9852 1979 01 Maintenance Instructions R

Atlas Copco
ROC D5/D7/D9
Maintenance instructions
PM No. 9852 1979 01

2007-08
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 2007, Atlas Copco Rock Drills AB, Sweden

Any 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.
Atlas Copco Rock Drills AB

SE-70191 rebro, Sweden
Safety
Safety
Reference................................................................................................................. 5
Safety
Safety
Reference
Note
Always read the information under Safety before starting to use the rig or starting
maintenance work.
1250 0099 89
Safety
1. General ................................................................................................................... 11
General .................................................................................................................. 11
Safety ................................................................................................................ 11
Target group and objective ............................................................................... 11
Contact details .................................................................................................. 12
Signs for outsourced components ..................................................................... 15
Dismantling and assembly................................................................................ 15
Scrapping .......................................................................................................... 16
Tightening torque in bolted joints..................................................................... 16
Welding............................................................................................................. 17
Points to be observed when welding:........................................................... 17
Electrode recommendations......................................................................... 18
Fault finding...................................................................................................... 19
Battery ................................................................................................................... 20
Environmental considerations regarding batteries............................................ 20
Charging the battery.......................................................................................... 20
Proceed as follows (24V charger) ................................................................ 21
Proceed as follows (12V charger) ................................................................ 22
Starting with an auxiliary battery...................................................................... 22
Steel cables ............................................................................................................ 23
Scrapping guidelines for steel cables................................................................ 23
Wire break at cable attachment .................................................................... 24
Occurrence of strand breaks......................................................................... 24
Concentrations of wire breaks...................................................................... 24
Effects of heat .............................................................................................. 24
Occurrence of wire breaks due to operating time. ....................................... 24
Reduced elasticity ........................................................................................ 24
Decrease in cable diameter .......................................................................... 25
Certain number and type of wire breaks ...................................................... 25
Corrosion...................................................................................................... 26
Surface wear................................................................................................. 26
Deformation of the cable.............................................................................. 27
Wire displacement........................................................................................ 27
Strand displacement ..................................................................................... 28
Waviness ...................................................................................................... 28
Cracks........................................................................................................... 28
Kinks ............................................................................................................ 29
Flattening ..................................................................................................... 29
Local cable diameter decrease ..................................................................... 29
Local cable diameter increase ...................................................................... 29
Basket formation .......................................................................................... 30
Tensioning the crawler tracks ................................................................................ 30
Air conditioning..................................................................................................... 31
Safety ................................................................................................................ 31
Environmental issues when handling refrigerant ............................................. 32
Changing air filter ............................................................................................. 32
Fault finding...................................................................................................... 33
No cooling.................................................................................................... 33
Poor cooling ................................................................................................. 33
Uneven cooling ............................................................................................ 33
Abnormal noise ............................................................................................ 34
2. Transport instructions............................................................................................. 35
Hoisting ................................................................................................................. 35
Single-section boom version............................................................................. 35
Folding boom version ....................................................................................... 37
Transport................................................................................................................ 39
Before loading the drill rig onto the transport vehicle...................................... 40
Once the drill rig is loaded onto the transport vehicle. ..................................... 40
Towing ................................................................................................................... 42
3. Drill system ............................................................................................................ 44
Adjusting the damper pressure .............................................................................. 44
Adjusting percussion pressure ............................................................................... 45
General.............................................................................................................. 45
Low percussion pressure................................................................................... 47
High percussion pressure .................................................................................. 47
Adjusting drill feed pressure.................................................................................. 48
General.............................................................................................................. 48
Low drill feed pressure ..................................................................................... 49
High drill feed pressure..................................................................................... 50
Adjusting rotation speed........................................................................................ 52
Setting rotation speed........................................................................................ 54
RPC-F system ........................................................................................................ 54
Adjusting........................................................................................................... 54
Pressure regulator adjustment................................................................................ 57
Anti-jamming protection ....................................................................................... 57
Air flow monitor B142 ..................................................................................... 58
Adjusting air flow switch.................................................................................. 58
Rotation pressure switch B134 ......................................................................... 59
Adjusting activation pressure............................................................................ 61
Setting lubrication to the rock drill........................................................................ 62
ECL collection....................................................................................................... 63
Locations........................................................................................................... 63
ECL collector pressure control valve................................................................ 63
Function ............................................................................................................ 64
4. Hydraulic systems .................................................................................................. 67
Environmental considerations when handling oil ................................................. 67
General................................................................................................................... 67
Repairing hydraulic components ........................................................................... 68
Replacement of hydraulic hoses ............................................................................ 68
Hydraulic workshops............................................................................................. 68
Filter ...................................................................................................................... 69
Return oil filter ................................................................................................. 69
General ......................................................................................................... 69
Changing the return oil filter........................................................................ 69
Breather filter.................................................................................................... 70
General ......................................................................................................... 70
Changing the breather filter ......................................................................... 71
Condensation in the hydraulic oil reservoir...................................................... 72
Draining condensation from the hydraulic oil tank ..................................... 72
5. Feeder ..................................................................................................................... 73
6000-series............................................................................................................. 73
Assembling the rock drill ...................................................................................... 73
Preparation ........................................................................................................ 73
Assembly .......................................................................................................... 73
Check after four hours ........................................................................................... 74
Haul and return ropes ............................................................................................ 75
Locations........................................................................................................... 75
Replacing the haul rope .................................................................................... 75
Adjusting haul and return ropes........................................................................ 76
Tension of return rope ........................................................................................... 76
Adjusting the cradle on the feed beam .................................................................. 76
Replacing the slide pieces in the holder ................................................................ 78
Replacing slide rails .............................................................................................. 78
Feed cylinder ......................................................................................................... 79
Dismantling the feed cylinder........................................................................... 79
Tension bushings for spacers ............................................................................ 80
Description ................................................................................................... 80
Dismantling.................................................................................................. 81
Assembly...................................................................................................... 81
Long-term storage............................................................................................. 81
6. Dust collector (DCT).............................................................................................. 82
Dust collector (DCT)............................................................................................. 82
Setting the dust collector (DCT)............................................................................ 83
Preset times ....................................................................................................... 84
Setting the times ............................................................................................... 84
Filter test, dust collector (DCT)............................................................................. 84
Dust collector (DCT) filter change........................................................................ 85
7. Radiator .................................................................................................................. 86
Environmental issues when handling coolant ....................................................... 86
Coolant .................................................................................................................. 86
8. Diesel engine .......................................................................................................... 88
Safety..................................................................................................................... 88
Environmental issues when handling oil............................................................... 88
Oil for diesel engine .............................................................................................. 89
Maintenance of components.................................................................................. 90
Air filter, service interval .................................................................................. 90
Cleaning or changing air filter .......................................................................... 91
Cleaning the main cartridge ......................................................................... 92
Checking air filter switches.......................................................................... 93
Fuel system ....................................................................................................... 93
Filter ............................................................................................................. 93
Prefilter......................................................................................................... 94
Fine filter...................................................................................................... 95
Environmental issues when handling fuel ........................................................ 96
Draining the fuel tank ....................................................................................... 96
Belts .................................................................................................................. 97
Belts.............................................................................................................. 97
Tension gauge............................................................................................... 97
Changing the generator belt ......................................................................... 98
For further instructions, see separate instructions for the diesel engine. ........ 100
9. Oil and fuel........................................................................................................... 101
Environmental issues when handling fuel ........................................................... 101
Filling fuel ........................................................................................................... 101
Environmental considerations when handling oil ............................................... 102
Compressor oil..................................................................................................... 102
Oil sampling ........................................................................................................ 104
Filling up with hydraulic oil ................................................................................ 104
Filling manually.............................................................................................. 104
Changing hydraulic oil ........................................................................................ 105
General............................................................................................................ 105
Draining .......................................................................................................... 105
Lubricating oil ..................................................................................................... 105
For engine oil see section Diesel engine.......................................................... 107
10
1. General
1. General
General
Safety
When maintenance work is carried out on the rig, observe the following points:
Never perform service or maintenance work while the rig is running
To prevent personal injury during service and maintenance work, all components
that can be brought into motion or fall down must be thoroughly secured.
Ensure that the hydraulic and pneumatic systems are depressurised before starting
work on them.
All controls must be deactivated during service and maintenance.
When changing hydraulic hoses, ensure they are replaced with hydraulic hoses fitted with the correct crimp couplings of correct quality and dimension. All pressurised hydraulic hoses have crimped couplings and should therefore be purchased
ready made from Atlas Copco. Quality classes and hose dimensions are specified
in the spare parts catalogue. Ensure also that all hose connections are clean,
undamaged and securely tightened.
Target group and objective

Note
This chapter (General) contains general recommendations for maintenance of the
drill rig and its peripheral equipment. This means that certain sections may not be
fully adapted to individual components.
The maintenance instructions are intended for mechanics and personnel in maintenance and service. The user should have undergone Atlas Copco's training courses
for the equipment concerned.
The objective of these maintenance instructions is to detect and rectify faults at an
early stage so that breakdowns, costly secondary damage and accidents can be prevented. Regular maintenance is a precondition for planning necessary interruptions in
operation such as reconditioning and repairs. This allows maintenance to be carried
out when most suitable with regard to production instead of causing complete breakdown.
11
1. General
Contact details
Table: Addresses, telephone numbers and fax numbers to Atlas Copco companies
Country
Address
Phone and fax number
Argentina
Juncal 2869
B1640GRE Martinez
Buenos Aires
Phone: +54 - (0)11 - 47 17 22 00

Fax: +54 - (0)11 - 47 17 09 88
Australia
P O Box 6134
Delivery Centre
Blacktown NSW 2148
Phone: +61 - (0)2 - 9621 9700

Fax: +61 - (0)2 - 9621 9813
Austria
Postfach 108
A-1111 Vienna
Phone: +43 - (0)1 -76 01 20

Fax: +43 - (0)1 - 769 56 72
Bolivia
P.O. Box 290

Santa Cruz de la Sierra
Phone: +591 - (0)3 - 343 68 68

Fax: +591 - 0(3) - 343 69 69
Brazil
P O Box 12737
Sao Paulo, SP
04744-970
Phone: +55 - (0)11 - 247 88 00

Fax: +55 - (0)11 - 55242347
Bulgaria
14, Vasil Levski Str., fl. 2

North Industrial Area
Kazichane
Sofia 1532
Phone: +55 - (0) - 29 76 30 98

Fax: +55 - (0) - 29 76 30 90
Canada
200 Mumford Road

Walden Industrial Park
Lively, Ontario P3Y 1L2
Phone: +1 - 705 - 673 67 11

Fax: +1 - 705 - 692 31 01
Chile
Panamericana Norte 5001 - Conchali

Santiago, Chile
6553935 Conchali
Phone: +56 - (0)2 - 442 3600

Fax: +56 -(0)2 - 623 44 60
China 1
No. 1, Heng Da Road

Nanjing Economic & Technological
Development Zone
Nanjing
Postal code 210038
Phone: +86 - 25 - 85 75 76 00
Fax: +86 - 25 - 85 75 75 30
China 2
No. 12, Kun Ming Hu Street

Shenyang Economic & Technological
Development Zone
CN-Shenyang 110027
Phone: +86 - 24 - 25 81 17 19
Fax: +86 - 24 - 25 81 18 67
CMT
International
S-105 23 Stockholm
Phone: +46 - (0)8 - 743 80 00

Fax: +46 - (0)8 - 702 21 29
Colombia
A.A. 95310
Santaf de Bogot, D.C.
Phone: +57 - 1 - 291 54 90

Fax: +57 - 1 - 430 6514
Czech Republic
Prumyslova 10
Praha 10, Post Code 102 00
Phone: +420 - (0)2 - 25 43 42 20

Fax: +420 - (0)2 - 25 43 42 22
Egypt
520 El-Obour Market

Cairo
Phone: +20 - (0)2 - 610 20 57

Fax: +20 - (0)2 - 610 20 56
12
1. General
Country
Address
Finland
Tuupakankuja 1
SF-01740 Vantaa
Phone: +358 - (0)9 - 296 64 42

Fax: +358 - (0)9 - 29 64 21 8
France
B.P. 67181
FR-95056 Cergy-Pontoise Cedex
Phone: +33 - (0)1 - 30 72 32 22

Fax: +33 - (0)1 - 30 72 32 49
Germany
Postfach 10 02 25
D-46002 Essen
Phone: +49 - (0)201 - 217 70

Fax: +49 - (0)201 - 217 74 54
Ghana
P O B 10071
Accra North
Phone: +233 - 21 77 45 12
Fax: +233 - 21 77 61 47
Great Britain
P O Box 79
Hemel Hempstead
Herts HP2 7HA
Phone: +44 - (0)1442 - 22 21 00

Fax: +44 - (0)1442 - 234467
Greece
93, Koropiou - Varis Avenue GR - 194 00

Koropi, Athens
Phone: +30 - (0)210 - 349 96 00

Fax: +30 - (0)1 - 345 47 83
Hong Kong
P O Box 1516
Shatin Central Post Office
New Territories
Phone: +852 - 24 88 01 03
Fax: +852 - 24 88 98 63
India
Sveanagar
Bombay Pune Road
Dapodi
Pune 411 012
Phone: +91- (0)20 -712 64 16

Fax: +91 - (0)20 - 712 65 87
Indonesia
P O Box 7021/JKS CCE

Jakarta 12075
Phone: +62 - 780 10 08

Fax: +62 - 780 18 37
Iran
PO Box 13145-1311
Tehran 1345654551
Phone: +98 - 21 - 669 377 11

Fax: +98 - 21 - 669 273 14
Ireland
Kylemore Road
Bluebell
Dublin 12
Phone: +353 - (0)1 - 450 5978

Fax: +353 - (0)1 - 456 7686
Italy
Casella Postale 77
IT-20092 Cinisello
Balsamo MI
Phone: +39 - (0)2 - 61 79 91

Fax: +39 - (0)2 - 66 01 32 99
Japan
Sumitomo Fudosan Shipa Bldg 4 llF

13-4 Shiba 2-chome
Minato-ku Tokyo 105-0014
Phone: +81 - (0)3 - 57 65 78 90

Fax: +81 - (0)3 - 57653199
Kazakhstan
Kurmangaliev Str 8A
050010 ALMATY
Phone: +7 - (0)327 - 258 85 34

Fax: +7 - (0)327 - 258 85 35
Kenya
PO Box 400 90
Nairobi
Phone: +254 - (0)20 - 660 50 00

Fax: +254 - (0)20 - 82 54 72
Korea
C-P.O. Box 8354

Seoul
Phone: +82 - (0)2 - 21 89 40 00

Fax: +82 - (0)2 - 522 82 39
Malaysia
26 Jalan Anggerik Mokara 31/47

Kota Kemuning, Seksyen 31
40460 Shah Alam
Selangor Darul Ehsan
Phone: +60 - (0)3 - 5123 88 88

Fax: +60 - (0)3 - 51 23 89 49
13
1. General
Country
Address
Mexico
Apartado Postal Box 104

Tlalnepantla
Edo. De Mexico
Phone: +52 - 5 - 626 06 00

Fax: +52 - 5 - 565 62 65
Morocco
P O Box 13 844
20 300 Casablanca
Phone: +212 - 2 - 600 040

Fax: +212 - 2 - 60 05 22
Mongolia
Building BP9, Tavan Erdene(MISHEEL)

Center, 2nd Khoroo, Khan Uul District,
Chinggis Avenue, Ulaanbaatar, Mongolia
Phone: +976 - (0)11 - 99 11 48 16

Fax: +976 - (0)11 - 11 31 26 13
Norway
P O Box 334
N-1401 Ski
Phone: +47 - 64 - 86 03 00
Fax: +47 - 64 - 86 03 30
Peru
Apartado 662
Lima 100
Phone: +51 - (0)1 - 224 86 80

Fax: +51 - (0)1 - 224 01 53
Philippines
P.O. Box 1373

1200 Makati City
Phone: +63 - (0)2 - 823 8178-80

Fax: +63 - (0)2 - 823 84 59
Poland
(Sales) ul. Katowicka 32

P-40-173 Katowice
(Service) ul.Krzywa 3,
59-100 Polkowice
Sales
Phone: +48 - (0)32 - 209 5774
Fax: +48 -(0)32 - 209 5776
Service
Phone: +48 76 8474 935
Portugal
Apartado 14P-2790-953 Carnaxide
Phone: +351 - (0)1- 416 85 00

Fax: +351 - (0)1 - 418 0782 Service
Russia
27, Viatskaya Street, Building 14

127015 Moscow
Phone: +7 - 495 - 933 55 52

Fax: +7 - 495 - 933 55 58
Saudi Arabia
P O Box 7330
Jeddah 21462
Phone: +966 - (0)2 - 693 33 57

Fax: +966 - (0)2 - 693 28 92
Singapore
Jurong Point
P O Box 438
Singapore 639456
Phone: +65 - 66 - 68 62 28 11
Fax: +65 - 66 - 68 63 60 98
South Africa
P O Box 14110
Witfield 1467
Phone: +27 - (0)11 - 821 90 00

Fax: +27 - (0)11 - 821 92 02
Spain
Apartado 24
E-28820 Coslada
Madrid
Phone: +34 - (9)1 - 627 91 00

Fax: +34 - (9)1 - 627 9239
Sweden
S-10523 Stockholm
Phone: +46 - (0)8 - 743 92 30

Fax: +46 - (0)8 - 743 92 46
Switzerland
Betigenstrasse 80
CH-2557 Studen/Biel
Phone: +41 - (0)32 - 374 15 00

Fax: +41 - (0)32 - 374 15 15
Taiwan
P O Box 14-45, Chungli

Tao Yuen Hsien
Phone: +886 - (0)3 - 479 68 38

Fax: +886 - (0)3 - 479 68 20
Thailand
1696 New Petchburi Road

Bangkapi
Huay Kwang
Bangkok 10320
Phone: +66 - (0)2 - 652 90 06

Fax: +66 - (0)2 - 652 81 94
14
1. General
Country
Address
Turkey
Istasyon Arkasi
81700 Tuzla
Istanbul
Phone: +90 - (0)216 - 581 05 81

Fax: +90 - (0)216 - 581 05 82
USA
PO Box 1159
Commerce City CO 80022
Phone: +1 - 303 - 287 88 22

Fax: +1 - 303 - 217 2839
Venezuela
Apartado 76111
Caracas 1071
Phone: +58 - (0)212 - 256 23 11

Fax: +58 -(0)212 - 257 18 10
Vietnam
No. 42, Street 37, Thao Dien Ward, District 2, Phone: +84 - (0)8 - 898 96 38
Ho Chi Minh City
Fax: +84 - (0)8 - 898 96 37
Zambia
P O Box 11291
Chingola
Phone: +260 - (0)2 - 31 12 81

Fax: +260 - (0)2 - 31 38 77
Zimbabwe
P.O. Box CY 935

Causeway
Phone: +263 -(0)4 - 62 17 61-5

Fax: +263 - (0)4 - 62 17 94
Signs for outsourced components

Signs are placed on the larger components of the drill rig. When ordering spare parts
or making enquiries in regard to the drill rig, the type designation and serial number
must always be stated. Type designations and serial numbers are specified in a separate document, MI (Machine Identification). Spare parts can always be ordered
through Atlas Copco.
Dismantling and assembly
CAUTION
Exercise extreme caution when slinging
and hoisting heavy objects
Can cause personal injury
Hoisting must take place at the centre of
gravity
Only use slings which are intact and
designed for the load they shall carry
Secure the slings in the lifting eyes,
where available
Before transporting in shafts or the like it may be necessary to fully or partially dismantle the drill rig. Observe the following when dismantling, lifting and assembling:
15
1. General
Before dismantling, hose the entire rig clean with water and/or detergent containing a grease solvent.
Observe the strictest cleanliness when dismantling hydraulic, compressed air and
water flushing hoses. Immediately plug all hoses, nipples and hydraulic oil pipes,
or seal and protect them from dirt in some other suitable way.
Mark hoses, pipes and other connections, where this has not already been done, to
make reassembly easier and prevent mix-ups.
Use properly secured lifting tackle of generous dimensions.
Note
When the drill rig is scrapped, all materials that are harmful to the environment must
be disposed of in a manner prescribed by the authorities.
Scrapping
When the entire drill rig or part of the rig is to be scrapped, local regulations in force
regarding handling, waste management, recycling and destruction must be followed.
Collect and dispose of:
Rest oil and oil spill

Oil waste such as filters
Rest fuel and fuel spill
Rest grease and grease spill
Batteries
Discarded refrigerant, air conditioning
Chemicals such as flushing additives, other additives and coolants.
Metals, e.g. steel and aluminium (metals that are recyclable)
Plastics and rubber (often marked in various classifications for recycling)
Electrical components such as cables, electronics
Tightening torque in bolted joints.

All joints are tightened to the torque required by Atlas Copco Standard K 4369 unless
otherwise specifically stated. In such cases, this will be specified in the maintenance
instructions of the module in question.
Table: Atlas Copco Standard torques.
16
Size
Strength
class
Torque in
Nm.
Tolerance
M6
8.8
M8
8.8
20
M10
8.8
41
10
M12
8.8
73
18
1. General
Size
Strength
class
Torque in
Nm.
Tolerance
M14
8.8
115
25
M16
8.8
185
45
M20
8.8
355
85
M24
8.8
600
150
M12 x 1.25
10.9
135
M16 x 1.25
10.9
315
15
M18 x 1.25
10.9
460
20
M6
12.9
14
M8
12.9
34
M10
12.9
70
17
M12
12.9
120
30
M14
12.9
195
45
M16
12.9
315
75
M20
12.9
600
150
M24
12.9
1020
250
Welding
Applies to drill rigs equipped with one of the following engines:
- CAT 3176
- CAT 3196
- CAT 6.6
- CAT 7
- CAT C9
- CAT C10
- CAT C11
- CAT C12
- CAT C13
- CAT C15
Note
It is important to consult Atlas Copco for approval of welding and choice of electrodes.
Points to be observed when welding:
Disconnect the cables from the generator, the battery and the engine's electronic
module (A).
17
1. General
Figure:
Grind off rust and paint from the area that is to be welded and carefully prepare the
joint.
Weld in a dry area.
Connect the welding earth cable to a clean surface as close as possible to the welding area. Avoid welding close to bearings and bushes. If these cannot be removed,
connect earth cables on both sides of the weld.
Alterations and reinforcements must not be made without previous consultation
with Atlas Copco.
Do NOT weld hydraulic tanks, valve blocks, compressed air tanks or pressure
lines.
Always keep a fire extinguisher for oil fires near at hand during all types of welding, cutting and grinding. Screen off the work area from flammable materials.
Always protect hoses, cables and electrical components.
Grind off spatter after welding. If possible, also grind the surface of the weld
smooth and treat it with anti-corrosion paint.
Electrode recommendations
Use only intact and clean electrodes that have been stored in a dry place. The generally recommended type of electrode is ESAB OK 48.00, ESAB OK 48.30 or the
equivalent in accordance with the standard below:
18
1. General
Table: Electrode recommendations

ISO:
2560 E51 5B 120 20 H
SS:
14 3211 H10
DIN 1913:
E51 55 B10
AWS:
A/SFA 5.1 E 7018
The use of MIG welding equipment is perfectly acceptable. The generally recommended type of electrode is ESAB-OK Autorod 12.51 or the equivalent in accordance with the standard below:
Table: MIG electrodes
SS:
14 3403 3423
DIN 8559:
SG 2
AWS:
A/SFA 5.18: ER 70 S-6
If in any doubt, contact Atlas Copco for advice.
Fault finding
Fault finding is a logical sequence of activities to locate a fault, thereby making it
possible to rectify the fault as soon as possible.
Always try to investigate the location of the fault in order to limit fault finding to a
certain system or function.
19
1. General
Battery
Environmental considerations regarding batteries
ENVIRONMENTAL DIRECTIONS
Think of the environment!
Batteries contain acids and heavy metals.
For this reason, expended batteries can
be hazardous to the environment and to
health.
Expended batteries must be sent for
destruction in accordance with local
regulations.
Charging the battery
WARNING
Risk of fire and explosion
May cause serious personal injury and
damage to property
Flammable hydrogen gas
Corrosive fluid
Avoid naked flames and sparks
Always detach the negative terminal first,
and connect it last
The battery is normally charged by the drill rig's generator. If the battery is fully discharged for some reason, it must be recharged using a battery charger. Follow the
instructions carefully. Cell plugs should be unscrewed but left in the holes during
charging.
20
1. General
Explosive gas is formed in the battery during charging. A short circuit, naked flame
or spark in the vicinity of the battery could cause a serious explosion. Ensure good
ventilation. Always turn off the charge current before disconnecting the clips. If the
density has not risen noticeably despite a number of hours of recharging, the battery
is probable expended.
Rapid charging, when carried out correctly, will not damage the battery. However, it
should not be undertaken too often and is not recommended for old batteries.
Repeated discharging for long periods, especially with low current such as leaving
the lights on while the engine is stationary, will impair the service life of the battery.
Discharging with high current is not normally harmful. The battery must be left to
rest between start attempts, however.
Since the drill rig's 24V electrical system is powered by two 12V batteries in series,
the following points should be observed:
The batteries must have the same capacity (Ah).
The batteries must be the same age. This is because the charging current required
to bring a battery up to a certain voltage changes with age.
The batteries must not be loaded unevenly.
Series coupling maintains the same capacity but increases the voltage (double).
When 2 x 12V 60Ah batteries are connected in series, the voltage will be 24V but
the capacity remains at 60Ah.
Ensure that the correct voltage is used before connecting a battery charger. Use a
24V charger when recharging both batteries and a 12V charger when charging
each battery individually.
Proceed as follows (24V charger)
Before charging
1. Inactivate battery switch S300.

2. Detach the cable between chassis earth and the negative cable on the battery G1B.
3. Connect the positive battery charger cable to the positive terminal on G1A.
4. Connect the negative charger cable to the negative terminal on G1B.
5. Start the battery charger.
After charging
1. Turn off the battery charger

2. Detach the battery charger's negative lead from the negative terminal on G1B.
3. Detach the battery charger's positive lead from the positive terminal on G1A.
21
1. General
4. Connect the cable between chassis earth and the negative terminal on G1B.
5. Activate battery switch S300.
Proceed as follows (12V charger)
Before charging
1. Turn off the battery switch S300

2. Disconnect the jumper lead between the negative terminal on battery G1A and the
positive terminal on battery G1B.
3. Connect the positive battery charger cable to the positive terminal on G1A.
4. Connect the batter charger's negative lead to the negative terminal on G1A.
5. Start the battery charger.
6. Once battery G1A is fully charged: Turn off the battery charger.
7. Detach the battery charger's negative lead from the negative terminal on G1A.
8. Detach the battery charger's positive lead from the positive terminal on G1A.
9. Detach the cable between chassis earth and the negative cable on the battery G1B.
10. Repeat steps 3 - 8 on G1B.
After charging
1. Turn off the battery charger

2. Reconnect the jumper lead between the negative terminal on battery G1A and the
positive terminal on battery G1B.
3. Connect the cable between chassis earth and the negative terminal on G1B.
4. Activate battery switch S300.
Starting with an auxiliary battery

Note
Owing to the surge of current, the batteries could explode if a fully-charged battery is
connected to a completely flat one.
The connections to the drill rig's batteries must under no circumstances be broken
during operation as this could lead to faults arising in the generator.
For this reason, proceed as follows:
22
1. General
1. Check that the auxiliary starting batteries (1) have the same voltage as the batteries on the chassis.
1250 0064 41
Figure: Starting assistance

1
2
Auxiliary batteries
Drill rig batteries
2. First connect the positive terminal of the auxiliary battery to the positive terminal
of the chassis battery (2).
3. Then connect the negative terminal of the auxiliary battery (1) to earth on the
chassis (not to the chassis battery's negative terminal).
4. Once the engine has started, first remove the starter cable between the chassis and
the negative terminal on the auxiliary battery (1).
5. Then remove the cable between the positive terminals of the batteries.
Steel cables
Scrapping guidelines for steel cables
Steel cables should be scrapped when they display any of the following:
Wire break at attachment

Occurrence of strand breaks
Concentrations of wire breaks
Effects of heat
Occurrence of wire breaks due to operating time.
Reduced elasticity
Decreased cable diameter
23
1. General
Certain number and type of wire breaks

Corrosion
Surface wear
Deformation of the cable
Permanent elongation of the cable
Wire break at cable attachment

Broken wires at cable ends indicate that they have been heavily loaded and can be
caused by faulty end attachments.
Shorten the cable and reattach it. However, the remaining cable length must be sufficient.
Occurrence of strand breaks
If there are strand breaks, the cable must be scrapped
Concentrations of wire breaks
If there are concentrations of cable breaks, the cable must be scrapped.
If such concentrations occur within a length less than 60 cm or on an individual
strand, the cable must be scrapped.
If this is the case, the cable must be scrapped even if the number of wire breaks is less
than the maximum specified in the table.
Effects of heat
Cables exposed to extreme heat must be scrapped. The effects of heat can be established through annealing colour.
Occurrence of wire breaks due to operating time.
Wire breaks occur first after a certain operating time depending on operating conditions and subsequently occur more frequently.
If this is the case, the number of wire breaks in relation to the operating time should
be determined and documented.
This can then be used to estimate the future increase in wire breaks and the foreseeable time point for scrapping.
Reduced elasticity
Under certain conditions, the cable loses its elasticity.
24
1. General
Reduced elasticity is difficult to detect. If in doubt, consult a specialist.

If the cable has lost elasticity, the following characteristics usually appear:
Decrease in cable diameter
Elongation of the cable
No gap between individual wires and between the strands. This is caused by its
components being pressed together.
Fine, brown dust inside the strands.
Even if there are no visible wire breaks, the cable is noticeably stiffer.
The cable's diameter decreases more quickly than during normal wear of the individual cable wires.
Reduced elasticity can lead to sudden cable breaks during heavy loads. The cable
should be scrapped.
Decrease in cable diameter
Decrease in cable diameter through material fatigue in the cable can have the following causes:
Inner surface wear and surface wear nicks

Inner surface wear through friction between the strands and wires in the cable
Fatigue of plastic core
Break in steel core
Break in inner layer in multi-strand cable
If the cable's diameter decreases more than 10% in relation to the nominal diameter
of the cable, it must be scrapped.
It should then be scrapped even if no wire breaks have been detected.
Certain number and type of wire breaks
The cable drums are designed in such a way that the cables do not have an unlimited
service life. Wire breaks can therefore occur during operation.
On 6 and 8-strand cables, wire breaks are primarily superficial.
The cables should be scrapped if the number of wire breaks specified in the table
have been detected
25
1. General
Table:
Number of load-bearing
Number of visible wire breaks 2 that require
1
scrapping
wires in the outer strand
Machine groups M1 and M2
Cross lay
Equal lay
Over a length of
Over a length of
6d
30d
6d
30d
201 - 220
18
221 - 240
10
19
10
d = Cable diameter
1
= Filler wire is not considered load-bearing.
In cables with several layers of strands, only the outer, visible layer is considered.
In cables with steel cores, the core is regarded as an inner strand and is not included.
2
= In the event of a wire break, two ends can be visible.
Corrosion
Corrosion is especially problematic in marine environments and in areas where the
air is polluted by industrial emissions.
Corrosion can reduce operational strength through rust spots and static tensile
strength through a reduction in the cross section of the metallic cable.
Severe corrosion can reduce elasticity.
Outer corrosion: Outer corrosion can be easily detected through visual examination.
Inner corrosion: Inner corrosion is more difficult to detect. Inner corrosion is characterised by the following:
Absence of gap between the strands in the outer layer of the cable, often in combination with wire breaks in the strands.
The cable diameter varies.
The parts of the cable that are bent over discs usually have a decreased diameter. At
any sign of corrosion, the cable should be checked by an authorised person. If inner
corrosion is detected, the cable must be scrapped.
Surface wear
Inner surface wear is caused by friction between the wires and the strands.
26
1. General
Outer surface wear is caused by friction between the cable drums (rolls) and the cable
under pressure (acceleration and braking). Outer surface wear is visible through the
formation of reflected images on the outer wires.
Surface wear is increased through faulty or no lubrication, thereby increasing the
effect of dirt and dust.
Surface wear reduces static tensile strength through reduction in the cable's metallic
cross section and dynamic strength through surface wear nicks.
If the cable's diameter decreases more than 7% in relation to the nominal diameter of
the cable, it must be scrapped.
It should then be scrapped even if no wire breaks have been detected.
Deformation of the cable
Deformations are characterised by visible deviations from the cable's normal form
that lead to uneven voltage distribution in the cable.
The following are the primary types of deformations:
Wire displacement
Strand displacement
Waviness
Cracking
Kinks
Flattening
Local cable diameter decrease
Local cable diameter increase
Basket formation
Wire displacement
Individual wires or wire groups stick out like hairpins on the side facing away from
the drum. Wire displacement is caused by spasmodic loads.
Cables with wire displacement must be scrapped.
Figure: Example of wire displacement
27
1. General
Strand displacement
Strand displacement, which often occurs in conjunction with basket formation, is
when the steel core pushes out between the strands.
Cables with strand displacement must be scrapped.
Waviness
Waviness is a deformation that gives the cable's longitudinal axis a helical curve.
Even though wave formation does not necessarily cause weakening of the cable, such
a deformation can cause a pulsing movement.
After a long time of operation, this can increase surface wear and wire breaks.
In the event of waviness, the cable should be scrapped if
d1 > 4d/3
d = Cable's nominal diameter
d1 = Diameter of the circle that would be formed if the cable were not deformed.
Check over a length not exceeding 25d.
Figure: Waviness
Cracks
Cracks are deformations through outer, violent influences.
Cables with cracks must be scrapped.
Figure: Cracks
28
1. General
Kinks
A kink is a deformation caused by the cable forming an eye that is contracted with
out the cable being able to rotate around its own axle.
Strand pitch is altered, which leads a great deal of surface wear and, in severe cases,
very low static strength.
Cables with kinks must be scrapped.
Figure: Kinks
Flattening
Flattening is deformation caused by mechanical damage.
Cables with severe flattening must be scrapped.
Figure: Flattening
Local cable diameter decrease
Local decrease in cable diameter is often connected to core break.
The area near the end attachments must be inspected especially carefully as it can be
difficult to detect cable diameter decrease at these spots.
Cables with severe cable diameter decrease must be scrapped.
Figure: Local cable diameter decrease

Local cable diameter increase
This means repeated thickening of the cable over a long stretch. At the thicker spots,
the core pushes out of the cable and causes unevenness of the outer strands.
29
1. General
Cables with severe cable diameter increase must be scrapped.
Figure: Local cable diameter increase

Basket formation
Basket formation occurs on cables with steel reinforcement or steel core when the
outer strand layer becomes longer than the inner strand layer.
Basket formation can also be caused by shock loads on slack cables.
Cables with basket formation must be scrapped.
Figure: Basket formation
Tensioning the crawler tracks

Track tension is checked between the front wheel (3) and support roller (1) when the
drill rig is parked on a level surface with the tracks are under normal load.
1
A
1250 0117 37
Figure: Crawler track
30
1. General
N.B.
The clearance (A, see illustration: Crawler track) between the wooden plank and
the crawler track should be between 25 and 50 mm (0.9 and 1.9").
N.B.
The grease nipple should not be filled with grease during normal inspection.
1. Place a wooden plank (2, see illustration: Crawler track) on top of each track.
2. Pack with grease via the nipple (4) to tension the track.
3. If necessary, grease can be removed from the tension cylinder by unscrewing the
nipple (4).
Air conditioning
Safety
WARNING
Refrigerant under pressure
Risk of serious personal injury
Service of refrigerant must always be
carried out by authorised personnel
Note
Do not use the system with too little refrigerant, leakage or any other fault until it is
rectified. Otherwise, there is risk of the compressor breaking down.
31
1. General
Environmental issues when handling refrigerant

Discarding air conditioning refrigerant
can be hazardous to the environment.
Air conditioning refrigerant must be sent
for destruction in accordance with
applicable local regulations.
Changing air filter

A
1250 0182 93
E B
b
B
Figure: Filter - air conditioning.

Changing the main filter:
32
1. General
Undo the screws around the cover (C).

Open the cover and lift out the filter.
Fit the new filter in place and screw back the cover.
Changing the prefilter:
Undo the screws on the louvre cover (D).
Lift away the louvre cover and the filter.
Fit the new filter in place and screw back the louvre cover.
Changing the circulation filters:
Undo the screws on the covers (b).
Lift away the covers and the filters.
Fit the new filters in place and screw back the covers.
Fault finding
No cooling
Check the following points:
Fuses, electric connections, compressor earth, electromagnets, switches and pressure switches
V-belt and compressor
Expansion valve and temperature control valve
Coolant hoses
Poor cooling
Fresh-air fan and V-belt tension
That the air does not evade the evaporator in the unit
That the evaporator and condenser are not clogged by rubbish and the filter in the
air intake is not dirty
That the expansion valve capillary tube is firmly against the evaporator outlet pipe
That the thermostat does not cut out too early
Uneven cooling
That connections to switches, magnetic coupling or pressure switch are not loose
That the expansion valve is not clogged
That the system is filled and the thermostat is not defective
33
1. General
Abnormal noise
That the multi-V-belt to the compressor is thoroughly tightened and that the compressor retaining bolts are tightened.
That the system is filled sufficiently and not overfull
That the expansion valve is in working order
That the airflow across the evaporator is sufficient
That the condenser is clean and the airflow is sufficient
Abnormal system noise is often connected to incorrectly assembled components. If
the compressor is noisy at a certain speed, for instance, and the noise disappears
when the speed increases or decreases, there is probably nothing wrong with the
compressor itself.
The difference between the pressure on the suction side and the pressure side also
affects the level of noise. A compressor with low suction makes more noise than a
compressor with high suction. Likewise, a compressor with high high-pressure
makes more noise because it puts more load on bearings, etc.
34
2. Transport instructions
Hoisting
Single-section boom version
WARNING
Hanging load
damage to property
Do not approach a hanging load
Only use lifting equipment and lifting
straps with adequate lifting capacity
Risk of tipping
Lock the track oscillation cylinders
before the drill rig is raised
Figure: Hoisting
Make sure the chassis is not damaged when you position the feed in the transport/
hoisting position.
35
Move the rock drill to its rear (upper) position

Use the boom and feed controls to lower the feed onto the feed support.
Position the feed against the outer boom.
Make sure that the hydraulic jack is retracted.
Track oscillation cylinders to LOCKED position. Switch (9) to position (b).
Figure: Drill panel

Make sure that none of the hoses, controls or any other components can fasten or
sustain damage when the hoisting slings are tensioned and under load.
Place the hoisting slings under both crawler tracks at points A and B as shown in
the illustration Hoisting.
36
Folding boom version
WARNING
Hanging load
damage to property
Do not approach a hanging load
Only use lifting equipment and lifting
straps with adequate lifting capacity
Risk of tipping
ROC
1250 0128 95
Figure: Lifting models with folding boom.

To achieve maximum drill rig stability, position the boom, feeder and rock drill as
follows:
Boom lift cylinder maximum OUT
Boom extension maximum IN
Feed dump cylinder maximum OUT (make sure that the feed does not collide with
the lifting equipment)
37
Rock drill in END POSITION (lower position)

Make sure that the hydraulic jack is retracted.
Track oscillation cylinders to LOCKED position, switch 9 to position (b)
Figure: Drill panel

Make sure that none of the hoses, controls or any other components can fasten or
sustain damage when the hoisting slings are tensioned and under load.
Place the hoisting slings under both crawler tracks at points A and B as shown in
the illustration.
38
Transport
WARNING
Risk of tipping
damage to property
Transportation equipment must be
adapted for the dimensions and weight of
the drill rig
All bodywork hatches must be correctly
installed and locked
ROC
1250 0129 02
1250 0128 69
Figure: Transport position for folding boom versions, alternative 1
ROC
1250 0128 69
1250
Figure: Transport position for folding boom versions, alternative 2
39
1250 0129 04
ROC
Figure: Transport position for single-section boom versions, alternative 1

A
1250 0129 06
ROC
Figure: Transport position for single-section boom versions, alternative 2
Before loading the drill rig onto the transport vehicle.

Run the rock drill to its lowest position.
Use the boom and feed controls alternately to bring the feed down into the transport position and firmly down on its jack (A).
Once the drill rig is loaded onto the transport vehicle.

Run the hydraulic jack down.*
Track oscillation cylinders to LOCKED position.
40
Figure: Drill panel

Switch off the diesel engine.
Support the feed beam against the vehicle to prevent overloading.
Strap the drill rig securely to the vehicle.
Attach straps or chains to the lifting eyes on the machine and vehicle.
Note
*Extra equipment
41
Towing
WARNING
Danger of moving parts
damage to property
Place a wedge under both of the track
frames, before disengaging the traction
gears
1. Remove the two M8 bolts from the cover plate.
1250 0131 32
Figure:
2. Remove the cover plate and turn the outside inwards
1250 0131 33
Figure:
42
1250 0131 34
3. Refit the cover plate by means of the two M8 bolts.
Figure:
4. When the cover plate is in place, the drill rig is ready for towing.
1250 0131 35
Figure:
Proceed in the same way on the other track frame
The drill rig can now be towed.
43
3. Drill system
3. Drill system
Adjusting the damper pressure
CAUTION
Danger of serious equipment damage
An incorrectly adjusted damper pressure
can cause serious damage to equipment
Adjustment of damper pressure should
only be carried out by trained staff
Figure: Constant flow valve for damper pressure.

Note
See also separate rock drill instructions.
Adjustment to be performed without drilling

The diesel engine runs at 1500 rpm
Close constant flow valve (See illustration: Constant flow valve) fully on drill rig.
Connect a pressure gauge to the rock drill between damper nipple and damper
hose .
Rock drill disconnected from drill rods and shank adapter relieved of load, in
advanced position.
44
3. Drill system
Move switch Drilling/Preheating/Tramming (see illustration: drill panel) to

position drilling (a).
The shank adapter should be completely clear of the frame.
Adjust the damper pressure on the constant flow valve . Undo the locking
screw (1b) on the constant flow valve and adjust the damper pressure with knob
(1a), clockwise to reduce pressure and anticlockwise to increase pressure.
Corresponding pressure on Cab pressure gauge :
- COP-1800 approx. 40 bar.
- COP-2150/2160 approx. 40 bar
Factory settings:
- COP-1800 32 - 35 bar
- COP-2150, COP2160 32 - 35 bar
Shut down the rig.
Disconnect Pressure gauge and connect the hose to Damper nipple
Note
The impact stops automatically if damper pressure rises above 120 bar or drops
below 35 bar while drilling is in progress.
Check that the shank adapter goes into float mode during drilling. (Constantly
pressed out approx. 4 - 6 mm from the frame.
Adjusting percussion pressure

General
Note
Impact pressure should only be set during drilling and the hydraulic oil should have
attained operating temperature, normally 40 C (104 F).
Percussion pressure can be checked on the pressure gauge Percussion pressure (8).
45
3. Drill system
1
2
3
4
5
6
7
8
1250 0177 16
Figure: Pressure gauge panel

Note
Valves Percussion pressure (7 and 8) are located inside the cab (on the right-hand
side).
46
3. Drill system
5
RPCF
1250 0177 18
Figure: Control panel for pressure
Low percussion pressure

Setting must be done while drilling.
Note
Pressure ex works is 120 bar (factory setting).
The switch on the drill lever must be in position LOW PERCUSSION PRESSURE.
1. Undo the lock nut (7).
2. Turn the adjusting screw (7) clockwise to increase low percussion pressure.
3. Turn the adjusting screw (7) anticlockwise to decrease low percussion pressure.
4. Tighten the lock nut (7).
High percussion pressure

Setting must be done while drilling.
Note
Pressure ex works is 200 bar (factory setting).
The switch on the drill lever must be in position HIGH PERCUSSION PRESSURE.
1. Undo the lock nut (8).
47
3. Drill system
2. Turn the adjusting screw (8) clockwise to increase high percussion pressure.
3. Turn the adjusting screw (8) anticlockwise to decrease high percussion pressure.
Adjusting drill feed pressure

General
Note
Feed pressure should only be adjusted during drilling
Valves Drill feed pressure (3 and 4) are located inside the cab (on right-hand side).
5
RPCF
1250 0177 18

Drill feed pressure can be checked on the Drill feed pressure pressure gauge (1)
48
3. Drill system
1
2
3
4
5
6
7
8
1250 0177 16
Figure: Pressure gauge panel
Low drill feed pressure

Note
Factory setting is 30 bar.
Button Percussion pressure (25) in position LOW PERCUSSION PRESSURE
(left).
Switch Flushing air (21) in position REDUCED FLUSHING AIR/DUST COLLECTOR ON.
49
3. Drill system
15
16
17
18
19
14
e f
b
20
d
21
13
1250 0128 41
23
22
Figure: Rod handling

Lever Feed in position DRILL FEED.
1. Undo the lock nut (3) on the control panel for pressure.
2. Turn adjusting screw (3) on the control panel for pressure clockwise to increase
drill feed pressure.
3. Turn adjusting screw (3) on the control panel for pressure anticlockwise to
decrease drill feed pressure.
4. Tighten the lock nut (3) on the control panel for pressure.
High drill feed pressure

Note
Button Percussion pressure (25) in position HIGH PERCUSSION PRESSURE
(right).
50
3. Drill system
Figure: Drill panel

Activate functions for drilling with full percussion (See drilling).
Switch Flushing air (21, see illustration: Rod handling) in position FULL FLUSHING AIR (a).
51
3. Drill system
15
16
17
18
19
14
e f
b
20
d
21
13
1250 0128 41
23
22
Figure: Rod handling

Lever Feed (26) in position DRILL FEED.
1. Undo the lock nut (4) on the control panel for pressure.
2. Turn adjusting screw (4, see illustration: Control panel for pressure) clockwise to
increase drill feed pressure.
3. Turn adjusting screw (4, see illustration: Control panel for pressure) anticlockwise
to decrease drill feed pressure.
4. Tighten the lock nut (4b, see illustration: Control panel for pressure).
Adjusting rotation speed

The valve for Rotation speed (1) is located inside the cab (on the right).
52
3. Drill system
5
RPCF
1
1250 0177 18

Note
Rotation speed can be set without drilling. The setting must be made when the diesel
engine is at maximum rpm.
The hydraulic oil should be at operating temperature, normally 40 C (104 F).
To measure rotation speed, count the number of revolutions the drill string completes
per minute (make a mark on the drill rod). Alternatively, use an electronic instrument.
Correct rotation speed should be set according to the type of drill bit and the properties of the rock.
Observe the following guidelines:
Table: Basic setting for ordinary button drill bits
Size of drill bit (mm)
76
89
102
115
Size of drill bit (inches)
3 1/2
4 1/2
Rotation speed (rpm)
120
110
90
70
Type of drill bit

- X drill bits (cross-drill bits) require a higher speed than button drill bits (10-20
rpm higher)
Rock properties
- Soft types of rock normally require a higher speed, harder rock requires a lower
rotation speed.
53
3. Drill system
Jerky rotation
- If rotation speed is jerky during drilling (not rotating at even speed), this could
indicate that rotation speed is too low.
- In certain types of rock, ballistic drill bits can cause jerky rotation.
Drill bit wear
- Diametric wear can be reduced if rotation speed is lowered
Drilling rate
- High rotation speed can give a higher drilling rate.
- Ballistic button drill bits normally give a higher drilling rate
- X drill bits give a lower drilling rate.
Note
In the case of heavy wear on drill bit diameter (skirt), reduced flushing air must be
used
Setting rotation speed
Undo the control knob (1) on the control panel for pressure.
Turn adjusting screw (1) clockwise to increase rotation speed.
Turn adjusting screw (1) anticlockwise to reduce rotation speed.
Tighten the lock nut (1).
RPC-F system
RPCF (Rotation Pressure Controlled Feed) is used to regulate the drill feed pressure
in order to maintain the rotation pressure at a sufficient level to keep the joins tight.
This is done by the RPCF valve detecting the rotation pressure while drilling. When
the rotation pressure exceeds the preset value for the RPCF valve, the feed pressure
will be lowered to minimum the low drill feed pressure. As the feed pressure drops,
so will the rotation pressure. This means that the feed pressure shown on the pressure
gauge while drilling in many cases will not be the same as the high feed pressure setting but a lower pressure. For a more detailed description, refer to the rock drill's
How to use instructions.
Adjusting
The RPCF valve is only to be adjusted while drilling with two drill rods in the drill
string and after the hydraulic oil has reached normal operating temperature 40 C
(104 F). In order to be able to make a good setting, the rock should be reasonably
homogenous so that a stable rotation pressure is obtained.
54
3. Drill system
5
RPCF
1250 0177 18
Figure: Control panel for pressure.

1. Undo the lock nut (2) and turn the adjusting screw (2) clockwise until it stops to
disengage the function. Oil may run out from around the adjusting screw while the
adjustment is being made.
2. Start drilling and set in a suitable feed pressure, percussion pressure and rotation
speed according to the rock drill's How to use instructions. See also the chapter
on pressure setting in this manual.
55
3. Drill system
3. Once an even and stable rotation pressure is achieved (pressure gauge 7), the
RPCF valve adjuster screw must be turned anticlockwise until the feed pressure
(pressure gauge 1) starts to drop.
1
2
3
4
5
6
7
8
1250 0177 16
Figure: Pressure gauge panel.

4. Screw back the adjuster screw clockwise a little way, about 1/2 a turn. The feed
pressure will now drop automatically if the rotation pressure exceeds the normal.
56
3. Drill system
Pressure regulator adjustment

1
2
1250 0115 93
Figure: Pressure regulator

1.
2.
3.
4.
Compressor pressure gauge

Temperature pressure gauge.
Regulator knob.
Locking the regulator knob.
Setting the compressor's maximum and operating pressures.

Table:
Compressor operating pressure
Rig model
Max. pressure
Max. temperature
ROC D7
10.5 bar
120 C
ROC D5
8.5 bar
120 C
Anti-jamming protection
The drill rig is fitted with two types of anti jamming protection.
Air flow switch
Rotation pressure switch
Both variants reverse the feed direction if they are activated by insufficient flushing
air flow or excessive drill rotation pressure respectively in order to avoid jamming.
57
3. Drill system
Air flow monitor B142

The airflow guard is connected after the flushing air valves and monitors the pressure
drop through the restriction in the flushing air line. An impaired or non-existent air
flow caused by a clogged drill bit, for example, means that the pressure drop will be
reduced or cease completely. The rock drill will then reverse automatically until the
pressure drop/flow is normal again.
Adjusting air flow switch
1250 0132 97
The airflow guard can be adjusted only while drilling and only with full flushing air
flow active.
Figure: Air flow switch
58
3. Drill system
S119
a
d
S187
S113
S182
f
e
S167
c
S111
S100
S170
S181
1250 0136 76
H129
Figure: Autodrilling panel.

1. Remove the flow switch cover.
2. Drill almost down to the greatest depth that will be drilled in the current position.
Make sure full flushing air is active. Switch 21, position a.
3. Turn the flow switch adjuster screw (1) anticlockwise until the rock drill starts to
reverse. The higher the number on the adjuster screw scale, the more sensitive the
flow switch will be. The factory setting is 30 mbar.
4. Screw back the adjuster screw until the rock drill starts downwards again.
5. Drill another hole to check that the anti-jamming protection does not activate
inadvertently due to the setting being made too sensitive. If this is the case, screw
back the adjuster screw slightly more.
6. Fit the flow switch cover.
When changing dimension of the drill bit or drill steel, or if the drill depth is changed,
it may be necessary to readjust the flow switch in order to maintain adequate antijamming protection.
Rotation pressure switch B134

The rotation pressure switch B134 is connected to valve QDS-K, which monitors the
drill rotation pressure while drilling. A considerable increase in rotation pressure
indicates that the drill is about to jam. If the rotation pressure rises above the set pres-
59
3. Drill system
sure on QDS-K, the rotation pressure switch will receive a signal and the rock drill
will reverse automatically. Reverse feed will continue until the pressure has again
dropped below the set value.
Note
1250 0003 34
Figure: Valves
A
B
60
B134
QDS-K
3. Drill system
Adjusting activation pressure
5
RPCF
1
1250 0177 18
Figure: Pressure adjustment panel.
WARNING
Risk of serious personal injury
During the procedure the rock drill will
reverse automatically
Make sure that no personnel are within
the rock drill's area of movement
The anti-jamming protection activation pressure is adjusted on the QDS-K valve. The
activation pressure can be difficult to adjust while drilling as it is often difficult to
force the rotation pressure sufficiently high. Instead, it is possible to carry out a simulation.
1. Turn the knob for adjusting the rotation speed (1) anticlockwise until you feel the
spring pressure release. The rotation speed will now be 0 rpm.
2. Run the rock drill down until the drill steel sleeve is in the upper drill-steel support. Close the drill-steel support to secure the sleeve.
3. Activate drill rotation.
4. Activate drill feed.
61
3. Drill system
5. Slowly screw the adjuster knob clockwise while observing the pressure gauge for
the rotation pressure. When the pressure exceeds the rotation pressure switch setting, the feed direction will reverse. This can be seen from the pressure on the feed
pressure gauge dropping to 0 and the rock drill trying to pull away from the drillsteel support.
6. Screw the adjuster knob anticlockwise to reduce the rotation pressure and allow
the feed to move down again.
7. If the pressure switch setting needs to be changed, it can be done by turning its
adjusting screw clockwise to increase the activation pressure or anticlockwise to
reduce it.
8. Repeat steps 1 - 6 to check the new setting.
9. Restore the rotation speed to its normal setting.
Setting lubrication to the rock drill

The relays for ECL and ECG located in the A1 cabinet. The pulse length and pause
length can be adjusted on the relays. These adjustments can be made without starting
the drill rig.
2
1250 0103 44
10
7
Figure: Electric cabinet.
62
3. Drill system
The upper adjusting screws on the ECL/ECG relays (3 and 4) adjust the pulses/min
and the lower adjusting screws adjust the delay time. To increase the values, turn the
adjusting screws clockwise, and to decrease them, turn the adjusting screws anticlockwise.
Factory settings ECL:
- Pulses: 20 - 25 pulses/min
- Extended time: 30 seconds
Factory setting ECG:
- Pulses: 20 - 25 pulses/min
- Extended time: 0 seconds
Rock drill lubrication must be set with regard to local conditions.
Make sure the threads on the shank adapter/drill rod lubricated by air flushing.
To check that the diode on the lubricating pumps flash, this indicates the pumps are
working.
1250 0115 92
b
Figure: Diode on ECG/ECL pumps.
a
b
ECL
ECG
ECL collection
Locations
ECL collector pressure control valve
The pressure to the ECL system limitation is set with the pressure control valve. The
pressure must be between 5 and 5-1/2 bar.
63
1250 0186 36
3. Drill system
Figure: Pressure control valve.
Function
1250 0106 10
B
Figure: Collecting tank.
The system consists of a collecting tank with two pressure sensors, control lamps and
strainer.
The system collects the ECL oil that has passed the rock drill via a hose to the collecting tank (A).
Strainer (E) should be cleaned every 40th percussion hour.
64
3. Drill system
1250 0107 13
Figure: Strainer
The collecting tank must be emptied via the cock (B) underneath the tank every time
ECL oil is filled.
Note
The collected oil must be sent for disposal and not reused!
The system is monitored by two pressure sensors:
B382
B381
Figure: Pressure sensor.

B381
- Detects low pressure in the system (0.4 bar). The low pressure indicator lamp
(H381) will come on if the pressure is too low.
- If the (H381) indicator comes on, check the airflow through the system and
remove any impurities.
65
3. Drill system
B382
- Detects high pressure from the pressure sensors to the collecting tank (1.5 bar).
(H382) on the display will come on if the pressure is too high.
- If the indicator comes on, check the airflow through the system and remove any
impurities, in this case between the pressure sensor and the collecting tank.
H180
P352
H207
H211
H212
H214
H213
H215
H203
H382
R354
66
1250 0177 17
H381
4. Hydraulic systems
Environmental considerations when handling oil
Leaking hydraulic connections and
lubrication grease are environmentally
hazardous
Changing oils, replacing hydraulic hoses
and different types of filter can be
environmentally hazardous.
Always collect oil residue, oil spillage,
waste with oil content, and lubrication
grease residue and spillage. Treat in
accordance with local regulations.
Use biodegradable hydraulic fluids and
lubrication oils for Atlas Copco products
wherever possible. Contact your local
Atlas Copco office for further information.
General
The hydraulic system is sensitive to impurities. The environment in which a drill rig
normally operates is usually unsuitable for repairing hydraulic components. Work on
the hydraulic system on-site should therefore be limited to absolute necessities, i.e.
only changing components. When changing valves, the unit in question must be well
strapped and supported. Components should then be repaired in a suitable environment.
Observe the following points to avoid breakdowns and interruptions in operation due
to fouled hydraulic oil:
Keep the drill rig clean. Hose it down at regular intervals, preferably with an
added grease solvent.
Before opening any connection, clean the area round it.
Use clean tools and work with clean hands.
Always plug hydraulic connections immediately after they have been detached.
67
Use clean protective plugs.

Hydraulic components, such as hoses, valves, motors, must always be kept with
suitable protective plugs fitted.
Spare parts for hydraulic components must always be kept in sealed plastic bags.
Change filter cartridges as soon as the filters indicate clogging.
Repairing hydraulic components

Repairing and/or reconditioning hydraulic components should be carried out by
expert personnel and in a suitable place. The following alternatives are possible:
Suitable premises for hydraulic repairs to be arranged at the workplace. Repairs to
be carried out by your own specially trained personnel, the manufacturer's technicians or Atlas Copco personnel.
Components to be sent to the manufacturer's local agent for repair.
Component repairs are carried out by Atlas Copco. Repair instructions are available for the most important and most complicated hydraulic components.
Replacement of hydraulic hoses

The high system pressure, with safety valves set at 280 bar, together with vibrations
and other mechanical strain, puts high demands on hydraulic hoses. All the hydraulic
hoses have crimped couplings and should therefore be purchased ready-made from
Atlas Copco. Hose dimensions and qualities are specified in the spare parts lists for
the relevant drill rig.
Hydraulic workshops
Workshops used for the repair of hydraulic components must:
Be separate from activities which generate dust and particles, such as welding,
grinding, the transportation of vehicles, etc.
Have their own suitable washing equipment which is required for repairing the
components.
Have the necessary tools, both standard and special, and that are only used in the
hydraulic workshop.
Have a ventilation system that does not admit dust into the premises.
Have well-trained mechanics.
68
Filter
Return oil filter
General
The return oil filter cleans the oil before it is returned to the tank.
There is a return oil filter on the drill rig. A return oil filter consists of a tube containing three filter inserts. The tubes are mounted inside the hydraulic oil reservoir.
1250 0177 84
The filter inserts must be changed according to the maintenance schedule, but if the
pressure gauge for the return filter indicates filter clogged (the red zone on the
scale), all the return oil filters must be changed immediately.
40
60
20
80
0
Figure: Pressure gauge for return filter with symbol

Note
The filter cartridges cannot be cleaned but must be replaced when they are clogged.
Changing the return oil filter
The filter inserts can be dismantled by removing the cover and lifting them up.
69
1. Clean on and around the filter cap and unscrew the nuts (A).
A
B
E
1250 0097 64
D
C
Figure: Changing filter

2. Lift off the cap (B) and change the O-ring (C) if it is damaged.
3. Lift up the whole filter canister by the handle.
4. Detach the overflow valve (E) by pressing down and turning the handle anticlockwise.
5. Take out the filter cartridges (D) and replace with new ones.
6. Refit the overflow valve and filter canister and screw on the cap.
Breather filter
General
There is a breather filter (A) fitted on the hydraulic oil reservoir. The purpose of the
breather filter is to equalise the pressure differences in the tank that would otherwise
arise when the level in the tank changes if, for example, a jack is lowered.
70
1250 0097 65
Figure: Breather filter

The breather filter must be replaced as set forth in the maintenance schedule and also
if it is severely fouled.
Note
If the breather filter becomes covered in oil it will be ruined. This can happen if the
tank is overfilled. The filter must then be changed.
Changing the breather filter
1. Wash clean on and around the filter (A).
1250 0097 65
Figure: Breather filter

2. Unscrew the old filter.
3. Fit a new filter.
4. Tighten the filter by hand.
71
Condensation in the hydraulic oil reservoir

Water in the hydraulic oil can seriously damage components in the hydraulic system
and cause corrosion.
Before draining the hydraulic oil tank, the system must stand unused for approx. 12
hours so that any condensation has had time to sink to the bottom of the tank. The
water can then be drained off through the ball valve on the bottom of the tank.
1250 0098 00
Figure: Ball valve underneath hydraulic oil tank

Draining condensation from the hydraulic oil tank
1. Underneath the hydraulic oil tank is a ball valve. On the ball valve there is a plug.
Remove the plug.
2. Place a receptacle under the ball valve.
3. Open the ball valve and allow the water to run out.
4. Close the valve when the water has been replaced with oil.
5. Screw back the plug to protect the valve.
72
5. Feeder
5. Feeder
1250 0117 36
6000-series
Figure: BMH 6000
Assembling the rock drill

Preparation
Preparatory measures:
Clean the feeder free from rust inhibitor.
Assembly
1. Remove burrs, paint or other coatings from the cradle and the contact surfaces on
the rock drill.
2. Remove the mounting bolts from the cradle.
73
5. Feeder
3. Position the rock drill with any shims on the cradle and refit the bolts. Make sure
the rock drill fits firmly in place.
4. Tighten the rock drill into place. Tighten the bolts (four pcs.) alternately until a
torque of 200 Nm (20 kgf m) has been attained.
5. Connect and fit the hoses to the rock drill.
6. Adjust slide rails and hoses according to the directions in this instruction manual.
Check after four hours

1. Check and tighten all bolted joints.
2. Check and adjust the tension of the ropes.
3. Check all hoses for leaks.
4. Tighten and adjust the tension of the hoses if necessary.
5. Check and adjust the slide rail alignment on the feed beam.
74
5. Feeder
Haul and return ropes

Locations
B
E
1250 0102 99
Figure: Locations
A
B
C
D
E
Adjustment for haul rope

Adjustment for return rope
Scraper plate
Haul rope tensioner
Holder for intermediate drill-steel support
Replacing the haul rope

1. Run the rock drill to about half its length of travel.
2. Slacken the tension on the ropes, bolt A and nut B.
3. Detach the pull rope from its front attachment on the rock drill cradle.
4. Remove the scraper plate C from the intermediate drill-steel support.
5. Loosen the intermediate drill-steel support holder E so that the intermediate drillsteel support can be lifted.
6. Remove the rope from the rope tensioner D in the rear part of the beam.
Note
Make sure the new rope is fitted in the same hole as the old one.
75
5. Feeder
7. Fit the new rope and bolt the scraper plate back on.
8. Adjust the ropes as described below.
Adjusting haul and return ropes

1. The haul rope is adjusted with bolt A and the return rope with nut B.
2. The cradle's position on the feed beam should be adjusted when it is in its rear
position and when the drill steel with bit is fitted on the rock drill.
1250 0133 83
3. Adjust the ropes so that the bit is behind the spike.
350mm
Figure: Adjustment measurement M1
Tension of return rope

1. Place a plank between the rock drill cradle and the intermediate drill-steel support.
2. Run the cradle forward until it stops against the plank. Keep the feed force
applied.
3. Tension the return rope so there is no risk of it jumping out of the cable drum. Do
not tension the cable too tightly. There should be a couple of centimetre's of slack
remaining when the cable is correctly tensioned.
Adjusting the cradle on the feed beam

The cradle plates for the rock drill, the intermediate drill-steel support and the hose
drum are guided along the feed beam with the help of holder A. Each pair of holders
is locked in position with bolts B. The bolt holes in the holders have been made as
angled grooves. By offsetting the holders longitudinally, the cradle can be adjusted
on the feed beam. Make sure the holders are turned as shown in the figure so that the
outer part of the angled grooves is turned to the back of the beam. Make sure the
feeder is horizontal and that the drill steel is threaded onto the rock drill.
76
5. Feeder
D
A
C
B
1250 0064 90
Figure: Adjusting the cradle holders

1. Remove the bolts B securing the holders.
2. Start by adjusting the upper holders so the cradle is lying straight on the beam and
is 5 - 7 mm above the beam. In this way, the rock drill adapter will be at the correct
height.
1250 0064 91
Figure: Adjustment measurement

3. Then shift the lower holders lengthways until a clearance of 1 mm has been
attained between the lower holder and feed beam.
4. Tighten the bolts B.
5. Check by running the cradle along the entire beam. The pressure required to run
the cradle forwards should be max 30 bar with the hydraulic oil at operating temperature. If the pressure exceeds 30 bar, this means that the holders are too tight
and must be readjusted.
6. Replace damaged hoses and tighten leaking connections. The hoses are correctly
adjusted when they do not hang down when the feeder is in the horizontal position.
77
5. Feeder
Replacing the slide pieces in the holder

Each holder has replaceable slide pieces. The slide piece C is kept in place by three
keys D. The slide pieces must be replaced at regular intervals so that the steel in the
holder does not wear against the beam. Replace if there is less than 1 mm of wear
allowance on the slide piece. It is a good idea to replace all the slide pieces at the
same time, even if some of them are slightly thicker.
D
A
C
B
1250 0064 90
Figure: Replacing slide pieces

1. Prise off the slide pieces C from the holder using a screwdriver and remove the
keys D.
2. Slide new slide pieces into the holder track and fit new keys.
3. Make sure the holders are refitted correctly in the cradle and are adjusted according to the directions.
Replacing slide rails

Slide rails should be replaced if they are worn or severely scratched.
1250 0020 11
Figure: Replacing slide rails
78
5. Feeder
1. Remove the cradle for the rock drill, intermediate drill-steel support and the hose
drum from the beam.
2. Remove the old slide rails A by prising the lower edges of the bars outwards using
a screwdriver.
3. Clean the beam surfaces thoroughly.
4. Fit the new slide rails. The larger edge on the slide rail must be facing upwards.
The rails should be pressed in place by hand.
5. Refit the rock drill cradles, intermediate drill-steel support and water-hose drum.
Adjust the holders on the cradles as described in the instructions.
Note
Always replace the slide pieces when replacing slide rails!
Feed cylinder
Dismantling the feed cylinder
WARNING
Hazardous hydraulic oil and water
pressure
Risk of personal injury
Ensure that the system is depressurised
before work
Never replace high-pressure hoses with
hoses of lower quality than the original or
with hoses with detachable couplings
1. Run the rock drill cradle to about half the feeder length.
2. Relieve the tension on the haul and return ropes, bolt A and nut B.
3. Remove the hose drum by undoing the 4 bolts in the centre of it and lifting off the
entire drum.
4. Detach the hoses at the hose retainer.
79
5. Feeder
5. Undo bolts C and D on cradle plates E and F.
C
E
B
SP
G
F
A
K
L
1250 0020 87
Figure: Dismantling the feed cylinder.

6. Remove bolt A completely. Remove also end piece G and the end plate H.
7. The cylinder and fork can now be pulled backwards out of the beam.
8. If necessary, dismantle the fork I by knocking away the pin K.
Note
Avoid dismantling the spacer L. If it must be dismantled, measure SP first so that
the spacer can be refitted in the same position.
Measurement SP = 492 mm
Tension bushings for spacers

Description
The spacer at the front end of the cylinder is kept in place with a tension bushing. In
order for the feed to function properly, the measurement SP on the spacer must be
correct. The measurement varies depending on the feed length and type of feed.
80
1250 0065 30
5. Feeder
Figure: Spacer and tension bushing

Dismantling
1. Remove the plastic plugs M from their holes.
2. Unscrew the bolts N from the bushing.
3. Fit the bolts into the threaded holes and pull them alternately until the bushing
parts.
Assembly
1. Assemble the bushing as illustrated but do not tighten the bolts.
2. Fit the spacer and bushing into the sleeve and make measurement SP is the same
as before.
3. Tighten the bolts N alternately until a torque of 38 Nm (3.8 kgf m) is attained.
Long-term storage
1. Clean the feeder thoroughly.
2. Lubricate as directed, see maintenance schedule Feed.
3. Protect unpainted surfaces with rust inhibitor.
4. Store the feeder in a dry and clean environment.
81
6. Dust collector (DCT)

Dust collector (DCT)
A
1250 0135 89
Figure: Dust collector (DCT).
Ignition key in position IGNITION.

Drilling button in DRILLING position. Button (30) on right control panel.
Note
A timer starts as soon as drilling is terminated by activating DCT, button (7) on left
control panel.
Set the dust collector button to On. Make sure flushing air is in position
Reduced flushing air. Activate the flushing air with the drill lever by moving it
max to the left. Terminate the function by pressing the rocker switch on the drill
lever.
- The LEDs on the air valves (A, B and C) flash at intervals.
Measure the pulse duration of one of the air valves (A, B or C). Adjust the time to
0.5 seconds in the DCT menu.
Measure the time between the pulse by air valve (A) and air valve (B). Adjust the
pause time to 3 seconds in menu DCT.
Number of After Clean Pulses
- All indicator flash at the same time. Count the number of pulses. Factory setting is 4 - 6 pulsed during the cleaning time.
82
Cease drilling with the rocker switch on the drill lever, all the indicator diodes on
the cleaning valve will flash at the same time.
Note
See setting for DCT, Maintenance instructions; drilling system.
Setting the dust collector (DCT)

C1
S456
S457
S458
S459
S456
S457
S458
S459
C4 C2
C5 C3
C1
S456
S457
S458
S459
A1
B1
C4
C2
C5
C3
15
t2
K542
t1
16
18
A2
2489.9870
Figure: A1 electric cabinet
Ignition key in position IGNITION.

Switch Tramming/Drilling in position DRILLING.
Note
Duration is counted as soon as switch Dust collector and flushing air is in position
FULL FLUSHING AIR/DUST COLLECTOR ON.
83
Set switch Dust collector and flushing air in position FULL FLUSHING AIR/
DUST COLLECTOR ON.
Preset times
Pulse time S457: 02-03 seconds

Pause time S458: 5 seconds
Propagation time S459: 50 seconds
Setting the times

To increase the times: Hold in S456 and press the respective button. (S457 for pulse
time, S458 for pause time, S459 for propagation time)
To decrease the times: Press the respective button. (S457 for pulse time, S458 for
pause time, S459 for propagation time)
Check the times: Hold in button S456 so that PLC/X37 comes on and the times are
checked.
Filter test, dust collector (DCT)
1250 0116 09
Figure: Measuring points for dust collector filter.

For checking filters in dust collector. Unscrew plugs (a) and apply a differential pressure gauge to the two holes.
84
Measure the pressure drop while air flushing is activated. If the drop is greater than
an 800 mm (wg) column of water, all the filters should be changed.
Dust collector (DCT) filter change

The dust collector filters are located in the dust collector. Open the hatch (a) and
change all the filters.
Use a ring spanner to unscrew the filters. Screw the nuts on the bottom of the filters
anticlockwise.
1250 0116 41
b
Figure: Dust collector
85
7. Radiator
7. Radiator
Environmental issues when handling coolant
Chemicals, e.g. flushing additives, other
additives and coolants, can be
Treat in accordance with local regulations
in force for both handling and waste
disposal.
Coolant
WARNING
Danger of scalding and pressure
Can cause serious personal injury
Release the pressure in the radiator
before removing the radiator cap
CAUTION
Danger of serious equipment damage
Mixing coolant can seriously damage the
equipment
N.B.
See separate instruction manual for details of diesel engine maintenance.
86
7. Radiator
N.B.
The cooling system is protected ex works from freezing at temperatures down to -30
C.
N.B.
The cooling system is factory-filled with Caterpillar coolant EL205
1. Loosen the radiator cap (1) to the stop position, release the pressure in the cooling
system and only then remove the cap.
1
1250 0117 41
Figure: Radiator
2. Check the coolant level (2, see illustration: Radiator).
Note
The level should be 1 cm under the filler cap.
3. Top up as necessary.
Note
Never mix coolants! Only use CAT ELC205.
Note
Apart from elements for engine coolant the radiator also has elements for cooling
hydraulic oil, compressor oil and intercooler air.
87
8. Diesel engine
8. Diesel engine
Safety
WARNING
Danger of rotating parts

Hot engine and components
Maintenance work on the drill rig must
only be carried out when the engine is
switched off
Environmental issues when handling oil

hazardous.
accordance with local regulations in
force.
Use biodegradable hydraulic fluids and
lubrication oils for Atlas Copco products
wherever possible. Contact your local
Atlas Copco office for further information.
88
8. Diesel engine
Oil for diesel engine

N.B.
See also the separate instruction manual for the diesel engine, for details of diesel
engine maintenance.
N.B.
Top up if the oil level is below or level with the lower mark. (Refer to the engine
maintenance manual for oil specifications.)
1. Check that the oil level is between the upper and lower marks on the dipstick (10).
4
9
5
1250 0183 75
3
2
10
Figure: Diesel engine

2. Top up (8) if the oil level is below or level with the lower mark. (Refer to the diesel engine's maintenance manual for oil specifications.)
89
8. Diesel engine
Maintenance of components
Air filter, service interval
The air filters comprise filter housing, a main cartridge and a safety cartridge. The
main cartridge can be cleaned and reused up to three times if service is performed
correctly. The safety cartridge, however, must never be cleaned and reused and must
be changed at least once for every four times the main cartridge is serviced.
The intervals specified in the maintenance schedule for changing and cleaning the
main air filter cartridge are given only as guidelines. The actual interval can vary
between different workplaces and applications.
Working in extremely dusty conditions may require shorter change intervals.
In order to indicate when a main cartridge requires changing or cleaning, there is a
service indicator mounted on each air filter housing. Both indicators are connected to
a warning lamp (H207) on the engine VDO panel in the cab.
90
8. Diesel engine
H180
P352
H207
H211
H212
H214
H213
H215
H203
H382
1250 0177 17
H381
R354
Figure: Warning lamp for clogged air filter
The filter cartridges, therefore, do not require service until the indicators warn otherwise. The cartridges should, however, be checked for damage to the filter material at
the specified intervals.
Table: Example
Hours
250
500
750
1000
Main cartridge service
New
Changing
Changing
Changing
Changi
ng
Safety cartridge service New
Changi
ng
Cleaning or changing air filter

Note
Never clean the filter cartridges.
The safety cartridge must not be cleaned and reused.
91
8. Diesel engine
When a drain valve is damaged, change it.

If the warning symbol for clogged air filter remains visible, the safety cartridge must
also be replaced.
1. Undo clamps (1) and remove the cover (2).
2
1
3
1250 0026 14
Figure: Air filter

2. Remove the main cartridge (3).
3. Clean inside the filter housing and lid with a clean, dry rag.
Note
NOTE! If the safety cartridge has also been removed for changing, the filter housing air outlet must be completely covered with adhesive tape before cleaning the
filter housing.
4. Check that the evacuation valve (4) is not damaged. Change it if necessary.
5. Remove any adhesive tape there may be on filter housing air outlet.
6. Install a new safety cartridge and a new main cartridge.
7. Refit the cover and fasten the clamps.
Cleaning the main cartridge
The filter cartridges are easily damaged. Cleaning can damage the filter material and
sealing surfaces, reducing service life or causing engine and compressor breakdown.
Note
Never run the engine without the air filters in place.
92
8. Diesel engine
Never clean filters by tapping them or tapping them against the ground. This can
damage the sealing surfaces and deform the filter cartridge.
Never clean filters in water or cleaning agent.
Never use a damaged filter cartridge!
For further information, see the diesel engine's maintenance manual.
Checking air filter switches
1250 0026 25
Figure: Air filter switch.

To ensure filter clogging is detected, the function of the filter switches (6) must be
checked regularly. This is done by gradually blocking the air intakes, one at a time.
The filter switches should trip and the filter warning light come on. If the lamp does
not light, start by checking the cable connections. If there are no problems with the
connections, the switch is faulty and must be changed.
Fuel system
Filter
There are two fuel filter for the diesel engine. The engine's diesel filter and a prefilter.
The prefilter has a loose insert that must be cleaned once a month. Change the filter
insert if it is damaged.
The diesel engine fine filter must be changed and not cleaned:
93
8. Diesel engine
Prefilter
4
9
5
1250 0183 75
3
2
10
Figure: Diesel filter

Draining
Drain the water from the prefilter container (3) daily by closing the fuel cock (9)
and opening the drain cock adjacent to the filter.
Changing fuel filter:
Remove the filter bowl (3) and clean it with pure diesel fuel.
Remove the fuel filter (3) and clean the sealing surface on the base of the filter.
Make sure all the remnants of the gasket have been removed.
Apply pure diesel oil to the new fuel filter gasket.
Screw on the new fuel filter on the base of the filter until the gasket makes contact
with the filter base. Use the twist marks to aid tightening. Tighten the filter a further three quarters of a turn by hand. Do not tighten the filter too hard.
Screw the clean filter bowl (3) back in place.
94
8. Diesel engine
Fine filter
1. Close the fuel cock (1).
4
9
5
1250 0183 75
3
2
10
Figure: Fuel filter.

2. Loosen the fuel filter (2) using a suitable tool and unscrew it.
3. Collect any residual fuel.
Figure: Changing fuel filter

4. Clean the filter holder sealing surface.
5. Oil the rubber seal of the new fuel filter sparingly.
95
8. Diesel engine
6. Screw in the filter by hand until the gasket is home.
Figure: Changing fuel filter

7. Tighten the filter an additional half turn.
8. Open the fuel cock.
9. Check that the fuel filter does not leak.
Environmental issues when handling fuel

Fuel spillage is environmentally
hazardous and a fire risk.
Always collect fuel residue and spillage.
in force.
Draining the fuel tank

Always fill the fuel tank with clean diesel oil and fuel of the correct grade for the
temperature.
1. Undo the front protective plate on the underside of the drill rig.
2. Undo the bottom plug by holding the nut with a 22 mm ring spanner and unscrewing with an 8 mm Allen key. Allow the water to drain.
3. Use track oscillation to tilt the drill rig so that the tank drains completely.
4. Tighten the plug so the diesel oil cannot leak out.
96
8. Diesel engine
Belts
Belts
The belts for the diesel engine must be replaced if necessary.
1250 0186 34
1
2
3
1
2
3
V-belt - generator.
V-belt - air conditioning.
V-belt - water pump.
Tension gauge
Check the belt tension with a tension gauge.
97
8. Diesel engine
1. Press down the arm (1) in the gauge.
Figure: Belt gauge

2. Place the guide (3) on the belt (2) between the two belt pulleys, making sure the
stop fits laterally.
3. Press the button (4) at right angles to the belt (2) so that the spring can be felt or
heard to release.
4. Carefully lift up the gauge without changing the position of arm (1).
5. Read off the value at the intersection (arrow) of the scale (5) and the arm (1).
6. Readjust the tension if necessary.
Changing the generator belt
Change belts only when the engine is stationary.
1. Remove the belt cover
98
8. Diesel engine
2. Undo the nut for the generator mounting.(1)

2
1250 0001 93
Figure: Generator.
3. Relieve the tension of the belts by screwing the upper adjuster arm nut away from
the stop (2).
1250 0105 03
4. Loosen and pull out the four bolts in the shaft coupling until there is some clearance (4).
4
Figure: Undo the bolts.
99
8. Diesel engine
5. Change belts by inserting them through the clearance between the coupling rubber
and the shaft flange.
6. Screw back the coupling rubber and tighten the bolts (185Nm).
7. Tension the belts by screwing the top adjuster arm nut towards the stop (2).
8. Once the belts are sufficiently taut (use the tension gauge), the adjuster arm must
be locked by screwing the lower adjuster arm nut against the stop (3).
9. Tighten the nut for the generator bracket (1).
10. Refit the belt cover.
For further instructions, see separate instructions for the diesel engine.
100
9. Oil and fuel
9. Oil and fuel

Environmental issues when handling fuel
Fuel spillage is environmentally
hazardous and a health risk.
Always collect fuel residue and spillage.
in force.
Filling fuel
Turn off the engine before topping up the fuel. Do not handle fuel in the vicinity of
hot surfaces, sparks or naked flames.
1250 0136 89
Figure: Filling fuel

(a) Location of fuel filler orifice.
101
9. Oil and fuel
Environmental considerations when handling oil

hazardous.
accordance with local regulations in
force.
Always use biodegradable hydraulic
fluids and lubrication oils for Atlas Copco
products wherever possible. Contact your
local Atlas Copco office for further
information.
Compressor oil
WARNING
Danger of rotating parts

Hot engine and components
Maintenance work on the drill rig must
only be carried out when the engine is not
running
See also compressor instruction manual for details of compressor maintenance.

The compressor oil level can be read in the sight glass on the front of the air receiver.
102
9. Oil and fuel
1250 0108 04
Figure: Compressor tank

1. Make sure the needle (1) is in the green zone.
1250 0109 51
Figure: Air Bleed

2. Depressurise the system by opening the extra air outlet (3).
3. Top up (2) if necessary. Unscrew the filler plug when filling (see table Recommendations for hydraulic oil and lubricants).
Note
Make sure the drill rig is standing horizontally before the check. This must always be
done when checking fluid levels in the drill rig.
103
9. Oil and fuel
Oil sampling
An oil sample gives a good indication of how well the hydraulic system has been
maintained.
Filling up with hydraulic oil

Filling manually
CAUTION
Protect your eyes from hydraulic oil
Use protective goggles
1. Check the return oil filter.
2. Make sure all the couplings and hoses normally filled with oil are clean.
3. Pump manually with the hand pump (3)
4. The hydraulic oil level can be read in the sight glass on the front of the hydraulic
oil tank. The lower sight glass (1) should be full and the upper sight glass (2)
should be half full.
2
1
4
3
1250 0109 69
Figure: Hydraulic oil reservoir

Note
Do not fill too much hydraulic oil as it can clog the breather filter.
104
9. Oil and fuel
Changing hydraulic oil

General
The hydraulic oil need not be changed as long as filter changes have been carried out
as directed and oil cooling has been working satisfactorily. If oil samples show signs
of oxidation or high water content, however, the oil must be changed.
Draining
1. Underneath the hydraulic oil tank is a ball valve (A). On the ball valve there is a
plug. Remove the plug.
1250 0098 00
Figure: Ball valve underneath hydraulic oil tank

2. Screw a hose to the ball valve and place the other end of the hose into an empty oil
drum.
3. Drain the oil from the tank by opening the ball valve.
4. Close the ball valve once the oil has stopped running out of the hose.
5. Unscrew the hose.
6. Screw back the plug to protect the ball valve.
Lubricating oil
The lubricating oil tank is mounted on the dust collector.
105
9. Oil and fuel
N.B.
If the lubricating system oil is drained completely the system will have to be bled.
So make sure that the reservoir is never emptied more than three-quarters, i.e. that
it is always at least one-quarter full.
1. Make sure the level is always above the 2nd sight glass from the bottom.
2. Top up (1) as necessary (see table Recommended hydraulic oil and lubricants).
1250 0111 01
Figure: Lubricating oil tank
1250 0115 92
b
Figure: ECG/ECL
Pump for thread lubrication (a) (ECG)
Pump for lubricating rock drill (b) (ECL)
106
9. Oil and fuel
Note
The level should not be below 40 mm (1.6").
Note
Always use a funnel with strainer when refilling.
For engine oil see section Diesel engine
107

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PM No. 9852 1979 01

Copyright 2007, Atlas Copco Rock Drills AB, Sweden

Atlas Copco Rock Drills AB

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Phone: +54 - (0)11 - 47 17 22 00

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