Maintenance Manual
Maintenance Manual
Maintenance Manual
PREFACE
CONTENTS
1. INTRODUCTION TO MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. Recommended operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1. Warning labels on the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2. Warning of injury risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3. Warning of damage to equipment or property . . . . . . . . . . . . . . . . . . . 12
2.4. Read the user or maintenance instructions . . . . . . . . . . . . . . . . . . . . . 12
2.5. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6. Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7. Pneumatics maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8. Rock drills pressure accumulators maintenance . . . . . . . . . . . . . . . . . 15
2.9. Hydraulics maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.10. Electric system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.11. Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.12. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3. IMPORTANCE OF PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1. General notes on maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2. First service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1. Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2. Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.2. Rock drill HL 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.3. Chain feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2.4. Rod handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2.5. Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2.6. Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2.7. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2.8. Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2.9. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2.10. Air circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.2.11. Dust collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INTRODUCTION TO MACHINE
1. INTRODUCTION TO MACHINE
1.1. Intended use
The Ranger 700 is intended for use at construction sites and quarries. It is and
independently operating hydraulic rig for open--air rig that drills vertical, inclined, and
horizontal holes 64 to 115 mm (2 1/2” to 4 1/2”) in diametre using 38 or 45 mm (1 1/2” or
1 3/4”) extension rods. The maximum hole depth is 29 metres when 14 foot MF steels are
used.
INTRODUCTION TO MACHINE
1.3. Components
FRONT
1. Rock drill
2. Feed
3 1
4 3. Rod handler
4. Boom
1. Rock drill
4 1. Pressure accumulator
2 2. Rotation motor
3 3. Flushing housing
4. Gear housing
2. Feed
1. Hose reel
1
2. Pito
3. Movable suction head
4. Carriage
5 5. Feed gear
2 4
INTRODUCTION TO MACHINE
3. Rod handler
4 3
4. Boom
2 1
INTRODUCTION TO MACHINE
MIDDLE
4 1. Cabin
3 2. Crawler base
2 3. Receivers
1 4. Drilling hydraulics
1. Controls
1 1. Roof panel
2. Pressure gauges
3. Rod handling control
4. Tramming control
5. Left hand panel
6. Drilling control
7. Boom control
8. Right hand panel
2
6
3
7
8
4
INTRODUCTION TO MACHINE
2. Crawler base
2 1. Final drive
2. Oscillation cylinder
1
3. Receivers
1. Hydraulic oil tank
1
2. Fuel tank
4. Drilling hydraulics
1. Pumps
2. Valve blocks
3. Drilling joystick
3 2 1
INTRODUCTION TO MACHINE
REAR
1. Powerpack
2. Air system
1 2 3 4 3. Dust collection system
4. Shank lubrication unit
1. Powerpack
1. Diesel engine
2. Compressor
1
3. Hydraulic pumps
4. Side pump
4
3
2. Air circuit
2 1. Compressor
2. Oil/air receiver
3. Air filter
3 4. Dust collector
1 4
INTRODUCTION TO MACHINE
3
4. Shank lubrication unit
1. Oil tank
2. Pump unit
3. Water separator
SAFETY INSTRUCTIONS
2. SAFETY INSTRUCTIONS
2.1. Warning labels on the equipment
All the warning labels on the device will be presented in the instructions chapter
dealing with the warning labels.
! DANGER DANGER
Immediate danger related to a feature of
the device, causing serious injury or death
if the proper safety precautions are not
taken.
Hazardous voltage.
Can cause severe WARNING
injury or death.
A dangerous or unsafe manner of
Disconnect main
supply cable before operation that may cause serious injury or
servicing.
GB ID = 207 241 08
death if the proper safety precautions are
not taken.
Risk of damage. Welding current can damage electric devices and circuit
boards. Disconnect the battery terminals and circuit boards before
welding the equipment.
CAUTION
Do not use the equipment unless you have been given proper training.
Read the operating instructions before using the equipment. The
operator must know the operating, maintenance, and safety instructions
CAUTION
of the equipment, as well as the local safety instructions of the mine,
before using the equipment.
E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
C 05430 - 6 en 0102 / MAH 13 (58)
SAFETY INSTRUCTIONS
2.5. General
Our recommendation is that records be kept on services and wearing part replacements.
Regular maintenance at correct intervals increases reliability, economy, and safety of the
equipment.
Even maintenance work can be dangerous, unless caution is observed. Everybody
involved in maintenance work should understand the possible hazards, and use safe
working methods. Before starting any maintenance or repair work, read the
manufacturer’s instructions and follow them.
The person responsible for maintenance and repairs should be clearly defined.
-- Do not do any work that you are not authorized to do.
-- Inform the users of the equipment of the start of special and maintenance work.
-- Ensure the area around the rig is clear and safe before commencing maintenance
work.
-- If the equipment or a part of it has been stopped for maintenance or repair, make
sure that it cannot be started accidentally.
D Turn main switch off
D Remove ignition key
D Put a DANGER DO NOT START warning sign on the main switch. The sign must
only be removed by a person who is fully aware of the situation.
-- Clean and wash the equipment regularly, and always before maintenance and
repair work.
-- Before starting to clean the equipment with water, high-pressure washer, steam,
or other cleaning methods, protect all such openings and other points that can
cause danger or become broken. Electric motors, switchgear cabinets and and
electric boxes especially need to be protected.
-- If required, ensure suitable and safe ladders or working platforms are available for
repair and maintenance work.
-- Do not use parts of the equipment as steps. If maintenance work must be done high
up, or in an otherwise dangerous place or position, use necessary safety devices
to prevent falling.
-- All platforms, steps, grips, rails, ladders, and other similar parts must be kept clean
of oil, dirt, snow, and ice to prevent accidents caused by slipping.
-- Always use the correct tools for the maintenance task.
-- Before commencing maintenance or repair work ensure vehicle is on level ground,
with both tracks chocked.
SAFETY INSTRUCTIONS
-- Pay special attention to the exhaust piping and the exhaust gas cleaning system.
Ensure sufficient ventilation.
-- Overheating indicates a fault. Stop the engine and repair the fault before more
serious damage is caused. Make sure that the engine radiator is not covered, and
that it is not clogged.
-- When checking engine coolant level, stop the engine and allow it and the radiator
to cool down. If an overheated engine must be stopped, allow the radiator to cool
down before checking coolant level. If there is no time for that, use thick gloves and
protective clothing when opening the radiator filling cap. Stand to the side, turn your
face away, and open the cap a little. Wait until the pressure is released and coolant
stops running out, then open the cap slowly.
-- When replacing heavy parts, use correct lifting apparatus and techniques.
2.6. Refuelling
The following precautions must be observed when refuelling
-- Do not fill the fuel tank when the engine is running.
-- Take care not to spill fuel on hot surfaces.
-- Refuelling should be done in a well ventilated space.
-- Smoking is strictly forbidden.
-- Open flame, and sparks are dangerous when refuelling.
-- Wipe off spilled fuel before starting the engine.
-- Keep the fuel nozzle in contact with the fuel tank. Arrange earthing to prevent
sparking caused by static electricity.
-- The cabin heater must be switched off.
-- The fuel tank cap must be taken back when the tank is filled.
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
2.12. Welding
Before starting to weld, determine the material to be welded, and the welding method and
fillers. Contact TAMROCK Service, if necessary.
-- Welding must be left to qualified personnel.
-- Disconnect both cables from the battery before starting to weld. The welding
voltage can damage electric devices.
-- Use a protective mask when welding.
-- Arrange adequate ventilation.
-- Arrange protection against fire.
Tighten the engine mounting, air intake and exhaust manifold bolts.
Check air suction hoses and connections.
Diesel engine:
Contact the local Caterpillar dealer for commissioning the engine. Caterpillar “Engine
Service Delivery Record” must be filled at that time.
PERIODIC MAINTENANCE
4. PERIODIC MAINTENANCE
4.1. Schedule
EVERY completed
Working lights
Tramming lights
PERIODIC MAINTENANCE
EVERY completed
Accumulator pressures
PERIODIC MAINTENANCE
EVERY completed
Lower sprocket
Greasing points
Retainer centralizer
Greasing points
PERIODIC MAINTENANCE
EVERY completed
Greasing points
Cradle clearances
Tension of tracks
Oscillation shafts
Operation of brakes
Winch oil
All weldings
PERIODIC MAINTENANCE
EVERY completed
Engine oil
Coolant temperature
Engine coolant
V-- belts
Radiator core
Crankcase breather
Engine earthing
Air filter
Valve clearances*
Turbo charger* S
Thermostat of cooling system*
PERIODIC MAINTENANCE
Water pump* S
Starter motor* S
Alternator* S
Injector units*
* Contact Caterpillar dealer
PERIODIC MAINTENANCE
EVERY completed
Fuel amount
Fuel filter
Breather
Fuel tank
DAILY 50 200 600 1200 1800 2400 3600 Y= N=
HYDRAULICS
Yes Note
Hydraulic oil
Radiator core
Temperature sensor
Breather
PERIODIC MAINTENANCE
EVERY completed
Compressor oil
Air filter
Oil filter
Oil separators
Oil receiver
PERIODIC MAINTENANCE
EVERY completed
Precyclone rubbers
Greasing points
Measuring accuracy
Mechanical condition
Breathers
PERIODIC MAINTENANCE
4.2. Instructions
4.2.1. General
EVERY 50 HOURS
PERIODIC MAINTENANCE
Warning devices:
-- Filter indicators, hydraulic oil
pressure filter, hydraulic oil return
filter and compressor oil filter.
-- Engine coolant temperature
-- Hydraulic oil temperature
-- SLU --oil level sensor and oil
pump
Stopping devices:
-- Compressor temperature
-- Hydraulic oil level
-- Engine oil pressure
PERIODIC MAINTENANCE
EVERY 50 HOURS
max.1 mm max.1 mm
Check shank adapter
The shank must be changed if the
2 mm bevel of the striking head or
Manufacturing 1 mm of the splines is worn out or
2 mm any other wear limit is execed.
Reject 1mm
Check coupling
Pull the coupling out from the rota-
tion bushing. Check and replace, if
the edges of the inner teeth are
worn sharp.
PERIODIC MAINTENANCE
EVERY 50 HOURS
A
Check rotation bushing.
Check the teeth and the bearing
surface for wear. Replace the rota-
tion bushing when the shoulder
(see picture) is worn down to the
surface.
Check chuck.
The chuck inside the rotation bush-
ing must be changed if the wear is
over 1 mm (picture) or if there are
hairline cracks . The chuck is
changed by the hydraulic press
and punch.
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
4.2.5. Boom
EVERY 50 HOURS
Grease all the greasing points.
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
4.2.6. Carrier
EVERY 50 HOURS
2
Grease the oscillation shafts (1).
PERIODIC MAINTENANCE
A = Oil drain
E = Oil fill
PERIODIC MAINTENANCE
1 2
Change the final drive oil.
1. Oil filling plug
2. Oil checking and draining plug
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
4.2.7. Engine
Refer to your engine operation and maintenance manual to get the detailed instructions.
EVERY 50 HOURS
4
1
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
2
1 Change the air intake filter (1).
PERIODIC MAINTENANCE
EVERY 50 HOURS
PERIODIC MAINTENANCE
2
EVERY 600 HOURS
PERIODIC MAINTENANCE
4.2.9. Hydraulics
EVERY 50 HOURS
1
4
Change the oil pressure filter (2).
1
Change the breather (4).
PERIODIC MAINTENANCE
1
Clean hydraulic oil tank.
EVERY 50 HOURS
PERIODIC MAINTENANCE
2
Change the air intake filter (1)
1
PERIODIC MAINTENANCE
2
1 Clean the oil regeneration line
strainer (1) and orifice (2).
PERIODIC MAINTENANCE
2
1
PERIODIC MAINTENANCE
EVERY 50 HOURS
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
Notes: