Epiroc SmartROC T35 Maintenance Manual
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Epiroc SmartROC T35 Maintenance Manual

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SmartROC T35/T40
Maintenance
Original Instructions
2018-05-04 | No: 7026962571.1.7027002891 en-US

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Summary of Contents for Epiroc SmartROC T35

  • Page 1 SmartROC T35/T40 Maintenance Original Instructions 2018-05-04 | No: 7026962571.1.7027002891 en-US...

  • Page 3: Table Of Contents

    SmartROC T35/T40 Table of Contents Table of Contents 1 Introduction ...................... 9 Safety First.......................... 9 The Purpose of This Publication .................... 9 Target Group .......................... 9 Product Warranty ........................ 9 2 About Maintenance Management .............. 11 Maintenance Management and Hour Meters ................. 11 Maintenance Records ...................... 11 3 Specifications......................
  • Page 4 SmartROC T35/T40 Table of Contents Lubricate Drill Rod Support .................... 34 Check Feed .......................... 35 9.5.1 Adjusting Haul and Return Wire Ropes..................  36 Check Feed .......................... 37 9.6.1 Replacing Slide Pieces in the Holder .................. 38 9.6.2 Replacing Slide Rails...................... 41 Check Silence Kit ........................ 42 Check Rod Handling ........................ 43...
  • Page 5 SmartROC T35/T40 Table of Contents 13 Diesel Engine.......................  69 13.1 Safety Precautions before Working on Diesel Engine ............ 69 13.2 Check Engine Oil Level ...................... 69 13.3 Drain Water Condensation from Preliminary Fuel Filter ............ 70 13.4 Drain Water Condensation from Fuel Tank ................ 71 13.5 Filling Fuel Manually........................ 72...
  • Page 6 SmartROC T35/T40 Table of Contents 16.2 Cleaning Remote Control ...................... 97 17 Compressed Air System.................. 99 17.1 Safety Precautions before Working on Pneumatic System .......... 99 17.2 Overview Air Compressor System .................. 99 17.3 Check Compressor Oil Level .................... 101 17.4 Drain Water Condensation from Compressor Tank ............ 101 17.5 Check Compressor Components .................. 102...
  • Page 7 SmartROC T35/T40 Table of Contents 21.2 Check Attachment of Winch Cable.................. 131 21.3 Check Winch Unit Attachment.................... 133 21.4 Lubricate Winch ........................ 134 21.5 Check Small Remote Control.................... 135 21.6 Check Tightening Torque on Winch.................. 135 21.7 General Checking Guidelines for Wire Ropes.............. 136 21.7.1 Checking Wire Rope for Wire Breaks...................  136 21.7.2 Checking Wire Rope for Strand Breaks................
  • Page 8 SmartROC T35/T40 Table of Contents viii No: 7026962571.1.7027002891 en-US...

  • Page 9: Introduction

    • Use only Epiroc original parts. Any damage or operational interruptions caused by us- ing spare parts of other manufactures than Epiroc will not be covered by warranty. • Epiroc is not liable for any damage caused by unauthorized modification to the ma- chine and its equipment.
  • Page 10 SmartROC T35/T40 1 Introduction No: 7026962571.1.7027002891 en-US...

  • Page 11: About Maintenance Management

    SmartROC T35/T40 2 About Maintenance Management 2 About Maintenance Management 2.1 Maintenance Management and Hour Meters Maintenance management is organized in scheduled intervals. Scheduled intervals supplement each other. A longer interval comprises maintenance tasks supplementary to tasks from a shorter interval. Maintenance management must be done regularly at the shortest interval of the unit or function (whichever comes first during operation of the machine).
  • Page 12 SmartROC T35/T40 2 About Maintenance Management No: 7026962571.1.7027002891 en-US...

  • Page 13: Specifications

    3 Specifications 3.1 Standard Tightening Torques Bolted Joints All bolted joints are tightened to the torque required by Epiroc Standard K 4369:01 K (met- ric) and 4368K/-01K (imperial) unless otherwise stated. In such cases, this torque is speci- fied in the maintenance instructions of the module in question.
  • Page 14 SmartROC T35/T40 3 Specifications No: 7026962571.1.7027002891 en-US...

  • Page 15: Maintenance Tables

    SmartROC T35/T40 4 Maintenance Tables 4 Maintenance Tables 4.1 Calender Time Maintenance Task Calendar Time Wash Machine Externally Daily Check Condition of Signs Daily Check Fire Extinguishers Daily 9.11 Check Rock Drill or Rotation Unit Daily 10.1 Check Rock Drill Daily 10.2...

  • Page 16: Diesel Engine Hours First Service

    SmartROC T35/T40 4 Maintenance Tables Maintenance Task Drilling Hours Check Feed Check Rod Handling 11.1 Check Dust Collector 9.12 Check Drill Rod Support 4.3 Diesel Engine Hours First Service Diesel Engine Hours First Maintenance Task Service 18.7 Replace Oil on Traction Gears for Track Frames 4.4 Diesel Engine Hours...
  • Page 17 SmartROC T35/T40 4 Maintenance Tables Maintenance Task Diesel Engine Hours 13.16 Replace Coarse Filter 15.3 Check Battery 18.1 Check Tension of Crawler Tracks 18.3.1 Check Front Wheel for Wear 18.3.2 Check Track Roller for Wear 18.3.3 Check Carrier Roller for Wear 18.3.4...
  • Page 18 SmartROC T35/T40 4 Maintenance Tables Maintenance Task Diesel Engine Hours 13.11 Replacing DEF Tank Filter 5000 14.5 Replace Long-term Effective Coolant 6000 No: 7026962571.1.7027002891 en-US...

  • Page 19: General Machine Condition

    SmartROC T35/T40 5 General Machine Condition 5 General Machine Condition 5.1 Wash Machine Externally Disconnect fire-fighting equipment if steam washing or high-pressure washing. Rinse the machine with water at least once a day to remove drill cuttings, mud, and dirt.
  • Page 20 SmartROC T35/T40 5 General Machine Condition No: 7026962571.1.7027002891 en-US...

  • Page 21: Fire Fighting Equipment

    SmartROC T35/T40 6 Fire Fighting Equipment 6 Fire Fighting Equipment 6.1 Check Fire Extinguishers Check that the indicator is in the green zone. Replace the fire extinguisher if the indicator is in the red zone. Check the seals for damage.
  • Page 22 SmartROC T35/T40 6 Fire Fighting Equipment No: 7026962571.1.7027002891 en-US...

  • Page 23: Operator Environment

    SmartROC T35/T40 7 Operator Environment 7 Operator Environment 7.1 Check Cab Clean or change the filter elements (C) in the circulation filters (A) and (B). Clean or change the primary filter (D). Clean or change the prefilter (E). Run the air conditioning system for 5 minutes.

  • Page 24: Check Attachment Of Cab

    SmartROC T35/T40 7 Operator Environment 7.2 Check Attachment of Cab Check the tightening torque (A). Check for damages on the cab. Torque Tolerance ± 185 Nm (136 lbf.ft) 45 Nm (33 lbf.ft) 7.3 Lubricate Cab Door Hinges Lubricate the cab door hinges (A).

  • Page 25: Replace Air Condition Main Air Filter

    SmartROC T35/T40 7 Operator Environment 7.4 Replace Air Condition Main Air Filter Remove the screws from the cover (A). Open the cover and lift out the filter. Replace with new filter. Close the cover and install the screws. 7.5 Replace Air Condition Pre-filter Remove the screws on the louvre cover (A).

  • Page 26: Replace Air Condition Circulation Filters

    SmartROC T35/T40 7 Operator Environment Close the cover and refit the screws. 7.6 Replace Air Condition Circulation Filters Remove the screws on the covers (A) and (B). Open the covers (A) and (B) and lift out the filters. Replace with new filters.
  • Page 27 SmartROC T35/T40 7 Operator Environment Fault Symptom Action Check that the system is filled and that the thermostat is working. Abnormal noise Check that the multi-V-belt to the compressor is properly tightened and that the compressor retaining bolts are tightened.
  • Page 28 SmartROC T35/T40 7 Operator Environment No: 7026962571.1.7027002891 en-US...

  • Page 29: Boom Unit

    SmartROC T35/T40 8 Boom Unit 8 Boom Unit 8.1 Lubricate Boom and Feed Pump grease into the 21 grease nipples (A). If Central Lubrication System (CLS) is installed, the functions and connections of CLS must be checked. No: 7026962571.1.7027002891 en-US...

  • Page 30: Check Boom Condition

    SmartROC T35/T40 8 Boom Unit 8.2 Check Boom Condition Check the attachment on the boom head (A). Check the clearance between the feed and feed attachment (B). Check the attachment on the feed attachment (C). Check the clearance between the bushings, shaft, and holder (D).

  • Page 31: Feed Unit

    SmartROC T35/T40 9 Feed Unit 9 Feed Unit 9.1 Safety Precautions before Working on Feed Unit WARNING Disassembling and Assembling Components Can cause personal injury. u Components that could move or fall down must be securely supported or strapped in place during service and maintenance work.

  • Page 32: Closing The Feed Guard

    SmartROC T35/T40 9 Feed Unit p The machine is parked in a safe location. Precondition p The machine is switched off. Loosen the bolts (A). Open the guard. Lock the guard in an open position with the latch (B). NOTE: Always lock the guard in position if it necessary to open it when performing maintenance.

  • Page 33: Feeder 6000-Series

    SmartROC T35/T40 9 Feed Unit 9.3 Feeder 6000-Series The hydraulic feeders on the BMH 6000 series are primarily intended for drift and tunnel drilling. The feeders are available in different versions depending on the rock drill installed on them. The different numbers are explained, for example, BMH 6618.

  • Page 34: Lubricate Drill Rod Support

    SmartROC T35/T40 9 Feed Unit 9.4 Lubricate Drill Rod Support Pump grease into 12 grease nipples (A). No: 7026962571.1.7027002891 en-US...

  • Page 35: Check Feed

    SmartROC T35/T40 9 Feed Unit 9.5 Check Feed Check feed cylinder (A) for leaks. Check haul and return wire ropes (B) for lubrication. Adjust tension. Check mounting and function of limit switches (C). Check for wear on the intermediate drill rod support bearing (D) and replace as nec- essary.

  • Page 36: Adjusting Haul And Return Wire Ropes

    SmartROC T35/T40 9 Feed Unit 9.5.1 Adjusting Haul and Return Wire Ropes p The cradle is located in the rear position on the feed beam. Precondition p Drill rods with drill bit is installed on the rock drill. Adjust the haul wire rope with bolt (C) and the return wire rope with nut (D).

  • Page 37: Check Feed

    SmartROC T35/T40 9 Feed Unit 9.6 Check Feed Check for damage on slide rails (A). Check that the play is 2–4 mm and the tightening torque is of 185 Nm (136.4 lb-ft). Check the slide pieces (B) for wear. Check that the thickness is at least 4 mm.

  • Page 38: Replacing Slide Pieces In The Holder

    SmartROC T35/T40 9 Feed Unit 9.6.1 Replacing Slide Pieces in the Holder WARNING Disassembling and Assembling Components Can cause personal injury. u Components that could move or fall down must be securely supported or strapped in place during service and maintenance work.
  • Page 39 SmartROC T35/T40 9 Feed Unit Remove the slide pieces (C) from the holder. Slide a new slide piece into the holder track and install it to the holder. Install new keys. Adjust the cradle on the feed beam. Adjusting Cradle on Feed Beam...
  • Page 40 SmartROC T35/T40 9 Feed Unit p Feed is in the horizontal position and the drill rod is installed in the rock drill. Precondition p Holders are turned the same way as in the illustration so that the outer part of the an- gled grooves is facing to the rear of the beam.

  • Page 41: Replacing Slide Rails

    SmartROC T35/T40 9 Feed Unit NOTE: The hoses are correctly adjusted as they do not hang down when the feeder is in the horizontal position. 9.6.2 Replacing Slide Rails WARNING Sharp Edges Worn slide rails are sharp and can cause injuries.

  • Page 42: Check Silence Kit

    SmartROC T35/T40 9 Feed Unit 9.7 Check Silence Kit Check mountings and tightening torque. No: 7026962571.1.7027002891 en-US...

  • Page 43: Check Rod Handling

    SmartROC T35/T40 9 Feed Unit 9.8 Check Rod Handling Check the attachment of the hydraulic motor (A). Applies only to machines installed with RHS. Check for wear and cracks on the bushing halves (B). Check the attachment of the hydraulic cylinders (C).

  • Page 44: Lubricate Rod Handling

    Check that the rock drill is properly positioned. Tighten the bolts alternately until the correct torque is achieved. Connect and fit the hoses to the rock drill. Rock Drill Bolts Tightening Metric Data Imperial Data Torque SmartROC T35 and T40 200 Nm 147.5 lb-ft No: 7026962571.1.7027002891 en-US...

  • Page 45: Check Rock Drill Or Rotation Unit

    SmartROC T35/T40 9 Feed Unit 9.11 Check Rock Drill or Rotation Unit Check and tighten all bolted joints. Check and adjust the tension of the ropes. Check all hoses for leakage. Tighten and adjust the tension of the hoses if necessary.

  • Page 46: Replacing Haul Wire Rope

    SmartROC T35/T40 9 Feed Unit 9.13 Replacing Haul Wire Rope Operate the drill to about half its length of travel. Slacken the tension on the wire ropes, bolt (A), and nut (B). Remove the haul wire rope from its front attachment on the rock drill cradle.

  • Page 47: Disassembling Feed Cylinder

    SmartROC T35/T40 9 Feed Unit Install the new wire rope and install the scraper plate again. Adjust the wire ropes. 9.14 Disassembling Feed Cylinder WARNING High Hydraulic Oil Pressure Working on the hydraulic system involves a high risk of personal injury.
  • Page 48 SmartROC T35/T40 9 Feed Unit p Hydraulic system is depressurized. Precondition Operate the rock drill cradle to about half the feed length. Relieve the tension from pull and return ropes with bolt (A) and nut (B). Remove the bolts from the center of the water hose drum and lift the entire drum.

  • Page 49: Tension Bushings For Spacers

    SmartROC T35/T40 9 Feed Unit Remove the end plate (H). Pull the cylinder and fork backwards, out of the beam. Remove the pin (K). Remove the fork (J) from the spacer (L). NOTE: Avoid removing the spacer (L). If the spacer must be removed, first measure (SP) so the spacer can be replaced in the same position.
  • Page 50 SmartROC T35/T40 9 Feed Unit WARNING Heavy Objects Can cause crushing injury or death. u Do not stand under the heavy object being lifted. u Use adequate lifting equipment. WARNING Moving Parts Can cause personal injury. u Shut off the machine and lock the battery isolation switch before starting any work.

  • Page 51: Assembling Tension Bushing For Spacer

    SmartROC T35/T40 9 Feed Unit 9.15.2 Assembling Tension Bushing for Spacer WARNING Disassembling and Assembling Components Can cause personal injury. u Components that could move or fall down must be securely supported or strapped in place during service and maintenance work.

  • Page 52: Preparing Feed For Long-Term Storage

    SmartROC T35/T40 9 Feed Unit Tightening Torque 38 Nm (28 lb-ft) Install the plastic plugs (A). 9.16 Preparing Feed for Long-Term Storage The feed must be stored in a dry and clean environment. Clean the feed thoroughly. Lubricate the feed.

  • Page 53: Lubrication System For Rock Drill

    SmartROC T35/T40 10 Lubrication System for Rock Drill 10 Lubrication System for Rock Drill 10.1 Check Rock Drill Visually check that the oil trickles out between the front and the shank adapter (A). 10.2 Check Lubricant Level The lubrication tank is attached on the dust collector.

  • Page 54: Drain Water Condensation From Lubrication Tank

    SmartROC T35/T40 10 Lubrication System for Rock Drill Thread lubrication pump (ECG) Rock drill lubricating pump (ECL) 10.4 Drain Water Condensation from Lubrication Tank Drain water from lubrication tank. No: 7026962571.1.7027002891 en-US...

  • Page 55: Dust Collector

    SmartROC T35/T40 11 Dust Collector 11 Dust Collector 11.1 Check Dust Collector Check the suction hoses (A) for damage. Check the dust gasket (B) for damage and sealing around the pipe. Check the inlet connector piece (C) for wear. Check the center hose (D) for its intactness and the sealing.

  • Page 56: Check Dust Collector Tightening Torque

    SmartROC T35/T40 11 Dust Collector 11.2 Check Dust Collector Tightening Torque Check the tightening torque on bolts (A). 11.3 Checking Function of Dust Collector Factory setting is 4-6 pulses during cleaning time. p The air pressure must be less than 8 bar (manual valve).

  • Page 57: Checking Dust Collector Filters

    SmartROC T35/T40 11 Dust Collector Activate flush air with the right drill lever by moving it maximal to the left. Terminate the function by pressing button (D/E) on the right drill lever. Check that air blows through the filters and check pulse interval.

  • Page 58: Replace Dust Collector Filters

    SmartROC T35/T40 11 Dust Collector 11.5 Replace Dust Collector Filters Open the door (A). Remove the old filters (B). Replace with new filters. Component Tightening Torque lbf.ft New filters 18–20 13–15 No: 7026962571.1.7027002891 en-US...

  • Page 59: Hydraulic System

    SmartROC T35/T40 12 Hydraulic System 12 Hydraulic System 12.1 Safety Precautions before Working on Hydraulic System WARNING High Hydraulic Oil Pressure Working on the hydraulic system involves a high risk of personal injury. u Make sure that the system is de-pressurized before starting any work.

  • Page 60: Replacing Hydraulic Hoses

    The correct quality class • The correct dimensions All pressurized components must be purchased from Epiroc. The grades and dimensions of hoses are specified in the spare part catalog. Make sure that hose couplings are clean, undamaged, and properly tightened.

  • Page 61: Check Mounting Hydraulic Jack

    SmartROC T35/T40 12 Hydraulic System Inspect all hydraulic hoses and connections thoroughly. Any cracking or swelling indi- cates an external or internal leak. Inspect the hose location and clips. Inspect the hose casing. Any swelling indicates inner hose or cord breakage.

  • Page 62: Hydraulic Tank

    SmartROC T35/T40 12 Hydraulic System Check the mounting and torque on foot plate (B). 12.7 Hydraulic Tank 12.7.1 Check Hydraulic Tank p The machine is parked on a flat and leveled surface. Precondition p The oil temperature is 40°C / 104°F.

  • Page 63: Drain Water Condensation From Hydraulic Oil Tank

    SmartROC T35/T40 12 Hydraulic System 12.7.2 Drain Water Condensation from Hydraulic Oil Tank The ball valve (A) is used to drain water that can seriously damage components in the hy- draulic system and cause corrosion. It is also used for draining all hydraulic oil from the tank.

  • Page 64: Draining Hydraulic Oil Tank

    SmartROC T35/T40 12 Hydraulic System Remove the plug from the ball valve (A) under the hydraulic tank. Fit a hose to the ball valve and place the other end of the hose into a vessel. Open the ball valve and empty the tank.

  • Page 65: Filling Hydraulic Oil

    SmartROC T35/T40 12 Hydraulic System 12.7.5 Filling Hydraulic Oil WARNING Hydraulic Oil Under Pressure There is a risk of personal injury when working with pressurized hydraulic systems. u Use personal protective equipment. Check the return oil filter. Check that all the couplings and hoses that are normally filled with hydraulic oil are clean.

  • Page 66: Replace Return Oil Filter

    SmartROC T35/T40 12 Hydraulic System Symbol for Clogged Filter 12.8.2 Replace Return Oil Filter The filter inserts are located in the hydraulic tank. Clean on and around the filter cap. Loosen and remove the nuts (A). Lift off the cap (B) and replace the O-ring (C) if damaged.

  • Page 67: Check Hydraulic Tank Breather Filter

    SmartROC T35/T40 12 Hydraulic System 12.8.3 Check Hydraulic Tank Breather Filter WARNING High Hydraulic Oil Pressure Working on the hydraulic system involves a high risk of personal injury. u Make sure that the system is de-pressurized before starting any work.
  • Page 68 SmartROC T35/T40 12 Hydraulic System Clean thoroughly on and around the filter housing (A). Remove the cover plate by turning it counterclockwise. Replace with a new filter. Apply a little hydraulic oil to the sealing surface and threads. Install the cover.

  • Page 69: Diesel Engine

    SmartROC T35/T40 13 Diesel Engine 13 Diesel Engine 13.1 Safety Precautions before Working on Diesel Engine WARNING Burning Hazard Hot components can cause serious personal injury. u Turn off the machine before starting maintenance work. u Be careful when draining hot oils and fluids.

  • Page 70: Drain Water Condensation From Preliminary Fuel Filter

    SmartROC T35/T40 13 Diesel Engine p The diesel engine is turned off. Precondition Check that the oil level is between the upper and lower mark on the dipstick (A). Top up the oil through the filler cap (B), if necessary.

  • Page 71: Drain Water Condensation From Fuel Tank

    SmartROC T35/T40 13 Diesel Engine Loosen the drain plug (A). Drain the water. Tighten the drain plug. 13.4 Drain Water Condensation from Fuel Tank Release the steel cover. Open the ball valve and allow the water to drain. Close the ball valve.

  • Page 72: Filling Fuel Manually

    SmartROC T35/T40 13 Diesel Engine 13.5 Filling Fuel Manually WARNING Flammable and Toxic Liquid Fuel is toxic and can cause injury. Fuel is flammable and causes burns, serious per- sonal injury, or death. u Shut off the engine. u Use personal protective gear.

  • Page 73: Filling Fuel Using Electric Fuel Filling System

    SmartROC T35/T40 13 Diesel Engine Fuel Quality Sulphur Grade Ultra Low Sulfur Diesel (ULSD) 13.6 Filling Fuel Using Electric Fuel Filling System This equipment is optional. Activate the Enable diesel filler pump function on the Settings/Rig menu in the con- trol system.

  • Page 74: Drain Diesel Exhaust Fluid (Def) Tank

    SmartROC T35/T40 13 Diesel Engine 13.8 Drain Diesel Exhaust Fluid (DEF) Tank Drain the DEF tank by loosening the plug (A). 13.9 Filling DEF Tank p The engine is switched off. Precondition Check that the DEF tank and funnel are clean.

  • Page 75: Maintain Diesel Engine

    SmartROC T35/T40 13 Diesel Engine See Reference Documentation Diesel engine instruction manual 13.10 Maintain Diesel Engine Replace the engine oil filter (A). Change the engine oil (B). Check the multi-belt (C) for wear. Check the hoses and clamping brackets for leaks and wear.

  • Page 76: Replace Engine Oil

    SmartROC T35/T40 13 Diesel Engine 13.12 Replace Engine Oil p Machine is placed on flat surface. Precondition Switch off the engine and allow the oil to drain down from the engine’s internal parts for some minutes. Place a vessel under the drain plug.
  • Page 77 SmartROC T35/T40 13 Diesel Engine Placement of oil filter can differ depending on brand and model. NOTE: Use engine oil that the engine manufacturer approves for engine and type of operation. NOTE: Always replace oil filter when replacing oil. p The engine oil is drained.

  • Page 78: Replace Preliminary Fuel Filter

    SmartROC T35/T40 13 Diesel Engine 13.14 Replace Preliminary Fuel Filter Loosen the preliminary fuel filter (A) using a suitable tool. Collect any residual fuel. Clean the surface of the filter holder. Oil the rubber seal of the new fuel filter sparingly.

  • Page 79: Replace Secondary Fuel Filter

    SmartROC T35/T40 13 Diesel Engine 13.15 Replace Secondary Fuel Filter Remove the secondary fuel filters (A) with a suitable tool. Collect any residual fuel. Clean the surface of the filter holder. Lubricate the rubber seal of the new fuel filter sparingly with a little oil.

  • Page 80: Replace Coarse Filter

    SmartROC T35/T40 13 Diesel Engine See Reference Documentation Diesel engine instruction manual 13.16 Replace Coarse Filter Replace coarse filter (A). 13.17 Replace Crankcase Ventilation Filter Replace the diesel engine crankcase ventilation filter (A). No: 7026962571.1.7027002891 en-US...

  • Page 81: Replace Primary Fuel Filter On Engine Heater

    SmartROC T35/T40 13 Diesel Engine 13.18 Replace Primary Fuel Filter on Engine Heater Engine Heater Replace primary fuel filter (A). 13.19 Check Diesel Engine Mounting Check the tightening torque of the bolts (A) on the power frame. Check mounting and tightening torque in hydraulic pumps (B).

  • Page 82: Belts

    SmartROC T35/T40 13 Diesel Engine Component Tightening Torque lbf.ft Bolts on power frame (A) Bolts on engine (D) Hydraulic pump 1 Hydraulic pump 2, 3, and 4 13.20 Belts 13.20.1 Replace Multi-belt p Engine is switched off. Precondition Remove the belt cover.

  • Page 83: Air System

    SmartROC T35/T40 13 Diesel Engine Remove the two bolts (C) to detach the pump. Replace the belt by inserting it through the clearance between the coupling rubber and the shaft flange. Tighten the bolts (C). Refit the coupling rubber and tighten the bolts (B) to tightening torque 185 Nm (136.44 lb-ft).

  • Page 84: Air Filter Indicator Function

    SmartROC T35/T40 13 Diesel Engine 13.21.1 Air Filter Indicator Function To ensure filter clogging is detected, the function of the air filter indicator must be checked regularly. This is done by gradually covering the air intake with a piece of wood or similar.

  • Page 85: Replace Air Filter Cartridge

    SmartROC T35/T40 13 Diesel Engine Allow the engine to idle. Use a piece of board or similar to cover part of the air intake. Check that the alarm indicator lamp is turned on. è The alarm indicator lamp is turned on.

  • Page 86: Replace Air Filter Safety Cartridge

    SmartROC T35/T40 13 Diesel Engine NOTE: Replace air filter cartridge every second year irrespective of how many hours the diesel engine has been running. 13.21.4 Replace Air Filter Safety Cartridge Remove the clamps (A). Remove the cover (B). Pull out the safety cartridge (C).

  • Page 87: Cooling System

    SmartROC T35/T40 14 Cooling System 14 Cooling System 14.1 Safety Precautions before Working on Cooling System WARNING Burning Hazard Hot fluids can cause severe personal injury. u Shut off the engine. u Wait for the diesel engine to cool down before working on the cooling system.

  • Page 88: Clean Radiators

    SmartROC T35/T40 14 Cooling System p Diesel engine is cold. Precondition Check that the coolant level (A) is between the upper and lower mark in sight glass. 14.3 Clean Radiators The radiators must be kept clean to maintain efficient cooling.

  • Page 89: Replace Long-Term Effective Coolant

    SmartROC T35/T40 14 Cooling System Loosen the radiator cap (A) to the stop position to release the pressure in the cooling system. Remove the radiator cap (A). Top up the coolant until the level is between the upper and the lower mark (B).
  • Page 90 SmartROC T35/T40 14 Cooling System No: 7026962571.1.7027002891 en-US...

  • Page 91: Electrical System

    SmartROC T35/T40 15 Electrical System 15 Electrical System 15.1 Safety Precautions before Working on Electrical System WARNING Dangerous Voltage Can cause severe personal injury. u Check that the electrical system is de-energized before starting to work. u The electrical system must only be serviced by authorized electrician.

  • Page 92: Check Battery

    SmartROC T35/T40 15 Electrical System Check that each emergency stop (A) stops the engine when activated. Before check- ing the next emergency stop, the previous emergency stop must be reset. Check the functionality of all work lights (B). 15.3 Check Battery Check electrolyte level in batteries (A).

  • Page 93: Charging Battery Using External 24-V Charger

    SmartROC T35/T40 15 Electrical System • Use a 24-V charger when charging both batteries connected. Use a 12-V charger when charging each battery individually. Observe the voltage before connecting a bat- tery charger. 15.5 Charging Battery Using External 24-V Charger...

  • Page 94: Charging Battery Using External 12-V Charger

    SmartROC T35/T40 15 Electrical System 15.6 Charging Battery Using External 12-V Charger WARNING Risk of Fire and Explosion Gas that is formed in the battery during charging and discharging is explosive which can cause serious personal injury and property damage.

  • Page 95: Starting With Auxiliary Battery

    SmartROC T35/T40 15 Electrical System Disconnect the battery chargers negative cable from the negative terminal on battery (B). Disconnect the battery chargers positive cable from the positive terminal on battery (B). Connect the jumper lead between the negative terminal on battery (B) and the posi- tive terminal on battery (A).
  • Page 96 SmartROC T35/T40 15 Electrical System Disconnect the cable from the chassis ground when the engine starts. Disconnect the cable from the negative terminal on the auxiliary batteries (A). Disconnect the cable between the positive terminal of the chassis batteries (B) and the auxiliary batteries (A).

  • Page 97: Control System And Sensors

    SmartROC T35/T40 16 Control System and Sensors 16 Control System and Sensors 16.1 Remote Control Batteries • The remote control batteries must be fully discharged and then fully recharged regu- larly. • Charging can only take place in the temperature range of +10 °C to +40 °C (+50 °F to +104 °F).
  • Page 98 SmartROC T35/T40 16 Control System and Sensors No: 7026962571.1.7027002891 en-US...

  • Page 99: Compressed Air System

    SmartROC T35/T40 17 Compressed Air System 17 Compressed Air System 17.1 Safety Precautions before Working on Pneumatic System WARNING High System Pressure There is a risk of personal injury when working with pressurized systems. u Do not perform maintenance work while the machine is operating.
  • Page 100 SmartROC T35/T40 17 Compressed Air System Diagram Air Compressor System Intake valve Outlet valve Air filter Air valve (pressure regulator) Pressure sensor Restriction Safety valve Pressure tank Minimum pressure valve Pressure reducing valve Pressure gauge Compressor Air filter Air filter switch...

  • Page 101: Check Compressor Oil Level

    SmartROC T35/T40 17 Compressed Air System 17.3 Check Compressor Oil Level p The machine is parked on a flat and level surface. Precondition Switch off the machine and allow the oil level to settle for at least 5 minutes. Check that the indicator on the gauge (A) is in the green zone.

  • Page 102: Check Compressor Components

    SmartROC T35/T40 17 Compressed Air System 17.5 Check Compressor Components Check for signs of oil or water or air leakage on the compressor (A). Check connections and couplings on intake manifolds (B) on the air filters for com- pressor and diesel engine.

  • Page 103: Replace Air Compressor Oil And Oil Filter

    SmartROC T35/T40 17 Compressed Air System 17.7 Replace Air Compressor Oil and Oil Filter WARNING Risk of Fire and Explosion Using incorrect or old oil may lead to a risk of fire or explosion in the compressor sys- u Use correct, new oil according to the Fluids and Lubricating Greases manual.

  • Page 104: Check Safety Valve On Compressor System

    SmartROC T35/T40 17 Compressed Air System NOTE: If the oil has been contaminated, the system must be flushed clean before new oil is filled. 17.8 Check Safety Valve on Compressor System Perform a 15 bar (217 psi) pressure test on the safety valve (A).

  • Page 105: Replace Separator Filter

    SmartROC T35/T40 17 Compressed Air System 17.9 Replace Separator Filter Replace the separator filter (A) in the pressure tank. NOTE: Check that the washer (B) under the filter remains in place. Do not throw it away with the old filter during replacement.

  • Page 106: Flushing Air Compressor

    SmartROC T35/T40 17 Compressed Air System Paroil Sxtreme Drainage ** Drainage Drainage * * When changing to the same oil within the interval between changes, drainage is sufficient ** Changing not recommended 17.11 Flushing Air Compressor WARNING Risk of Fire and Explosion Using incorrect or old oil may lead to a risk of fire or explosion in the compressor sys- u Use correct, new oil according to the Fluids and Lubricating Greases manual.

  • Page 107: Troubleshooting Air Compressor

    SmartROC T35/T40 17 Compressed Air System Remove drain plugs for compressor tank, compressor cooler, and compressor ele- ment and drain the oil. Install and tighten the plugs. Remove the oil filters (D). Open the cover plate (A) on the air reservoir and remove the oil separator element.
  • Page 108 SmartROC T35/T40 17 Compressed Air System Air Compressor System Fault Symptom Possible Faults Action The compressor is automatically The intake valve (A) has jammed Remove and inspect the intake loaded to full capacity after start- in open position valve, replace parts if necessary.
  • Page 109 The restriction (D) is clogged Remove the hoses and clean the restriction Oil separator filter faulty Call a service technician from Epiroc to remove and inspect the oil filter Compressor capacity or pres- The air consumption exceeds Check the connected equipment...
  • Page 110 SmartROC T35/T40 17 Compressed Air System Fault Symptom Possible Faults Action Low oil level Before checking the oil level, wait for about 30 minutes after the unit has stopped. Check the oil level and top up with oil, if necessary.

  • Page 111: Track Frames

    SmartROC T35/T40 18 Track Frames 18 Track Frames 18.1 Check Tension of Crawler Tracks Track tension is checked between the front wheel (C) and carrier roller (A). p The machine is parked on a flat and level surface. Precondition p Tracks are under normal load.

  • Page 112: Checking Tightening Torques On Track Frames

    SmartROC T35/T40 18 Track Frames 18.2 Checking Tightening Torques on Track Frames Check tightening torques on track frames. Size Torque Quantity/Track Frames 347 Nm (256 lbf.ft) 289 Nm (213 lbf.ft) 289 Nm (213 lbf.ft) 90 Nm (66 lbf.ft) 347 Nm (256 lbf.ft) 260 ±...

  • Page 113: Procedures For Checking Wear

    SmartROC T35/T40 18 Track Frames 18.3 Procedures for Checking Wear • When components on the track frames are worn down to the minimum recommended levels, they must be replaced with new components. • Regular and accurate measuring is required in order to establish the extent of the wear and when replacement is necessary.

  • Page 114: Check Carrier Roller For Wear

    SmartROC T35/T40 18 Track Frames Specification Metric Data Imperial U.S Data New Track Roller 160.0 mm 6.30 in Wear 25% 159.5 mm 6.27 in Wear 50% 159 mm 6.25 in Wear 75% 158.5 mm 6.24 in Wear 100% 158 mm 6.22 in...

  • Page 115: Check Track Shoe For Wear

    SmartROC T35/T40 18 Track Frames Specification Metric Data Imperial U.S Data New Track Shoe 22 mm 0.86 in Wear 25% 21.2 mm 0.83 in Wear 50% 20.4 mm 0.80 in Wear 75% 19.6 mm 0.77 in Wear 100% 18.8 mm 0.74 in...

  • Page 116: Check Track Link Depth For Wear

    SmartROC T35/T40 18 Track Frames 18.3.6 Check Track Link Depth for Wear Check the wear by measuring the dimension (A) for the chain. 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...

  • Page 117: Check Track Chain Elongation For Wear

    SmartROC T35/T40 18 Track Frames 18.3.8 Check Track Chain Elongation for Wear Check chain wear by measuring the distance (A) between the center point in the first pin to the center point of the fifth pin. Specification Metric Data Imperial U.S Data...

  • Page 118: Check Track Frames

    SmartROC T35/T40 18 Track Frames Visually inspect the tension on the crawler tracks (E). Check that the springs and dampeners move freely on the front wheel (F). Clean, if necessary. Check for loose screws and nuts. 18.5 Check Track Frames Check for signs of leakage on the traction gears (A).

  • Page 119: Replace Oil On Traction Gears For Track Frames

    SmartROC T35/T40 18 Track Frames 18.7 Replace Oil on Traction Gears for Track Frames p The inlet plug on the traction gear is positioned at 12 o'clock. Precondition Flush the gear with oil. Fill the traction gear (A) with new oil until some oil drains from the oil level bore.
  • Page 120 SmartROC T35/T40 18 Track Frames No: 7026962571.1.7027002891 en-US...

  • Page 121: Water Mist System

    SmartROC T35/T40 19 Water Mist System 19 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.

  • Page 122: Check Seals On Water Mist Pump

    SmartROC T35/T40 19 Water Mist System 19.1 Check Seals on Water Mist Pump Run the water mist pump (A) for a minute. Count the number of water drops that run out from the drain holes (B). è Replace all old seals with new ones if more than 10 drops leak out of the drain holes for a minute.

  • Page 123: Filling Water Mist Tank

    SmartROC T35/T40 19 Water Mist System 19.2 Filling Water Mist Tank WARNING Explosion Risk Adding wrong type of fluid to the water tank could result in injury and damage to ma- chine. u Always fill the water mist tank with clean water.

  • Page 124: Draining Water Mist System

    SmartROC T35/T40 19 Water Mist System 19.3 Draining Water Mist System Remove bolt from the drain hole (B). Drain water from water mist tank. Install the bolt back into the drain hole (B). Put the machine in drilling mode. Turn off flushing air.

  • Page 125: Clean Filter In Water Mist Tank

    SmartROC T35/T40 19 Water Mist System Turn off flushing air. Run the water mist pump at full speed for a few seconds so that the system fills up with water. 19.5 Clean Filter in Water Mist Tank p The water mist tank is empty.
  • Page 126 SmartROC T35/T40 19 Water Mist System No: 7026962571.1.7027002891 en-US...

  • Page 127: Automatic Central Lubrication System Cls

    SmartROC T35/T40 20 Automatic Central Lubrication System CLS 20 Automatic Central Lubrication System CLS 20.1 Automatic Central Lubrication System (CLS) The CLS is auxiliary equipment that lubricates all joints on the complete machine. Pump element Safety valve Plug (timer for pause and running time)

  • Page 128: Lubrication Pump Safety Valve

    SmartROC T35/T40 20 Automatic Central Lubrication System CLS • Pause time can be adjusted to increments of 15 with the blue rotary switch (A). Pause time is preset from factory. • Running time can be adjusted to increments of 15 with the red rotary switch (B). Run- ning time is preset from factory.

  • Page 129: Filling Lubricant

    SmartROC T35/T40 20 Automatic Central Lubrication System CLS 20.4 Filling Lubricant The container is transparent for visual inspection of the level. The filler nipple (A) is located directly on the pump. NOTE: Use a filler pump to fill the lubricant.
  • Page 130 SmartROC T35/T40 20 Automatic Central Lubrication System CLS Lubrication System Timer Turn on the ignition key. è The diode (C) for ignition current comes on. Press the push button (A) for two seconds. è The pump starts to run the preset running time and the diode (B) for the electric motor comes on.

  • Page 131: Winch

    SmartROC T35/T40 21 Winch 21 Winch 21.1 Check Winch Check for damage, unwinding, wear, and corrosion on the winch wire rope (A). Check for damage, cracks, and wear on the hook (B) and check that it is properly mounted. 21.2 Check Attachment of Winch Cable...
  • Page 132 SmartROC T35/T40 21 Winch Cable Rope lock Connector sleeve with wedge plug Hook Correct assembly: • The cable must run in line with the eye on the connector sleeve. • The rope lock must only lock the end cable. •...

  • Page 133: Check Winch Unit Attachment

    SmartROC T35/T40 21 Winch 21.3 Check Winch Unit Attachment Check the tightening torque on attachment bolts (A). Number of Bolts Tightening Torque Value 350 Nm (258 lbf.ft) No: 7026962571.1.7027002891 en-US...

  • Page 134: Lubricate Winch

    SmartROC T35/T40 21 Winch 21.4 Lubricate Winch Remove the plug (A) in the bottom of the gear housing for draining. The gearing is permanently lubricated. Lubricate with oil if the drum brake (B) does not rotate freely. No: 7026962571.1.7027002891 en-US...

  • Page 135: Check Small Remote Control

    SmartROC T35/T40 21 Winch 21.5 Check Small Remote Control Make sure none of the rubber bellows (A) on the switches/levers of the control unit are damaged 21.6 Check Tightening Torque on Winch Check that the mounting and the tightening torque for winch frame (A).

  • Page 136: General Checking Guidelines For Wire Ropes

    SmartROC T35/T40 21 Winch Check that the tightening torque on (D). Check that the tightening torque for hydraulic motor (E). Component Tightening torque Winch frame 350 Nm (258 lbf.ft) Slide bolts 140 Nm (103.25 lbf.ft) Attachment bolts 350 Nm (258 lbf.ft) Hydraulic motor 29 Nm (21.38 lbf.ft)

  • Page 137: Checking Wire Rope For Strand Breaks

    SmartROC T35/T40 21 Winch 221–240 In wire ropes with several layers of strands, only the outer, visible layer is considered. In wire ropes 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.

  • Page 138: Checking Wire Rope For Reduced Elasticity

    SmartROC T35/T40 21 Winch 21.7.6 Checking Wire Rope for Reduced Elasticity Under certain conditions, the wire rope loses its elasticity. Reduced elasticity is difficult to detect. If in doubt, consult a specialist. If the wire rope has lost elasticity, the following char- acteristics usually appear: •...

  • Page 139: Service Tool Bag Rcs

    SmartROC T35/T40 22 Service Tool Bag RCS 22 Service Tool Bag RCS The service tool bag is used for troubleshooting machines that are equipped with Epiroc RCS. CAN tester Resolver tester Multimeter Encoder tester CAN open cable I/O tester Signal cable...

  • Page 140: Checking Can Network

    SmartROC T35/T40 22 Service Tool Bag RCS Torque tools Contact 22.1 Checking CAN Network The power supply for the module, the CAN power supply and the CAN communication can be measured and checked using the CAN test equipment. CAN Test Equipment Connect the CAN tester (B) on the multimeter (A).

  • Page 141: Checking Can Power Supply

    SmartROC T35/T40 22 Service Tool Bag RCS Function CAN Low Table 8: Pin Configuration, CAN Inputs and Outputs, Other Modules Set the multimeter range to DC volt. Connect the 5-pin connectors of the tester to the CAN network requiring measure- ment:...
  • Page 142 SmartROC T35/T40 22 Service Tool Bag RCS CAN Test Equipment Connect the CAN tester (B) on the multimeter (A). Make certain the pins are positioned correctly as indicated by the colour coding. The red pin goes to V/Ohm on the multimeter.

  • Page 143: Checking Can Cable

    SmartROC T35/T40 22 Service Tool Bag RCS 22.3 Checking CAN Cable The power supply for the module, the CAN power supply and the CAN communication can be measured and checked using the CAN test equipment. CAN Test Equipment Connect the CAN tester (B) on the multimeter (A). Make certain the pins are positioned correctly as indicated by the colour coding.

  • Page 144: Checking Digital Inputs On I/O Module

    SmartROC T35/T40 22 Service Tool Bag RCS Connect the 5-pin connectors of the tester to the CAN network requiring measure- ment: Decoder: contact X3 or X4 Display, application, and master modules: connector X2, X3, or X4 I/O modules: contact X1 or X19 Resolver modules: contact X3 or X4 Select cable test on the CAN tester.

  • Page 145: Checking Digital Outputs Voltage On I/O Module

    SmartROC T35/T40 22 Service Tool Bag RCS è The signal is 0 V for an open contact and +24 V for a closed contact. Function +24 V DC Signal B Ground Signal A Ground Table 15: Pin Configuration 22.5 Checking Digital Outputs Voltage on I/O Module Each designated contact has two digital outputs, A and B.

  • Page 146: Checking Digital Outputs Current On I/O Module

    SmartROC T35/T40 22 Service Tool Bag RCS è The multimeter reads 24 ±1 V. 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.

  • Page 147: Checking Pwm Outputs Current On I/O Module

    SmartROC T35/T40 22 Service Tool Bag RCS 22.7 Checking PWM Outputs Current on I/O Module Each designated contact has two PWM outputs, A and B. Connect the 5-position connector on the I/O tester between the output of interest on the I/O module and the valve.

  • Page 148: Encoder Inputs

    SmartROC T35/T40 22 Service Tool Bag RCS Connect the 5-position connector on the I/O tester between the input of interest on the I/O model and the sensor. Measure the values according to the table. è Function +24 V DC 0–5 V Ground 4–20 mA...

  • Page 149: Checking Resolver Module Resolver Inputs

    SmartROC T35/T40 22 Service Tool Bag RCS 22.10 Checking Resolver Module Resolver Inputs For the inputsX6 - X9 there are designated contacts. Connect the resolver tester to the relevant cable. Turn the test sensor slowly and check that the angle shown on the sensor menu changes.

  • Page 150: Checking Resolver Module Analog Inputs

    SmartROC T35/T40 22 Service Tool Bag RCS If the measured value does NOT change, the cable on the boom must be checked. 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.

  • Page 151: Replacing Rcs Module

    SmartROC T35/T40 22 Service Tool Bag RCS Function + 15-V DC power supply out Signal in Not Used Not Used Table 22: Pin Configuration for Input X12 Connect the resolver module connector X11 or X12 to test box connector (B). Connect the multimeter to test box pins 2 and 3.
  • Page 152 SmartROC T35/T40 22 Service Tool Bag RCS No: 7026962571.1.7027002891 en-US...

  • Page 153: Welding

    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. Contact Epiroc before repair welding on components or frames, approval of welding method and choice of electrodes.

  • Page 154: Can Bus System Disconnection Before Welding

    23.2 CAN Bus System Disconnection before Welding NOTE: The CAN bus and RCS can be severely damaged when welding. NOTE: Consult Epiroc for approval of welding and choice of electrodes. • Locate all modules present on the machine. Disconnect supply voltage to all modules, both + (positive) and - (ground).

  • Page 155: Storage

    SmartROC T35/T40 24 Storage 24 Storage 24.1 Preparations before Long-Term Storage Protect the equipment from corrosion and storage damage if the storage is expected to last three months or longer. If environment is, for example, corrosive or dusty, extra protection is necessary.

  • Page 156: Preparing Rock Drill For Long-Term Storage

    SmartROC T35/T40 24 Storage 24.1.3 Preparing Rock Drill for Long-Term Storage Remove the rock drill. Apply corrosion inhibitor (For example, Tectyl 506) to the machined surfaces. Apply touch-up paint to any scratches and damage on painted areas. 24.1.4 Preparing Water Mist System for Long-Term Storage Drain the water mist system.
  • Page 157 24 Storage No: 7026962571.1.7027002891 en-US...
  • Page 158 SmartROC T35/T40 24 Storage No: 7026962571.1.7027002891 en-US...
  • Page 159 24 Storage No: 7026962571.1.7027002891 en-US...
  • Page 160 www.epiroc.com...

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