Smartroc T45 11: Maintenance

Atlas
Copco
SmartROC T4511
Maintenance
Original instructions
© 2015 Atlas Copco AB
20150317 | No: 871696139.2.9007200127358475 enUS
SmartROC T45-11 Table of Contents
Table of Contents
1 Introduction ........................................................................................................... 9
1.1 Safety First.................................................................................................................................. 9
1.2 The Purpose of This Publication .............................................................................................. 9
1.3 Target Group .............................................................................................................................. 9
1.4 Product Warranty ....................................................................................................................... 9
2 About Maintenance Management ...................................................................... 11

2.1 Maintenance Planning and Counters ..................................................................................... 11
2.2 Maintenance Records .............................................................................................................. 11
3 General Machine Condition................................................................................ 13
3.1 Wash Machine Externally ........................................................................................................ 13
3.2 Check Condition of Signs ....................................................................................................... 13
4 Boom Unit ............................................................................................................ 15

4.1 Lubricate Boom and Feeder.................................................................................................... 15
4.2 Check Boom Condition ........................................................................................................... 16
5 Feeder Unit .......................................................................................................... 17

5.1 Checking Chain Feed Tension................................................................................................ 17
5.2 Check Jack Chain Cover ......................................................................................................... 18
5.3 Check Feed Beam .................................................................................................................... 19
5.4 Check Chain Guide .................................................................................................................. 20
5.5 Check Sprocket Wheel ............................................................................................................ 20
5.6 Check DrillSteel Support........................................................................................................ 21
5.7 Check DrillSteel Support........................................................................................................ 22
5.8 Check Chain Feed .................................................................................................................... 23
5.9 Check Rod Handling ................................................................................................................ 24
5.10 Clean Behind Sealing Disc...................................................................................................... 25
5.11 Lubricate Rod Handling........................................................................................................... 26
5.12 Lubricate Chain Feed............................................................................................................... 26
5.13 Replace Bearing Unit ............................................................................................................... 27
5.14 Replace Slide Rails .................................................................................................................. 27
5.15 Replace Slide Pieces in the Holder ........................................................................................ 28
5.16 Adjusting Chain Feed Tension ............................................................................................... 29
5.17 General Checking Guidelines for Steel Cables ..................................................................... 29
5.17.1 Checking Cable for Wire Breaks ............................................................................................ 30
5.17.2 Checking Cable for Strand Breaks ......................................................................................... 30
5.17.3 Checking Cable for Surface Wear .......................................................................................... 30
5.17.4 Checking Cable for Corrosion ................................................................................................ 30
5.17.5 Checking Cable for Decreased Diameter ............................................................................... 31
5.17.6 Checking Cable for Reduced Elasticity .................................................................................. 31
5.17.7 Checking Cable for Heat Exposure ........................................................................................ 31
6 Drilling Machine .................................................................................................. 33

6.1 Check Lubrication Oil Level Tank .......................................................................................... 33
6.2 Drill Lubrication Pumps........................................................................................................... 33
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7 Hydraulic System ................................................................................................ 35

7.1 About Working on Hydraulic Components............................................................................ 35
7.2 About Hydraulic Workshops................................................................................................... 35
7.3 About Replacing Hydraulic Hoses ......................................................................................... 35
7.4 Check Hoses and Couplings................................................................................................... 35
7.5 Hydraulic Filters ....................................................................................................................... 36
7.5.1 Return Oil Filter ...................................................................................................................... 36
7.5.2 Check Breather Filter.............................................................................................................. 36
7.5.3 Replace Return Oil Filter ........................................................................................................ 37
7.5.4 Replace Breather Filter........................................................................................................... 38
7.6 Tanks......................................................................................................................................... 38
7.6.1 Drain Condensate from Hydraulic Oil Tank ............................................................................ 38
7.6.2 Drain Condensate in Pressure Tank ...................................................................................... 39
7.6.3 Clean Hydraulic Tank ............................................................................................................. 39
7.6.4 Drain Hydraulic Oil Tank......................................................................................................... 40
7.6.5 Fill Hydraulic Oil...................................................................................................................... 40
7.7 Check Mounting Hydraulic Jack............................................................................................. 42
8 Electrical System ................................................................................................ 43

8.1 Charging the Battery................................................................................................................ 43
8.2 Charging Battery Using 24V Charger..................................................................................... 44
8.3 Charging Battery Using 12V Charger..................................................................................... 45
8.4 Starting with Auxiliary Battery................................................................................................ 46
9 Fire Fighting Equipment..................................................................................... 47
9.1 Check Fire Extinguishers ........................................................................................................ 47
9.2 Check Emergency Stops and Work Lights............................................................................ 48
9.3 Check Fire Extinguishers ........................................................................................................ 49
10 Control System and Sensors ............................................................................. 51

10.1 General Maintenance Control System and Sensors............................................................. 51
10.1.1 Remote Control Battery .......................................................................................................... 51
10.1.2 Cleaning Remote Control ....................................................................................................... 51
11 Cooling System ................................................................................................... 53

11.1 Cooling System Overview ....................................................................................................... 53
11.1.1 Clean Radiators...................................................................................................................... 54
11.1.2 Check Coolant Level .............................................................................................................. 55
11.1.3 Add Coolant............................................................................................................................ 56
12 Operator's Environment ..................................................................................... 57

12.1 Check Cabin ............................................................................................................................. 57
12.2 Replacing Air Condition Main Air Filter ................................................................................. 58
12.3 Replacing Air Condition Prefilter .......................................................................................... 58
12.4 Replacing Air Condition Circulation Filters........................................................................... 59
12.5 Troubleshooting AC................................................................................................................. 59
13 Track Frames....................................................................................................... 61
13.1 Tensioning the Crawler Tracks............................................................................................... 61
13.2 Checking Track Frames Torques ........................................................................................... 62
13.3 Procedures for Checking Wear............................................................................................... 63
13.3.1 Checking for Front Wheel Wear ............................................................................................. 63
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13.3.2 Checking for Track Roller Wear ............................................................................................. 64

13.3.3 Checking for Carrier Roller Wear ........................................................................................... 64
13.3.4 Checking for Track Shoe Wear .............................................................................................. 65
13.3.5 Checking for Wear on Track Shoe ......................................................................................... 65
13.3.6 Checking for Track Link Depth Wear...................................................................................... 66
13.3.7 Checking for Bushing Wear.................................................................................................... 66
13.3.8 Checking for Track Chain Elongation Wear ........................................................................... 67
13.4 Check Track Frames ................................................................................................................ 68
13.7 Change Oil on Track Frames .................................................................................................. 70
14 Dust Collector...................................................................................................... 71
14.1 Checking Function of Dust Collector..................................................................................... 71
14.2 Check Dust Collector Filters .................................................................................................. 72
14.3 Replace Dust Collector Filters ................................................................................................ 72
15 Diesel Engine....................................................................................................... 75
15.1 Check Motor Oil Level ............................................................................................................. 75
15.2 Drain PreFilter ......................................................................................................................... 76
15.3 Fuel Quality............................................................................................................................... 76
15.4 Draining Fuel Tank................................................................................................................... 76
15.5 Filling with Fuel ........................................................................................................................ 77
15.6 DEF Fluid .................................................................................................................................. 77
15.7 Location of DEF Tank .............................................................................................................. 78
15.8 Draining DEF Tank ................................................................................................................... 78
15.9 Filling with DEF Fluid............................................................................................................... 79
15.10Replace PreFilter..................................................................................................................... 79
15.11Replace Secondary Fuel Filter................................................................................................ 80
15.12Replacing DEF Tank Filter....................................................................................................... 80
15.13Belts .......................................................................................................................................... 81
15.13.1 Replace Multibelt................................................................................................................... 81
15.14Replace Longterm Effective Coolant .................................................................................... 82
15.15Air System ................................................................................................................................ 83
15.15.1 Air Filter Indicator Function..................................................................................................... 84
15.15.2 Replace the Filter Cartridge.................................................................................................... 84
16 Compressed Air System..................................................................................... 87
16.1 Overview Air Compressor System ......................................................................................... 87
16.2 Check Compressor Oil Level .................................................................................................. 89
16.3 Oil Change and Oil Filter Replacement.................................................................................. 89
16.4 Replacing Air Compressor Oil and Oil Filter ......................................................................... 89
16.5 Change Oil on Compressor..................................................................................................... 91
16.6 Replace Separator Filter.......................................................................................................... 92
16.7 Changing to New Type of Compressor Oil ............................................................................ 92
16.8 Flushing Air Compressor ........................................................................................................ 94
16.9 Check Compressor Components ........................................................................................... 96
16.10Drain Compressor.................................................................................................................... 96
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16.11Clean Compressor Oil Cooler ................................................................................................. 97
17 Automatic Central Lubrication System CLS..................................................... 99
17.1 Central Lubrication System Pump ......................................................................................... 99
17.2 Setting Lubrication and Interval Time.................................................................................. 100
17.3 Check Condition of CLS pump ............................................................................................. 101
17.4 Setting Lubrication Pump ..................................................................................................... 102
17.5 Filling Lubricant ..................................................................................................................... 103
17.6 Bleeding Lubrication Pump .................................................................................................. 103
17.7 Lubrication Pump Program Display Alarm List .................................................................. 104
17.8 Troubleshooting CLS............................................................................................................. 104
18 Water Mist System ............................................................................................ 107

18.1 Check Seals on Water Mist Pump ........................................................................................ 108
18.2 Filling Water Mist Tank .......................................................................................................... 109
18.3 Draining Water Mist System.................................................................................................. 110
18.4 Starting Up Water Mist System from Dry............................................................................. 111
18.5 Clean Filter in Water Mist Tank............................................................................................. 112
19 Welding .............................................................................................................. 113

19.1 About Welding........................................................................................................................ 113
19.2 CAN Bus System Disconnection Before Welding............................................................... 113
20 Downtime ........................................................................................................... 115

20.1 Preparations Before Long Period of Downtime .................................................................. 115
20.2 Restoring After Long Period of Downtime .......................................................................... 115
20.3 Inspection and Maintenance During Period of Downtime.................................................. 116
21 StartUp .............................................................................................................. 117

21.1 About Special StartUp .......................................................................................................... 117
21.2 Performing Special StartUp ................................................................................................. 117
21.3 Flushing of Hoses and Pipes ................................................................................................ 117
21.4 About Testing Pressure Release Valves.............................................................................. 118
22 Options............................................................................................................... 119
22.1 Winch ...................................................................................................................................... 119
22.1.1 Check Attachment of Winch Cable....................................................................................... 119
22.1.2 Check Winch Unit Attachment.............................................................................................. 120
22.1.3 Lubricate Winch.................................................................................................................... 121
22.1.4 Check Winch ........................................................................................................................ 122
22.1.5 Check Small Remote Control ............................................................................................... 122
22.2 Service Tool Bag RCS ........................................................................................................... 123
22.3 Checking CAN Network ......................................................................................................... 124
22.4 Checking CAN Power Supply ............................................................................................... 124
22.5 Checking CAN Cable ............................................................................................................. 124
22.6 Checking Digital Inputs on I/O Module ................................................................................ 125
22.7 Checking Digital Outputs Voltage on I/O Module ............................................................... 126
22.8 Checking Digital Outputs Current on I/O Module ............................................................... 127
22.9 Checking PWM Outputs Current on I/O Module.................................................................. 128
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22.10Checking Analog Inputs on I/O Module ............................................................................... 129
22.11Encoder Inputs ....................................................................................................................... 129
22.12Checking Resolver Module Resolver Inputs ....................................................................... 130
22.13Checking Resolver Module Encoder Inputs ........................................................................ 131
22.14Checking Resolver Module Analog Inputs .......................................................................... 131
22.15Replacing a RCS Module....................................................................................................... 133
23 Specifications.................................................................................................... 135
23.1 Standard Tightening Torques Bolted Joints ....................................................................... 135
23.2 Signs for Ordering Spare Parts ............................................................................................ 136
Maintenance table ............................................................................................. 137
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SmartROC T45-11 1 Introduction
1 Introduction
1.1 Safety First
Always read the information in the Safety document before starting to use the product or
starting maintenance work.
1.2 The Purpose of This Publication
The objective of these maintenance instructions is to detect and rectify faults at an early
stage so that breakdowns, costly secondary damage and accidents can be prevented.
Regular maintenance is a precondition for planning necessary interruptions in operation
such as reconditioning and repairs. This allows maintenance to be carried out when most
suitable with regard to production instead of causing complete breakdown.
1.3 Target Group
The information in this publication is intended for everyone involved in the application, op
eration, and maintenance of the machine and related equipment. All readers are expected
to possess basic competence regarding mining methods, construction methods, and the
machines used for that kind of operation.
Atlas Copco is not liable for any damage, injuries, or deaths caused by users who misun
derstand the published information and/or use it incorrectly.
1.4 Product Warranty
The product warranty relies on correct use, maintenance and repair of the machine and its
components at all times.
n Use only Atlas Copco original parts. Any damage or operational interruptions caused
by using spare parts of other manufacture than Atlas Copco will not be covered by
warranty.
n Atlas Copco is not liable for any damage caused by unauthorised modification to the
machine and its equipment.
n Atlas Copco is not liable for damage caused by inappropriate use.
n Overloading the machine can result in damage to the structure which is not noticed
during normal usage. Such damage is not covered by the warranty.
n Damage that occurs as a result of inadequate maintenance, substandard repairs, or
damage to equipment that is attributable to older unrepaired damage, is not covered
by the warranty.
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SmartROC T45-11 1 Introduction
10
SmartROC T45-11 2 About Maintenance Management
2 About Maintenance Management
2.1 Maintenance Planning and Counters
Maintenance is organised at scheduled intervals.
Scheduled intervals supplement each other. Longer interval contains maintenance tasks
supplementary to tasks from shorter interval. Maintenance scheduling should be applied
periodically to unit/ function's shortest interval (whichever comes first during operation).
Operational maintenance is planned based on the following counters:
n Hour meters for the rock operation system
n Hour meter for the engine or motor
n Calendar based maintenance applies to all rubber details, lubricants that risks break
ing up during standstills, pressure vessels. Corrosion and such where age, substance
regression and environmental exposure are vital to maintenance factors.
2.2 Maintenance Records
Correct records enable maintenance personnel to identify and evaluate problems and/or
high cost areas. All maintenance procedures should be checked off as the inspection or
procedure is completed. Quantities of refilled lubricants and fluids, and pressure and flow
readings, should be recorded. Any faults or deviations should be recorded irrespective of
whether they have been rectified or are waiting for rectification.
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SmartROC T45-11 2 About Maintenance Management
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SmartROC T45-11 3 General Machine Condition
3 General Machine Condition
3.1 Wash Machine Externally
n Rinse the machine with water at least once a day to remove drill cuttings, mud and
dirt.
The feeder, front part of the boom and track frames are particularly important to keep
clean.
3.2 Check Condition of Signs
n Make sure all signs are intact, clean and fully readable.
n Make sure all signs are in place. Compare with the drawing.
n Always replace defect or missing signs.
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SmartROC T45-11 3 General Machine Condition
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SmartROC T45-11 4 Boom Unit
4 Boom Unit
4.1 Lubricate Boom and Feeder
n Pump grease into 21 grease nipples (A).
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SmartROC T45-11 4 Boom Unit
4.2 Check Boom Condition
n Check mounting on boom head (A). Tightening torque 73 Nm (54 lbf.ft).
n Check clearance between feed and feed bracket (B). Clearance 24 mm.
n Check mounting on the feed bracket (C). Tightening torque 185 Nm (136 Ibf.ft).
n Check clearance between bushes, shaft and holder (D). If necessary change bushes
and perhaps also the shaft.
n Check clearance on the bearings in cylinder lugs (E). Maximum clearance 1 mm.
n Check mounting, damage. 9 plates on locking plates (F). Tightening torque 73 Nm (54
lbf.ft).
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SmartROC T45-11 5 Feeder Unit
5 Feeder Unit
5.1 Checking Chain Feed Tension
C Feed beam
D Chain
Condition p A poorly tensioned chain causes increased wear on the chain and associated parts.
n Check that the chain feed is correctly tensioned.
Result è When the chain feed is correctly tensioned, it should come into contact with the inner
edge on the lower prism on the feed beam at point (B) when the feed is placed in a
horizontal position (transport position).
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5.2 Check Jack Chain Cover
n Check if the chain links chafe against the jack chain cover (A).
Result è Replace the jack chain cover if worn.
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5.3 Check Feed Beam
The feed beam is fitted with black protective plastic covers (A). The covers is designed to
prevent the chain and beam from damaging each other
1. Check covers for wear.
Result è If covers are worn, they must be replaced.
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5.4 Check Chain Guide
n Check the chain guide (B) for wear. If chain guide is damaged or overly worn, replace
it.
5.5 Check Sprocket Wheel
As a general rule, replace the drive on every third chain change.
A Worn Sprocket Wheel
n Check whether there are uneven patches.
n Check that the chain runs smoothly when the chain is coupled in and out of the
sprocket wheel.
n Inspect the teeth for reduced areas and sharp points.
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Result è If the teeth are too worn, the sprocket wheel should be replaced.
! NOTE: Do not run a new chain on a worn sprocket wheel.
NOTE: Do not run a worn chain on a new drive.
5.6 Check DrillSteel Support
n Check the torque of the cylinder mounting, upper drillsteel support (A).
n Check the torque of the lock nut for adjusting screw, lower drillsteel support (B).
n Check the torque of the cylinder mounting, lower drillsteel support (C).
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n Check adjustment and check for wear and cracks on the upper drillsteel support
halves (A).
n Check adjustment and check for wear and cracks on the lower drillsteel support
halves (B).
n Check mounting, play and centering of the lower drillsteel support (C) and check for
damage.
n Check that bolted joints are properly tightened.
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5.8 Check Chain Feed
1. Check slide pieces (A) regarding to play, damage and tightening torque. Play should
be 24 mm.
2. Check slide rails (B) for wear.
3. Check mounting and function of the sensors (C). Check distance, approximately 5
mm.
4. Check bushing halves (D) for wear and cracks.
5. Check mounting of hydraulic cylinders (E).
6. Check clearance for ball bearings in cylinder lugs (F). Maximum 5 mm clearance.
7. Check drillsteel support halves (G) for adjustment, wear and cracks.
8. Clean cutting behind the sealing disc (H).
9. Check the attachment of the feed cylinders and check for damage.
10. Check chain feed tension.
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5.9 Check Rod Handling
n Check the mounting of the hydraulic motor (A). Applies only to machines equipped
with RHS.
n Check for wear and cracks on the bushing halves (B).
n Check the mounting of the hydraulic cylinders (C).
n Check the mounting and functionality of the sensors (D). Applies only to machines
equipped with RHS.
n Check the bracket (E) for cracks and proper attachment. Applies only to machines
equipped with RHS.
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5.10 Clean Behind Sealing Disc
Over time cuttings collect behind the sealing disc (B). Cuttings can damage the chain and
drive.
n Bend the sealing disc down to clean out dust which has collected behind it.
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5.11 Lubricate Rod Handling
n Pump grease into the 14 grease nipples (A).
5.12 Lubricate Chain Feed
n Grease the nipples (A) on drive.
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n Lubricate the jack chain drive (B) with 23 pump strokes of grease in the grease nip
ple on the drive shaft.
n Grease the nipples (C) of the jack chain drive.
5.13 Replace Bearing Unit
n Replace the bearing unit (B) every 5000 engine hours.
5.14 Replace Slide Rails
27
Condition p Slide rails should be replaced if they are worn or severely scratched.
p Before replacing the front slide rails, run the rock drill/rotation unit to its rear end posi
tion.
p Before replacing the rear slide rails, run the rock drill/rotation unit to its front end posi
tion.
1. Remove the cradle for the rock drill, intermediate drillsteel support and the hose
drum from the beam.
2. Remove the slide rails (A) by prising the lower edges of the bars outwards.
3. Clean the beam surfaces thoroughly.
4. Fit the new slide rails. The larger edge on the slide rail must be facing upwards. The
rails should be pressed in place by hand.
5. Refit the rock drill cradles, intermediate drillsteel support and waterhose drum.
5.15 Replace Slide Pieces in the Holder
The slide pieces must be replaced at regular intervals so the steel in the holder does not
wear against the beam.
Condition p Replace if there is less than 1 mm of wear allowance on any the slide pieces. Replace
all slide pieces at the same time.
1. Remove the bolts (B) to dismantle the holder (A) from the cradle (E).
2. Remove the keys (D). Each slide piece is kept in place by three keys.
3. Remove the slide pieces (C) from the holder.
4. Slide a new slide piece into the holder track and fit it to the holder.
5. Fit new keys.
6. Refit the holders to the cradle correctly and adjust so the total lateral play is 23 mm.
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5.16 Adjusting Chain Feed Tension
The distance (C) must be at least 280 mm.
1. Lubricate the bolts (A) using the grease nipples (B). A little grease should be placed
directly on the boltthreads (A).
2. Tighten or loosen the chain feed tension by screwing the bolts (A) clockwise or anti
clockwise.
5.17 General Checking Guidelines for Steel Cables
Steel cables should be scrapped when they display any of the following:
n Wire break at attachment
n Certain number and type of wire breaks
n Concentrations of wire breaks
n Occurrence of wire breaks due to operating time
n Occurrence of strand breaks
n Surface wear
n Effects of heat
n Reduced elasticity
n Decreased cable diameter
n Permanent extension of the cable
n Deformation of the cable
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5.17.1 Checking Cable for Wire Breaks
Wire breaks occur after a certain operating time depending on operating conditions and
subsequently occur more frequently. The number of wire breaks in relation to the operating
time should be determined and documented. This can then be used to estimate the future
increase in wire breaks and the foreseeable time point for scrapping. On 6 and 8strand ca
bles, wire breaks are primarily superficial.
n Broken wires at cable ends indicate that they have been heavily loaded and can be
caused by faulty end mountings. Shorten the cable and reattach it. Check that the
length of the remaining cable sufficient.
n If there are concentrations of cable breaks, the cable must be scrapped. If such con
centrations occur within a length less than 60 cm or on an individual strand, the cable
must be scrapped. even if the number of wire breaks is less than the maximum speci
fied in the table.
Number of load Number of visible wire breaks that require scrapping
bearing wires in
Machine groups M1 and M2
the outer strand.
Filler wire is not Cross Lay Equal Lay
considered load
Over a length of cable diameter (d)
bearing.
30d 6d 30d 6d
21220 9 18 4 9
221240 10 19 5 10
In cables with several layers of strands, only the outer, visible layer is considered. In cables
with steel cores, the core is regarded as an inner strand and is not included. In the event of
a wire break, two ends can be visible.
5.17.2 Checking Cable for Strand Breaks
If there are strand breaks, the cable must be scrapped.
5.17.3 Checking Cable for Surface Wear
Inner surface wear is caused by friction between the wires and the strands.
Outer surface wear is caused by friction between the cable drums (rolls) and the cable un
der pressure (acceleration and braking). Outer surface wear is visible through the forma
tion of reflected images on the outer wires.
Surface wear is increased through faulty or no lubrication, thereby increasing the effect of
dirt and dust. Surface wear reduces static tensile strength through reduction in the cable's
metallic cross section and dynamic strength through surface wear nicks. If the cable's di
ameter decreases more than 7% in relation to the nominal diameter of the cable, it must be
scrapped. It should be scrapped even if no wire breaks have been detected.
5.17.4 Checking Cable for Corrosion
Corrosion is especially problematic in marine environments and in areas where the air is
polluted by industrial emissions. Corrosion can reduce operational strength through rust
spots and static tensile strength through a reduction in the cross section of the metallic ca
ble. Severe corrosion can reduce elasticity.
Outer corrosion can be easily detected through visual examination.
30
Inner corrosion is more difficult to detect. Inner corrosion is characterised by the following:
n Absence of gap between the strands in the outer layer of the cable, often in combina
tion with wire breaks in the strands.
n The cable diameter varies.
The parts of the cable that are bent over discs usually have a decreased diameter. At any
sign of corrosion, the cable should be checked by an authorised person. If inner corrosion
is detected, the cable must be scrapped.
5.17.5 Checking Cable for Decreased Diameter
Decrease in cable (steel wire) diameter through material fatigue in the cable can have the
causes:
n Inner surface wear and surface wear nicks
n Inner surface wear through friction between the strands and wires in the cable
n Fatigue of plastic core
n Break in steel core
n Break in inner layer in multistrand cable
If the cable's diameter decreases more than 10% in relation to the nominal diameter of the
cable, it must be scrapped. It should be scrapped even if no wire breaks have been de
tected.
5.17.6 Checking Cable for Reduced Elasticity
Under certain conditions, the cable loses its elasticity. Reduced elasticity is difficult to de
tect. If in doubt, consult a specialist. If the cable has lost elasticity, the following character
istics usually appear:
n Decrease in cable diameter
n Extension of the cable
n No gap between individual wires and between the strands. This is caused by its com
ponents being pressed together.
n Fine, brown dust inside the strands.
n Even if there are no visible wire breaks, the cable is noticeably stiffer.
n The cable's diameter decreases more quickly than during normal wear of the individual
cable strands.
Reduced elasticity can lead to sudden cable breaks during heavy loads. The cable should
be scrapped.
5.17.7 Checking Cable for Heat Exposure
The effects of heat can be established through annealing colour. Cables exposed to ex
treme heat must be scrapped.
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SmartROC T45-11 6 Drilling Machine
6 Drilling Machine
6.1 Check Lubrication Oil Level Tank
The lubricating oil tank is mounted on the left side of the machine frame.
n Check the tank and connections for signs of leakage.
n Make sure the lubrication oil level is above the top sight glass (B).
n Refill with lubrication oil (A) if necessary. Always use a funnel with strainer.
! NOTE: The lubrication oil level should not be below 40 mm (1.6"). If the lubricating sys
tem is completely drained the system will have to be bled.
6.2 Drill Lubrication Pumps
The lubrication pumps are placed behind the lubricant tank.
A Pump for thread lubrication (ECG)
B Pump for lubricating rock drill (ECL)
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SmartROC T45-11 6 Drilling Machine
34
SmartROC T45-11 7 Hydraulic System
7 Hydraulic System
7.1 About Working on Hydraulic Components
The hydraulic system is sensitive to contamination. The environment where the machine is
normally used is generally an unsuitable place for repairing hydraulic components. Avoid
repairing hydraulic systems outside workshops.
Observe the following points to minimize interruptions in operation due to contaminated hy
draulic oil:
n Keep the machine clean. Use a degreasing additive for washing.
n Before opening any hydraulic connection, clean the area round it.
n Use clean tools and work with clean hands.
n Always plug hydraulic connections immediately after they have been detached.
n Use clean protective plugs.
n Hydraulic components, for example like hoses, valves, engines, must always be stored
with suitable protective plugs fitted.
n Spare parts for hydraulic components must always be kept in sealed plastic bags.
n Change filter cartridges when filters indicate clogging.
7.2 About Hydraulic Workshops
Workshops used for the repair of hydraulic components must include:
n A clean environment to avoid dust and particles
n Suitable washing equipment which is required for repairing the components
n Suitable tools for work on hydraulic systems
n Adequate ventilation system
7.3 About Replacing Hydraulic Hoses
Load, vibration and other mechanical stresses put high demands on hydraulic hoses.
When replacing, check that replacement hoses are made:
n With correct crimped couplings
n With correct quality class
n With correct dimensions
All pressurised components should be purchased from Atlas Copco. Grades and dimen
sions of hoses are specified in the spare parts catalogue. Also make sure that hose cou
plings are clean, not damaged and properly tightened.
7.4 Check Hoses and Couplings
n Inspect all hydraulic hoses and connections thoroughly with respect to cracking and
swelling that indicates an external or internal leak. Inspect hose location and clips.
n Inspect hose casing with respect to any swelling that indicates inner hose or cord
breakage.
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n Inspect hydraulic couplings with respect to leaks, indentations and adapters. Cou
plings should be fastened securely if they have screw flanges. If there are any signs
of connection leaks, change sealings or the complete coupling.
n Inspect that all hose attachments and clamps are intact.
n Inspect all pressed couplings for signs of cracks or damage to compression sleeves.
Replace defective hoses with new ones.
7.5 Hydraulic Filters
7.5.1 Return Oil Filter
The return oil filter cleans the oil before it returns to the tank. The filter cartridges should be
replaced according to the maintenance schedule. If the return filter pressure gauge on the
operator display indicates a clogged filter, all return oil filters must be replaced immedi
ately.
Symbol for Clogged Filter
7.5.2 Check Breather Filter
The purpose of the breather filter is to equalise the pressure differences in the tank that
would otherwise arise when the level in the tank changes. The breather filter is fitted on the
hydraulic oil reservoir.
n Check breather filter (A).
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! NOTE: If the breather filter becomes covered in oil it will be ruined.
7.5.3 Replace Return Oil Filter
The filter inserts are located in the hydraulic tank.
1. Clean on and around the filter cap. Loosen and remove the nuts (A).
2. Lift off the cap (B) and replace the Oring (C) if damaged.
3. Lift out the filter cannister (D).
4. Remove the nut (E). Lift out and clean the magnetic rod (F).
5. Take out filter cartridge (G) from the cover (H) and replace with a new filter cartridge.
Only the filter cartridge is replaced. The filter cover is reused.
6. Refit all parts.
37
7.5.4 Replace Breather Filter
1. Clean thoroughly on and around the filter housing (A).
2. Detach the cover plate by turning it anticlockwise.
3. Replace with a new filter. Apply a little hydraulic oil to the ceiling surface/threads.
4. Replace the cover.
! NOTE: If the breather filter is covered in oil it is ruined and must be replaced.
7.6 Tanks
7.6.1 Drain Condensate from Hydraulic Oil Tank
Water in the hydraulic oil can seriously damage components in the hydraulic system and
cause corrosion.
38
Condition p The hydraulic system has not been in operation for twelve hours before draining the hy
draulic oil tank.
1. Remove the plug on the ball valve (A) underneath the hydraulic oil tank.
2. Place a vessel under the ball valve.
3. Open the ball valve to drain the water.
4. Close the ball valve when oil starts to drain.
5. Refit the plug.
6. Check oil level and top up if necessary.
7.6.2 Drain Condensate in Pressure Tank
A Compressor Tank
B Compressor Cooler
C Compressor Element
Condition p The machine must have been switched off for at least 1 hour.
n Drain the condensate from plug 1 at the draining point on the righthand side of the
machine.
7.6.3 Clean Hydraulic Tank
Hydraulic tank is cleaned manually through the access hatch at the top.
Condition p The hydraulic tank is drained from oil.
1. Remove the access hatch.
2. Clean the inside of the tank completely.
3. Use only lintfree rags. Wipe all sides, top and bottom of the tank. Be especially thor
ough in corners, hedges, and around connecting holes. Make sure no pieces of rag
get stuck or get left in the tank.
4. Refit the access hatch as fast as possible after cleaning to prevent any particles from
entering. Make sure the access hatch closes tightly.
39
7.6.4 Drain Hydraulic Oil Tank
1. Remove the plug from the ball valve (A) underneath the hydraulic tank.
2. Fit a hose to the ball valve and place the other end of the hose into a vessel.
3. Open the ball valve and empty the tank.
4. Close the ball valve and remove the hose.
5. Refit the plug on the ball valve.
7.6.5 Fill Hydraulic Oil
WARNING
Risk of Eye Injuries
Hydraulic oil can cause eye injuries
u Use protective goggles
1. Check the return oil filter.
2. Check that all the couplings and hoses normally filled with hydraulic oil are clean.
3. Activate the Enable hydraulic oil filler pump function in the Settings 2 menu in the
control system.
4. Connect the attached hose to the oil source.
40
5. Press button (A) to start filling.
6. Check that the lower sight glass is fully covered and the upper sight glass is half cov
ered.
Result è The electric filler pump stops automatically when the hydraulic tank is full. It also
stops if the source of oil runs out.
41
7.7 Check Mounting Hydraulic Jack
n Check mounting and torque on hydraulic jack (A).
n Check mounting and torque on footplate (B).
42
SmartROC T45-11 8 Electrical System
8 Electrical System
8.1 Charging the Battery
WARNING
Risk of Fire and Explosion
May cause serious personal injury and damage to property.
u Explosive gas is formed in the battery during charging.
u Avoid naked flames and sparks.
u Ensure good ventilation.
u Always disconnect the negative terminal first, and connect it last.
The battery is normally charged by the alternator. If the battery is fully discharged for some
reason, it must be recharged using a battery charger. Cell plugs should be unscrewed and
left in the holes during charging. Batteries contains corrosive fluid. Always turn off the
charge current before disconnecting the clips. If the density has not risen noticeably de
spite a number of hours of charging, the battery is probable expended. Rapid charging,
when carried out correctly, will not damage the battery. Rapid charging should not be un
dertaken too often and is not recommended for old batteries. Repeated discharging for
long periods will impair the service life of the battery. Avoid, for example, leaving the lights
on while the engine is stationary. Discharging with high current is not normally harmful.
Since the 24V electrical system is powered by two 12V batteries connected in series, ob
serve:
n The batteries must have the same capacity (Ah).
n The batteries must be the same age. This is because the charging current required to
bring a battery up to a certain voltage changes with age.
n The batteries must not be loaded unevenly.
n Series coupling maintains the same capacity but increases the voltage. For example,
when 2 x 12V 60Ah batteries are connected in series, the voltage will be 24V but the
capacity remains at 60Ah.
n Use a 24V charger when charging both batteries connected. Use a 12V charger when
charging each battery individually. Observe the voltage before connecting a battery
charger.
43
8.2 Charging Battery Using 24V Charger
WARNING
1. Turn off battery isolation switch.
2. Disconnect the cable between chassis ground and the negative terminal on battery
(A).
3. Connect the battery charger's positive cable to the batteries positive terminal (B).
Connect the battery chargers negative cable to the batteries negative terminal (A).
4. Start the battery charger.
5. Turn off the battery charger when batteries are fully charged.
6. Disconnect the battery charger's negative cable from the batteries negative terminal
(A). Disconnect the battery charger's positive cable from the batteries positive termi
nal (B).
7. Connect the cable between chassis ground and the negative terminal on battery (A).
8. Turn on battery isolation switch.
44
8.3 Charging Battery Using 12V Charger
WARNING
Serial Connected 12V Batteries
1. Turn off the battery isolation switch.
2. Disconnect the cable between chassis ground and the negative terminal on battery
(A).
3. Disconnect the jumper lead between the negative terminal on battery (B) and the pos
itive terminal on battery (A).
4. Connect the battery charger's positive cable to the positive terminal on battery (A).
Connect the battery charger's negative cable to the negative terminal on battery (A).
6. Turn off the battery charger when battery (A) is fully charged.
7. Disconnect the battery charger's negative cable from the negative terminal on battery
(A). Disconnect the battery charger's positive cable from the positive terminal on bat
tery (A).
8. Connect the battery charger's positive cable to the positive terminal on battery (B).
Connect the battery charger's negative cable to the negative terminal on battery (B).
10. Turn off the battery charger when battery (B) is fully charged.
11. Disconnect the battery charger's negative cable from the negative terminal on battery
(B). Disconnect the battery charger's positive cable from the positive terminal on bat
tery (B).
45
12. Connect the jumper lead between the negative terminal on battery (B) and the posi
tive terminal on battery (A).
13. Connect the cable between chassis ground and the negative terminal on battery (A).
14. Turn on battery isolation switch.
8.4 Starting with Auxiliary Battery
WARNING
Explosion Risk
The batteries could explode if a fullycharged battery is connected to a completely dis
charged battery.
Condition p Switch off the RCS system on the control system panel, if present.
1. Check that the auxiliary batteries (A) have the same voltage as the chassis batteries
(B).
2. Connect the positive terminal of the auxiliary batteries (A) to the positive terminal of
the chassis batteries (B).
3. Connect the negative terminal of the auxiliary batteries (A) to ground on the chassis.
! NOTE: Do not connect the negative terminal of the auxiliary batter
ies (A) to the chassis batteries (B) negative terminal.
4. Disconnect the cable from the chassis ground as soon as the engine starts.
5. Disconnect the cable from the negative terminal on the auxiliary batteries (A).
6. Disconnect the cable between the positive terminal of the chassis batteries (B) and
the auxiliary batteries (A).
46
SmartROC T45-11 9 Fire Fighting Equipment
9 Fire Fighting Equipment
9.1 Check Fire Extinguishers
1. Check that the indicator is in the green zone.
è Replace the fire extinguisher if the indicator is within, or close to, any of the red
zones.
2. Check that none of the seals are broken and that service has been performed within
the prescribed time.
3. Inspect the complete fire extinguisher and holder for loose parts, defects or damages.
47
9.2 Check Emergency Stops and Work Lights
n Check each emergency stop (A) individually. The engine must be off. Before the next
emergency stop is checked, the previous one must be reset before restarting.
n Check the functionality of the work lights, front and rear (B).
48
1. Check that the instructions are legible.
2. Check the condition of the fire extinguisher (A).
49
50
SmartROC T45-11 10 Control System and Sensors
10 Control System and Sensors
10.1 General Maintenance Control System and Sensors
10.1.1 Remote Control Battery
n The remote control batteries should be regularly fully discharged and then fully
recharged.
n Charging can only take place in the temperature range +10 °C and +40 °C.
n NiCd batteries can be partially charged or discharged before arrival. Batteries must al
ways be fully charged before use.
! NOTE: Protect the batteries against short circuiting. Do not store them in a tool box or
loose in a pocket together with metal objects as these can short circuit the battery.
10.1.2 Cleaning Remote Control
The remote control may require cleaning. It is important that the remote control is not dam
aged.
n Make sure the active stop on the remote control is not blocked by dirt or similar.
n The battery contacts should be cleaned and lubricated at regular intervals.
n To clean the remote control use a damp rag or a fine brush to remove dirt and dust.
! NOTE: Never clean the remote control using highpressure or steam washing. Strong
chemicals can destroy the remote control rubber bellows.
51
SmartROC T45-11 10 Control System and Sensors
52
SmartROC T45-11 11 Cooling System
11 Cooling System
11.1 Cooling System Overview
DANGER
Scalding and Pressure
High pressure in the radiator can cause serious personal injury.
u Undo the radiator cap slowly to gradually release the pressure.
The machine has two radiators. The lefthand radiator (A) is for the compressor oil and hy
draulic oil. The righthand radiator (B) is for the engine coolant. When delivered from the
factory, the coolant is protected from freezing down to 30° C ( 22° F).
See the separate instructions for the diesel engine.
53
See reference documentation
Diesel engine instruction manual
11.1.1 Clean Radiators
! NOTE: High pressure water jets must be directed parallel to the radiator flanges
(straight ahead or from behind).
Clean radiators frequently to maintain the systems cooling capacity.
1. Blow compressed air to clean the radiator flanges. Use degreaser and high pressure
water jet if dirt remains.
2. Blow compressed air on the fan blades until the blades are clean.
3. Remove the fan grille and wipe the fan blades clean from dirt.
4. Clean the inside of the fan grille.
54
11.1.2 Check Coolant Level
Condition p The coolant level must be checked when the diesel engine is cold.
n Check the coolant level (B).
è The level should be between the upper and lower mark.
55
11.1.3 Add Coolant
1. Loosen the radiator cap (A) to the stop position, release the pressure in the cooling
system and only then remove the cap.
2. Add coolant until the level is between the upper and the lower mark (B). Only CAT
ELC coolant may be used.
56
SmartROC T45-11 12 Operator's Environment
12 Operator's Environment
12.1 Check Cabin
n Clean or change the filter element in the circulation filter (A, B).
n Clean or change the primary filter (C).
n Clean or change the prefilter (D).
n Run the air conditioning system for five minutes (winter and summer).
n Clean the condenser element with compressed air.
n Check that the instructions on the fire extinguisher (E) are legible.
n Check the mounting on steps (F) for cracks and other damage.
n Check the mounting on the handle for cracks and other damage.
n Check the protective roof mountings for damage.
n Check that the horn is in working.
n Check function of the backup warning signal and beacon.
n Check that all warning and safety labels are properly attached and legible.
n Replace the circulation filter
n Replace primary filter
n Replace prefilter
n Lubricate door hinges.
n Check the cabin mounting tightening torque and for damage.
57
12.2 Replacing Air Condition Main Air Filter
1. Remove screws from the cover (A).
2. Open cover and lift out the filter.
3. Replace with new filter.
4. Close cover and refit screws.
12.3 Replacing Air Condition Prefilter
1. Remove screws on the louvre cover (A).
2. Open louvre cover and lift out the filter.
58
3. Replace with new filter.
4. Close cover and refit screws.
12.4 Replacing Air Condition Circulation Filters
1. Remove screws on the covers (A and B).
2. Open covers and lift out the filters.
3. Replace with new filters.
4. Close covers and refit screws.
12.5 Troubleshooting AC
Fault Symptom Action
No cooling at all Check fuses, electric connections, compressor
ground, electromagnets, switches and pressure
switches
Check Vbelt and compressor
Check expansion valve and temperature control
valve
Check coolant hoses
Poor cooling Check freshair fan and Vbelt tension
Check if the air is passing the evaporator in the
unit
Check the expansion valve capillary tube is firmly
tightened against the evaporator outlet pipe
59
Fault Symptom Action
Check the thermostat does not cut out too early
Uneven cooling Check connections to switches, magnetic coupling
or pressure switch are not loose
Check the expansion valve is not clogged
Check that the system is filled and that the ther
mostat is working
n Abnormal system noise is often related to incorrectly assembled components. If the compressor is
noisy at a certain speed, and the noise disappears when the speed increases or decreases, there
is probably nothing wrong with the compressor itself. The difference between the pressure on the
suction side and the pressure side also affects the level of noise. A compressor with low suction
makes more noise than a compressor with high suction. Likewise, a compressor with highpres
sure makes more noise because it puts more load on bearings and other components.
Abnormal noise Check the multiVbelt to the compressor is thor
oughly tightened and that the compressor retain
ing bolts are tightened
Check the system is filled sufficiently and not over
filled
Check the expansion valve is in working order
Check the airflow across the evaporator is suffi
cient
Check the condenser is clean and the airflow is
sufficient
60
SmartROC T45-11 13 Track Frames
13 Track Frames
13.1 Tensioning the Crawler Tracks
Track tension is checked between the front wheel (C) and support roller (A).
Condition p Machine is on a levelled ground.
p Tracks are under normal load
1. Place a levelling board (B) on top of each track and maintain a clearance (E) of 25
mm to 50 mm (0.98" to 1,97") between them.
! NOTE: If the tracks do not have any support roller (A) position the
levelling board between the end wheels with a maximum of 50 mm
slack in the centre.
2. Fill grease via the nipple (D) to tension the track.
! NOTE: The grease nipple is not to be used during lubrication, but
only during this procedure.
3. If the track tension becomes too tight, grease can also be drained from the tension
cylinder by unscrewing the nipple (D).
61
13.2 Checking Track Frames Torques
Size Torque in Nm Quantity/track Comments

(lbft) frames
A M16 295 20
B1 M12 86 4 T50LF, D60, D65,
C65LF
B2 M16 210 1 T45, C50, D50,

D55, T50SF,
C65SF
C M16 210 32
D M12 90 3
E M16 295 18
F1 9/16” UNF 260 ± 10 176 T45, C50, D50,

D55, T50SF,
C65SF
62
Size Torque in Nm Quantity/track Comments

(lbft) frames
F2 M16 370 ± 20 176 T50LF, D60, D65,

C65LF
G M16 210 28
G M16 210 10
Table 1: Tightening Torques for Track Frames
13.3 Procedures for Checking Wear
n When components on the track frames are worn down to the minimum recommended
levels, they must be replaced with new components.
n Regular and accurate measuring is required in order to establish the extent of the wear
and when replacement is necessary.
n The components must be thoroughly cleaned for measuring.
n Measurements must be taken at several points. The degree of wear is determined by
the maximum value, not the average value.
13.3.1 Checking for Front Wheel Wear
n Check the wear by measuring the distance (A) between the top and bottom of the
front wheel.
Specification Metric Data Imperial U.S Data
New Front Wheel 16.5 mm 0.65 in
Wear 25% 17.6 mm 0.70 in
Wear 50% 19.4 mm 0.77 in
Wear 75% 21.7 mm 0.86 in
Wear 100% 24.4 mm 0.96 in
Also see about this
2 Procedures for Checking Wear [} 63]
63
13.3.2 Checking for Track Roller Wear
n Check the wear by measuring the diameter (A) of the track rollers.
New Track Roller 160.0 mm 6.30 in
Wear 25% 156.8 mm 6.18 in
Wear 50% 153.0 mm 6.03 in
Wear 75% 148.9 mm 5.86 in
Wear 100% 143.7 mm 5.66 in
Also see about this
13.3.3 Checking for Carrier Roller Wear
n Check the wear by measuring the diameter (A) of the carrier roller.
New Carrier Roller 100.0 mm 3.93 in
Wear 25% 97.0 mm 3.82 in
Wear 50% 93.7 mm 3.68 in
Wear 75% 89.6 mm 3.53 in
Wear 100% 84.7 mm 3.33 in
Also see about this
64
13.3.4 Checking for Track Shoe Wear
CAUTION
Increased Risk of Sliding
Worn track shoes reduce the friction with the ground considerably and increase the risk
of sliding
u Always follow the maintenance recommendation for wear of track shoes.
n Check the track shoe wear by measuring the distance (A) between the top and bot
tom of the track shoe.
New Track Shoe 22.0 mm 0.87 in
Wear 25% 19.2 mm 0.76 in
Wear 50% 16.0 mm 0.63 in
Wear 75% 12.9 mm 0.51 in
Wear 100% 9.7 mm 0.38 in
Also see about this
13.3.5 Checking for Wear on Track Shoe
Condition n Check the track shoe wear by measuring the distance (A) between the top and bot
tom of the track shoe.
65
New Track Shoe 47.0 mm 1.85 in
Wear 25% 40.9 mm 1.61 in
Wear 50% 34.2 mm 1.35 in
Wear 75% 27.5 mm 1.08 in
Wear 100% 20.8 mm 0.82 in
Also see about this
13.3.6 Checking for Track Link Depth Wear
n Check the wear by measuring the dimension (A) for the chain.
New Chain 83.0 mm 3.27 in
Wear 25% 81.6 mm 3.22 in
Wear 50% 79.8 mm 3.15 in
Wear 75% 77.9 mm 3.07 in
Wear 100% 75.7 mm 2.98 in
Also see about this
13.3.7 Checking for Bushing Wear
n Check the wear by measuring the dimension (A) for the bushing.
66
New Bushing 45.0 mm 1.77 in
Wear 25% 44.6 mm 1.76 in
Wear 50% 44.2 mm 1.74 in
Wear 75% 43.7 mm 1.72 in
Wear 100% 43.0 mm 1.69 in
Also see about this
13.3.8 Checking for Track Chain Elongation Wear
n Check chain wear by measuring the distance (A) between the center point in the first
pin to the center point of the fifth pin.
New Track Roller 160.0 mm 6.29 in
Wear 25% 162.0 mm 6.37 in
Wear 50% 164.0 mm 6.45 in
Wear 75% 166.0 mm 6.53 in
Wear 100% 168.0 mm 6.60 in
Also see about this
67
13.4 Check Track Frames
1. Check for signs of leakage on the traction motor (A).
2. Check for signs of leakage on the traction gears (B).
3. Check for signs of leakage on the carrier roller (C).
4. Check for signs of leakage on the track rollers (D).
5. Check the tension on the crawler tracks (E), visual inspection.
6. Check that the springs and dampeners move freely on the front wheel (F). Clean if
necessary.
7. Check for loose screws and nuts.
! NOTE: First oil change after 150 engine hours, then every 1500 engine hours. Flush
the gears with oil before new oil is added. Volume approximately 2 liters. The level plug
(E) must be positioned just above the center of the traction gear.
68
n Check for signs of leakage on the traction gears (A).
n Pump grease into the two grease nipples (B).
n Check for signs of leakage on the front wheel (C) and dampener.
n Check the position of the dampener (D). If the slide block sticks out more than 50 mm
outside the frame, the chain must be replaced.
n Tighten all mountings after 50 engine hours and then every 250 engine hours.
69
1. Check oil level on the traction gear (A). The level plug must be positioned above the
centre of the traction gear.
2. Check for signs of leakage and wear on the track rollers (B).
3. Check the crawler track tension (C).
4. Check the wear on the track shoe and link chain on the crawler tracks (C).
5. Check for signs of leakage and wear on the carrier roller (D).
6. Check for drive wheel wear (E).
7. Check for front wheel wear (F).
8. Check for any damage to the frame.
9. Check the mountings.
13.7 Change Oil on Track Frames
n Change the oil on the traction gear. Flush the gears with oil before adding new oil.
Volume approximately 2 liters. The level plug must be positioned above the center of
the traction gear.
70
SmartROC T45-11 14 Dust Collector
14 Dust Collector
14.1 Checking Function of Dust Collector
Factory setting is 46 pulses during cleaning time.
Condition p The air pressure must be less than 8 bar (manual valve).
1. Turn the ignition key to ignition position. Set the switch mode (A) in the position for
drilling on the operator's panel.
2. Activate the dust collector by turning button (C). Make sure flushing air (B) is in posi
tion “Reduced flushing air”.
3. Activate the flushing air with the right drill lever by moving it maximal to the left. Termi
nate the function by pressing button (D, E) on the right drill lever.
4. Check that air blows through the filters and check pulse interval.
Adjust the number of pulses if necessary.
71
14.2 Check Dust Collector Filters
1. Remove the plugs (A) and apply a differential pressure gauge to the 2 holes.
2. Measure the pressure drop while air flushing is activated.
è If the pressure drop is greater than an 800 mm (wg) column of water, all filters
must be replaced.
14.3 Replace Dust Collector Filters
72
1. Open the door (A).
2. Remove the old filters (B).
3. Replace with new filters. The recommended tightening torque when installing the new
filters is 13 Nm.
73
74
SmartROC T45-11 15 Diesel Engine
15 Diesel Engine
15.1 Check Motor Oil Level
WARNING
Burning Hazard
Hot components and surfaces can cause serious injury.
u Use working gloves and cover your arms with long sleeves.
Condition p The diesel engine is off.
1. Check that the oil level is between the upper and lower mark on the dipstick (A).
2. Top up through the fill cap (B) if necessary.
75
15.2 Drain PreFilter
n Drain water from the prefilter by opening the drain outlet (A).
15.3 Fuel Quality
n The engine must be off before refueling starts. Do not handle fuel in the vicinity of hot
surfaces, sparks or open flames.
n Cleanliness is important when filling fuel. Ensure that the tank and tank cover are
clean. Fuel must not be added if there is a risk that it is contaminated, for example in
windy or wet weather or when there is dust in the air.
n Fuel that is stored must not have contact with the air, but must be stored in a closed
vessel. The vessel must be clean and approved for its purpose.
n Use Ultra Low Sulfur Diesel (ULSD). Its sulfur level must not exceed 15 ppm.
15.4 Draining Fuel Tank
! NOTE: Always fill the fuel tank with clean diesel oil and fuel of the correct grade for the
temperature.
1. Undo the front protective plate on the underside of the machine.
2. Undo the bottom plug by holding the nut with a 22 mm box end wrench and unscrew
ing with an 8 mm Allen key. Allow the water to drain.
3. Use track oscillation to tilt the drill rig in order to drain the tank completely.
4. Tighten the plug so the diesel oil cannot leak out.
76
15.5 Filling with Fuel
n Unscrew the filler cap (A) to fill with fuel.
15.6 DEF Fluid
n DEF fluid is topped up with each refueling. The DEF tank must not be overfilled. In a
cold climate DEF fluid freezes and needs space to expand.
n Cleanliness is important during the filling of DEF fluid. Make sure that the container
and funnel are clean.
n The DEF fluid must fulfil the requirements specified in ISO 222411. See the operator's
instructions for the diesel engine.
n See the operator's instructions for the diesel engine regarding the storage of DEF fluid.
n When the DEF tank is almost empty, a series of warnings will be shown on the ma
chine's display. When the tank is empty, the engine will switch off.
77
15.7 Location of DEF Tank
DEF Tank
A DEF tank
15.8 Draining DEF Tank
n Drain the DEF tank by loosening the plug (A).
78
15.9 Filling with DEF Fluid
n Unscrew the filler cap (A) to fill with DEF fluid.
15.10 Replace PreFilter
1. Unscrew the prefilter (B) using a suitable tool.
2. Collect any residual fuel.
3. Clean the surface of the filter holder.
4. Oil the rubber seal of the new fuel filter sparingly.
5. Screw on the filter all the way by hand.
6. Tighten the filter an additional half turn using a suitable tool.
7. Check that the fuel filter does not leak.
79
15.11 Replace Secondary Fuel Filter
1. Unscrew the secondary filter/filters (A) using a suitable tool.
2. Collect any residual fuel.
3. Clean the surface of the filter holder.
4. Lubricate the rubber seal of the new fuel filter sparingly with a little oil.
5. Screw on the filter by hand until the gasket makes contact with the surface of the filter
holder.
6. Tighten the filter an additional half turn.
7. Check that the fuel filter does not leak.
15.12 Replacing DEF Tank Filter
n See the separate instructions for the diesel engine regarding DEF tank filter replace
ment.
80
15.13 Belts
15.13.1 Replace Multibelt
Condition p The engine must be off.
1. Remove the belt cover.
2. Turn the tensioning wheel (A) to loosen the belt tension.
3. Use a pin to lock the tensioning wheel in position at the point where the belt is slack.
81
4. Remove the bolts (4) in the axle coupling to create a gap between the coupling rubber
and the shaft flange.
5. Remove the old belt.
6. Insert a new belt through the gap.
7. Insert and tighten the bolts (185 Nm).
è The belt is tensioned automatically when the pin is removed from the tensioning
wheel.
8. Reinstall the belt cover.
15.14 Replace Longterm Effective Coolant
n Replace the longterm effective coolant (ECL).
82
15.15 Air System
The air filters consist of a filter housing with cover, filter cartridge, safety cartridge, indicator
and evacuation valve. Air filtration is performed in two stages. The first stage comprises a
cyclone and the second stage a normal filter. Both filtration stages take place in the filter
housing. A filter's performance will improve right up until it becomes clogged. For this rea
son, the filter cartridge should not be replaced at regular intervals, but only when it starts to
become clogged. The filter cartridges must never be cleaned as this impairs filtration and
also risks damaging the filter element. There is an indicator situated on the filter housing to
advise when the filter cartridge is clogged. It is connected to the display in the cabin. A yel
low warning symbol appears on the status bar at the bottom of the display if a filter is start
ing to clog.
Warning Symbol for Engine Air Filter
Warning Symbol for Compressor Air Filter
83
15.15.1 Air Filter Indicator Function
To ensure filter clogging is detected, the function of the air filter indicator (A) must be
checked regularly. This is done by gradually covering the air intake with a piece of wood or
similar. The air filter indicator should then send a signal and the warning symbol or the
warning light should come on. If a warning is not indicated, start by checking the cable con
nections. If there are no problems with the connections, then the air filter indicator is faulty
and must be replaced. The air filter indicator is not included in the filter housing, but is or
dered separately.
! NOTE: Be sure to use an intact and clean piece of wood so that dirt or other particles
do not enter the filter housing.
15.15.2 Replace the Filter Cartridge
84
! NOTE: Never clean the filter cartridges. When an evacuation valve is damaged, re
place it. If the warning symbol for clogged air filter continues to be shown, the safety
cartridge must be replaced.
Condition p The diesel engine is off.
1. Undo the clamps (A) and remove the cover (B).
2. Remove the main cartridge (C).
3. Clean inside the filter housing and lid with a clean, dry cloth.
! NOTE: If the safety cartridge (E) has also been removed for chang
ing, the filter housing air outlet must be completely covered with ad
hesive tape before cleaning the filter housing.
4. Check that the evacuation valve (D) is not damaged. Change it if necessary.
5. Remove any adhesive tape on filter housing air outlet.
6. Install a new main cartridge and a new safety cartridge if required.
7. Refit the cover and fasten the clamps.
85
86
SmartROC T45-11 16 Compressed Air System
16 Compressed Air System
16.1 Overview Air Compressor System
The machine is equipped with a singlestage screw compressor which is driven by the
diesel engine. The compressed air from the compressor flows to an air receiver which also
functions as an oil separator. The majority of the oil is removed in the air tank by centrifugal
force. The remaining oil is separated in an oil separator element in the air receiver. The
separated oil is collected in the lower section of the air receiver, which functions as an oil
tank.
Compressor System Parts
A Safety Valve
B Thermostat
C Oil Filter
D Inlet Valve
E Compressor
F Exhaust valve
G Air Filter
H Air valve
I Ball Valve
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J Pressure Gauge
K Pressure Reducing Valve
L Air Filter
M Air Filter Switch
N Oil Stop Valve
O Temperature Sensor
P Check Valve
Q Restrictor
R Pressure Tank
S Minimum Pressure Valve
T Pressure Sensor
Diagram Air Compressor System
Pos See Compressor System Parts
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16.2 Check Compressor Oil Level
1. Make sure the machine is on flat ground.
2. Switch off the machine and allow the oil level to settle for at least 5 minutes.
3. Check the compressor oil level. The indicator on the gauge (A) must be in the green
zone.
Fill with oil at (B), if required. Use the correct amount and oil grade.
16.3 Oil Change and Oil Filter Replacement
The intervals for oil change are determined by oil grade and operating temperature. The
prescribed interval is based on an oil temperature of up to 120 °C and normal operating
conditions. Oil should be changed more frequently when working in high ambient tempera
tures or very dusty or damp conditions.
The system must be flushed clean before new oil is filled if the oil has been
n contaminated by incorrect oil
n broken down due to excessive temperature
n used beyond the operating interval
16.4 Replacing Air Compressor Oil and Oil Filter
WARNING
Fire and Explosion Risk
Using incorrect or old oil may lead to risk of fire or explosion in the compressor system
u Use correct, new oil according to the Fluids and Lubricating Greases manual.
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1. Run the compressor to operating temperature. Confirm that the pressure is zero.
2. Put vessels under the drain plugs. Remove drain plugs for compressor tank, com
pressor cooler and compressor element. Drain the oil. Tighten the plugs after drain
ing.
3. Remove the oil filters (C). Collect the oil in vessels.
4. Clean the filter seat on the manifold using new oil, and make sure that no dirt falls
down into the system. Lubricate the gasket on the new filters with new oil. Replace
the filters.
5. Remove the filler plug and fill oil into the air receiver (B) until the oil level reaches the
filler pipe. The indicator on the gauge (A) must be in the upper section of the green
zone. Fit and tighten the filler plug.
6. Operate the unit without any load for several minutes in order to circulate the oil and
force out any air in the oil system.
7. Stop the compressor. Allow the oil to settle for several minutes. Confirm that the pres
sure is zero. Remove the filler plug and fill with oil until the indicator on the oil level
gauge (A) is in the green zone. Fit and tighten the filler plug.
! NOTE: If the oil has been destroyed the system must be flushed clean before new oil is
filled.
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16.5 Change Oil on Compressor
1. Change the compressor oil (A).
2. Replace the old cartridge on the oil filter (B) with a new one.
3. Perform a 15 bar pressure test on the safety valve (C).
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16.6 Replace Separator Filter
n Replace separator filter (A) in the pressure tank.
! NOTE: Check that the washer (1) under the filter remains in place.
Do not throw it away with the old filter during replacement.
16.7 Changing to New Type of Compressor Oil
To avoid problems when changing to a new type of oil, a special procedure for compressor
oil flushing must be followed. The table is only applicable if the replaced oil has not passed
its expiration date. Old oil is best detected by using an analysis program for oil samples,
SOS (Scheduled Oil Sampling). Indications that the oil is old are that it smells strongly, that
there are contaminants such as sediments inside the oil reservoir and the stop valve, or
that the oil has a brownish colour.
Paroil M Paroil S Paroil Sxtreme
Paroil M Drainage * Flushing Flushing
Paroil S Drainage ** Drainage * Drainage
Paroil Sxtreme Drainage ** Drainage Drainage *
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* When changing to the same oil within the interval between changes, drainage is sufficient
** Changing not recommended
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16.8 Flushing Air Compressor
WARNING
Fire and Explosion Risk
Using incorrect or old oil may lead to risk of fire or explosion in the compressor system
u Use correct, new oil according to the Fluids and Lubricating Greases manual.
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Condition p Run the compressor to operating temperature and confirm that the pressure is zero.
1. Place vessels under the drain plugs.
2. Remove drain plugs for compressor tank, compressor cooler and compressor ele
ment and drain the oil.
3. Refit and tighten the plugs.
4. Remove the oil filters (E).
5. Open the cover plate (A) on the air reservoir and remove the oil separator element.
6. Check the inside of the oil reservoir (B).
è If sediments are detected, the parts (AD) must be thoroughly cleaned before
the procedure is completed.
7. Insert a new oil separator element and refit the cover plate (A).
8. Clean the filter seat on the manifold using new oil, and make sure that no dirt falls
down into the system.
9. Lubricate the gasket on the new filters with new oil.
10. Replace the filters (E) and close the valve (C).
11. Fill the oil reservoir with the minimum amount of oil permissible thru the oil inlet (F).
12. Run the compressor unloaded in light mode for 30 minutes.
13. Drain the oil.
14. Fill the system with new oil.
The indicator on the gauge (G) must be in the upper section of the green zone.
15. Run the compressor without load in light mode for 15 minutes and check for leaks.
16. Check that the oil level on gauge is in green zone and top up if necessary.
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16.9 Check Compressor Components
n Check for signs of oil or water leakage on the compressor (A).
n Check connections and couplings on intake manifold on the air filters (B) for compres
sor and diesel engine.
16.10 Drain Compressor
Condition p The drill rig must have been standing still for eight hours before draining off the water.
n Open the drain plug (A) and drain off the water.
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16.11 Clean Compressor Oil Cooler
n Use compressed air to keep the compressor oil cooler clean in order to maintain effi
cient cooling.
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SmartROC T45-11 17 Automatic Central Lubrication System CLS
17 Automatic Central Lubrication
System CLS
17.1 Central Lubrication System Pump
The central lubricating pump is a piston pump. An electric motor powers the pump element,
which pumps grease into the lubricating system. There is room for six pump elements. The
required pump time intervals can be set on the Program Display of the pump. The pump is
designed for maximum two hours continuous operation. The system can be damaged by
continuous operation under maximum pressure.
A Spring
B Grease outlet
C Safety valve
D Outlet
E Suction port
F Piston
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17.2 Setting Lubrication and Interval Time
Adjustment Unit
Condition p A time limit of 20 seconds must not be exceeded without touching any symbol. If so, the
program returns to the last time interval stored.
p If the power is cut off, the last program set is used.
p The pump is designed for maximum two hours continuous operation.
1. Start the adjustment of lubrication time by quickly moving the adjustment unit (A) over
the SERVICE symbol twice. A green light comes on and the second digit starts to
flash.
2. Change the second digit by moving the magnetic coupling over the ADDITIONAL
CYCLE symbol until the correct value is obtained.
3. Confirm by touching the SERVICE symbol.
4. The first digit starts to flash. Change the first digit by moving the magnetic coupling
over the ADDITIONAL CYCLE symbol until the correct value is obtained.
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6. The minutes or seconds start to flash in the program display. Select the correct time
unit by moving the adjustment unit over the ADDITIONAL CYCLE symbol.
8. A yellow light comes on and the second digit starts to flash, indicating setting of inter
val time.
9. Change the second digit by moving the magnetic coupling over the ADDITIONAL
CYCLE symbol until the correct time is obtained.
11. The first digit starts to flash. Change the first digit by moving the magnetic coupling
over the ADDITIONAL CYCLE symbol until the correct time is obtained.
12. Finish by touching the SERVICE symbol for two seconds with the adjustment unit.
Result è The time will be counted down to the next cycle in the display. If the pump runs for
one lubrication cycle, the time is counted down to the next interval. If the pump is sta
tionary, it counts down to the next lubrication cycle.
17.3 Check Condition of CLS pump
n Check that there is no leakage on the safety valve (A) on the CLS pump.
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17.4 Setting Lubrication Pump
The adjustments are made by moving an adjustment unit (A) over the SERVICE and
ADDITIONAL CYCLE symbols on the Program display. The adjustment unit (A) is mounted
below the pump (B). If there is no adjustment unit, a strong magnet can be used. If a fault
signal caused by the engine or control equipment appears, contact Atlas Copco. Do not
open the protective engine cover.
Display Function
WAIT. Yellow LED Interval
LUB. Green LED Lubrication
WARN. Red LED warning, error
HOUR Time Unit
MINUTE Time Unit
SECOND Time Unit
SERVICE Used When Setting
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Display Function
ADDITIONAL CYCLE Extra Lubrication Cycle and Used When Setting
17.5 Filling Lubricant
! NOTE: When lubricant is added to the container, maximum cleanliness is required.
Use a filler pump when filling with lubricant.
n Fill with lubricant via the nipple (A) or fast coupling (B).
17.6 Bleeding Lubrication Pump
! NOTE: It is important to bleed the pump after filling with lubricant when replacing the
pump or pump element.
Condition p The lubrication pump must be switched off.
1. Remove the pump element from the pump housing.
2. Remove the piston and spring.
3. Add grease to the housing.
4. Compress with the piston.
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5. Repeat until the grease is free from air and emerges at the outlet.
6. Install the pump element in the pump housing.
17.7 Lubrication Pump Program Display Alarm List
Alarms shown in the program display:
Alarm Type Function
A1 Low Level Alarm Fill the container. Not all containers are equipped
with a low level sensor.
A2 Pressure Alarm Set pressure is achieved. Not all pump elements
are equipped with a pressure monitor.
A3 Motor Alarm There is an open circuit in a cable or a motor mal
function.
A4 Fuse Alarm A fuse has blown.
17.8 Troubleshooting CLS
! NOTE: Flushing with high pressure water can damage the pump and control system.
Fault Symptom Indication Action
Pump does not work. The system has paused. Wait until the next lubrication cy

cle or move the adjustment unit
over the ADDITIONAL CYCLE
symbol (EC type) to start a lubri
cation cycle.
The electrical contact has come Check all cables and electrical
loose or been damaged. connections.
The pump works but does not The container is empty. Add lubricant.

deliver lubricant.
There is air in the pump element. Bleed the pump.
If lubricant leaks from the safety valve, this is because some of the distributors have been blocked.
Carry out a fault search, replace or clean the blocked distributor. A blocked distributor means that the
pressure in the system is the same as the pressure set at the safety valve.
All lubrication points are dry. Container is empty Add grease in container
Break in feed line Repair feed line
Control unit incorrectly set Reset control unit
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Dirt in check valve in pump ele Check the pump element by de
ment. taching the line. Run manual lu
brication and check that the
pump is supplying grease with
out it being drawn back in.
Overpressure valve trips. One of the metering pistons is With the pump switched on, start

stuck due to contamination by releasing outgoing lines from
the main block one at a time to
Lubricant line or lubrication point see if there is overpressure in
blocked one of the lines.
If there is no overpressure, the
fault lies in the lower block to
which the lines are connected.
Do the same there, release one
line at a time.
If there is overpressure in the lu
brication point line, the fault lies
between the metering block and
the lubrication point.
If there is no overpressure, one
of the metering pistons in the
metering block has stuck. Re
place or clean the metering
block.
Pump does not run Cable break Check that there is power to the

pump unit. If there is power, the
fault lies in the pump.
If there is no power, check that
there is power to the fuse for
supplying the pump.
Check if electrical contact de
tached.
Fuse blown Replace the fuse.
Not enough lubrication Lubrication time too short Increase lubrication
Pause time too long Shorten the pause time
Dirt in pump element check Check the pump element by de
valve taching the line. Run manual lu
brication and check that the
pump is supplying grease with
out it being drawn back in.
Overpressure valve trips One of the metering pistons has With the pump switched on, start

stuck due to contamination by releasing outgoing lines from
the main block one at a time to
Lubricant line or lubrication point
see if there is overpressure in
blocked
one of the lines.
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If there is no overpressure, the
fault lies in the lower block to
which the lines are connected.
Do the same there, release one
line at a time.
If there is overpressure in the lu
brication point line, the fault lies
between the metering block and
the lubrication point.
If there is no overpressure, one
of the metering pistons in the
metering block has stuck.
Replace or clean the metering
block.
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SmartROC T45-11 18 Water Mist System
18 Water Mist System
NOTICE
Damage to Water Mist Pump
Risk of damage to water mist pump if it is run without water in the system.
u Do not run the pump without water in the system.
NOTICE
Risk of Damage to Water Mist System
During cold weather, the water present in the water mist system can freeze and dam
age the system when the machine is turned off for a prolonged period.
u Drain the water mist tank.
u Flush antifreeze through the system.
NOTICE
Risk of Damage to DCT
If the dust collecting in the DCT is damp or if water starts flushing out of the drill hole,
hoses and filters in the DCT can start to clog.
u Switch off the dust collector if the dust is damp or if water starts flushing out of the drill
hole.
Water is pumped from a tank on the machine into the air circuit by a hydraulicdriven
pump. The pump is located in a compartment on top of the water tank. The water mist sys
tem is not pressurized.
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18.1 Check Seals on Water Mist Pump
1. Run the water mist pump (A) for 1 minute.
2. Count the number of water drops that run out from the drain holes (B).
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è Replace the all old seals with new ones if more than 10 drops leak out of the
drain holes during one minute.
Seals on Water Mist Pump
A Seals
B Piston seals
18.2 Filling Water Mist Tank
NOTICE
Filling the water mist tank with dirty water can cause damage to the system.
u Always fill the water mist tank with clean water.
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1. Remove the filler cap (B).
2. Add water to the tank via hole (A).
3. Refit the filler cap (B).
18.3 Draining Water Mist System
1. Unscrew bolt from the drain hole (B).
2. Drain water from water mist tank.
3. Screw the bolt back into the drain hole (B).
4. Put the machine in drilling mode.
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5. Turn off flushing air.
6. Run the water mist pump for 20 seconds at full power to purge the water from the
hoses.
7. Turn on flushing air for a few seconds to blow out the remaining water from the sys
tem.
18.4 Starting Up Water Mist System from Dry
NOTICE
Filling the water mist tank with dirty water can cause damage to the system.
u Always fill the water mist tank with clean water.
NOTICE
Damage to Water Mist Pump
Risk of damage to water mist pump if it is run without water in the system.
u Do not run the pump without water in the system.
1. Fill up the water mist tank.
2. Turn off flushing air.
3. Run the water mist pump at full speed for a few seconds so that the system fills up
with water.
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18.5 Clean Filter in Water Mist Tank
Condition p The water mist tank must be empty.
1. Unscrew and remove the 6 bolts holding the cover (A) in place.
2. Reach into the hole and slide the filter (B) off the water intake pipe and remove it from
inside the tank.
3. Inspect and clean the filter. If the wire mesh is damaged, replace it with a new filter.
4. Reach into the tank and push the filter back onto the water intake pipe.
5. Refit the cover using the 6 bolts. Ensure that all washers and seals are correctly
placed.
6. Fill up the water mist tank with clean water and check that the cover does not leak.
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SmartROC T45-11 19 Welding
19 Welding
19.1 About Welding
WARNING
Risk of Poisoning
Substances are formed when the paint is heated which are hazardous to health and
could cause eczema, eye irritation, respiratory system difficulties and in severe cases
asthma or other health problems.
u Always use personal protection such as appropriate breathing apparatus, eye protec
tion and gloves.
u Always ensure there is good ventilation when welding, grinding and other hot work that
involves heating the paint.
! NOTE: Any modification to the machine, associated equipment and accessories is not
allowed in any form.
Contact Atlas Copco before welding on components or frames. Consult Atlas Copco for ap
proval of welding and choice of electrodes.
n All welding must be performed by authorized personnel.
n If repair welding is necessary, damaged units should preferably be removed and re
paired separately.
n Disconnect the cables from the alternator, the battery and the electronic modules.
n Welding equipment must be grounded correctly.
n Framework, brackets and loadcarrying structures are made of special materials. Any
repair welding carried out using incorrect materials or additives can weaken the struc
ture.
n Avoid welding close to bearings and bushes.
n Do not weld hydraulic tanks, valve blocks, compressed air tanks or pressure lines.
n Protect hoses, cables and electric components.
n If possible, grind the surface of the weld smooth and treat it with anticorrosion paint.
! NOTE: Always keep a fire extinguisher for oil fires near during all types of welding, cut
ting and grinding. Screen off the work area from flammable materials.
19.2 CAN Bus System Disconnection Before Welding
! NOTE: The CAN bus and RCS can be severely damaged when welding.
NOTE: Consult Atlas Copco for approval of welding and choice of electrodes.
n Locate all modules present on the machine. Disconnect supply voltage to all modules,
both + (positive) and (ground).
l Example of modules which can be present: application module, I/O module,
resolver module and CSmodule.
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SmartROC T45-11 19 Welding
n Locate all sensors on the machine and disconnect them.
n Locate the safety controller and disconnect supply voltage, both + (positive) and
(ground).
n Locate all panels included in RCS and disconnect supply voltage, both + (positive) and
(ground).
n Remove the battery's ground cable.
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SmartROC T45-11 20 Downtime
20 Downtime
20.1 Preparations Before Long Period of Downtime
Protect the equipment from corrosion and storage damage if downtime is expected to last
three months or longer. If environment is, for example corrosive or dusty, additional protec
tion may be necessary.
n Wash the equipment thoroughly and wipe it dry. Use compressed air to blow any col
lections of water out of cavities and pockets.
n Protect from rain, snow and strong sunshine. Keep regulated temperature and ventila
tion. Recommended storage environments should maintain a temperature of 1020 ºC
and maximum 2050% humidity. Storage site must be free from severe vibration in or
der to avoid spot damage to the equipment.
n Apply corrosive protection compound (Tectyl 506 for example) to machined surfaces.
n Apply touchup paint to any scratches and damage on painted areas.
n Cover all equipment with plastic sheet.
n Clean old grease from lubrication points to prevent coke formation. Pump new grease
into lubrication nipples. Apply grease with a brush to sliding surfaces and splines
where these occur. Use the correct grease for each point.
n Observe the strictest cleanliness when dismantling hydraulic, compressed air and wa
ter flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes, or seal
and protect them from dirt in some other suitable way.
n Mark hoses, pipes and other connections to make reassembly easier and prevent mix
ups.
n Hoses and rubber parts should be packed in airtight plastic to reduce ageing and dry
ing out. Ensure that components are dry before packing.
n The water mist system must be drained and rinsed with antifreeze.
n The battery must be disconnected. If the temperature falls below freezing point then
the battery must be stored indoors.
n The gas accumulator must be drained.
n The shank adapter must be greased.
n Fuel and oil tanks must be filled.
n If shutdown is planned for a long time, the rock drill must be removed and protected
before storage.
20.2 Restoring After Long Period of Downtime
n Change lubricant and hydraulic oil where appropriate.
n Change filter and drain water separators where appropriate.
n Inspect joints, bushings and splines for corrosion. Remedy any corrosion by cleaning
or replacing components.
n In order to remove any moisture binding from lubrication points: Pump new grease into
the grease nipples and apply grease with a brush to sliding surfaces and splines where
these occur. Use the correct grease for each point.
n Carry out special startup as instructed.
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SmartROC T45-11 20 Downtime
20.3 Inspection and Maintenance During Period of
Downtime
n Check levels for oils and coolants.
n Start the diesel engine and let it run until normal operating temperature has been
reached.
n Operate the rig a few metres back and forth so that the tramming gears are lubricated.
n Operate the tilt cylinders, boom, feeder, drill support and rod handling so that all cylin
ders reach their end positions.
n Drain condensed water from the hydraulic oil tank and compressor oil tank.
n Rotate the electric motors a few turns at least every three months to avoid spot dam
age on motor bearings.
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SmartROC T45-11 21 Start-Up
21 StartUp
21.1 About Special StartUp
Special startup is performed when commissioning the machine for the first time. An Atlas
Copco representative will perform a special startup procedure.
Special startup of drilling machine and associated equipment is also performed in the fol
lowing cases:
n After a long standstill (one month or more).
n After major change of components or repairs.
Maintenance personnel or an Atlas Copco representative shall take part when starting up
or during a test startup after maintenance.
21.2 Performing Special StartUp
WARNING
Risk of Serious Personal Injury
u Stay out of the machine's operating zone.
1. Followup on any installation or maintenance work that has been carried out and com
ponents that have been changed. These will require special attention during special
startup.
2. The pumps must be primed before start if the circuits have been drained.
3. At the startup moment, the operator and any personnel present should stay out of the
machine's operating zone (4 m allround). Maintenance technicians can later enter
this zone. Operators should remain with the operating console or remote panel in the
immediate vicinity of the emergency stop.
4. Check that the fire extinguisher and fire fighting system are fully functional.
5. Pay extra attention to any electrical work that has been carried out.
6. Listen for any noise that indicates defects. Stop the machine immediately if this
should occur.
7. Look for any signs of overheating or fire.
8. After a special startup, the operator and maintenance technician must carry out re
maining checks as instructed.
21.3 Flushing of Hoses and Pipes
After first startup and after long standstill, flushing of the external hoses and pipes are rec
ommended.
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SmartROC T45-11 21 Start-Up
1. Disconnect the hoses from the hydraulic cylinders and join together the hose piston
and piston rod end.
2. Flush each circuit for approximately 10 minutes. Use a high flow at low pressure.
3. Check the hydraulic oil level on the level gauge before flushing the next circuit.
4. After flushing all the circuits, switch off and connect the hoses to the cylinders.
5. Place a vessel by the hydraulic tank with a hose from the filling/draining system in the
vessel. Remove the protective hose plug.
6. Top up the oil level in the hydraulic tank after bleeding air from the system.
21.4 About Testing Pressure Release Valves
The test procedure involves removing each valve and loading it with pressure in a test
bench to ensure its setting and function. This requires special test equipment and a sound
knowledge of the hydraulic system. Contact Atlas Copco for pressure testing relief valves
used in critical safety functions.
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SmartROC T45-11 22 Options
22 Options
22.1 Winch
22.1.1 Check Attachment of Winch Cable
WARNING
Risk of Tipping and Cable Failure
u The anchorage point must be firm and secure.
u The safety hook must not slide or detach from the attachment point.
u Do not use a damaged cable or hook.
! NOTE: It is important that the cable is correctly fitted in the winch eye.
A Cable
B Rope lock
C Connector sleeve with wedge plug
D Hook
Correct assembly:
n The cable must run in line with the eye on the connector sleeve.
n The rope lock must only lock the end cable.
n The free end must be at least 69 times the diameter of the cable in order to ensure
that the whole section of the cable, that is either lashedin or annealed and tapered, is
outside the connector sleeve.
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The cable and winch eye must be checked:
n before each use.
n when replacing the cable.
n when attaching the cable after shortening.
Check that the winch locking mechanism is fully engaged in the drum before use, following
the attachment of the cable eye on the anchorage point.
22.1.2 Check Winch Unit Attachment
n Check tightening torque (A).
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22.1.3 Lubricate Winch
1. Remove the plug (A) in the bottom of the gear housing for draining. The gearing is
permanently lubricated.
2. Lubricate with oil if the drum brake (B) does not rotate freely.
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22.1.4 Check Winch
n Check for damage, unwinding, wear and corrosion on the winch wire rope (A).
n Check for damage, cracks and wear on the hook (B) and check that it is properly
mounted.
22.1.5 Check Small Remote Control
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n Make sure none of the rubber bellows (A) on switches/levers on the winch box is
damaged
22.2 Service Tool Bag RCS
The service tool bag is used for troubleshooting machines equipped with Atlas Copco
RCS.
A CAN Tester
B Resolver Tester
C Multimeter
D Encoder Tester
E CAN Open Cable
F I/O Tester
G Signal Cable
H Test Cables
I Test Box
J Connectors
K Torque tools
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L Torque tools
M Contact
22.3 Checking CAN Network
1. Set the multimeter range to DC Volt.
2. Connect the tester's 5pin connectors to the CAN network requiring measurement:
a. Decoder: contact X3 or X4
b. Display, application and master modules: connector X2, X3 or X4
c. I/O modules: contact X1 or X19
d. Resolver modules: contact X3 or X4
Result è MAIN POWER (Supply voltage) 2428 V (shines green)
CAN POWER (CAN power supply) 2024V (shines green)
CAN HI (CAN communication), about 2.5V (flashes green)
CAN LO (CAN communication), about 2.3 V (flashes green)
Table 2: Normal State
CAN HI glows red constantly for short circuit to ground
CAN HI glows green constantly for voltage above 3.5 V
CAN LO glows green constantly for short circuit to ground
CAN LO glows red constantly for voltage above 3.5 V
If neither CAN HI nor CAN LO is lit, there is no communication even though power
is being supplied to CAN
If any light is flashing red, then CAN communication is at the wrong level or is in
verted
Table 3: Fault Indication
22.4 Checking CAN Power Supply
1. Set the multimeter range to DC Volt .
2. Connect the tester's 5pin connector to the module's power supply.
3. I/O modules: contact X25. 7pin contact. Use enclosed Tcross.
4. Other modules: connector X1. 4pin connectors.
Result è MAIN POWER (The power supply) must be 2428V (lights green).
22.5 Checking CAN Cable
Condition p Make sure the RCS system is shut down.
1. Set the multimeter measuring range to ohms.
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2. Connect the tester's 5pin connectors to the CAN network requiring measurement:
a. Decoder: contact X3 or X4
b. Display, application and master modules: connector X2, X3 or X4
c. I/O modules: contact X1 or X19
d. Resolver modules: contact X3 or X4
3. Select CABLE TEST on the CAN tester.
è The multimeter should read about 6065 Ohms if the cable is intact.
Because of the internal resistance in the tester the multimeter reads about 100 kOhm if the
cables are not connected or if there is an open circuit.
22.6 Checking Digital Inputs on I/O Module
In each designated contact there are two digital inputs, A and B.
1. Connect the 5position connector on the I/O tester between the input of interest on the
I/O model and the guard.
2. Connect the multimeter between Ground and the Signal A (+A) or Signal B (+B) out
put of interest.
3. Measure the voltage according to the table.
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è The signal is 0V for an open contact and +24V for a closed contact.
Pin Function
1 +24V DC
2 Signal B
3 Ground
4 Signal A
5 Ground
Table 4: Pin Configuration
22.7 Checking Digital Outputs Voltage on I/O Module
In each designated contact there are two digital outputs, A and B.
1. Connect the 5position connector on the I/O tester between the output of interest on
the I/O module and the valve.
2. Connect the multimeter between Ground and the Signal A (+A) or Signal B (+B) out
put of interest.
3. Activate the function. The multimeter should read 24V.
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Result è If the valve is not activated, there can be an open circuit in the cable running to the
valve or in the coil in the valve.
Pin Function
1 +24V DC
2 Signal B
3 Ground
4 Signal A
5 Ground
22.8 Checking Digital Outputs Current on I/O Module
In each designated contact there are two digital outputs, A and B.
2. Connect the multimeter in series with the +A or +B output.
3. Activate the function. The multimeter should read 1A.
Result è If the multimeter reads 0.00A and the solenoid coil diode comes on, there could be
an open circuit in the valve's coil.
127
22.9 Checking PWM Outputs Current on I/O Module
In each designated contact there are two PWM outputs, A and B.
2. Connect the multimeter in series with the +A or +B output that is of interest.
3. Activate the function. Check that the current corresponds with the actuated value on
the display.
Pin Function
1 Not Used
2 Out +B
3 Out B
4 Out +A
5 Out A
128
22.10 Checking Analog Inputs on I/O Module
In each designated contact there are one analog input.
1. Connect the 5position connector on the I/O tester between the input of interest on the
I/O model and the sensor.
2. Measure the values according to the table.
Pin Function
1 +24V DC
2 05V
3 Ground
4 420mA
5 +5V DV
22.11 Encoder Inputs
Each encoder connector has two signals, A and B.
There are two designated contacts, X12 and X18, for the pulse sensor.
Pin Function
1 +24V DC
2 B
3 Ground
129
Pin Function
4 A
5 Ground
22.12 Checking Resolver Module Resolver Inputs
There are designated contacts, X6 X9, for the inputs.
1. Connect the resolver tester to the relevant cable. Turn the test sensor slowly and
check that the angle shown on the sensor menu changes.
a. If the angle changes, the sensor on the boom is faulty.
b. If the angle does NOT change, the cable on the boom must be checked.
2. Connect the test sensor and test cable directly to the resolver module input. Turn the
test sensor slowly and check that the angle on the sensor menu changes.
a. If the angle changes, the cable on the boom is faulty
b. If the angle does NOT change, the resolver module is faulty.
Pin Function
1 Ref +
2 Ref
3 Sine Signal
4 Sine Ground
5 Cosine Signal
6 Cosine Ground
130
22.13 Checking Resolver Module Encoder Inputs
There are a designated contact, X10, for the pulse sensor.
1. Connect the encoder tester to the relevant cable. Turn the test sensor slowly and
check that the length measurement shown on the sensor menu changes.
a. If the measured value changes, the sensor on the boom is faulty.
b. If the measured value does NOT change, the cable on the boom must be
checked.
2. Connect the test sensor with test cable directly to the resolver module input. Turn the
test sensor slowly and check that the length measurement shown on the sensor menu
changes.
a. If the measured value changes, the cable on the boom is faulty.
b. If the measured value does NOT change, the resolver module is faulty.
Pin Function
1 + 15V
2 + 15V
3 Signal A
4 Ground
5 Signal B
6 Ground
22.14 Checking Resolver Module Analog Inputs
There are two designated connectors, X11 and X12, for analog input.
131
1. Connect the resolver module connector X11 or X12 to test box connector (B).
2. Connect the multimeter to test box pins 2 and 3.
3. Set the multimeter to DC voltage. It should read 4.5V on connector X11 and 15V on
connector X12.
If the multimeter reading is 0V there may be a fault in the signal cable or resolver
module. Continue as follows:
a. Connect the cable (C) on the test box to resolver module input X11 or X12 and
measure between 1 and 2.
b. Recheck the multimeter reading. If it is 0V, there is a fault on the resolver module
input , X11 or X12.
Pin Function
1 Ground
2 + 4.5V DC Power Supply Out
3 Signal In
4 Not Used
5 Not Used
Table 10: Pin configuration for input X11
Pin Function
1 Ground
2 + 15V DC Power Supply Out
3 Signal In
4 Not Used
5 Not Used
Table 11: Pin configuration for input X12
132
22.15 Replacing a RCS Module
Condition p Make certain that electric power is present at the machine or that the diesel engine is
running before loading the program. Avoid starting the diesel engine while the program is
being loaded. Never turn off the system while the program is being loaded.
1. Make certain the module has the correct address plug and that the end plug (if any) is
mounted in place.
2. When any of the application module, I/O or resolver module is replaced, the program
must be read into the system again.
3. Insert the USB memory stick with the program into the USB port and start the RCS
system.
4. When the program has been fully loaded, the following will appear on the display: Re
move card and restart the system!.
5. Switch off the system remove the USB memory stick and start the RCS system.
133
134
SmartROC T45-11 23 Specifications
23 Specifications
23.1 Standard Tightening Torques Bolted Joints
All bolted joints are tightened to the torque required by Atlas Copco Standard K 4369:01 K
(metric) and 4368K/01K (imperial) unless otherwise specifically stated. In such cases, this
will be specified in the maintenance instructions of the module in question.
All bolted joints must be lubricated with Molycote 1000 or corresponding thread lubricant
with a coefficient of friction 0.11 μ.
Size Grade 8.8 Nm Grade 10.9 Nm Grade 12.9 Nm Tolerance

(lbft) (lbft) (lbft)
M6 8.6 (6.4) 12.4 (9.2) 14.5 (10.7) ±5%
M8 21 (16) 30 (22) 35 (26) ±5%
M10 42 (31) 60 (44) 70 (51) ±5%
M12 73 (54) 104 (77) 122 (90) ±5%
M14 116 (85) 166 (122) 194 (143) ±5%
M16 181 (133) 258 (190) 302 (222) ±5%
M18 257 (189) 355 (262) 415 (306) ±5%
M20 365 (269) 503 (371) 590 (435) ±5%
M24 631 (465) 872 (643) 1018 (751) ±5%
M30 1254 (925) 1734 (1279) 2024 (1493) ±5%
M36 2187 (1613) 3027 (2232) 3535 (2608) ±5%
M39 2834 (2090) 3917 (2889) 4580 (3378) ±5%
Table 12: Tightening Torques Metric
Size SAE Grade 5 Nm SAE Grade 8 Nm Tolerance

(lbft) (lbft)
.2520 10 (7) 13 (10) ±5%
.3816 35 (26) 50 (36) ±5%
.5013 85 (62) 120 (88) ±5%
.6311 170 (124) 240 (175) ±5%
.7510 300 (220) 420 (310) ±5%
.889 480 (355) 680 (500) ±5%
1.008 720 (530) 1020 (750) ±5%
1.137 890 (655) 1445 (1065) ±5%
1.257 1260 (930) 2040 (1500) ±5%
135
SmartROC T45-11 23 Specifications
Size SAE Grade 5 Nm SAE Grade 8 Nm Tolerance

(lbft) (lbft)
1.386 2120 (1560) 3442 (2540) ±5%
1.506 2190 (1610) 3540 (2610) ±5%
Table 13: Tightening Torques Imperial U.S
23.2 Signs for Ordering Spare Parts
Signs are placed on the larger components. When ordering spare parts or making inquiries
regarding the machine, the type designation and serial number must always be stated.
Type designations and serial numbers are specified in a separate document, MI (Machine
Identification). Spare parts can be ordered from Atlas Copco.
136
SmartROC T45-11 Maintenance table
Maintenance table
Maintenance cycle Personnel Additional information
50 Percussion Hours Operating Personnel 7.6.1 Drain Condensate from Hydraulic Oil

Tank
Maintenance Personnel 7.6.1 Drain Condensate from Hydraulic Oil

Tank
100 Percussion Hours Maintenance Personnel 5.7 Check DrillSteel Support
5.9 Check Rod Handling
250 Percussion Hours Maintenance Personnel 5.10 Clean Behind Sealing Disc
500 Percussion Hours Maintenance Personnel 14.2 Check Dust Collector Filters
50 Diesel Engine Hours Maintenance Personnel 5.5 Check Sprocket Wheel
5.12 Lubricate Chain Feed
7.5.2 Check Breather Filter
12.1 Check Cabin
16.9 Check Compressor Components
16.10 Drain Compressor
16.11 Clean Compressor Oil Cooler
22.1.2 Check Winch Unit Attachment
250 Diesel Engine Maintenance Personnel 4.2 Check Boom Condition

Hours
5.8 Check Chain Feed
5.14 Replace Slide Rails
5.15 Replace Slide Pieces in the Holder
7.5.4 Replace Breather Filter
11.1.1 Clean Radiators
18.1 Check Seals on Water Mist Pump
500 Diesel Engine Maintenance Personnel 5.2 Check Jack Chain Cover

Hours
5.3 Check Feed Beam
5.4 Check Chain Guide
137
7.7 Check Mounting Hydraulic Jack
15.15.2 Replace the Filter Cartridge
1000 Diesel Engine Maintenance Personnel 3.2 Check Condition of Signs

Hours
7.6.4 Drain Hydraulic Oil Tank
15.11 Replace Secondary Fuel Filter
15.15.1 Air Filter Indicator Function
16.5 Change Oil on Compressor
18.5 Clean Filter in Water Mist Tank
1500 Diesel Engine Maintenance Personnel 13.7 Change Oil on Track Frames

Hours
22.1.3 Lubricate Winch
2000 Diesel Engine Maintenance Personnel 7.4 Check Hoses and Couplings

Hours
14.3 Replace Dust Collector Filters
16.6 Replace Separator Filter
5000 Diesel Engine Maintenance Personnel 5.13 Replace Bearing Unit

Hours
15.10 Replace PreFilter
6000 Diesel Engine Maintenance Personnel 15.14 Replace Longterm Effective Coolant

Hours
Daily Operating Personnel 3.1 Wash Machine Externally
6.1 Check Lubrication Oil Level Tank
7.6.2 Drain Condensate in Pressure Tank
9.2 Check Emergency Stops and Work
Lights
11.1.2 Check Coolant Level
15.1 Check Motor Oil Level
15.2 Drain PreFilter
16.2 Check Compressor Oil Level
17.3 Check Condition of CLS pump
22.1.1 Check Attachment of Winch Cable
22.1.4 Check Winch
138
22.1.5 Check Small Remote Control
Weekly Maintenance Personnel 5.11 Lubricate Rod Handling
Quarterly Maintenance Personnel 3.2 Check Condition of Signs
Annually Maintenance Personnel 7.4 Check Hoses and Couplings
7.6.3 Clean Hydraulic Tank
139

Smartroc T45 11: Maintenance

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Smartroc T45 11: Maintenance

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2 About Maintenance Management ...................................................................... 11

4 Boom Unit ............................................................................................................ 15

5 Feeder Unit .......................................................................................................... 17

6 Drilling Machine .................................................................................................. 33

7 Hydraulic System ................................................................................................ 35

8 Electrical System ................................................................................................ 43

10 Control System and Sensors ............................................................................. 51

11 Cooling System ................................................................................................... 53

12 Operator's Environment ..................................................................................... 57

13.3.2 Checking for Track Roller Wear ............................................................................................. 64

18 Water Mist System ............................................................................................ 107

19 Welding .............................................................................................................. 113

20 Downtime ........................................................................................................... 115

21 Start­Up .............................................................................................................. 117

Maintenance table ............................................................................................. 137

Size Torque in Nm Quantity/track Comments

B2 M16 210 1 T45, C50, D50,

F1 9/16” UNF 260 ± 10 176 T45, C50, D50,

Size Torque in Nm Quantity/track Comments

F2 M16 370 ± 20 176 T50LF, D60, D65,

Specification Metric Data Imperial U.S Data

New Front Wheel 16.5 mm 0.65 in

Wear 25% 17.6 mm 0.70 in

Wear 50% 19.4 mm 0.77 in

Wear 75% 21.7 mm 0.86 in

Wear 100% 24.4 mm 0.96 in

Specification Metric Data Imperial U.S Data

New Track Roller 160.0 mm 6.30 in

Wear 25% 156.8 mm 6.18 in

Wear 50% 153.0 mm 6.03 in

Wear 75% 148.9 mm 5.86 in

Wear 100% 143.7 mm 5.66 in

Specification Metric Data Imperial U.S Data

New Carrier Roller 100.0 mm 3.93 in

Wear 25% 97.0 mm 3.82 in

Wear 50% 93.7 mm 3.68 in

Wear 75% 89.6 mm 3.53 in

Wear 100% 84.7 mm 3.33 in

Specification Metric Data Imperial U.S Data

New Track Shoe 22.0 mm 0.87 in

Wear 25% 19.2 mm 0.76 in

Wear 50% 16.0 mm 0.63 in

Wear 75% 12.9 mm 0.51 in

Wear 100% 9.7 mm 0.38 in

Specification Metric Data Imperial U.S Data

New Track Shoe 47.0 mm 1.85 in

Wear 25% 40.9 mm 1.61 in

Wear 50% 34.2 mm 1.35 in

Wear 75% 27.5 mm 1.08 in

Wear 100% 20.8 mm 0.82 in

Specification Metric Data Imperial U.S Data

New Chain 83.0 mm 3.27 in

Wear 25% 81.6 mm 3.22 in

Wear 50% 79.8 mm 3.15 in

Wear 75% 77.9 mm 3.07 in

Wear 100% 75.7 mm 2.98 in

Specification Metric Data Imperial U.S Data

New Bushing 45.0 mm 1.77 in

Wear 25% 44.6 mm 1.76 in

Wear 50% 44.2 mm 1.74 in

Wear 75% 43.7 mm 1.72 in

Wear 100% 43.0 mm 1.69 in

21 StartUp .............................................................................................................. 117

Pump does not work. The system has paused. Wait until the next lubrication cy

.2520 10 (7) 13 (10) ±5%

.3816 35 (26) 50 (36) ±5%

.5013 85 (62) 120 (88) ±5%

.6311 170 (124) 240 (175) ±5%

.7510 300 (220) 420 (310) ±5%

.889 480 (355) 680 (500) ±5%

1.008 720 (530) 1020 (750) ±5%

1.137 890 (655) 1445 (1065) ±5%

1.257 1260 (930) 2040 (1500) ±5%

1.386 2120 (1560) 3442 (2540) ±5%

1.506 2190 (1610) 3540 (2610) ±5%

100 Percussion Hours Maintenance Personnel 5.7 Check DrillSteel Support

6000 Diesel Engine Maintenance Personnel 15.14 Replace Longterm Effective Coolant