9852 2423 01 Boom Overhaul Kit But 28

Atlas Copco

Boom Overhaul Kit BUT 28

Maintenance instructions
PM No. 9852 2423 01

2009-07
SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.
Special attention must be paid

to information alongside
this symbol.
Only use genuine Atlas Copco parts.
1250 0071 04
© Copyright 2009, Atlas Copco Rock Drills AB, Sweden

All product names in this publication are trademarks of Atlas Copco. Any unauthorized use or copying of the
contents or any part thereof is prohibited. Illustrations and photos may show equipment with optional extras. No
warranty is made regarding specifications or otherwise. Specifications and equipment are subject to change
without notice. Consult your Atlas Copco Customer Center for specific information.
Operating instructions in original
Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
Safety
Safety
Reference................................................................................................................. 5
3
Safety
4
Safety
Reference
Note
Always read the information under Safety before starting to use the rig or starting
maintenance work.
1250 0099 89
5
Safety
6
1. Conditions ................................................................................................................ 9
Work ........................................................................................................................ 9
2. Instructions ............................................................................................................. 10
General .................................................................................................................. 10
Tightening torques ............................................................................................ 10
Torque tightening retaining bolts on telescope tube flange .............................. 11
Expander shafts................................................................................................. 11
Dismantling.................................................................................................. 12
Assembly...................................................................................................... 12
Rear boom ............................................................................................................. 13
Safety ................................................................................................................ 13
Dismantling/assembling the rear cylinder links ............................................... 13
Dismantling the boom body.............................................................................. 14
Boom Extension .................................................................................................... 15
Dismantling the boom telescope....................................................................... 15
Safety ........................................................................................................... 15
Dismantling the boom telescope .................................................................. 15
Dismantling of telescope and bearing housing ............................................ 16
Checking the bushings in the bearing housing ................................................. 18
Checking the keys............................................................................................. 19
Checking the slide rails..................................................................................... 19
Front boom ............................................................................................................ 20
Dismantling/assembling the front cylinder links .............................................. 20
Rotation unit .......................................................................................................... 22
Safety ................................................................................................................ 22
Reconditioning rotary actuators........................................................................ 22
Dismantling of rotary actuator from boom .................................................. 22
Constituent parts of the rotary actuator........................................................ 25
Removing the rotary actuator....................................................................... 27
Assembly of rotary actuator......................................................................... 31
Mounting of rotary actuator on boom .......................................................... 35
7
8
1. Conditions
1. Conditions
Work
The main procedures of performing the service intended with this service kit are the
following:
• Replacing rear and front boom cylinder links

• Replacing rear and front boom links
• Replacing bushings
• Repair telescope key
• Replace seals and bearings in turning device
9
2. Instructions
2. Instructions
General
Tightening torques
The following table specifies the bolted joints requiring a special tightening torque.
Other bolted joints can be tightened to the torque specified in Atlas Copco standard
K4369, see maintenance instructions General.
Note
All bolted joints in the following table should be lubricated with Molycote 1000
thread grease or other thread grease having a friction coefficient of 0.11 μ.
20 2 5 10 15 14 19
1250 0142 09
1 4 6 7 8 16 13
12 18
3
9 11 17
Figure: Tightening torques
Table: Torque table

Torque Tolerance +/ Quant
No. Bolted joints Thread Quality (Nm) - (Nm) ity
1 Boom link M20 8.8 304 76 1
2 Boom link M20 8.8 304 76 1
3 Rear boom link M16 8.8 156 39 2
4 Rear lift cylinder M16 8.8 156 39 2
10
2. Instructions
Torque Tolerance +/ Quant

No. Bolted joints Thread Quality (Nm) - (Nm) ity
5 Boom telescope M12 8.8 63 16 1
6 Bearing housing - telescope, bolts M12 8.8 120 12 16
7 Boom telescope, flange M16 12.9 263 66 10
8 Front boom link M20 8.8 304 76 1
9 Front boom link M16 8.8 156 39 1
10 Front lift cylinder M16 8.8 156 39 2
11 Front cylinder link M16 8.8 156 39 2
12 Rotary actuator rear joint M16 12.9 263 66 12
13 Cylinder link, feed lookout cylinder M12 8.8 63 16 2
14 Cover M12 12.9 107 27 4
15 Feed extension cylinder, rear M24 8.8 522 131 1
16 Rotary actuator front joint M16 12.9 263 66 12
17 Feed holder M16 8.8 156 39 8
18 Swivel M16 8.8 315 32 1
19 Feed lookout cylinder, locking screw M10 8.8 30 3 2
20 Attachment plate - boom bracket M24 12.9 / 8.8 627 63 18
Torque tightening retaining bolts on telescope tube flange

The boom is supplied with an Allen key (part no. 3128 3024 15) for checking and
retightening the retaining bolts on the telescope tube flange. This special tool is
required to reach three of the retaining bolts on the telescope tube flange.
1250 0064 64
Figure: Retaining bolt for telescope tube flange
Expander shafts
Most of the cylinder brackets and links are fitted with expander shafts. Play can be
eliminated by tightening a nut. The slotted bushings will then be forced up on the
tapered shaft so that the joints will be free from play.
11
2. Instructions
Dismantling
1. Fit a sling round that part of the boom that is held by the expander shaft or rest it
on supports before starting to dismantle the shaft.
2. Undo nut (A) and withdraw bolt (B).
3. Screw in a bolt that fits the threads in the bushings (C) and tighten it until one of
the bushings loosens.
4. Remove the other bushing and shaft (D).
Figure: Expander shaft
Assembly
1. Fit the shaft (D) in the cylinder lug or link. Lubricate the shaft before assembly.
2. Fit the two bushings (C). Make sure that they are located symmetrically at the
attachment point.
3. Fit the bolt (B) and nut (A) in the expander shaft and tighten. The nut should only
be tightened until there is no play. If it is tightened too much, the attaching lug
may crack. Only use the recommended tightening torques specified in the torque
table, see section Bolted joints.
12
2. Instructions
Rear boom
Safety
WARNING
• Dismantling and assembly of
components.
• Risk of personal injury.
• During service and maintenance work,
components that could move or fall down
must be securely supported or strapped
in place.
Note
No modification or reinforcement work on the boom should be performed without
first consulting Atlas Copco Rock Drills AB.
Dismantling/assembling the rear cylinder links

The boom is journaled by links (2 and 3) on the boom plate (1).
13
2. Instructions
4 2 7
20
1 19
6
1250 0234 89
51
16
Figure: Rear cylinder bracket
1. When dismantling or assembling the rear cylinder links, provide sufficient support
for the boom body using straps or stands.
2. Check the wear of the bushings and replace if necessary.
3. The thrust bushings (19 and 20) must be fitted to the top of the boom link and the
bottom of the cylinder links.
Dismantling the boom body

The boom can be shortened by separating it between the telescope tube and the front
boom beam.
1250 0142 11
A
Figure: Dismantling the boom body
14
2. Instructions
1. Fit a sling round the front boom beam or support it on stands before starting dis-
mantling work.
2. Detach the hydraulic hoses from the cylinders and plug the hoses and nipples.
3. Disconnect the sensor cables.
4. Then remove the ten bolts (A) and washers.
Boom Extension
Dismantling the boom telescope
Safety
CAUTION
• Observe great care when dismantling the
boom telescope.
• Can cause personal injury.
• Support rotary actuators and front boom
member securely before dismantling the
boom telescope.
Dismantling the boom telescope
CAUTION
boom telescope.
• Support rotary actuators and front boom
member securely before dismantling the
boom telescope.
1. Extend the telescope to its front end position.
15
2. Instructions
2. Rotate the feed beam up and down.
3. Lower the boom until the feed beam rests on the ground.
4. Position supports firmly under the rotary actuator and front cylinder attachment
before dismantling the telescope.
C D
1250 0142 12
Figure: Dismantling the boom telescope
5. Unscrew the bolts (A) from the front cylinder attachment.
6. Retract the telescope to its rear end position.
7. Fit slings round the bearing housing. Use an overhead travelling crane or hoist,
etc.
8. Unscrew the bearing housing bolts (B).

9. Detach the hydraulic hoses (C).
10. Remove the expander shaft (D).
11. Carefully withdraw the entire telescope assembly, telescope tube, cylinder and
bearing housing.
Dismantling of telescope and bearing housing

The figure below shows the BUT 35 G model M. The method of dismantling the tel-
escope and bearing housing is the same as for model L. The only difference is that the
bearing housing (B) on model L is screwed into the extension segment instead of in
the rear boom body.
16
2. Instructions
A 1
2
1250 0105 77
Figure: Dismantling of telescope and bearing housing
1. Retract the telescope to the rear end position.
2. Fit slings round the bearing housing. Use an overhead travelling crane or hoist,
etc.
3. Detach the hydraulic hoses (C).
4. Unscrew the bearing housing bolts (B).

5. Remove the expander shaft (D).
6. Carefully withdraw the telescope tube, cylinder and bearing housing.
17
2. Instructions
Checking the bushings in the bearing housing
Figure: Checking the bushings in the bearing housing

A Telescope tube
B Cover
C Bushings
D Bearing housing
G Washer
H Seal
Thoroughly inspect the telescope device for signs of damage and wear.
1. Extend the telescope tube (A).
2. Remove the washer (G) and seal (H) and then undo the cover (B).
3. Measure the play between the telescope tube (A) and the two upper bushings (C).
If the play (I) is greater than 1 mm, dismantle the bearing housing (D) and change
the worn bushings.
D
A
1250 0043 28
Figure: Play between the telescope tube and bushings
18
2. Instructions
Checking the keys

1. Check the keys (E) carefully. If the keys are deformed, the damaged area should
be ground smooth so that future damage to the slide rails (F) and bearing house
(D) can be avoided.
Figure: Telescope device

D Bearing housing
E Keys
F Cradles
Checking the slide rails

1. Remove the washer (G) and seal (H) and then undo the cover (B).
2. Place the feeder on a support and rotate the boom so that the load is taken up on
only one side of the keys.
19
2. Instructions
3. The slide rails (F), see above figure, can then be removed from the bearing hous-
ing and inspected. Change them if they are worn or scratched.
Figure: Bearing housing

A Telescope tube
B Cover
C Bushing
D Bearing housing
G Washer
H Seal
Front boom
Dismantling/assembling the front cylinder links

The boom is journaled by links (9 and 10) on the boom beam.
20
2. Instructions
10
20
9
1250 0234 90
19
18
Figure: Rear cylinder bracket
1. When dismantling or assembling the front cylinder links, provide sufficient sup-
port for the boom body using straps or stands.
2. Check the wear of the bushings and replace if necessary.
3. The thrust bushings (18, 19 and 20) must be fitted to the top of the boom link and
the bottom of the cylinder links.
21
2. Instructions
Rotation unit
Safety
CAUTION
rotation unit.
• Support the feeder securely so it is
stable.
Reconditioning rotary actuators
Dismantling of rotary actuator from boom

1. Rotate the feeder 90° until it and the rock drill are under the boom. Position sup-
ports firmly under the feeder to hold it steadily in place.
22
2. Instructions
Figure: Dismantling the feeder

2. Remove the expander shaft (11) of the feed lookout cylinder.
3. Remove the bolts (1) and protection (2).
4. Remove the bolts (3) and sensor (4).
Note
This point applies only to rigs with the RCS electronic control system and one of
the ABC Regular or ABC Total options.
23
2. Instructions
5. Remove the bolts (5) and the outer cover (6).
6. Remove the bolts (7), the inner cover (8) and the shim (9).
7. Detach the hydraulic hoses to the feeder. Plug all hoses and connections.
8. Carefully lift the boom straight up so that the sliding bearings (10) in the bearing
housing are not damaged.
9. Rotate so that the bearing housing (E) reaches its original position.
10. Apply slings round the bearing housing (E).
11. Remove the bolts (A), hose retainer (B) and cover (C).
E
1250 0107 35
A
D B
Figure: Removing the cover and hose retainer
12. Remove the bearing housing by unscrewing the bolts (D).
13. Remove the hydraulic hoses from the overcentre valve and plug the hoses and
connections.
24
2. Instructions
14. Apply slings round the rotary actuator and remove it from the boom head by undo-
ing the bolts (F).
Figure: Removing the rotary actuator
Constituent parts of the rotary actuator
Figure: Rotary actuator, cross section illustration
25
2. Instructions
406
401
111
111
01
300
302
304
02
106
112
106
112
205 05 109 105

04
12
50
206
01
304
7 7
48
302
300
105
301 109
100
03 209
208
206
205
200
202
203
200
201
100
Figure: Constituent parts of the rotary actuator
Table: Constituent parts of the rotary actuator

Pos. no. Description Pos. no. Description
01 Housing 202 Seal
02 Shaft 203 Seal
03 Piston sleeve, assembly 205 Main pressure seal. Z-seal
04 End cover 206 Outer seal
05 Lock nut 208 Outer O-ring, lock nut
209 Inner O-ring, lock nut
100 Locking pin
105 Screw plug 300 Wear ring
106 Screw plug 301 Wear ring
109 Locking pin 302 Wear ring
111 Lubricating nipple 304 Thrust washer
26
2. Instructions
Pos. no. Description Pos. no. Description

112 Grease relief valve
401 Pressure retaining valve
200 Seal 406 Hydraulic pipe
201 Seal
Removing the rotary actuator

Note
When assembling the component parts of the rotary actuator, the splined parts (shaft
and piston) must be refitted in their original positions.
There are two permanent position marks:
• One mark for piston-ring gear

• One mark for shaft-piston
Figure: Permanent marking piston-ring gear
1250
0181
91
Figure: Permanent marking shaft-piston
27
2. Instructions
Assembly of the rotary actuator will be facilitated if additional positioning marks are
made during dismantling.
1. Place the rotary actuator on a clean workbench.
2. Remove all hydraulic connections and drain the hydraulic oil from the rotary actu-
ator.
3. Remove the overcentre valve and associated components.
4. Mark the relative positions of the retaining ring (05), cover (04) and shaft (02)
using a scriber or pen.
5. Screw out the screw plugs (105), thread two 10x32 screws into the lock plugs
(109) fitted under two of the screw plugs (105) in the lock ring's (5) threaded hole.
Remove the lock plugs by releasing the screws straight out from the lock ring (5).
1250
0181
87
Figure: Removing the lock plugs
6. Screw two SAE-4 adapters into the lock ring (05) and use a tommy bar to unscrew
the lock ring (05) anticlockwise from the shaft (02).
1250
0181
88
Figure: Removing the retaining ring
Note
In certain cases the cover may be screwed in extremely hard. An iron bar can then
be welded to the cover to provide greater leverage.
28
2. Instructions
7. Screw in two 5/8"-11 bolts with washers or sleeves in the cover (04) and use a
tommy bar to make the sealing friction release the cover from the housing (01)
and pull the cover straight out.
1250
0181
89
Figure: Removing the cover
Note
In certain cases the cover may be screwed in extremely hard. An iron bar can then
be welded to the cover to provide greater leverage.
8. Screw two M16x2 bolts in the shaft (02) flange. These bolts enable the shaft to be
turned with the aid of a tommy bar. Turn the shaft clockwise. It will start to rotate
out of the housing.
Note
Do not turn the shaft so much that it no longer engages with the piston. Before the
shaft is unscrewed all the way out its position relative to the piston must be
marked, see next point.
Figure: Removing the shaft
29
2. Instructions
9. Using a pen, mark the position of the shaft relative to the piston, i.e. mark one of
the shaft splines and the corresponding groove in the piston. See example in the
following figure.
Figure: Marking shaft-piston
10. Unscrew the shaft all the way out of the housing.
11. Use a plastic drift and a hammer to drive the piston sleeve (3) out from the hous-
ing (1).
Note
Guide marks must be made to ensure that the piston will be refitted in its correct
position. For this to be possible, however, the piston must first be released fully
from the ring gear. Hold the piston in this position and use a pen to mark the hous-
ing (01) and the piston sleeve (03).
1250 0181 90
Figure: Marking housing-piston skirt-piston

After marking, the piston can be removed from the housing. Exercise care to avoid
damaging the piston and housing.
30
2. Instructions
12. Unscrew the grease nipples (111) and valves (112).
13. Remove all seals and bearings.
14. Clean all parts thoroughly and check them for wear.
Note
The maximum thickness of the wear rings (300, 301 and 302) should be 3.098 mm.
The washers (304) should have a maximum thickness of 3.048 mm.
Assembly of rotary actuator

1. Thoroughly clean all parts and blow them dry with compressed air. Make sure that
all position marks are still clearly visible.
406
401
111
111
01
300
302
304
02
106
112
106
112
205 05 109 105

04
12
50
206
01
304
7 7
48
302
300
105
301 109
100
03 209
208
206
205
200
202
203
200
201
100
Figure: constituent parts of the rotary actuator
2. Carefully inspect the threads on the shaft (02) and the lock ring (05) and rub down
any burrs with abrasive cloth.
31
2. Instructions
3. Test fit the cover (04) and the lock ring (05) on the shaft (02) and check that the
cover and lock ring do not jam in the ring gear and thread.
4. Lubricate all seals and contact surfaces with hydraulic oil.
Note
Always change the seals and bearings when assembling rotary actuators.
Never use sharp tools when fitting seals.
5. Fit the seals (200, 201, 202, 203, 206) and the wear rings (300 and 301) on the pis-
ton sleeve (03).
Note
Fitting the piston is the most difficult part of reassembling the rotary actuator. It
may therefore be a good idea to practice this without any seals on the piston.
6. Stand the housing (01) upright with the flange upwards. Fit the piston sleeve in the
housing. Use the guide markings to make sure it is in the right position. Lay the
housing down in a horizontal position when the piston has engaged with the ring
gear and check at the other end of the housing that the position of the piston coin-
cides with the permanent markings.
Figure: Permanent markings piston-ring gear
Screw the piston in fully so that the piston skirt bottoms against the ring gear.
7. Grease the washers (304).
32
2. Instructions
8. Fit the seals (205, 206) and wear washers (300, 302, 304) on the shaft (02) as well
as seals (200, 205, 206) and wear rings (302, 304) on the cover (04).
300
302
304
02
205
04
12
50
206
01
304
83
39
302
206
205
200
Figure: Fitting washers and seals
9. Stick masking tape on the ring gear of the shaft so that the piston seals will not be
damaged when the shaft (02) is fitted.
Figure: Shaft ring gear and threads

10. Fit the shaft in place so that its marking is opposite the piston skirt marking. Then
remove the masking tape.
11. Apply grease on the cover's (04) ring gear and fit the cover. Also grease the bright
metal surfaces of the cover.
33
2. Instructions
12. Use a tommy bar to slowly turn the piston's (02) ring gear clockwise, in towards
the corresponding ring gear in the cover 04. If necessary, screw two 5/8"-11
screws into the cover to facilitate its fitting. After aligning the ring gear, turn the
piston to end position
Note
Be careful not to damage the ring gear or the cover, and make sure that they do
not make contact with the piston's ring gear
13. Fit the seals (208, 209) on the lock ring. Apply grease on the threads and contact
surfaces on the cover, (04) the shaft (02) and the lock ring (05). Screw two SAE #4
adapters opposite each other into the lock ring, use a tommy bar to screw in the
lock ring clockwise and tighten to 200ft-lbs (271 Nm)
1250
0183
12
Figure: Fitting the lock ring

14. Rotate the lock ring (05) anticlockwise exactly as much as required to fit the lock
pins (109) in the cover (04).
15. Apply sealing compound to the screw plugs (105) and tighten them.
16. Pump grease into the grease nipples (111) to remove any impurities and to check
that they are in working order. Wipe off surplus grease.
17. Screw the grease nipples (111) and valves (112) in place.
18. Fit the hydraulic connections and overcentre valve.
34
2. Instructions
Mounting of rotary actuator on boom

1. Apply slings round the rotary actuator and mount it on the boom head using the
bolts (F).
Figure: Mounting of rotary actuator on boom
2. Connect the hydraulic hoses to the overcentre valve.
3. When mounting the bearing housing it is important to ensure that the stop position
for feed rotation is correct.
Figure: Stop position for feed rotation

A Bearing housing in horizontal position
B Bearing housing rotated in under boom to stop position
35
2. Instructions
a. Rotate the rotary actuator to the stop position.
b. Then rotate it in the opposite direction so that the pattern of holes on the rotary
actuator's shaft flange is displaced two holes.
c. With the rotary actuator rotated to this position it is possible to fit the bearing
housing (E) hanging vertically.
Figure: Mounting the bearing housing
36
2. Instructions
4. Fit the cover (C) and hose retainer (B) using the screws (A).
Figure: Mounting of cover and hose retainer
37
2. Instructions
5. Mount the feeder by rotating the bearing housing through 90°. Lower the boom
straight down against the feed holder's attachment shaft (12). Take care to avoid
damaging the sliding bearings (10) in the bearing housing.
1250 0109 91
Figure: Mounting the feeder
6. Fit shim (9) and inner cover (8).
7. Fit the inner cover (6) using the screws (5).
8. Mount the sensor (4) using the bolts (3).
38
2. Instructions
Note
This point applies only to rigs with the RCS electronic control system and one of
the ABC Regular or ABC Total options.
9. Mount the protection (2).
10. Fit the feed lookout cylinder using the expander shaft (11).
11. Lift the boom and rotate the feeder through 90°. Refit the hydraulic hoses.
39

9852 2423 01 Boom Overhaul Kit But 28

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9852 2423 01 Boom Overhaul Kit But 28

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Available Formats

Atlas Copco

Boom Overhaul Kit BUT 28

PM No. 9852 2423 01

Special attention must be paid

Only use genuine Atlas Copco parts.

© Copyright 2009, Atlas Copco Rock Drills AB, Sweden

Operating instructions in original

Atlas Copco Rock Drills AB

• Replacing rear and front boom cylinder links

Table: Torque table

Torque Tolerance +/ Quant

Torque tightening retaining bolts on telescope tube flange

Figure: Retaining bolt for telescope tube flange

2. Undo nut (A) and withdraw bolt (B).

4. Remove the other bushing and shaft (D).

Figure: Expander shaft

Dismantling/assembling the rear cylinder links

Figure: Rear cylinder bracket

2. Check the wear of the bushings and replace if necessary.

Dismantling the boom body

Figure: Dismantling the boom body

3. Disconnect the sensor cables.

4. Then remove the ten bolts (A) and washers.

Dismantling the boom telescope

Dismantling the boom telescope

1. Extend the telescope to its front end position.

2. Rotate the feed beam up and down.

Figure: Dismantling the boom telescope

5. Unscrew the bolts (A) from the front cylinder attachment.

6. Retract the telescope to its rear end position.

8. Unscrew the bearing housing bolts (B).

10. Remove the expander shaft (D).

Dismantling of telescope and bearing housing

Figure: Dismantling of telescope and bearing housing

1. Retract the telescope to the rear end position.

3. Detach the hydraulic hoses (C).

4. Unscrew the bearing housing bolts (B).

6. Carefully withdraw the telescope tube, cylinder and bearing housing.

Checking the bushings in the bearing housing

Figure: Checking the bushings in the bearing housing

1. Extend the telescope tube (A).

Figure: Play between the telescope tube and bushings

Checking the keys

Figure: Telescope device

Checking the slide rails

Figure: Bearing housing

Dismantling/assembling the front cylinder links

Figure: Rear cylinder bracket

2. Check the wear of the bushings and replace if necessary.

Reconditioning rotary actuators

Dismantling of rotary actuator from boom

Figure: Dismantling the feeder

3. Remove the bolts (1) and protection (2).

4. Remove the bolts (3) and sensor (4).

5. Remove the bolts (5) and the outer cover (6).

10. Apply slings round the bearing housing (E).

Figure: Removing the rotary actuator

Constituent parts of the rotary actuator

Figure: Rotary actuator, cross section illustration