PM No. 9852 1413 01

2003-01

Atlas Copco

Swellex pump HC 1Manual

PM No. 9852 1413 01

2003-01

Atlas Copco

Swellex pump HC 1Manual

Atlas Copco Rock Drills AB

SAFETY INSTRUCTIONS

Before starting, read all instructions carefully.

Special attention must be paidto information alongsidethis symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

© Copyright 2003, Atlas Copco Rock Drills AB, SwedenAny unauthorized use or copying of the contents or any part thereof is prohibited.This applies in particular to trademarks, model denominations, part numbers and drawings.

Table of Content

Safety ............................................................................................................. 5

Operator’s instructions .............................................................................. 15

Maintenance instructions .......................................................................... 23

3

4

SafetyContents................................................................................................................... 7Safety regulations .................................................................................................... 7

Safety .................................................................................................................. 7General safety rules ............................................................................................ 7

Prohibitory and warning signs................................................................................. 9Regulatory signs .................................................................................................... 12Rig stability ........................................................................................................... 14

Maximum permissible inclination angles ......................................................... 14

5

6

ContentsSince the Safety instruction manual contains safety-related infor-mation for handling the rig and its peripheral equipment, some sec-tions are not fully adapted for individual components.

Safety regulations

Safety

• These instructions contain important sections concerning safety.

• Special notice should be taken to the boxed texts starting with awarning triangle followed by a cue word.

Figure 1. Warning headings

General safety rules

• Only personnel who are trained for it are allowed to use theequipment.

• The equipment may only be used for the purposes described inthese instructions.

• Read all instructions carefully and follow them.

• Make sure that the unit has been maintained in accordance withthe appropriate maintenance schedule.

• Make sure that all controls and emergency stops are in satisfac-tory working order.

• Report all damage and defects immediately. Do not operate thesystem until all faults have been rectified.

• Make sure that all warning signs and safety labels are posted,clean and fully legible. In regard to locations and part numbers,see the Spare parts list.

• Find out where the nearest fire extinguisher is located.

• Always wear a safety helmet, ear protectors and goggles whentravelling and drilling. Also observe local safety regulations.

! DANGERindicates imminent risk that WILL result inserious or lethal injury if the warning isnot heeded

! WARNINGindicates risk or hazardous action that MAYresult in serious or lethal injury if the warningis not heeded

! CAUTIONindicates risk or hazardous action that MAYcause personal injury or damage to propertyif the warning is not heeded

1250 0100 25

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• Always check the safety equipment and emergency stop aftermoving the rig and also before the start of each shift.

• Before travelling and before the start of drilling, always makesure that nobody is standing close to the unit or inside the dan-ger area.

• Never leave the unit before the brakes have been applied andthe wheels blocked.

• Engine exhaust gases are poisonous. Good ventilation is essen-tial when the engine is running.

• Never carry out service or maintenance work when the unit isrunning.

• Switch off the engine before refuelling. Do not handle flamma-ble liquids near hot surfaces, sparks or a naked flame.

• To prevent injury during service and maintenance work, com-ponents that could move or fall down must be securely sup-ported or strapped in place.

• Make sure that the hydraulic, water and air systems are depres-surised and that the electrical system is without current beforestarting any work on these systems.

• Do not use the system if any lamp indicating a fault is alight onthe electric cubicle. Call service personnel instead so that thefault will be rectified.

• Only qualified electricians are allowed to carry out any work onthe high-tension part of the electrical system.

• After changing the hydraulic hoses, make sure the replacementhoses have the correct crimped couplings, are the correct qual-ity and are the correct dimension. All pressurised hydraulichoses have crimped couplings and should therefore be pur-chased ready made from Atlas Copco. Qualities and hosedimensions are specified in the spare parts catalogue for eachrig. Make also sure that hose couplings are clean, in good con-dition and properly tightened.

• The drilling machine may only be used for the purposes forwhich it is intended.

• All work on tyres and wheels must be carried out by speciallytrained maintenance personnel as it is extremely important toensure that correct procedures are followed and that the righttools are used.

• Make sure that the drilling rig has been maintained in accord-ance with the appropriate instructions.

• In the event of a hose fracture, accident or other emergency sit-uation the electric motor, and thus the hydraulic pump, can bestopped immediately by pressing the red stop buttons on thecontrol and operator panels.

• Caution must be observed when changing a drill bit or drillsteel.

8

• Checks and adjustments that are necessary when the drilling rigis in operation must be carried out by at least two persons. Oneperson must then be present at the operating station and have agood view of the work.

• Use only genuine Atlas Copco spare parts. Damage or break-downs caused by other than genuine Atlas Copco spares areNOT covered by Guarantee or Product Liability.

• Overloading of the equipment could result in damage to themachinery which is not noticed during normal usage. Suchdamage is not covered by guarantee.

• Damage that has occurred as a result of substandard repairs, aswell as injury to personnel and damage to equipment that isattributable to older unrepaired damage, are not covered by theguarantee.

• Stay only within the marked areas when carrying out servicework on the drilling rig's engine cover. Do not step on openservice access covers.

• When maintenance work is carried out under a raised cab, thecab must be secured in the raised position.

Prohibitory and warning signs

Table 1. Warnings

Symbol Description Symbol DescriptionProhibitions

• No admittance.

• No admittance to un-authorised personnel.

• Violation can causepersonal injury.

Prohibitions

• Don't step here.

Warning

• High tension

• Incorrect handlingcould be fatal.

• All work on the electri-cal system must becarried out by especial-ly trained personnel.

Warning

• Danger of swingingand crushing parts.

• Could cause severe in-juries.

• Keep out of the hazard-ous area during opera-tion.

1250 0098 911250 0098 97

1250 0099 80 1250 0098 98

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Warning

• High noise level.

• Could cause perma-nent hearing impair-ment.

• Use approved ear de-fenders.

Warning

• The rig's operating cy-cle is preprogrammedand can start automati-cally without the pres-ence of an operator.

• May cause severe per-sonal injury.

• Keep out of the ma-chine's working area.

Warning

• Stability.

See section Rig stability.

Warning

• Danger of tipping whenmoving rig.

• Injuries and damage tomachinery could occur.

• When travelling, rigsmay only have boomsand service platformsswung out within therig's turning radius.

Warning

• Tipping risk during drill-ing.

• Injuries and damage tomachinery could occur.

• The jacks on a rig inoperation must be fullyextended, have con-tact with the groundand take the weight ful-ly off the wheels.

Warning

• In the event of a break-down or during servicework the boom falls di-agonally.

• Injuries or machinerydamage could occur.

• During service workthe boom must be se-cured in place withstraps or supports.

Warning

• Danger of moving androtating parts.

• Could cause severe in-juries.

• Keep out of the ma-chine's working areawhen it is in operation.

Warning

• Danger of crushing in-juries.

• Injuries could be sus-tained.

• A manned service plat-form may only be oper-ated from the cage, notfrom the operator pan-el.

Warning

• Danger of broken wire.

• Can cause serious in-jury or damage to prop-erty.

• Do not use the winchwith less than fourturns of wire remain-ing.

Warning

• Danger of scalding andpressure.

• Can cause serious in-juries.

• The pressure must bereleased before thecap is removed.

Symbol Description Symbol Description

1250 0099 81 1250 0099 82

1250 0099 00

Max.

Max.

1250 0099 83

Max.

1250 0099 84 1250 0099 85

1250 0099 79 1250 0098 99

1250 0100 12 1250 0100 13

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Warning

• Danger of air pressure.

• Can cause serious in-juries.

• The pressure must bereleased before thecap is removed.

Warning

• Slip risk

Warning

• Laser beam.

Warning

• Laser beam.

• Danger of injury to theeyes.

• Do not look into thebeam.

Warning

• Laser beam.

• Danger of injury to theeyes.

• Do not look into thebeam.

• Do not put optical in-struments in the way ofthe beam.

Warning

• Laser beam.

• Risk of personal injury.

• Avoid exposure to radi-ation.

Symbol Description Symbol Description

1250 0100 14

1250 0100 07

CLASS 1

LASER PRODUCT

1250 0100 04

DO NOT STARE

INTO BEAM

CLASS 2

LASER PRODUCT

LASER RADIATION

1250 0100 05

DO NOT STARE INTO

BEAM OR VIEW

CLASS 3ALASER PRODUCT

LASER RADIATION

DIRECTLY WITH

OPTICAL INSTRUMENTS

1250 0100 06

AVOID EXPOSURE

TO BEAM

CLASS 3B

LASER PRODUCT

LASER RADIATION

11

Regulatory signs

Table 2. Regulatory signs

Warning

• Maximum load on ser-vice platform. (Illustra-tion of “Max. load1000kg”)

• Overloading can causepersonal injury andmachine damage.

• Maximum load in cageincluding one person.

Other loads that can oc-cur: 250kg, 300kg, 350kg,400kg, 500kg and 560kg.

Warning

• Refrigerants underpressure.

• Danger of serious per-sonal injury.

• Risk of compressorbreaking down.

• Service of refrigerantsystem must be carriedout by authorised per-sonnel.

• Do not use the air con-ditioning/climate unitwith low refrigerant lev-els, leaks or otherfaults are present.

Symbol Description Symbol DescriptionRegulation

• Read the instructionmanual before usingthe rig.

• Incorrect use of the ma-chine may cause per-sonal injury anddamage to machinery.

• Serious injuries anddamage will be avoidedif you heed the warningsigns and follow the in-structions.

Regulation

• Read the instructions.

• This rig is equipped witha battery switch.

Symbol Description Symbol Description

1250 0100 27

MAX1000kg

R134aMax 32 bar

1250 0099 89

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Regulation

• Read the instructions.

• The carrier's batterysupplies the hydraulicoil level switch with cur-rent.

• The battery switch mustbe turned on when drill-ing is in progress.

• Switch off the batterydisconnector when therig is not in operation. Ifthis is not done the bat-tery will be discharged.

Regulation

• Read the instructions.

• This rig is equipped withdata boxes.

• Isolate or remove databoxes when giving thebattery a boostercharge or carrying outwelding on the rig.

Regulation

• Read the instructions.

• This rig is equipped withan alternating currentgenerator (alternator).

• Disconnect the batterycables before removingthe generator or regula-tor and when giving thebattery a boostercharge.

• Also disconnect and in-sulate the regulator'sleads when carrying outelectric welding on therig or equipment mount-ed on it.

Regulation

• Read the instructions.

• The hydraulic systemmust be filled with hy-draulic oil.

Regulation

• Read the instructions.

• Fill with engine oil.

Regulation

• Read the instructions.

• Fill with brake fluid.

Symbol Description Symbol Description

1250 0100 09 1250 0100 08

PLC

1250 0099 90 1250 0099 91

1250 0099 93 1250 0100 11

13

Rig stability

Maximum permissible inclination angles

Maximum permissible inclination angles depend on the type of rig,see relevant manual.

Regulation

• Read the instructions.

• Fill with lubricant.

Regulation

• Read the instructions.

• Emergency stop.

Symbol Description Symbol Description

1250 0100 10 1250 0101 41

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Operator’s instructions1. Swellex pump......................................................................................................... 17

HC 1....................................................................................................................... 17Swellex arm........................................................................................................... 18System description................................................................................................. 18Before installing a bolt .......................................................................................... 19

Safety ................................................................................................................ 19Before bolting ................................................................................................... 19

Installing bolts ....................................................................................................... 20Safety ................................................................................................................ 20Installing bolts with the Swellex arm ............................................................... 20

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1. Swellex pump

HC 1

1 Pump unit2 Directional valve Y5333 Shut-off valve4 Strainer5 Electrical box6 Pressure switch B317:2 = 240/300 bar7 Pressure gauge8 Flow regulator9 Pressure regulator

Figure 1.1. Swellex pump

17

Swellex arm

A Pressure gaugeB ChuckC TriggerD Inductive sensor B397

Figure 1.2. Swellex arm

System description

The Swellex pump HC 1 is a hydraulic pump that is intended forAtlas Copco Swellex bolts only.

The control system ensures bolting is done completely and to thecorrect pressure.

• The operator starts the swelling process by pressing the trigger(C) on the Swellex arm.

• An inductive sensor (D) will send a signal to the control system,which opens the directional valve (2) on the pump.

• Once the bolt has swelled to correct pressure and duration, thepressure switch (6) will send a signal to the control system thatmakes the directional valve drain the bolt.

Note

If any faults should occur in the control system or if the electricpower supply should go down, bolting can be done temporarilywith a standard Swellex arm connected to the outlet (8) on thepump. see section Connecting the Swellex pump.

Bolting using the outlet (8) should only take place in emergenciesand the operator must be very observant to the pressure and dura-tion.

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Before installing a bolt

Safety

Before bolting

1. The operator has to check that the pumps water pressure is setaccording to the type of bolt to be installed. The pumps waterpressure can be set to 240 or 300 bar.

A pull test must be done on the first bolt.

Atlas Copco takes no responsibility for bolts installed withincorrect water pressure.

• Bolt type Swellex Mn12, Mn24, Standard Swellex and SuperSwellex should be swelled with a pressure of 300 bar.

• Bolt type Swellex Mn16 and Midi Swellex should be swelledwith a pressure of 240 bar.

2. Make sure the equipment is not damaged.

3. Connect hydraulic and water. see maintenance instructionsConnecting the Swellex pump.

The bolt expands in the hole and the resultantpressure could cause a fall of nearby stones.

Thoroughly scale the rock before installing a bolt.

CAUTION

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Pipe sleeves may be used if there are surfacecracks in the rock.

Adapt the length of the pipe sleeves to the qualityof the rock. Several pipe sleeves may be used.

Could cause injury.

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Installing bolts

Safety

Installing bolts with the Swellex arm

1. Make sure the bolt sleeve is clean and not damaged.

2. If a washer is being used, mount it on the bolt before the bolt isinserted into the hole. Use a tube sleeve if necessary.

3. Insert the bolt a short way into the hole if the bolt is lower thantwo metres.

4. Insert the bolt into the chuck on the Swellex arm. Make sure thebolt reaches to the bottom of the chuck.

Figure 1.3. Mounting the bolt in the chuck

Risk of falling stones

Never stand directly under a bolt which is beinginstalled

Use the full length of the installation arm to standunder safe rock when the bolt is expanded

1250 0035 30

CAUTION!

1250 0035 42

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5. Insert the bolt into the bore hole using the Swellex arm. Pressthe bolt hard against the opening of the bore hole.

Figure 1.4. Bolt installation

6. Start the swelling process by pressing the trigger (C) on theSwellex arm.

Figure 1.5. Swellex arm

7. When the bolt has swelled to correct pressure and duration, thepressure switch (6) will send a signal to the control system thatmakes the directional valve drain the bolt. Then take down theinstallation arm from the bolt.

1250 0035 48

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Maintenance instructions1. Swellex pump......................................................................................................... 25

HC 1....................................................................................................................... 25Swellex arm........................................................................................................... 26System description................................................................................................. 26Pressure setting when bolting................................................................................ 27

Pressure setting ................................................................................................. 27Safety..................................................................................................................... 27Technical data........................................................................................................ 28

HC 1.................................................................................................................. 28Connecting the Swellex pump............................................................................... 28Component parts.................................................................................................... 30

Electrical system............................................................................................... 30Water strainer.................................................................................................... 31Swellex arm ...................................................................................................... 32

Changing chuck seals................................................................................... 32Fitting/adjusting the inductive sensor .......................................................... 32

Test running ........................................................................................................... 33Long-term storage ................................................................................................. 33Freeze prevention measures .................................................................................. 33

Draining the Swellex pump .............................................................................. 33Fault finding .......................................................................................................... 34

General.............................................................................................................. 34Fault tracing help .............................................................................................. 34

23

24

1. Swellex pump

HC 1

1 Pump unit2 Directional valve Y5333 Shut-off valve4 Strainer5 Switch box6 Pressure switch B317:2 = 240/300 bar7 Pressure gauge8 Flow regulator9 Pressure regulator

Figure 1.1. Swellex pump

25

Swellex arm

A Pressure gaugeB ChuckC TriggerD Inductive sensor B397

Figure 1.2. Swellex arm

System descriptionThe Swellex pump HC 1 is a hydraulic pump that is intended forAtlas Copco Swellex bolts only.

The control system ensures bolting is done completely and to thecorrect pressure.

• The operator starts the swelling process by pressing the trigger(C) on the Swellex arm.

• An inductive sensor (D) will send a signal to the control system,which opens the directional valve (2) on the pump.

• Once the bolt has swelled to correct pressure and duration, thepressure switch (6) will send a signal to the control system thatmakes the directional valve drain the bolt.

Note

If any faults should occur in the control system or if the electricpower supply should go down, bolting can be done temporarilywith a standard Swellex arm connected to the outlet (8) on thepump. see section Connecting the Swellex pump.

Bolting using the outlet (8) should only take place in emergenciesand the operator must be very observant to the pressure and dura-tion.

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Pressure setting when bolting

Pressure setting

The Swellex pumps water pressure can be set to 240 or 300 bar.When changing the water pressure the pump has to be marked withthe right marking plate. Atlas Copco takes no responsibility forbolts installed with incorrect water pressure.

Figure 1.3. Marking plates

• Bolt type Swellex Mn12, Mn24, Standard Swellex and SuperSwellex should be swelled with a pressure of 300 bar.

• Bolt type Swellex Mn16 and Midi Swellex should be swelledwith a pressure of 240 bar.

Safety

Extremely high water pressure from the pump.

Risk of injury.

Rectify any leakage in high-pressure lines andcouplings without delay.

WARNING

1250 0035 31

Before carrying out any work on the pump,turn off the main switch for the power supply.

Before starting work on the pump, check thatthe hydraulic system is depressurized.

Before starting work on the pump, check thatthe water system is not under pressure. Do thisby pressing the release button on the Swellex arm.

27

Technical data

HC 1

Water pressure, water consumption and water temperature

Water pressure, in 2-20 barMax. water pressure, out 420 barMax water consumption 10 litres/minMax water temperature 70°C

Hydraulic pressure and flow rates

Min hydraulic pressure 120 barMax hydraulic pressure 250 barFlow 40 litres/min

Installation data

Voltage 24 VDC/2A (Min 22V, Max28V)

Weight

Swellex arm with valve chuck 6.5 kgChuck only 1.0 kgPump unit 38 kg

Size

Pump unit (length x width x height)xxxxx

EC - Declaration of conformity

CE marked Yes

Miscellaneous

Vibration in installation arm UnmeasurableSound level at operator's ear Unmeasurable

Connecting the Swellex pump

The pump has to be mounted on a flat surface and it must be possi-bly to check if there is coming any water och hydraulic oil from theoverflow hole under the pump.

28

It is recommended to install a shut-off valve on the incominghydraulic oil.

Figure 1.4. Swellex pump connections

Table 1.1. Descriptions of Swellex pump connections

Pos. FunctionConnectiondim. Comment:

1 Reset Pushbutton

2 Water connection 3/4” see Technical data

3 Pressure gauge Water pressure 0-400bar

X6 External connec-tion

X1 24 VDC/2A Min 22V, Max 28V

6 Oil, pressure in 3/8” see Technical data

7 Oil, return 1/2”

8 Extra outlet 3/8”

9 Draining 1/4”

10 Swellex arm, signal

11 Swellex arm, water 1/4”

29

Component parts

Electrical system

Figure 1.5. Switch box

Table 1.2. Switch box

Description Symbol Function1 Reset

2 Relay, controls respite duration on the handle

3 Relay, duration of swelling after pressure hasreached 300 or 240 bar.

4 Relay, directional valve

X1 Connection, 24 VDC/2A (Min 22V, Max 28V)

30

Water strainer

The water strainer is cleaned by opening the valve (3) and flushingwith water through the strainer for a few seconds.

X6 External connection (Option)

X2=B317:2 External connection, pressure switch

X3=B397 External connection, inductive sensor in handle

X4 External connection, directional valve

X5 External connection, reset

X7 External connection, directional valve

Description Symbol Function

31

Swellex arm

Changing chuck seals

The chuck seals must be changed if the chuck leaks while install-ing bolts. This can be done on site. Other chuck repairs must becarried out in a workshop.

1. Undo nut (1).

Figure 1.6. Chuck

2. Remove the seals (2) and spacer ring (3).

3. Clean all parts thoroughly. Change the seals, spacer ring (3) andany damaged parts.

4. Lubricate the plunger 4 with waterproof grease.

5. Fit the chuck with the new seals.

6. Tighten the nut (1).

Fitting/adjusting the inductive sensor

Figure 1.7. Swellex arm with inductive sensor

32

Test running1. Make sure the equipment is not damaged.

2. Connect hydraulics and water to the pump. see the section Con-necting the Swellex pump.

3. Check that all hoses are tightened securely and that none ofthem have been damaged.

4. Check the water pressure to the Swellex pump. see sectionTechnical data.

5. Check that the water strainer is clean.

6. Check that the gaskets in the chuck (B) are intact and that thechuck is clean. For changing gaskets, see section Componentparts, Swellex arm.

Figure 1.8. Swellex arm

Long-term storage

• Protect the pump with rust inhibitor.

• Always drain the pump prior to storage and store it in a frost-free place. See section Freeze prevention measures.

Note

Starting a frozen pump can cause extensive damage.

Freeze prevention measures

Draining the Swellex pump

If the ambient air temperature around the pump is below 0°C(32°F), the water system must be drained to prevent the pumpfreezing.

33

1. Undo the water hose from the connection (2) on the pump.

2. Undo the Swellex arm, outlet (11) from the pump.

3. Connect compressed air to the Swellex arm.

4. Run the pump for about 10 seconds by pressing the Swellexarm trigger.

5. Cancel by pressing the reset button (1) on the pump.

6. Turn off the compressed air.

7. Drain the water strainer by opening the valve (3)

Note

Protect the Swellex pump against frost by storing it in an above-freezing environment if possible.

Fault finding

General

• Start by determining what is functioning normally and what ismalfunctioning so that fault tracing can be confined to a certainsystem or a certain function.

• Then refer to the table below for help in fault tracing the pump.

Fault tracing help

Table 1.3. Fault finding

FAULT CAUSE ActionNo water whenpressing in theSwellex arm han-dle.

Green and yellow LED on connec-tion X1 do not come on.

Is there power to the pump? Check cables.

“ Green LED on handle does notcome on.

Check the cable between the pump and the han-dle.

“ Yellow LED on handle does notcome on when the handle ispressed in.

Inductive sensor defective or out of adjustment.

“ No or little flow of hydraulic fluid. Adjust the hydraulic flow rate.

Reverse flow of hydraulic fluid. Check the connection of the hydraulic hoses.The delivery hose must be fitted to connection(6) and the return to connection (7).

Hydraulic pressure too low. Adjust the hydraulic pressure.

34

Water flow too low. Insufficient hydraulic flow or pres-sure.

Adjust to the recommended hydraulic flow rateand pressure.

Water pressure toolow.

Insufficient hydraulic flow or pres-sure.

Adjust to the recommended hydraulic flow rateand pressure.

“ Leaking seals in Swellex armchuck.

Change seals.

“ Insufficient water flow. Check the hose and connections. Use a pres-surised supply of water if possible.

Pulsing water pres-sure.

The pump is cavitating becausewater hose diameter too small.

Check the diameter of the hose and change asnecessary.

“ The pump is cavitating due to thewater connection drawing in air.

Check the water hose and rectify any faults.

The pump is not re-ceiving water.

The water hose is not connectedor leaking.

Check the hose and the connections.

The water connection is clogged. Check and clean the water strainer.

Leakage. Hydraulic oil leak. Check bolted joints, couplings and seals.

“ Water leak. Check bolted joints, couplings and seals.

“ The hydraulic oil or water is leak-ing from the overflow hole underthe pump.

If the number of drops exceeds 10 per minute,the pump seals must be changed. see ManualDynaset.

FAULT CAUSE Action

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