Operation- & Safety instruction Surface Drill Rig MDR 1600 & 2400

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1 Operation- & Safety instruction Surface Drill Rig MDR 1600 & 2400 Aalborg 02/2017

2 Contents TonTec ApS Introduction and description Description / Technicial data Function principles - Operation & remote control - Drilling functions - Angulaton of the drillmast - Rotation of the rockdrill - Drill function - Pressure relief valve Electric diagram Hydraulic diagram Connection to the carrier s hydraulic system Operation Maintenance Safety precautions Repair & maintenance Accessories Warranty conditions If the Drill rig do not function EC- Declaration of Conformity Sparepart list Introduction and description This manual has been created to assist the operator to operate the MDR drill rig in a safety and effective way, as well as the hydraulic Chicago Pneumatic (CP) RDR 48R rockdrill. (See the separate Operation manual for the RDR 48R rockdrill). Operation and service, which is not in accordance with the given guidelines, may expose the drillrig, rockdrill and the carrier for stress to which they are not designed for this can result in system errors and injuries. 1. Before use - read carefully the Operation- & safety instruction as well as the warranty conditions. Pay special attention to the "Safety precautions" 2. Read the manual for the carrier which the drill rig is mounted on 3. Read the Operation & safety manual for the CP Rock drill RDR48R The rockdrill RDR 48R is a powerful hydraulic impact hammerdrill for drilling in rock and concrete materials with a drill diameter from ø25-50 mm. to a depth of 2400 mm. At a drilling depth of 200 mm, compressed air for flushing is required with a capacity of 400 l/min. at 5 bar.

3 The drillrig is to be mounted onto mini excavators etc. in the weight class tons. The carrier has to be strong enough to carry the drillrig. The core of the drill, is the hydraulic rockdrill RDR48R which is to be mounted onto the drill sleigh which is pulled up / down via hydraulic chain guide. The roc drill and rig functions is to being controlled with the cable control unit. Description / Technical data Drillmast: Is produced out of steel u-profiles, with adjustable hitchframe for the carrier. The drillmast is to be hydraulic angled, and can be turned 180º to the right and left side for optimal operator visibility. The sladeconsole for the rockdrill have respectively a stroke of 1600 and 2400 mm (MDR1600 / MDR 2400). Control of the drillrig functions controlled via a cable control unit. Rockdrill: Chicago Pneumatic hydraulic rockdrill RDR 48R. See the separate Chicago Pneumatic Safety- and operation manual. Rockdrill sladeconsole: Mounted with polypropylene plain bearings onto the tower u-profiles, and driven by a hydraulic motor. Weight: MDR 1600 / 2400 Kg. 170 / 190 Sladeconsole movement Approx / 2400 mm Drillmast max length 2350 / 3150 mm Oil flow requiered Max. 25 l/min. Oil pressure Max. 150 bar Max. Returnpressure 5 bar Operation temperature - hydraulicoil C Pressurerelief valve (Max.) 150 bar Drill steel (standard) Hex 22x108 mm Accumulator (Nitrogen) 40 bar Impact frequency Hz ( /min.) Impace energy (ISO 2787) Joule Torque 65 Nm Drill rotations r.p.m. Power electric 12V DC Cooling capacity necessary ca. 3 kw Rotation directions Clockweise / counter clockweise Hydraulichoses: P = Pressure Max 275 bar - DN mm T = Tank (Return) Max 180 bar - DN mm

4 FUNCTION PRINCIPLES Operation & remote controll Connect the drillrig to the carrier s 12V electrical system. ÅKERSTRÖMS CONTROL ON/OFF ROTATION - CW SLADE UP ANGLING - MAST - FORWARD SLADE DOWN ANGLING - MAST - BACK ON/OFF ROTATION - CCW Drillfunction Activating of the DRILLING DIRECTIONS the rockdrill hammer- and drill function starts at the same time. Angulation of the drillmast When the drillrig for an example is mounted onto an excavator, the drillmast can be angled op/down, as well as vertical and horizontal directions. The drillrig can also turned to the left and right side (180º) which optimize the operator s visibility of the drilling area. Bye use of the drillrig hydraulic angling cylinder makes precise drilling. Rotation of the rockdrill The drilling speed is to be adjusted before each drilling project in terms of drilling diameter and drilling surface to secure optimal drilling performance. As a basic rule, we recommend a slow drill speed for drilling in granite and concrete to achieve the best result. Conversely, when drilling in soft materials we recommended a higher drilling speed.

If not sufficient compressed air is used to clean the borehole during drilling, the bore dust will remain in the borehole, build up resistance, and stop the drillsteel.

5 If not sufficient compressed air is used to clean the borehole during drilling, the bore dust will remain in the borehole, build up resistance, and stop the drillsteel. Drill function Correct drilling load is an important factor to achieve optimal drilling speed (Fig. 7. Pos. 10) The drill load should be adjusted in the way that the drillsteel have constant contact to the drilling material, to secure full impact. Air blow has to be avoided If the load is poor the rockdrill do not obtained a constant drill pressure, which can result in damage to the drillsteel and an unsatisfied performance. If the load is too heavy the compressed air might be insufficient, and the drilled materiel remain in the borehole and the drillsteel stuck. An overheating of the drillhead, may cause damage to the drillsteel. Torque switch of the rockdrill (picture to the right) is mounted onto the hydraulic valve box, that can be manual adjusted from outside. Switch out = Low torque Switch inn = High torque The load onto the rockdrill sleigh is newer to be adjusted to a higher load than approx. 30 kg. The load can be adjusted at pressurereliefe valve (Fig. 7. POS7) valve in front of the manometer valve box. On the manometer, inside the hydraulic valve box, the drill pressure can be read. (Fig. 7. pos. 11). For horizontal drilling, it might occur that the drilling pressure must be increased as the weight of the rockdrill- and sleigh is not the same as drilling vertical direction. When drilling in soft materials the drill pressure must be reduced as the drillsteel might get stuck in the rock/material. Pressurereliefe valve The drillrig is mounted with a pressurereliefe valve that is set to open at 140 bar. (Fig. 11. pos.7)

6 Electrical diagram Hydraulic diagram

7 Connection to the carrier s hydraulic system Olieflow: If the carrier supply a higher oilflow as required, the rpm. of the engine has to be reduced, to achieve correct oilflow and pressure. Oilflow devider: If it not possible to reach the requiered oilflow, an oilflow divider has to be mounted between the carrier and the drillrig. This secure that the drillrig get the required oilflow, and the remaining oil goes back into the returnline. Pressurereliefe valve: To secure the rockdrill against a too high pressure, the carrier s pressure relief valve has to be adjusted according the specifications. Possible a pressure relief valve should be mounted in the carrier s hydraulic system. Hoses: High-pressure hydraulic hoses (internal diameter of ½ ) that are suitable for minimum a pressure of 140 bar. It is recommended to use two layer steel reinforced hoses that is resistant against external wear. Returpressure: Has to be as low as possible, to achieve optimal performance. The returnpressure, measured at the drillrig, must not exceed the max. returnpressure shown in the technical data. A too high backpressure create low performance, and heating of the rockdrill, and might cause damage to the hydraulic system. Filter: The carrier has to be mounted with an return oilfilter with a filtering of 10-25µ Oilcooler: It is recommended that the carrier is mounted with an oilcooler, as the rockdrill generates heat. Operation Start up. 1. Mount the drillrig securely to the carrier 2. Hydraulic hoses has to be connected to the P & T port 3. Mount the electric cable to carrier power supply. OBS: BROWN cable = Plus (+) 4. Place the rockdrill in position, via the controlbox, to mount the drillsteel 5. Place the drillsteel, and lock the retainer 6. Place the drillrig at the desired position with the use of the carrier, and adjust the drill frame where drilling is taken place 7. Adjust the drilling load with the load switch (Fig. 7. pos. 10) when turning on the rockdrill in order to achieve correct drill load and speed. Stop 1. Turn off the rockdrill with the use of the controlbox 2. Turn off the carrier (according the carriers user s manual)

8 3. Remove the hydraulic hoses, electric cable, and place the drill rig in the storage stand IMPORTANT Secure that the rockdrill get correct oil flow and pressure according to the technical data. Avoid airblow which is activating the rockdrill hammer function without pressure onto the drillsteel. His might cause damaged to the rockdrill and create heat of the hydraulic oil Maintenance 4 Daily maintenance of the drillrig: Control the chain, all bolts and nuts if necessary retightening Control the drill mast, rockdrill, drillsteel retainer, hitch, controlbox for any damage and cracks - if necessary repair Control the hydraulic hoses for any damage or leaks if necessary replace for safety reasons Control the slide plates of the rockdrill sleigh (Fig. 4 POS 6) which is wearparts, if too much slack, the nylon slideplates has to be replaced Clean after use; grease the nipples of the drillrig and rockdrill as well as the chain. Avoid high pressure cleaning of the exposed components like the control box, chain, sprocket and the electrical system For longer-term storage the striking piston of the rockdrill has to be protected against corrosion - by pressing the piston in the upper position with the use of the tip of the drillsteel through the HEX bushing. This has to be done by turning the carrier of, with the hydraulic hoses connected. 5 Important Do not operate the rockdrill without grease of the chisel bushing. Which is required approximately every 8 hours with Molykotegrease ex. Mobiltac 81. For further information, see the operation manual for the Rockdrill. Check the drillrig s bolts and nots are proper tightened - if necessary tighten the bolts and nuts. Check the whole construction for any damaged or cracks and hydraulic hoses for leaks. Check whether the chain is tight and lubricated if necessary tighten the chain and lubricate.

9 Safety precautions The design of the drillrig provide the operator with the best operator comfort and safety operation like the noise level is to be kept to a minimum. However, incorrect use of the drillrig might cause serious damage. Therefor the following precautions has to be respected: 1. Use only the drillrig according to the local health and safety regulations. 2. Constant exposure to noise may cause long-term hearing damage. 3. Use always safety equipment such as ear protectors, safety glasses, gloves, safetyshoes and helmet 3. Drilling above the carrier s height, as well as horizontal drilling the operator has to pay attention that danger of falling materials that the operator himself may be at risk. 4. Please note that the rockdrill can become warmer than the air temperature - therefore always use suitable clothing and gloves. 5. Always make sure to turn off the carrier, and disconnect the hydraulic hoses bye servicing the drillrig, as well as changing the drillsteel. 6. Fine jets of hydraulic oil at high pressure can penetrate the skin. Do NOT use the fingers to check for leaks. Hold instead, a piece of cardboard up and check for oil leak. If the oil has penetrated the skin, seek prompt medical attention. 7. Do newer leave the drillrig with the carrier turned on. Repair & Maintanance The rockdrill RDR 48R may only be repaired / serviced at an authorized workshop. Yearly service: The accumulator has to be checked and or refilled with nitrogen. (dismounting is associated with safety hazard) Moving parts like; bushings, seals and bolts etc. Has to be checked and replaced if necessary. Test the functionality of the rockdrill. See the separate Safety- and operation instructions for rockdrill RDR 48R

10 Accessories Oilflow devider type OFD 5 Max. Inlet flow 60 l.p.m. Standard setting: 20 l.p.m./150 bar (adjustable) TANK CONNECTION PUMP CONNECTION P = Pressure T = Tank C = Controlled flow R = Return Warranty conditions The production of the drillrig is based on many years of experience and the use of high quality material, which enables the equipment to resist the mechanical and thermic stress occurring under normal working conditions Should it happened in spite of thorough testing procedures, defects in material or manufacture occur; these will be covered in accordance with ORGALIME S 2000/NL 92. General Warranty Conditions From the delivery date there is a twelve-month warranty The warranty covers all functional disturbances caused by defects in material or manufacture When liable under the warranty, the factory is free to decide whether to offer repayment, replacement or repair Shipping costs are to be paid by the purchaser Any parts replaced are the property of the factory The factory assumes no liability for indirect damage and other costs such as loss of production Warranty claims will be considered only when reported to the dealer immediately upon discovery of the defect

11 The Warranty Does Not Cover Damage caused by faulty connection or improper handling Costs to cover repairs undertaken by a non-authorized TonTec/CP dealer Damage caused by imperfect maintenance, improper use or damage in transit Fair wear and tear Damage to hoses and quick-release couplings caused by wear or imperfect maintenance The warranty ceases on change of ownership of the equipment and in case of repairs undertaken by a non-authorized TonTec ApS shop without the factory s express authorization. If the drillrig do not function Check the following: Check whether the hydraulic couplings are correct mounted (P & T) Check the hydraulic couplings for oil troughput Check the carriers oilflow and pressure Check voltage on the electric circuit (listen if necessary to the controlboks weather the relay is being activating (Click / Click) Check voltage of the carrier If these conditions are checked and the drillrig still does not work - contact your dealer

12 EC- Deceleration of Conformity EC- Declaration of Conformity, Annex II, A Manufacturer: TonTec ApS Troensevej 19c DK 9220 Aalborg Øst Denmark hereby declares that: Drillrig: MDR 1600 and 1400 Drillrig. Serial No.: Is manufactured in conformity with the EF-directive 2006/42/EF (Machinery Directive) General Manager: Jens Jørgen Poulsen Signed: Place and Date: Aalborg d. 25. april 2015

13 Fig. 1 SPAREPART LIST Pos. Partnumber Description Pcs Mast cplt. 1, Mast cplt. 2,4 m Carrier hitch cplt Sleigh cplt Valveblock cplt Hydraulichose holder 1

14 Fig. 2 Pos. Partnumber Description Pcs Mast frame 1,6 m Mast frame 2,4 m Sprocket ½ lower Oilmotor Oilmotor protion Pin Sprocket upper Bolt M8x Nut M Nut M Bolt M12x Bronze bearing Bolt M10x Bushing drillsteell Lock Bolt M8x Bakelite ball ø Bolt M8x Washer ø Nut M Mut M Washer ø Nut M Locking screw M12 1

15 Fig. 3 Pos. Partnumber Description Pcs Hitch º angle bracket Mast bracket Bronze bushing Washer ø17/ø60/ Nut M16x Pinbolt ø Springsplit ø Pin DELETED Springsplit DELETED Pinbolt w/lock Pinbolt w/lock Pinbolt w/lock Bracket Bolt M12x Washerr M Nut M Bolt M10x Hydraulic Cylinder Washer ø Bronze bushing 2

16 Fig. 4 TonTec ApS Partnumber Description Pcs Sleigh RDR 48R Hyd. Rockdrill Spacer Chain ½ x 5x16 (MRD1600) Chain ½ x 5x16 (MRD2400) Backplate Plate holder Bolt M8x Washer ø Bolt M10x Washer ø Bolt M8x Wascher M Spacer Sleigh plate ½ x5/ Bolt Connector - DELETED Nut M Bolt M6x Bolt M12x25 2

17 Fig. 5 Partnumber Description Pcs Mounting plate cplt Bolt M8x Washer ø Backplate Valveblock cplt Bracket Bolt M5x Box Bolt M8x Washer ø Nut M Bolt M8x40 2

18 Fig. 7 Partnumber Description Pcs Valveblock Shuttle valvel Magnet valve Magnet valvel 1 4a Magnet spool DC 12V NG6 7 til pos. 3 & 4 4b Magnet spoole DC 24V NG6 7 til pos 3 & Pilot operated checkvalve Valvehouse Pressure regulating valve Valvehaous Pressure reduction valve Pressure switch Pressure gauge bar ø Flow directionvalve Quick releasecoupling ½ Flat-face male Quick releasecoupling ½ Flat-face female Fitting Seal 3/ Fitting Pack-ring Adapter Adapter O-ring ø22x1, Seal ¼ Nipple nozzle ø1,1 mm Adapter Protection 3/8 han Protection 3/8 hun 1

19 Fig. 8 Partnumber Description Pcs Hyd. hose A 1, Hyd. hose A 2, Hyd. hose B 1, Hyd. hose B 2, Hyd. hose C 1, Hyd. hose C 2, Hyd. hose D 1, Hyd. hose D 2, Hyd. hose F Hyd. hose F Hyd. hose G 1,6 M Hyd. hose G 2,4 M Hyd. hose H 1,6 M Hyd. hose H 2,4 M 1

LH 25 S/E HYDRAULIC BREAKER OPERATING MANUAL Serial Nos Issued 22/10-03 Revised 11/06-04

LH 25 S/E HYDRAULIC BREAKER OPERATING MANUAL Serial Nos. 252000- Issued 22/10-03 Revised 11/06-04 Introduction and Description Technical Data Operation Recommended Hydraulic Oil Safety Precautions Connection