
bit from the rod
• Use caution when loosening the bit from
the rod

40
Button bits

41
Troubleshooting

Damage classification

Button bits

B4 Piece missing from the skirt of the bit

C1 Upset threads

K Location of breakage measured from the bit end

Example

K20u Broken skirt, starting 20 mm from bottom of insert

42
 Button bits
B4

C1

B4 Piece missing from the skirt of the bit

Cause Remedy

• Loose connection between rod and bit • Make sure that rod and bit are tightened
before drilling

C1 Upset threads

Cause Remedy

• Upset thread • Avoid empty hammering

• Worn out thread • Change the bit

K20u Broken skirt, starting 20 mm from bottom of insert

Cause Remedy

• Low flushing pressure • Increase flushing pressure

• Check pressure settings and rotation
speed

• Worn out threads • Check the condition of the threads

(A2-A3)

• Marks from using sledge hammer • Avoid using sledge hammer

• Use knock-off tools on tapered bits
• Avoid empty hammering

43
Troubleshooting

Damage classification

Rods and tubes

A Wear damage

B Cracks, pieces broken loose

C Damage through upsetting

N Location of breakage measured from the shank end

K Location of breakage measured from the bit end

i Breakage starting from flushing hole

u Breakage starting from outside of the rod

h Breakage starting from corner (hex rod)

x Starting point of breakage unable to be determined

Examples

N50 Thread broken 50 mm from end surface nearest to rock drill

N50x Thread broken 50 mm from end surface nearest to rock drill. Starting point
unknown

K200a Rod broken 200 mm from end surface nearest to drill bit starting from a notch

Rods broken 200 mm from end surface nearest to drill bit starting from
K200u
outside

B2 Longitudinal crack

C2 Riveted striking surface

Always indicate the point of crack initiation, if this can be determined.

44
 Rods and tubes
u
i i

Speedrod

B2 C2

N K

TDS tubes

B2 C2

N K

Extension rods

C2

N K

45
Troubleshooting

Rod breakage

u
i i
u

Cause Remedy

• Breakage from inside (i) is most probably • Clean and oil equipment before storage
due to corrosion on used steel after
storage

• Inside breakage (i) can also be caused by • Check water quality, use clean water
corrosion due to aggressive water

• Breakage from outside (u) is caused • Check drill steel support

by damage, e.g. from worn out drilling • Handle equipment with care, use proper
support wrenches

• Scratches appear due to bad centralizer • Check and replace worn out drilling sup-
and/or drill steel support from outside (h) port and centralizers

• Use of sledge hammer • Never use sledge hammer to open the

connections

46
 Rods and tubes
N140u Rod broken 140 mm from end surface nearest
to rock drill starting from outside

Cause Remedy

• Bending, worn out drill steel support • Always maintain proper alignment
between the rock drill, drill rod and the
rock face

B2 Longitudinal crack

Cause Remedy

• Alignment of drill string • Always maintain proper alignment

• Loose joints between the rock drill, drill rod and the
rock face

• Worn out thread (A3), caused by outside • Check the settings of the drill rig e.g.
damage, e.g. using sledge-hammer rotation speed

C2 Upset impact surface

Cause Remedy

• Empty hammering as a result of jammed • Avoid empty hammering

drill string

K70u Rod broken 70 mm from end surface

starting from outside

Cause Remedy

• Bending problem in combination with • Check the settings of the drill rig
pitting • Alignment of the drill string

• Careless collaring • Collaring with reduced effect

47
Troubleshooting

B1 Transversal crack

Cause Remedy

• Empty hammering • Tighten the threads before starting the

• Loose joints percussion

• Worn out thread (A3), caused by outside • Check the settings of the drill rig e.g.
damage, e.g. using sledge-hammer rotation speed

A3 Worn out thread

Cause Remedy

• Empty hammering • Check the threads on the female rod end

• Loose joints plus the shank adapter

• Mix of new and worn out threads

A1-A3 Thread wear

A1 Thread slightly worn

A2 Thread half-worn

A3 Thread worn out

A1

A2

A3

48
Rods and tubes

49
Troubleshooting

Damage classification

Couplings

A Wear damage

B1 Transversal crack

B2 Longitudinal crack

C1 Upset thread

N/K The position of breakage unknown

A1-A3 Thread wear

A1 Thread slightly worn

A2 Thread half-worn

A3 Thread worn out

A12

A3

50
 Couplings
C1

B2 B1

N/K

B1 Transversal crack

Cause Remedy

• Empty hammering • Tighten the threads before starting the

• Loose joints percussion

• Worn out thread A3. Caused by outside • Check the settings of the drill rig e.g.
damage, e.g. using sledge-hammer rotation speed

B2 Longitudinal crack

Cause Remedy

• Alignment of drill string • Always maintain proper alignment

• Loose joints
• Worn out thread A3. Caused by outside
damage, e.g. using sledge-hammer
between the rock drill, drill rod and the
rock face
• Check the settings of the drill rig e.g.
rotation speed

C1 Upset thread

Cause Remedy

• Alignment • Tighten the threads before starting the

• Loose joints percussion
• Check the settings of the drill rig, e.g.
rotation speed

51
Troubleshooting

Damage classification

Shank adapters

C1 Upset thread

C2 Upset striking face

C3 Upset or worn out splines or collar

K Location of breakage measured from the bit end

N Location of breakage measured from the shank end

Examples

K350u Breakage 350 mm from bit end starting from outside

K500i Breakage 500 mm from bit end starting from inside flushing hole

N50u Breakage 50mm from striking surface. Splines breakage

N100uh Breakage 100 mm from impact surface start from outside a corner

C2 C3 C1

N K

C2 C1
C3
C2

52
 Shank adapters
C1 Upset thread

Cause Remedy

• Alignment • Tighten the threads before starting the

• Loose joints percussion
• Check the settings of the drill rig, e.g.
rotation speed

C2 Upset shank striking face

C3 Upset or worn out splines or collar

Cause Remedy

• Empty hammering as a result of jammed • Check the impact surface of the piston
drill string • Avoid empty hammering
• Replace parts according to rock drill
manufactures service interval

C2 Upset impact surface on integral,

taper equipment and shank rods

Cause Remedy

• Excessive water pressure, creating a pil-
low of water working as a damper
• Check the impact surface of the piston
• Check the water pressure at the work
site and length of the flushing tube.
Water pressure should be 1 bar below air
pressure

K70 Breakage, 70 mm from bit end

N20 Breakage, 20 mm from striking surface

Cause Remedy

• Bending problem in combination with • Check the settings of the drill rig and
pitting alignment of the drill string

53
Troubleshooting

K350u Breakage 350 mm from bit end

starting from outside

Cause Remedy

• Worn out front/nose bushing • Replace parts according to rock drill

manufactures service interval
• Check the nose bushing lubrication

Breakage 500 mm from bit end

K500i starting from inside flushing hole

Cause Remedy

• Worn out front/nose bushing • Replace parts according to rock drill

• Use of aggressive water
manufactures service interval
• Check the nose bushing lubrication
• Make sure that the water quality is not
acidic
• Clean the flushing holes after drilling with
air and add some oil in the shank

N50u Breakage 50 mm from striking

surface. Splines breakage

Cause Remedy

• Lack of shank lubrication • Check the shank lubrication

• Worn out driver • Replace parts according to rock drill
manufactures service interval

54
 Shank adapters
Breakage 100 mm from impact surface
N100uh starting from outside a corner

Cause Remedy

• Lack of shank lubrication • Check the shank lubrication

• Worn out shank bushing • Replace parts according to rock drill
manufactures service interval

C2, C3 Riveted striking face and lugs, splines or collar

Cause Remedy

• Worn-out bushing • Repair the rock drill and change worn

parts

• Insufficient lubrication of the shank • Check the lubricator

• Deformed striking face of the piston • Replace the piston

C2 C3

N K

55
Troubleshooting

Damage classification

Complete tube driver

N Fracture from rock drill end (mm)

K Fracture from bit end (mm)

Examples

K50 Damage 50 mm from bit end

N50 Damage 50 mm from rock drill end

N50i Interior damage, 50 mm from rock drill end

K50u Exterior damage, 50 mm from bit end

56
 COPROD system
Complete COPROD section C2

Tube N

N Fracture from rock drill end (mm)

K Fracture from bit end (mm)

B2
B1 Transversal crack

B2 Longitudinal crack

B1

Rod

N Fracture from rock drill end (mm) K

K Fracture from bit end (mm) C2

C2 Upset striking face N

B2
B1

K K
End piece

N Fracture from rock drill end (mm)

K Fracture from bit end (mm)

57
Troubleshooting

N, K Tube driver breakage

Cause Remedy

• Misalignment • Align rock drill with breakout table.

See Operator Instruction – Aligning

• Threads riding • Set flow valve: QDS I-valve and QDS

• Empty hammering O-valve

N Adapter cylinder thread breakage

Cause Remedy

• Bolts tightened too hard • See Operator Instruction – Tube driver

• Bolts tightened too loose assembly

K Adapter API-thread breakage

Cause Remedy

• Misalignment • Align rock drill with breakout table.

See Operator Instruction – Aligning

• Poor lubrication • Lubricate the thread more often

• Thread tightened too hard • Decrease feed force

A1-A3 Adapter thread wear

Cause Remedy

• Too fast or too slow threading • Adjust to correct threading speed

• Misalignment • Align rock drill with breakout table.

See Operator Instruction – Aligning

• Poor lubrication • Lubricate the thread more often

58
COPROD system – Tube driver

59
K
N

A3
A2
A1
Troubleshooting

N, K Rod breakage

Cause Remedy

• Rod guide missing or damaged • Check rod guides

C2 Upset impact surface

Cause Remedy

• Rod guide missing or damaged • Check rod guides

• Parts trapped between rod and tube • Remove rod and clean inside tube

• Upset striking surface of the rods • Remove upset steel by grinding carefully

60
 COPROD system – Rods
C2

B2

B1

C2

B2
B1

K K

61
Troubleshooting

Bit rod stuck in bit tube

Cause Remedy

• Metal pieces from rod ends • Remove upset steel by grinding carefully

• Metal pieces from anvil • Remove upset steel by grinding carefully

• Metal pieces from threads • Lubricate the threads more often

• Clean the threads more often the flushing
air

• Poor lubrication (HECL) • Increase the dose of lubrication in the

flushing air

62
COPROD system – Rods

63
Troubleshooting

N, K Thread breakage

Cause Remedy

• Empty hammering • Set flow valve: QDS I-valve and QDS

O-valve

• Too fast or too slow threading • Adjust to correct threading speed

N Female thread breakage

Cause Remedy

• Not enough rotational pressure • Increase rotational pressure

• Misalignment • Align rock drill with break out table

K Male thread breakage

Cause Remedy

• Not enough rotational pressure • Increase rotational pressure

B1 Friction welding breakage

Cause Remedy

• Jaws clamping on friction-weld • Adjust sensor position

• Check positioning of clamping chucks.
Should be positioned as close together
as possible

• Empty hammering • Set flow valve: QDS I-valve and QDS

O-valve

64
 COPROD system – Tubes
A1-A3 Female thread wear

Cause Remedy

• Too fast or too slow threading • Adjust to correct threading speed

• Misalignment • Align rock drill and RHS.

See Operator Instruction

C2
A1

A2
N

A3 B2

B1

C2

B2
B1

K K

65
Troubleshooting

N120i Interior tube famage, starting 120 mm

from rock drill end

Cause Remedy

• Rod guide missing or damaged • Check rod guides

N120u Exterior tube damage, starting 120 mm

from rock drill end

Cause Remedy

• Premature steel wear • Adjust flushing pressure

• Increase diameter difference between bit
and tube

C2

B2

B1

K
C2
N
B2
B1

K K

66
COPROD system – Tubes

67
Troubleshooting

COPROD heads

N, K Bit driver wear or damage

Cause Remedy

• Insufficient lubrication • Increase lubrication (HECL)

• Worn out splines

Stop ring damage

Cause Remedy

• Empty hammering • Set flow valve: QDS I-valve and QDS

O-valve

COPROD bits

K
N

B2 B1

B4

i
h

68
 COPROD system – Heads and bits
F Steel wear

Cause Remedy

• Incorrect flushing pressure • Adjust flushing pressure

• Change bit design

K Bit head breakage

Cause Remedy

• Additional steel damage • Change bit and check the flushing

pressure

Bit splines breakage

Cause Remedy

• Insufficient lubrication • Increace the lubrication (HECL)

• Pitting • Check the wear limit of the driver

• Worn out driver

B4 Piece broken from striking face

Cause Remedy

• Worn or damaged bit’s or bit rod’s • Check the bit rod’s end surface for
striking face damage
• Check the bit’s striking face for damage

69
Troubleshooting

Damage classification

GB CB

S4
S3
S1 S7

S7u

Button bits

S1 Button cracked

S3 Button crushed

S4 Top of button crushed on same level as surrounding steel

S7 Top of button torn loose on same level as surrounding steel

S7u Button broken-off inside the bit body

GB Gauge Button

CB Center Button

S1 Button cracked

S7 Top of button torn loose on same level as surrounding steel

Cause Remedy

• Overdrilled GB and CB • Reduce intervals between regrinding

• Snakeskin • Shorter intervals between regrinding

• Wrong regrinding method or equipment
• Use proper equipment and technique for
regrinding
• Regrind despite the button not being
worn. Microscopic cracks in the carbide will
develop into failures

70
 COPROD system – COPROD bits
S3 Button crushed

S7u Button broken-off inside the bit body

Cause Remedy

• Overdrilled GB and CB • Reduce intervals between regrinding

• Snakeskin • Shorter intervals between regrinding

• Wrong regrinding method or equipment
• Use proper equipment and technique for
regrinding
• Regrind despite the button not being
worn. Microscopic cracks in the carbide will
develop into failures

• Anti-taper (when gauge buttons are
crushed )
• Use grinding templates to control the
grinding result
• Buttons must be reground when anti-
taper exceeds recommen­dations:
– Crossbits/X-bit max 6 mm
– Integrals max 8 mm

S4 Top of button crushed on same level as surrounding steel

Cause Remedy

• The button protrudes too far due to high • Regrind the button to normal height,
wear of the surrounding steel according to the bit size. Make sure the
height of the buttons are even

71
Troubleshooting

Damage classification

CB GB
L1

F5
F1

F3
F1b

F4

Button bits

F1 Crack close to gauge button

F1b Crack in the flank starting from bottom of button hole

F3 Button undamaged but surrounding flank partly missing

F4 Button and part of surrounding flank missing

F5 Button and whole surrounding flank missing

L1 Button loose

GB Gauge Button

CB Center Button

F1 Crack close to gauge button

Cause Remedy

• Overdrilled GB • Shorten grinding intervals

• Take out the bit for re-sharpening hen
the wear diameter is 1/3 of the button
diameter

72
 COPROD system – COPROD bits
Crack in the flank starting
F1b from bottom of button hole

Cause Remedy

• Overdrilled GB. Repeated • Shorten grinding intervals and make sure

overdrilling, which causes that the clearance angle is correct
excessive wear of bit head • Take out the bit for re-sharpening when
diameter the wear diameter is 1/3 of the button
diameter

F3 Button undamaged but surrounding

flank partly missing

Cause Remedy

• Damage caused by external object • Avoid drilling into ground support, e.g.
roof bolts

F4 Button and part of surrounding flank missing

Cause Remedy

• Diameter too small in combination
with overdrilling of GB
• Shorten grinding intervals and make sure
that the clearance angle is correct
• Take out the bit for re-sharpening when
the wear diameter is 1/3 of the button
diameter
• Check the bit diameter

73
Troubleshooting

F5 Button and whole surrounding flank missing

Cause Remedy

• A result from F4 damage • Shorten grinding intervals and make sure

that the clearance angle is correct
• Take out the bit for re-sharpening when
the wear diameter is 1/3 of the button
diameter
• Check the bit diameter

L1 Button loose

Cause Remedy

• Empty hammering • Make sure that the front of the bit has full
contact with the rock when loosening the
bit from the rod
• Use caution when loosening the bit from
the rod

74
COPROD system – COPROD bits

75
Notes

76
Notes

77
Notes

78
79
 9866 0233 01 Subjected to alterations without prior notice.
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