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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*
&$87,21
The following safety rules must also be observed:
• 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 . . . . . . . . . . . . . . . . 2
Action list . . . . . . . . . . . . . . . . . . . . . 3
Hose connections . . . . . . . . . . . . . . . . 4
Tightening torques . . . . . . . . . . . . . . . . 5
Accumulators . . . . . . . . . . . . . . . . . . 6
– Charging the accumulators . . . . . . . . . . 6
– Checks in the event of hose vibration . . . . . 7
– Changing the accumulators . . . . . . . . . . 8
– Changing the return accumulator . . . . . . . 9
Changing the hydraulic motor . . . . . . . . . . 9
Filling with lubricating oil and bleeding the system....10
............
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, air and water sys-
tems are without pressure, and that the electri-
cal 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.
Setting of ECL lubricating system . . . . . . . 10
Lubrication of gear . . . . . . . . . . . . . . . 11
Setting the damper pressure . . . . . . . . . . 11
Setting the extractor-unit pressure (MEX/HEX) 11
Removing the front head . . . . . . . . . . . . 12
Checking the front head . . . . . . . . . . . . 13
Changing the flushing head and driver . . . . 14
Mounting the front head . . . . . . . . . . . . 16
Slinging . . . . . . . . . . . . . . . . . . . . 18
Long-term storage . . . . . . . . . . . . . . . 18
Recommended hydraulic oils and lubricants . 19
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• Connect up the hoses . . . . . . . . . . . . 4
• Charge the accumulators . . . . . . . . . . . 6
• Select a suitable hydraulic oil and lubricant . 19
• Fill the lubricating system with oil . . . . . . . 10
• Adjust and set the lubricating system . . . . 10
• Set the damper pressure . . . . . . . . . . . 11
• Set the extractor-unit pressure (MEX/HEX) . 11
(YHU\VKLIW
• Check that air and lubricating oil come out
between the shank adapter and front guide
and also out of the hole in the front head . . 13
• Check that the damper-pressure gauge on
the drill rig shows the normal value. In case
of deviation, adjust the damper pressure . . . 11
• Check that the shank-adapter threads are
not damaged . . . . . . . . . . . . . . . . . 13
• 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 hole in the front head, change the
seals and O-rings . . . . . . . . . . . . . . . 13
• When changing the shank adapter or remov-
ing the front head, check the internal compo-
nents, including the visible parts of the piston,
driver and rotation chuck bushing . . . . . . 13
In the event of defect, remove to a suitable
workshop for repair or replacement.
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• Tighten all threaded unions . . . . . . . . . 5
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• 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*.
* The rock drill should be overhauled at suitable intervals,
based on local conditions. The characteristics of the rock will
have a great influence on the rate of wear, and thus on the
required frequency of overhauling.
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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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N.B. 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
3A 2 Side bolts (ME/HE/HF 350 260 Tighten the front nuts
3B 3 Side bolts (MEX/HEX) 300 220 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 4 Hydraulic motor 65 48 Tighten the nuts alternately
8 2 Clamping attachment,
return accumulator 30 22
9 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque
10 1 Plug 45 33
11 4 Valve covers 145 105 Tighten the screws alternately to full torque
12 2 Connection plate 120 90 Tighten the screws alternately to full torque
13 1 Flushing connection 300 220
14 4 Inlet, flushing medium 90 65 Tighten the screws alternately to full torque
15 1 Intake, extractor unit 120 90
16 1 Return, extractor unit 120 90

5
$FFXPXODWRUV

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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'DPSHUDFFXPXODWRU
,QWDNHDFFXPXODWRU = Must be charged with nitrogen only
5HWXUQDFFXPXODWRU
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&KDUJLQJWKHDFFXPXODWRUV
:$51,1* 1. Remove the protective cap (4).
• 7KHDFFXPXODWRUVPXVWEHFKDUJHGZLWK 2. Open the valve nut (5) by 2–3 turns, and con-
QLWURJHQ1RQO\
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nect the gas hose.
3. Open the gas valve (6).
4. Charge the accumulators to the correct
pressure, as follows:
– Damper accumulator (1): ±EDU
 ±SVL
&$87,21 – Intake accumulator (2): EDU
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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.
The return accumulator (3) must not be charged.
&KHFNLQJWKHDFFXPXODWRUVLQWKHHYHQWRIKRVHYLEUDWLRQ
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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 (diaphragm damaged).
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
(Check every 40th percussion-hour)
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. Change the diaphragm if necessary.
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.
1250 0027 20

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Remove the accumulators (1 and 2) together with 7KHGDPSHUDFFXPXODWRUPXVWKDYH
the sealings (3) by removing the screws (4 and 5 WZRVFUHZVRIOHQJWKPP
or 6). &KDQJHERWKVFUHZVDWWKHVDPHWLPH
HYHQLIRQO\RQHRIWKHPLVFRUURGHGRU
Now send the accumulators to a workshop for GDPDJHGLQVRPHRWKHUZD\
overhauling! 'HIHFWLYHVFUHZVFDQFDXVHGDQJHURXVRLO
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Fit the sealings (3) to accumulators (1 or 2), and

then fit the accumulators to the intermediate part
(7).
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, or 6) alternately
to a torque of 220 Nm (160 lbf.ft).
Now charge the accumulators with nitrogen (N2).
See page 6.

8
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1250 0027 22 PRWRU

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1250 0027 23
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Disconnect the hydraulic hoses (1).
&$87,21 Remove the return accumulator (3).

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Remove the nuts (2) and take off the hydraulic mo-
tor (3).
Pull out the coupling (4).
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Make sure that the circlip (5) is fitted into the coup-
7KHUHLVDULVNRILQMXU\LIWKHVHLQVWUXFWLRQV ling (4).
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Grease the splines inside the coupling, and slide
the coupling on to the output shaft of the hydraulic
Disconnect the hydraulic hose (8) from the return motor (3).
accumulator (3).
Fit the hydraulic motor (3) with gasket (7) to the
Remove the return accumulator (3) by removing cylinder (6). Change the gasket if it is damaged.
the nuts (2), screws (1).
Tighten the nuts (2) to a torque of 65 Nm (48 lbf.ft).
Pull off the clamp (5) and unscrew the accumulator
from the nipple (7 on surface drill rigs) or Connect the hydraulic hoses (1). Check that the
(9 on underground drill rigs). motor rotates in the correct direction.
Now send the accumulator to a workshop for over-
hauling!

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Fit the return accumulator (3) to the nipple (7 or 9)
and tighten in such a way that the plug (10) is ac-
cessible for checking the accumulator diaphragm.
Slide the clamp (5) on to the accumulator, by me-
ans of the screws (1) and nuts (2).
Connect the hydraulic hose (8) to the return
accumulator (3).

9
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• Check the oil level in the lubricating-oil container
(1) once a shift. Observe a high standard of cle-
anliness and fill with oil of the right quality (see
page 19). The lubricating-oil container holds 5
litres.
must be bled after filling.
This is done as follows:
– Loosen the cap (7) and let the lubricating oil
escape until all air has been discharged from
the lubricating oil pump. Now tighten the cap.
– Start the lubricating system and loosen the
hose connection at pressure gauge (8), so that
all air is released from the system. Now
tighten the hose connection.
– Disconnect the lubricating-air hose (12) from
the nipple (11) on the rock drill.
– Start the lubricating pump and let it pump until
oil comes out of the plastic hose (10).
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 (10) for lubricating
oil is of the correct length. It must not protrude
into the machine.
– Re-connect the lubricating-air hose (12).

6HWWLQJRI(&/OXEULFDWLQJV\VWHP
1. Open the electrical cabinet. underground-
drill rigs
surface-
drill rigs

2. Start the lubricating system (see the operator’s 10

3 4 A
instructions for the drill rig).
R 6
3. Check the lubricating air pressure at the rock T1 T2
drill (11) using a pressure gauge (A). The pres- 5 B
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sure should be ±EDU If the pressure is too
low, clean the restrictor (9) or increase the dia- B
2 1
meter of the restrictor.
8QGHUJURXQGGULOOULJV B
Min. oil level
4. Check that the green light emitting diode (G) 11
indicates power on. 7
F 12
5. Adjust the screw (T1) so that the light emitting
time of the yellow diode (R) is 0.5 seconds.
6. Observe the yellow diode (R) and adjust the
lubricating oil dosage to ±SXOVHVPLQ, by 9
1250 0027 77

+ _
means of the screw (T2). 8
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4. Observe the relay window (5) and adjust the
lubricating oil dosage to ±SXOVHVPLQ, by  /XEULFDWLQJRLOFRQWDLQHU /XEULFDWLQJDLUFRQQHFWLRQ
means of the potentiometer (6).  )LOOHUFDS /XEULFDWLQJDLUKRVH
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After making the respective setting, check the LED  3XOVHUHOD\
(F) on the lubricating pump to ensure that the right )/LJKWHPLWWLQJGLRGH/('
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pulse frequency has been obtained. Check also
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that oil comes out of the hole (B) in the front head
 &DSEOHHGLQJ 7$GMXVWPHQWVFUHZ
and between the shank adapter and front guide.
 3UHVVXUHJDXJH   OLJKWHPLWWLQJWLPH
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1. Remove the bleeder plug (1).

2. Grease the gear through the nipple (2) until gre-
ase comes out of the hole (3). Use heat-
resistant grease (see "Recommended hydraulic
oils and lubricants", page 19).
1250 0027 25

3. Fit back the plug (1).

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1. Shut completely the constant-flow valve (B) on
the drill rig.
2. Connect a pressure gauge (A) [calibrated from
0 to 60 bar] between the hose and the damper
1250 0027 26

nipple (1).
3. Pressurize the damper circuit.
4. Check that the shank adapter is unloaded, and
that it has been pushed into the forward position.
5. Adjust the constant-flow valve until the pressure
gauge (A) reads 30–35 bar.
6. Read off the pressure on the damper pressure
gauge on the drill rig.
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 (1).

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SUHVVXUH0(;+(;
1. Close the constant-flow valve (B) on the drill rig
completely.
1250 0027 29

2. Connect a pressure gauge (A) [calibrated from

0 to 60 bar] between the hydraulic hose and the
extractor-unit intake nipple (P).
3. Connect the circuit for the extractor unit by acti-
vating feed reverse and running the cradle to
the stop at the rear end of the feed beam. Hold
the feed lever in the "feed-reverse" position.
4. Adjust the constant-flow valve (B) until the pres-
sure gauge (A) reads 20–25 bar.
5. Disconnect the pressure gauge (A) and re-
connect the hydraulic hose to the extractor-unit
intake nipple (P).

11
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• Never attempt maintenance work while the
drill rig is in operation.
• %HIRUHLQWHUYHQLQJLQWKHK\GUDXOLFZDWHU
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N.B. Always clean the outside of the rock drill befo-

re disassembly.
1250 0027 30

&230(+(+)
Remove the flushing hose (5).
Remove the connection plate (1) and nipple (2) by
removing the screws (3) and washers (6).
Remove the cup seal (4).

Remove the front side-bolt nuts (3) with their

washers (2).
Remove the front head (1) by tugging the shank
adapter (4).
Now pull out the shank adapter (4) from the front
head (1).
1250 0027 31

Check the internal components of the front head

when changing the shank adapter.

&230(;+(;
Remove the front side-bolt nuts (3) with their
washers (2).
Remove the front head (1) by tugging the shank
adapter (4) or by tapping the front head with a cop-
per hammer.
1250 0027 32

Now pull out the shank adapter (4) from the front
head (1). Check the internal components of the
front head when changing the shank adapter.

12
 &KHFNLQJWKHIURQWKHDG
11 11 11 3 3 3 3 A 12 9
8 7 3 A 3 3 1 5 6 2 9
1250 0071 63

C
4 B 8 7 C C
12 10 4 B 6 5 2 9
COP 1838ME/HE COP 1838MEX/HEX
1 1m
m 3 3 4 3 3 11 10 11 11
1 mm

R38
T38
ME/HF ME/HE MEX/HEX
1 1m
m 3 3 4 3 3
5

T45 2 mm
T51
ME/HE MEX/HEX
2
m 6
1m 7 7

R38 T38
39 mm 53 mm T45
T38
T51

• Check that air and lubricating oil come out be-
tween the shank adapter (6) and front guide
(7), and also out of the hole (B).
• Blow clean the lubricating oil ducts (A) using
compressed air, and check that the restrictors
(9) are open.
• Change the guide (7) if its internal diameter is
greater than PP or PP.
• Check the O-rings and flushing seals (3) if
air/water is escaping from the hole (C) in the
front head. Change the O-rings and flushing
seals if they are worn or damaged.
• Change the flushing head (4) if it is seriously cor-
roded, or if it contains cracks.
• Change the stop ring (1) if it is worn by more
than PP.
• Change the extractor-unit piston (10) if the surfa-
ce toward the shank adapter has worn by more
than PP.
When changing the extractor-unit piston, check
the seals and O-rings (11). Change them if they
are worn or damaged.
• Look inside the gear housing and check the spli-
nes of the driver (5). If the splines are less than
PP in width, the driver must be changed (see
page 14).
Fit a new driver with the aid of a suitable mand-
rel and a copper hammer.
• If the rotation chuck bushing (2) is worn by more
than PP, or if the striking surface of the im-
pact piston (12) is damaged in any way, the rock
drill must be sent to a suitable workshop for over-
hauling. See the overhauling instructions.
• Change the shank adapter (6) if the thread is
worn out or the impact surface is upset or chip-
ped, or if the front or rear end surfaces of the
splines are worn.
• Check that the drill collar (8), which must be
used in upwards-directed drilling, is not dama-
ged and that it rotates with the shank adapter.

13
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&$87,21
• 7DNHFDUHZKHQUHPRYLQJWKHIOXVKLQJ
KHDGDQGGULYHU0LQG\RXUILQJHUV

Remove the flushing hose (1) from the nipple (2).

Remove the nipple (3) and its O-rings.
Press the disassembly tool (A) into the gear hou-
sing (4) until it comes to a stop, i.e. until the spli-
ned part of the tool has passed the splines of the
driver (5).
Turn the disassembly tool clockwise a little.
Tap out the driver (5) and flushing head (6) by stri-
king with the impact hammer (B).
1250 0027 34

14
 $VVHPEO\

1250 0027 35

Tap the driver (2) into the rotation chuck in the

gear housing (1) with the aid of a mandrel (A) and
a copper hammer.

Fit the O-rings (3) and seals (4) into the flushing
1250 0027 36

head (2).
IMPORTANT! The seals (4) must be turned as
shown in the figure opposite.
Place the flushing head (2) into the cover (1) and
tap it in using a copper hammer. Check carefully
that the flushing intake in the cover lines up with
the hole in the flushing head.
Fit the O-rings (5 and 6) and back-up ring (7) on to
the nipple (8).
Fit the nipples (8, 9 and 10) and the nut (11).
Tighten the nipple (8) to a torque of 300 Nm
(220 lbf.ft) and the nipple (9) to a torque of 180 Nm
(130 lbf.ft).

15
 0RXQWLQJWKHIURQWKHDG
&230(+(+)
Fit the stop ring and shank adapter (4) into the
front head (1).
Check that the pin (6) is fitted into the cover. Fit
the front head (1) on to the side bolts (5).
Fit the washers (2) and nuts (3).
N.B. Before assembly, smear the threads with gre-
ase (type NEVER-SEEZ).
1250 0027 37

Check the tightening torques of the rear 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).

Fit the cup seal (4) into the flushing head.

Fit the connection plate (1) to the front head using
the washers (6) and screws (3). Tighten the
screws (3) to a torque of 90 Nm (65 lbf.ft).
Change the seal washer (7) if it is damaged.
1250 0027 38

Fit the nipple (2) to the connection plate, and

tighten to a torque of 300 Nm (220 lbf.ft).
Connect the flushing hose (5) and tighten the coup-
ling nut.
After assembly, check that air and lubricating oil
come out of the hole in the front head and also be-
tween the shank adapter and the front guide.

16
 &230(;+(;

1250 0027 39

Fit the shank adapter (4) into the front head of the
extractor unit.
Check the tightening torques of the rear side-bolt
nuts and front side bolt (see 1–2, page 5).
Fit the cylindrical pin (5).
Fit the front head (1) over the stud bolts (6).
Fit the washers (2) and nuts (3).
N.B. Before assembly, smear the threads with gre-
ase (type NEVER-SEEZ).
Tighten the nuts (3) alternately to a torque of
300 Nm (220 lbf.ft).
Connect the flushing hose to the nipple (7).
After assembly, check that air and lubricating oil
come out of the hole in the front head and also be-
tween the shank adapter and the front guide.

17
6OLQJLQJ
1250 0027 40

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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&$87,21 COP 1838ME/HF . 170 kg (375 lbs)
COP 1838HE . . . 176 kg (390 lbs)
• /LIWLQJJHDUDQGVOLQJVPXVWEHDSSURYHG COP 1838MEX . . 230 kg (505 lbs)
IRUDZHLJKWRINJOEV
COP 1838HEX . . 236 kg (520 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.

18
5HFRPPHQGHGK\GUDXOLFRLOVDQGOXEULFDQWV
/XEULFDQW 5HFRPPHQGDWLRQ

+\GUDXOLFRLO • Use a mineral-base or synthetic (polyalpha-olefin or diester based) hydraulic oil with good anti-wear, anti-rust,
anti-oxidation 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.

Hydraulic oil temperature in tank R&R) 9LVFRVLW\ 9LVFRVLW\

Normal operating temp. Min. starting temp. Max. temp. JUDGH9* LQGH[9,
YLVFRVLW\±F6W YLVFRVLW\PLQF6W ,62

+50 to +70 (122 to 158) +5 (41) 80 (176) ISO VG 100 Min. 100
+45 to +60 (113 to 140) –5 (23) 75 (167) ISO VG 68 Min. 100
+35 to +50 (95 to 122) –10 (14) 65 (149) ISO VG 46 Min. 100
+25 to +40 (77 to 104) –15 (5) 55 (131) ISO VG 32 Min. 100
+10 to +25 (50 to 77) –25 (–13) 35 (95) ISO VG 15 Min. 100

$LUWRRORLO • Use a mineral base air tool oil.

Ambient temperature R&R) 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

*UHDVH • IMPORTANT! Because of the operating temperature in the rock drill gear housing (see "Lubrication of gear"),
always use a high-temperature grease containing an ashless thickening agent and additives that give
resistance to oxidation and rust. The grease should also have good resistance to water.
R R
Grease properties 1/*,QXPEHU  %DVHRLOYLVFRVLW\ F6WDW & )
R R R R
'URSSLQJSRLQW  & ) 2SHUDWLQJWHPS ±WR &±WR )

19
Printed in Sweden
Atlas Copco, 2002