Atlas Copco Service & Maintenance Instructions

6991 1252 01d | 2016-03-17

 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

Contents
Introduction ...................................................................................................................................................................... 2
Safety Regulations............................................................................................................................................................. 3
Disassembly Instructions .................................................................................................................................................. 4
Assembly Instructions ....................................................................................................................................................... 7
Nitrogen gas charging ..................................................................................................................................................... 13
Charging instructions .................................................................................................................................................. 13
RCSU 50 & 85 kN (3719 0116 58 & 3719 0116 59) ......................................................................................................... 15
Repair Kit (3719 0005 67) contents ................................................................................................................................ 15
Tool Kit (3719 0005 68) contents .................................................................................................................................... 16
RCSU 130 kN (3719 0032 88) .......................................................................................................................................... 17
Repair Kit (3719 0020 66) contents ................................................................................................................................ 17
Tool kit (3719 0020 67) contents .................................................................................................................................... 18

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

Introduction
The purpose of this manual is to describe how to service the Kaller Rod Clamp Spring Units (RCSU). This service
instruction is valid for the following RCSU models with part numbers:

 3719 0005 67 (RCSU 85 kN)

 3719 0116 58 (RCSU 50 kN)

 3719 0032 88 (RCSU 130 kN)

Pictures in service instruction may differ from the RCSU model being serviced.

The manual contains step-by-step instructions; showing you how to disassemble the RCSU, replace all seals,
reassemble the RCSU and finally charge the RCSU with nitrogen gas to the correct charging pressure.

Repair kits, part numbers 3719 0005 67 (for RSCU 50 and 85 kN models) and 3719 0020 66 (for RCSU 130 kN model),
are available containing all seals, replenishing valve, lubricating oil, etc. necessary to service the RCSU.

Tool kit, part numbers 3719 0005 68 (for RSCU 50 and 85 kN models) and 3719 0020 67 (for RCSU 130 kN model), are
available containing specialized tools necessary to carry out the service.

It is our recommendation that this manual is read thoroughly and both the repair kit and the tool kit are purchased
before attempting to service the RCSU.

When servicing the RCSU, we recommend you replace the whole unit if there are signs of excessive wear shown on
any gas-sealing surface, such as the Piston (Item 1) and Cylinder (Item 2). If there is hydraulic oil leakage, then the
Piston Rod (Item 3) can be replaced.

All Safety Regulations must be followed when servicing the RCSU – read the section on Safety Regulations
thoroughly before you start.

KALLER Rod Clamp Spring Unit

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

Safety Regulations
This symbol indicates WARNING of the risk of personal injury!

 Read all instructions carefully before you service the RCSU

 Do not attempt to service the RCSU if you are unfamiliar with the procedure.

 Do not remove the gas valve until all gas pressure has been released.

 Never lean over the gas valve. Direct the charging port away from you and other people when working with
the valve plug and valve.

 Never use unnecessary force when working on the RCSU and protect the unit from mechanical damage.

 Do not attempt to modify the unit in any way.

 Do not attempt to recharge the RCSU until you are sure everything is correctly assembled.

 When recharging the RCSU, use only nitrogen (N2) gas. The use of other gas types could result in personal
injury or failure of the RCSU.

 Never charge the RCSU with nitrogen pressure above the maximum allowed pressure.

 Always use the correct torque setting when fitting the mounting screws.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

Disassembly Instructions
1. Fix the Rod Clamp Spring Unit (RCSU) in a vice fitted with protective
jaws as shown and remove the valve plug using a 5mm Allen key.
Using the valve tool, carefully release the gas pressure by screwing
the G1/8” threaded end of the tool into the gas port. When all gas
pressure is released use a plastic mallet to tap on the bottom to
make sure that it moves when tapped. Remove the valve using the
other end of the valve tool.

Never attempt to remove the valve until all gas pressure is released.
Avoid leaning over the valve when removing it in case it should fly out.

2. Using a mounting sleeve, tap in the bottom of the RCSU to expose

the lock ring. Remove the lock ring using the lock ring tool as
follows. Hold the lock ring steady in the groove opposite to the lock
ring opening with your left hand and with the lock ring tool in your
right hand, hook the tip of the tool under the left edge of the lock
ring. Push down on the tool against the edge of the cylinder and
remove the lock ring. Remove the RCSU bottom using a G1/8”
threaded T-handle in the gas port.

3. Drain the assembly oil from the RCSU into a suitable container.
Remove the two M12 screws from the mounting plate (only for
RCSU 50 and 85 kN models) using a hook spanner to prevent the
plate from rotating.

4. Remove the circlip from around the top of the RCSU. Then using an
O-ring hook or small screwdriver remove the dirt cover.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

5. Push down the guide using the mounting sleeve and plastic
mallet until the lock ring is exposed. Remove the lock ring
as previously described.

6. It is recommended to use two M12 screws for grip to

remove the piston rod assembly and guide. You may need
to first loosen the assembly from the tube using the
mounting sleeve and the plastic mallet on the underside of
the piston.

7. Fix the piston rod assembly in a vice using protective jaws to

prevent damage to the chromed piston rod. Remove the
circlip and unscrew the piston from the piston rod using a
hook spanner.

8. Remove and discard all seals, wear rings and back-up rings
from the piston both externally and internally.
Make sure not to scratch the sealing grooves when
removing the seals. The piston should be replaced if
scratches are found on any sealing surface.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

9. Remove the piston rod wiper from the guide using a plastic
hammer and flat-headed screwdriver for leverage. Carefully
remove the two wear rings and piston rod seal, avoiding
damage to the seal groove. Remove the external O-ring and
back-up ring also. The guide should be replaced if scratches
are found on any sealing surface.

10. Wash all parts thoroughly and check for scratches and
damage to sealed surfaces. Damaged or scratched parts
should be replaced.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

Assembly Instructions
1. Before assembling the piston seals make sure the piston has
been washed thoroughly. Lightly lubricate all O-rings, wear
rings and back-up rings with assembly oil. Assemble the piston
seals using the piston assembly tools making sure they are
assembled according to the drawing.

2. Secure the piston rod in a vice fitted with protective

jaws and assemble the piston. Fit the small circlip
around the end of the piston rod.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

3. Check to make sure the guide has been washed

thoroughly. Using a piston rod wiper assembly tool,
press in the wiper until the metal casing fits flush into
the groove. Lightly lubricate all O-rings, wear rings and
back-up rings with assembly oil. When fitting the piston
rod seal make sure it is assembled according to the
drawing shown here.

4. Using a mounting sleeve and plastic mallet, fit the guide onto
the piston rod assembly making sure the piston rod wiper faces
upwards.

5. Lubricate the inside opening of the cylinder using assembly oil at

the end closest to the hydraulic oil connection.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

6. It is recommended to use two M12 threaded screws to

lower the complete assembly into the lubricated end of the
cylinder.

7. Remove the M12 screws and tap down the assembly using
the mounting sleeve until the lock ring groove is fully
exposed. Initially you may need to apply a fair amount of
force to tap down the assembly.

8. Fit the lock ring by first positioning one edge of the lock ring
into the groove whilst holding the lock ring as flat to the
cylinder as possible. With the lock ring held down as flat as
you can manage, hit the other free end of the lock ring
sideways with a plastic mallet until you hear the lock ring
snap into place.

9. Use two M12 screws again to help pull out the assembly
against the lock ring.
The groove in the guide should be in-line with the end of the
cylinder.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

10. Press the dirt cover into the gap around the top of the
cylinder and fit the circlip into the groove in the guide.

11. Hold the RCSU in a vice fitted with protective jaws as shown
and fill with assembly oil.

Oil volumes:
40 ml. for RCSU 50 & 85 kN
150 ml. for RCSU 130 kN

12. Make sure the RCSU bottom is clean before lightly

lubricating and fitting the O-ring and back-up ring as shown
here.

Note! The back-up ring should sit closest to the threaded holes
in the base.

13. Position the RCSU in the vice. Use the mounting sleeve and
plastic mallet to fit the bottom into the cylinder with the four
threaded holes facing upwards. Tap down the bottom until
the lock ring groove is exposed.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

14. Fit the lock ring using the same technique as before.

15. Screw the T-handle into the G1/8” gas charging port and
pull out the bottom against the lock ring. Remove the T-
handle from the gas port.

16. Use the valve tool to fit the valve into the gas port. Only
finger strength is required to tighten the valve.

17. Assemble the front mounting plate (only for 50 and 85

kN models). Use Loctite 242 thread lock and apply 135
NM torque with the help of a hook spanner to fasten the
M12 screws.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

18. RCSU 50 and 85 kN

The two M12 threaded holes in the front mounting plate

and two of the opposing M10 threaded holes in the
bottom should be aligned in the same plane. This plane
must be perpendicular to the hydraulic G3/8” oil
connection port. Use M12 and M10 screws together with a
long screwdriver to help line up the holes.

19. RCSU 130 kN

Two of the M12 threaded holes in the front of the piston

rod and two of the opposing M12 threaded holes in the
bottom should be aligned in the same plane. This plane
must be perpendicular to the hydraulic G1/2” oil
connection port. Use M12 screws together with a long
screwdriver to help line up the holes.

Front View Rear View

20. The RCSU is now ready to be charged with nitrogen (N2)
gas.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

Nitrogen gas charging

Before attempting to charge the RCSU, give consideration to the following safety points:

 For safety reasons, never lean over the charging port.

 Do not attempt to charge the RCSU unless you are familiar with gas charging.

 We recommend your nitrogen gas bottle be fitted with a pressure regulator to control the output pressure
from the bottle.

Charging instructions
1. Secure the RCSU firmly in a vice fitted with protective jaws
with the bottom facing upwards.

2. Before connecting the replenishing armature to the bottom

plate make sure the sealing washer and G1/8” adapter are in
place. Next attach the armature to the charging port by
screwing the larger knob clockwise. Make sure the smaller
knob has not been twisted clockwise to expose the valve pin.

Note!

Twisting the smaller knob clockwise pushes out the valve pin from
inside the armature. This valve pin can be used to open the valve
when the armature is in place but is not needed when charging.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

3. Close the armature’s pressure release valve by screwing it

Charging Pressure Table
clockwise.
Part No. Model Charging
4. With the nitrogen gas bottle regulated to deliver 3 bar
Pressure
above the stated charging pressure in table to the right,
[bar]
slowly open the shutoff valve.
3719 0005 67 RCSU 85 kN 107
5. Slowly charge the RCSU until the pressure gauge fitted to
the armature reads correct pressure (charging pressure 3719 0116 58 RCSU 50 kN 70
plus 3 bar).
3719 0032 88 RCSU 130 kN 65
6. Close the shutoff valve and then open the pressure release
valve until the pressure gauge reads 0 bar.

7. With the pressure release valve closed, slowly twist the small
knob clockwise to open the valve. The moment the pressure
gauge displays the pressure in the RCSU stop twisting the
small knob.

8. By opening and closing the pressure release valve, reduce the

pressure to correct pressure according to charging table to
the right. Twist the small knob anticlockwise to close the
valve.

9. Open the pressure release valve before removing the

armature by twisting the larger knob anticlockwise.

10. Fit the G1/8” protective plug to the gas charging port and the
G3/8” or G1/2” plug to the oil connection port. The RCSU is
now ready for service once again.

11. In order to make sure all seals have been correctly assembled,
allow the RCSU to stand on its Mounting Plate end (RCSU 50
and 85 kN) or Piston Rod end (RCSU 130 kN) for 24 hours.
After 24 hours, compress the RSCU in a suitable Test Rig to
measure the initial force of the RCSU.

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

RCSU 50 & 85 kN (3719 0116 58 & 3719 0116 59)

Repair Kit (3719 0005 67)

contents

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

Tool Kit (3719 0005 68) contents

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

RCSU 130 kN (3719 0032 88)

Repair Kit (3719 0020 66) contents

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 ATLAS COPCO SERVICE & MAINTENANCE INSTRUCTIONS

Tool kit (3719 0020 67) contents

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 © Copyright 2016, Epiroc Rock Drills AB, Örebro, Sweden. Any unauthorized use or copying of the contents or any part
thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. Illustrations
and photos in this document may show equipment with optional extras. Specifications and equipment subjects to change
6991 1252 01d Örebro, Sweden, 17 March 2016 without notice. Consult your Atlas Copco Customer Center for specific information.

www.atlascopco.com