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© Atlas Copco Rock Drills AB, 2002. All rights reserved.

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 6$)(7<5(*8/$7,216
• Important safety information is given at various points in these instructions.
• Special attention must be paid to the safety information contained in frames and accompanied by a war-
ning symbol (triangle) and a signal word, as shown below:
:$51,1*
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7KHIROORZLQJVDIHW\UXOHVPXVWDOVREHREVHUYHG
• Carefully read through all operating- and main-
tenance instructions for the drill rig and rock
drill before putting the rock drill to use. Always
follow the instructions given.
• Do not use or intervene in the rock drill unless
you have been trained to do so.
• The rock drill may only be used for the pre-
scribed purposes.
• Make sure that the drill rig has been maintai-
ned in accordance with the current instructions.
• Make sure that all safety labels remain in pla-
ce, and that they are kept clean and fully legib-
le. See the spare parts list for details of label
locations and part numbers.
• Always wear a safety helmet and ear protec-
tors during drilling. Any local regulations that
exist must also be observed.
• Before moving the drill rig or starting to drill,
make sure that there are no personnel in the
immediate vicinity of the drill rig.
&RQWHQWV            3DJH
Safety regulations . . . . . . . . . . . . . . .
Action list . . . . . . . . . . . . . . . . . . . .
Hose connections . . . . . . . . . . . . . . .
Tightening torques . . . . . . . . . . . . . . .
Accumulators . . . . . . . . . . . . . . . . . .
– Charging the accumulators . . . . . . . . . .
– Checks in the event of hose vibration . . . .
– Changing the accumulators . . . . . . . . .
– Changing the return accumulator . . . . . . .
Changing the hydraulic motor . . . . . . . . .
2
indicates hazards or hazardous procedures which &28/'
result in serious or fatal injury if the warning is not observed.
indicates hazards or hazardous procedures which &28/'
result in injury or damage to equipment if the warning is not
observed.
• Use Atlas Copco Genuine Parts only. Any
damage or malfunction caused by the use of
unauthorized parts is not covered by Warranty
or Product Liability.
• Never attempt to carry out maintenance while
the drill rig is in operation.
• Those checks and adjustments that must be
made while the drill rig is in operation must be
carried out by at least two persons. One per-
son must man the control station and keep a
strict watch over the work.
• To prevent injury during service and mainte-
nance, all components that could possibly
move or drop must be supported safely on
blocks or trestles, or secured by means of
adequately dimensioned slings.
• Before starting work on any of the systems,
make sure that the hydraulic and air systems
are without pressure, and that the electrical
system is dead.
• Check that the hoses used are of the right qua-
lity, and that all hose connections are in good
condition and properly tightened.
. 2 Filling with lubricating oil and bleeding the system . 10
. 3 Adjusting/setting the lubricating system . . . . . 11
. 4 Lubrication of gear . . . . . . . . . . . . . . . . 11
. 5 Recommended hydraulic oils and lubricants . . . 11
. 6 Setting the damper pressure . . . . . . . . . . . 12
. 6 Checking the front head . . . . . . . . . . . . . 12
. 7 Removing the front head . . . . . . . . . . . . . 13
. 8 Mounting the front head . . . . . . . . . . . . . 14
. 9 Slinging . . . . . . . . . . . . . . . . . . . . . . 15
. 9 Long-term storage . . . . . . . . . . . . . . . . 15
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• Connect up the hoses . . . . . . . . . . . . 4
• Charge the accumulators . . . . . . . . . . . 6
• Select a suitable hydraulic oil and lubricant . 11
• Fill the lubricating system with oil . . . . . . . 10
• Adjust and set the lubricating system . . . . 11
• Set the damper pressure . . . . . . . . . . . 12
(YHU\VKLIW
• Check that air and lubricating oil are squeezing
out around the annulus between the front guide
and the shank adapter, and also through the
hole in the front head. . . . . . . . . . . . . 12
• Check that air and lubricating oil come out aro-
und the front guide.
• Keep an eye on the hydraulic hoses. If they
vibrate too much, check the accumulators. . 7
• Check that there is no leakage from the rock
drill. If the flushing medium leaks out of the
overflow holes in the front head, change the
seals and O-rings. . . . . . . . . . . . . . . 12
Other malfunctions must be repaired in a
suitable workshop.
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• Tighten all threaded unions. . . . . . . . . . 5
$IWHUHYHU\WKSHUFXVVLRQKRXU
• Checking the flushing seals . . . . . . . . . 12
• Grease the gear. . . . . . . . . . . . . . . . 11
• Tighten all threaded unions. . . . . . . . . . 5
• Check the safety labels on the accumulators.
Replace them if they are damaged or illegible. . 6
• Check the return accumulator. . . . . . . . . 7
(YHU\WKSHUFXVVLRQKRXU
• Remove the rock drill from the drill rig and
send it to a suitable workshop for over-
hauling*.
• Remove the front head of the rock drill
and check the constituent components . 12–14
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• Clean the hose connections on the rock drill be-
fore removing the protective plugs (or caps).
• Never remove a protective plug until the hose is
ready to be connected.
• Always store the rock drill with all hose connec-
tions plugged. Use suitable protective plugs or
caps, and make sure that they are clean.
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1% Tighten item Nos. 1–3 in the prescribed order.

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1 2 Side bolts 300 220 Tighten the rear nuts

2 1 Front bolt 300 220 Tighten the front bolt
3 2 Side bolts 350 260 Tighten the front nuts
4 3 Back head 220 160 Tighten the screws alternately to full torque
(uppermost screw last)
5 1 Regulating plug 80 60
6 4 Accumulators 220 160 Tighten the screws alternately to full torque
7 8 Hydraulic motors 65 48 Tighten the nuts alternately
8 5 Motor attachment 65 48 Tighten the screws alternately
9 2 Clamping attachment,
return accumulator 30 22
10 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque
11 1 Plug 45 33
12 4 Valve covers 145 105 Tighten the screws alternately to full torque
13 2 Connection plate 120 90 Tighten the screws alternately to full torque
14 1 Flushing connection 300 220
15 4 Inlet, flushing medium 90 65 Tighten the screws alternately to full torque
16 2 Coupling 250 185 Tighten the nuts alternately to full torque

5
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The accumulators are fitted with safety labels as = Read the instruction book carefully
shown in the figure below. before servicing or changing

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:$51,1* 1. Remove the protective cap (4).
2. Open the valve nut (5) by 2–3 turns, and con-
• 7KHDFFXPXODWRUVPXVWEHFKDUJHGZLWK nect the gas hose.
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3. Open the gas valve (6).
4. Charge the accumulators to the correct pressu-
re, as follows:
– Damper accumulator (1): ±EDU
 ±SVL
– Intake accumulator (2): EDUEHORZ
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The return accumulator (3) must not be charged.
5. Tighten the valve nut (5) and close the gas val-
ve (6).
6. Remove the gas hose and fit back the protecti-
ve cap (4) to the accumulator valve.
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1. Press in the pin on the test valve (7). If the ac-
cumulator is charged, the pin will stick out by
4.5 mm and give a firm resistance when pres-
sed in.
1% The damper-accumulator pin is somewhat
easier to press in.
If it is easy to press in the pin, it means that the-
re is no gas pressure damaged diaphragmor de-
fektive charging-valve).
2. Change the accumulator if it is not functioning
properly (see page 8).
3. After fitting a new accumulator, charge it with
nitrogen.
N.B. The seat of the charging valve can easily
become deformed when opened and closed re-
peatedly. The charging valve should therefore
be changed regularly.

5HWXUQDFFXPXODWRU
1. Put the rock drill in the horizontal position, as
shown in the figure.
2. Remove the plug with O-ring (8). If oil comes
out, the diaphragm is damaged.
3. Fit a new diaphragm or replace the accumulator
altogether.
4. If the diaphragm is touching the outer pipe,
press down the diaphragm using a blunt,
cylindrical mandrel (ø 7–9 mm). See fig. A.
For the correct diaphragm position, see fig. B.
5. Fit back the plug and O-ring.

2 1

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Remove the accumulators (1 and 2) together with
the seal rings (3) by removing the screws (4 and 5).
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Fit the seal rings (3) to accumulators (1 and 2),

and then fit the accumulators to the intermediate
part (6).
Fit the damper accumulator (1) to the left-hand
side of the rock drill. Fit the intake accumulator (2)
to the right-hand side of the rock drill, i.e. the hose
side. Tighten the screws (4 and 5) alternately to a
torque of 220 Nm (160 lbf.ft).
Now charge the accumulators with nitrogen (N2).
See page 6.

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Disconnect the hydraulic hoses (1 or 9).
&$87,21 Remove the return accumulator (3).

• %HIRUHLQWHUYHQLQJLQWKHK\GUDXOLFRUDLU Remove the nuts (2) and take off the hydraulic mo-
V\VWHPVPDNHVXUHWKDWWKHUHLVQRSUHV tor (4).
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Pull out the coupling (5).
• 3UHVVXUHKRVHVZLWKDQLQWHUQDOGLDPHWHU
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Make sure that the circlip (6) is fitted into the coup-
7KHUHLVDULVNRILQMXU\LIWKHVHLQVWUXFWLRQV ling (5).
DUHQRWREVHUYHG
Grease the splines inside the coupling, and slide
the coupling on to the output shaft of the hydraulic
Disconnect the hydraulic hose (9) from the return motor (4).
accumulator (3).
Fit the hydraulic motor (4) with gasket (10) to the
Remove the return accumulator (3) by removing cylinder (7), or to the motor bracket (8). Change
the nuts (2) and screws (1). Pull off the clamp (5) the gasket if it is damaged.
and unscrew the accumulator from the nipple (7).
Tighten the nuts (2) to a torque of 65 Nm (48 lbf.ft).
1RZVHQGWKHDFFXPXODWRUWRDZRUNVKRSIRU
RYHUKDXOLQJ Connect the hydraulic hoses (1 or 9). Check that
the motor rotates in the correct direction.
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Fit the return accumulator (3) to the nipple (7) and
tighten in such a way that the plug (8) is accessible
for checking the accumulator diaphragm.
Slide the clamp (5) on to the accumulator, and fit
by means of the screws (1 and nuts (2).
Connect the hydraulic hose (9) to the return
accumulator (3).

9
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• Check the oil level in the lubricating-oil containers

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(1) once a shift. Observe a high standard of cle- To flushing air

anliness and fill with oil of the right quality. Each 5
lubricating-oil container holds 5 litres.
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– Loosen the cap/plug (5) and let the lubricating )LOOHUFDS &KHFNYDOYH
oil escape until all air has been discharged 3RWHQWLRPHWHU 3ODVWLFKRVH
from the lubricating oil pump. Now tighten the 5HOD\ZLQGRZ /XEULFDWLQJDLUKRVH
cap/plug. &DS3OXJ /XEULFDWLQJRLOKRVH
– Start the lubricating system and loosen the 3UHVVXUHJDXJH
hose connection at pressure gauge (6), so that 5HVWULFWRU $3UHVVXUHJDXJH
all air is released from the system. Now /XEULFDWLQJDLUFRQQHFWLRQ
tighten the hose connection.

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– Disconnect the lubricating-air hose (12) from the
nipple (8) on the rock drill.
– Start the lubricating pump and let it pump until
oil comes out of the plastic hose (11).
When re-starting (after standstill), oil must
come out of the plastic hose directly when the
lubricating pump is started.
– Check that the plastic hose (11) for lubricating
oil is of the correct length so that it reaches the
rock drill.
– Re-connect the lubricating-air hose (12).
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– Disconnect the lubricating-oil hose (13) from the
check valve (10).
– Start the lubricating pump and let it pump until
oil comes out of the lubricating-oil hose (13).
When re-starting (after standstill), oil must
come out of the lubricating-oil hose directly when
the lubricating pump is started.
– Re-connect the lubricating-oil hose (13).

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1. Open the electrical cabinet.
3
2. Start the lubricating system (see the operator’s
instructions for the drill rig).
3. Check the lubricating air pressure at the rock
drill (8) using a pressure gauge (A). The pressu-
re should be ±EDU If the pressure is too low,
clean the restrictor (7) or ream out the
orifice in the restrictor so that the pressure is

1250 0072 00
2–3 bar.

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4. Keeping an eye on the relay window (4), adjust
the potentiometer (3) until a lubricating oil dosage 2
of ±SXOVHVPLQ is obtained.
5. After making the setting, check the LED (9) on 1. Remove the bleeder plug (1).
the lubricating pump to see that the right pulse 2. Grease the gear through the nipple (2) until gre-
frequency has been obtained. ase comes out of the hole (3). Use heat-
resistant grease (see "Recommended hydraulic
+(&/±IRUOXEULFDWLRQRI&2352' oils and lubricants").
4. Keeping an eye on the relay window (4), adjust 3. Fit back the plug (1) and washer (4). Tighten the
the potentiometer (3) until a lubricating oil dosage plug.
of ±SXOVHVPLQ is obtained.
5. After making the setting, check the LED (9) on
the lubricating pump to see that the right pulsa-
tion frequency has been obtained.Check also
that lubricating oil comes out at the rock drill,
COPROD sections and drill bit.
1% The HECL lubricating oil pressure must be
  EDU higher than the flushing air pressure.

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• anti-oxidation
Use a mineral-base or synthetic (polyalpha-olefin or diester based) hydraulic oil with good anti-wear, anti-rust,
and foam inhibiting properties, and with good air and water separation characteristics. Choose an
oil with viscosity grade (VG) and viscosity index (VI), in accordance with the table below. An oil with a high
viscosity index is less sensitive to the effects of temperature.
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+50 to +70 (122 to 158) +5 (41) 80 (176) ISO VG 100 Min. 100
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+10 to +25 (50 to 77) –25 (–13) 35 (95) ISO VG 15 Min. 100

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• Use a mineral base airR toolR oil.
$PELHQWWHPSHUDWXUH & ) 9LVFRVLW\JUDGH,62

–30 to 0 (–22 to +32) ISO VG 32–68

–10 to +20 (14 to 68) ISO VG 68–100
+10 to +50 (50 to 122) ISO VG 100–150
  
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• always use a high-temperature
,03257$17 Because of the operating temperature in the rock drill gear housing (see "Lubrication of gear"),
grease containing an ashless thickening agent and additives that give
resistance to oxidation and rust. The grease should also have good resistance to water.
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11
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1. Shut completely the constant-flow valve on the
drill rig.
2. Connect a pressure gauge (A) (with a mea-
suring range of 0–60 bar) between the hose and A
the damper nipple.
3. Pressurize the damper circuit.
4. Check that the anvil is unloaded, and that it has
been pushed into the forward position.
5. Adjust the constant-flow valve until the pressure
gauge reads 30–35 bar.
6. Read off the pressure on the damper pressure
gauge on the drill rig.

1250 0072 01
If the pressure gauge later shows a different va-
lue, make a new pressure setting.
7. Disconnect the pressure gauge (A) and re-
connect the hose to the nipple.

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B

4 4 4
2 B 3 3 6

1250 0081 76
5 A

7
D

t 2 3 4 5 4 3 6

• Check that air and lubricating oil seep out be-

tween the shank adapter and the front guide,
and out the outlet hole in the cover (7) in front of
the gear housing.
• Check the front part of the anvil (1) for cracks
and upsetting. • Change the flushing head (5) if it is seriously cor-
If the front surface is upset and its diameter (D) roded, or if it contains cracks.
is greater than PP, the anvil must be ground. • Checking the flushing seals around the anvil:
If the impact surface of the anvil is so worn Remove the lubricating hose, switch on the flus-
down that the depression (t*) cannot be seen, hing air and check that flushing air does not
then the anvil must be changed. Send the rock come out through either hole A or the grease
drill to a workshop for this purpose. nipple (item 7, page 4). If flushing air does come
• Blow clean the lubricating ducts (B) with comp- out, the flushing seals must be changed; otherwi-
ressed air. se the gear housing will be emptied of grease.
• Change the guide (2) if its internal diameter is
greater than PP.
QHZDQYLOW PP
• Check the O-rings (3 and 6) and flushing seals
(4) if air is escaping from the hole (A). Change
the O-rings and flushing seals if they are worn or
damaged.

12
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1% Always clean the outside of the rock drill befo-
re disassembly.
1250 0072 03

A
1

Remove the tube driver (1) by removing the nuts

(3) and screws (2). Screw one of the screws into
the hole (A) (it reduces the friction), and unscrew
3 the tube driver.
1250 0072 04

Remove the flushing hose (5).

4 Remove the connection plate (1) and nipple (2) by

removing the screws (3) and washers (6).
1
Remove the O-ring (4).
6
3
5 2
1250 0072 05

Remove the front side-bolt nuts (3) and washers

(2). Remove the front head (1) with the aid of a par-
ting tool.
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RYHUKDXOLQJ

2 3

13
 0RXQWLQJWKHIURQWKHDG
4 Check that the pin (4) is fitted into the cover. Fit
the front head (1) on to the side bolts (5).
1250 0072 06

1 Fit the washers (2) and nuts (3).

1% Before assembly, smear the threads with gre-
ase (type NEVER-SEEZ).
Check the tightening torques of the side-bolt nuts
and front side bolt (see 1–2, page 5).
Now tighten the nuts (3) alternately to a torque of
350 Nm (260 lbf.ft).

5 2 3

Fit the O-ring (4) to the connection plate (1).

1250 0072 04

Fit the connection plate (1) to the front head by me-

ans of the screws (3) with washers (6). Tighten the
4 screws (3) to a torque of 90 Nm (65 lbf.ft). Screw
the nipple (2) into the connection plate, and tighten
1 to a torque of 300 Nm (220 lbf.ft).
6
Fit the flushing hose (5) and tighten the nut.
3
5 2

Smear the threads of the coupling (5) with grease

2 (type NEVER-SEEZ).
5 Thread on the tube driver (1) so that it presses firm-
ly against the coupling (5).
1250 0072 07

1 Remove the screw from the hole (A).

A
Thread the coupling and the tube adapter on the
rotation chuck (4) of the rock drill by hand.
Clamp the tube adapter securely in the break-out
table and tighten the threads using the rock drill ro-
tation
3 Fit the screws (2) and nuts (3). Tighten to a torque
of 350 Nm (260 lbf.ft).
4
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14
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1250 0072 08

Make sure that the rock drill is safely slung for

lifting. Make sure that the rock drill is securely
anchored for transportation.

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COP 2550CRL . . . 247 kg (545 lbs)
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If the rock drill is not going to be used for a long
time, the following precautions should be taken:

• Check that all connections, including the one for

the flushing medium, are properly plugged or
capped. Use clean protective plugs or caps of
the right size.
• Clean the rock drill thoroughly. Use a degre-
asing agent and hose down the rock drill with wa-
ter.
• Thoroughly clean the front head parts that are in
contact with the flushing medium, especially in
the case of high air humidity. After cleaning, oil
the parts with clean hydraulic oil.
• Release the gas from the accumulators (see in-
structions on page 8).
• Store the rock drill in a dry place.

15
Printed in Sweden
Atlas Copco, 2002