9852 1880 01 Maintenance Instructions ROC L7CR II

Atlas Copco
ROC L7CR II
Maintenance instructions
PM No. 9852 1880 01

2006-09
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 2006, 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 Örebro, Sweden
Safety
Safety
Reference................................................................................................................. 5
3
Safety
4
Safety
Reference
Note
Always read the information under Safety before starting to use the rig or starting
maintenance work.
1250 0099 89
5
Safety
6
1. 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 torques for bolted joints.................................................................. 16
Welding............................................................................................................. 17
The following must be observed when welding: ......................................... 17
Electrode recommendations......................................................................... 18
Fault finding...................................................................................................... 18
Battery ................................................................................................................... 19
Environmental considerations regarding batteries............................................ 19
Battery charging................................................................................................ 19
Proceed as follows (24V charger) ................................................................ 20
Proceed as follows (12V charger) ................................................................ 21
Starting with an auxiliary battery...................................................................... 21
Steel cables ............................................................................................................ 22
Scrapping guidelines for steel cables................................................................ 22
Wire break at cable mounting ...................................................................... 23
Occurrence of strand breaks......................................................................... 23
Concentrations of wire breaks...................................................................... 23
Effects of heat .............................................................................................. 23
Occurrence of wire breaks due to operating time. ....................................... 23
Reduced elasticity ........................................................................................ 23
Decrease in cable diameter .......................................................................... 24
Certain number and type of wire breaks ...................................................... 24
Corrosion...................................................................................................... 25
Surface wear................................................................................................. 25
Deformation of the cable.............................................................................. 26
Wire displacement........................................................................................ 26
Strand displacement ..................................................................................... 27
Waviness ...................................................................................................... 27
Cracks........................................................................................................... 27
Kinks ............................................................................................................ 28
Flattening ..................................................................................................... 28
Local cable diameter decrease ..................................................................... 28
Local cable diameter increase ...................................................................... 28
Basket formation .......................................................................................... 29
Tensioning the crawler tracks ................................................................................ 29
Air conditioning..................................................................................................... 30
Safety ................................................................................................................ 30
Environmental issues regarding refrigerant handling....................................... 31
7
Changing air filter ............................................................................................. 31

Fault finding...................................................................................................... 32
No cooling.................................................................................................... 32
Poor cooling ................................................................................................. 32
Uneven cooling ............................................................................................ 32
Abnormal noise ............................................................................................ 32
2. Transport instructions............................................................................................. 34
Hoisting ................................................................................................................. 34
Single-section boom version............................................................................. 34
Transport................................................................................................................ 36
Before loading the drill rig onto the transport vehicle...................................... 36
Once the drill rig is loaded onto the transport vehicle. ..................................... 37
Towing ................................................................................................................... 38
3. Drilling system ....................................................................................................... 40

Adjusting damper pressure .................................................................................... 40
DPCI system .......................................................................................................... 41
Function ............................................................................................................ 41
Adjustment........................................................................................................ 42
Settings during drilling ..................................................................................... 43
QDS-I Adjustment during drilling ............................................................... 43
QDS-O Adjustment during drilling.............................................................. 44
QDS-A Adjustment during drilling.............................................................. 45
QDS-J Adjustment during drilling ............................................................... 45
Settings in the workshop................................................................................... 46
QDS-I Adjustment in the workshop............................................................. 46
QDS-O Adjustment in the workshop ........................................................... 46
QDS-A Adjustment in the workshop ........................................................... 47
QDS-J Adjustment in the workshop ............................................................ 48
Adjusting percussion pressure ............................................................................... 49
General.............................................................................................................. 49
Low percussion pressure................................................................................... 50
High percussion pressure .................................................................................. 50
Percussion mode selection on COP 4050 .............................................................. 51
Adjusting drill feed pressure.................................................................................. 52
General.............................................................................................................. 52
Low drill feed pressure ..................................................................................... 54
High drill feed pressure..................................................................................... 54
Adjusting rotation speed........................................................................................ 54
Adjusting feed speed for threading and unthreading............................................. 56
Threading .......................................................................................................... 57
Unthreading ...................................................................................................... 58
RPC-F system ........................................................................................................ 58
Adjustment........................................................................................................ 58
Pressure regulator adjustment................................................................................ 61
Flushing air ............................................................................................................ 62
Adjusting reduced flushing air.......................................................................... 62
8
Anti-jamming protection ....................................................................................... 62

Air flow switch, B142....................................................................................... 63
Adjusting air flow switch.................................................................................. 63
Rotation pressure switch, B134 ........................................................................ 64
Adjusting activation pressure ........................................................................... 65
Lubrication settings ............................................................................................... 66
Bleeding (ECL and HECL) ................................................................................... 66
4. Hydraulic systems .................................................................................................. 68

Environmental considerations when handling oils................................................ 68
General .................................................................................................................. 68
Repairing hydraulic components........................................................................... 69
Replacement of hydraulic hoses............................................................................ 69
Hydraulic workshops............................................................................................. 69
Filter ...................................................................................................................... 70
Return oil filter ................................................................................................. 70
General ......................................................................................................... 70
Changing the return oil filter........................................................................ 70
5. Feeder ..................................................................................................................... 72
Cables .................................................................................................................... 72
Feeder cables .................................................................................................... 72
Elongation of cables ......................................................................................... 72
Replacing the haul cable ................................................................................... 73
Replacing the return cable ................................................................................ 76
Replacing the drum cradle haul cable............................................................... 78
Replacing the drum cradle return cable ............................................................ 78
Replacing the slide pieces in the holder ................................................................ 79
Replacing slide rails .............................................................................................. 79
Feed cylinder ......................................................................................................... 81
Dismantling the feed cylinder........................................................................... 81
Tension bushings for spacers ............................................................................ 82
Description ................................................................................................... 82
Dismantling.................................................................................................. 83
Assembly...................................................................................................... 83
6. Dust collector (DCT).............................................................................................. 84

Filter test, dust collector (DCT)............................................................................. 84
Dust collector (DCT) filter change........................................................................ 84
7. Radiator .................................................................................................................. 86
Coolant .................................................................................................................. 86
8. Diesel engine .......................................................................................................... 87

Safety..................................................................................................................... 87
Environmental issues when handling oil............................................................... 87
Oil for diesel engine .............................................................................................. 88
Maintenance of engine components ...................................................................... 88
9
Air filter, service interval .................................................................................. 88

Cleaning or changing air filter .......................................................................... 89
Cleaning the main cartridge ......................................................................... 90
Checking air filter switches.......................................................................... 91
Fuel system ....................................................................................................... 91
Filter ............................................................................................................. 91
Prefilter......................................................................................................... 91
Fine filter...................................................................................................... 93
Environmental issues when handling fuel ........................................................ 94
Draining the fuel tank ....................................................................................... 94
Belts .................................................................................................................. 95
Tension gauge............................................................................................... 95
Changing the generator belt ......................................................................... 95
For further instruction refer to the separate instructions for the diesel engine. 97
9. Oils and fuel ........................................................................................................... 98

Environmental issues when handling fuel ............................................................. 98
Refuelling .............................................................................................................. 98
Environmental considerations when handling oils.............................................. 100
Compressor oil..................................................................................................... 100
Oil sampling ........................................................................................................ 101
Hydraulic oil ........................................................................................................ 102
For engine oil see section “Diesel engine”.......................................................... 102
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

• Always secure all components that can be set in motion or fall down during serv-
ice and maintenance work to prevent personal injury.
• Ensure hydraulic and pneumatic systems are depressurised before starting work
on the system in question.
• All controls must be inactivated during service and maintenance.
• When changing hydraulic hoses, ensure they are replaced with hydraulic hoses fit-
ted with the correct crimp couplings of correct quality and dimension. All pressu-
rised 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 mainte-
nance and service. The user should have undergone Atlas Copse'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 pre-
vented. 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 break-
down.
11
1. General
Contact details
Table: Addresses, phone numbers and fax numbers to Atlas Copco companies
Country Address Phone and fax number
Argentina P.O. Box 192 Suc. 37 Phone: +54 - (0)1 - 912 4421/24
1437 - Buenos Aires Fax: +54 - (0)1 - 912 6622
Australia P.O. Box 6134 Phone: +61 - (0)2 - 9621 9700
Delivery Centre Fax: +61 - (0)2 - 9621 9813
Blacktown NSW 2148
Austria Postfach 108 Phone: +43- (0)1 -76 01 20
A-1111 Wien Fax: +43 - (0)1 - 769 56 72
Bolivia Casilla 8742 Phone: +591 - 2-22 98 62
La Paz Fax: +591 - 2-22 10 36
Brazil P.O. Box 12737 Phone: +55 - (0)11 - 247 88 00
Sao Paulo, SP Fax: +55 - (0)11 - 541 76 71
04744-970
Canada P.O. Box 745 Phone: +1 - 514 631- 5571
Pointe-Claire Dorval Fax: +1 - 514 631-9217
Quebec, H9R 4S8
Chile Casilla 10239 Phone: +56 - (0)2-442 3600
Santiago Fax: +56 - (0)2 - 623 5131
China / Hong 41-1 Huang Jia Wei Phone: +86 - 25 - 5620 115-8
Kong Zhong yang Men Wai Fax: +86 - 25 - 551 5225
210037 Nanjing
CMT S-105 23 Stockholm Phone: +46 - (0)8 - 743 80 00
International Fax: +46 - (0)8 - 702 21 29
Colombia A.A. 95310 Phone: +57 - 1 - 430 4146
Santafé de Bogotá, D.C. Fax: +57 - 1 - 430 6514
Czech Republic Belohorska 159/187 Phone: +420 - (0)2 -205 14 604
169 00 PRAHA 6 Fax: +420 - (0)2- 205 14 614
Brenov
Finland Tuupakankuja 1 Phone: +358 - (0)9 - 296 64 42
SF-01740 Vantaa Fax: +358 - (0)9 - 29 64 21 8
France B.P. 50 Phone: +33 - (0)1 - 30 72 32 22
F-95132 Franconville Fax: +33 - (0)1 - 30 72 32 49
Germany Postfach 10 02 25 Phone: +49 - (0)201 - 217 70
D-46002 Essen Fax: +49 - (0)201 - 217 74 54
Ghana P O B 10071 Phone: +233 - 21 77 45 12
Accra North Fax: +233 - 21 77 61 47
Great Britain P.O. Box 79 Phone: +44 - (0)1442 - 22 21 00
Hemel Hempstead Fax: +44 - (0)1442 - 234467
Herts HP2 7HA
Greece 78, Kifissou Avenue Phone: +30 - (0)1 - 342 6600
GR-182 33 Ag. I. Rentis Fax: +30 - (0)1 - 345 4783
12
1. General

Hong Kong P.O. Box 69407 Phone: +852 - 24 88 01 03
Kwun Tong Fax: +852 - 2488 9863
Kowloon/Hong Kong
India Sveanagar Phone: +91- (0)20 -712 64 16
Bombay Pune Road Fax: +91 - (0)20 - 712 65 87
Dapodi
Pune 411 012
Indonesia P.O. Box 7021/JKS CCE Phone: +62 - 21 - 780 1008
Jakarta 12075 Fax: +62 - 21 - 780 1469
Iran P.O. Box 13145-1311 Phone: +98 - 21 - 93 7710-19
Tehran 13454 Fax: +98 - 21 - 92 7314
Ireland Kylemore Road Phone: +353 - (0)1 - 450 5978
Bluebell Fax: +353 - (0)1 - 456 7686
Dublin 12
Italy Casella Postale 10076 Phone: +39 - (0)2 - 61 79 91
I-20110 Milano MI Fax: +39 - (0)2 - 66 01 32 99
Japan New Nishi-shimbashi Bldg. 3F Phone: +81 - (0)436 - 24 62 31
2-11-6 Nishi-shimbashi Fax: +81 - (0)436 - 24 62 55
Minato-ku Tokyo 105-0003
Kenya P.O. Box 400 90 Phone: +254 - (0)2 - 82 52 65/6
Nairobi Fax: +254 - (0)2 - 82 52 15
Korea C-P.O. Box 8354 Phone: +82 - (0)2 - 52 28 23 4-8
Seoul Fax: +82 - (0)2 - 522 82 39
Malaysia Lot 6-36 & 2-38 Phone: +60 - (0)3 - 511 33 33
Pesiaran Tengku Ampuan Fax: +60 -(0)3 - 511 99 08
Lion Industrial Park
40400 Shah Alam
Selangor Darul Ehsan
Mexico Apartado Postal Box 104 Phone: +52 - 5 - 626 06 00
Tlalnepantla Fax: +52 - 5 - 565 62 65, 626 06 80
Edo. De Mexico
Marocco P.O. Box 13 844 Phone: +212 - 2 - 600 040
20 300 Casablanca Fax: +212 - 2 - 60 05 22
Norway P.O. Box 334 Phone: +47 - 64 - 86 03 00
N-1401 Ski Fax: +47 - 64 - 86 03 22
Peru Apartado 662 Phone: +51 - 1 - 224 87 05 Service
Lima 100 Fax: +51 - 1 - 224 77 12 Service
Philippines P.O. Box 1373 Phone: +63 - (0)2 - 823 8178-80
1200 Makati City Fax: +63 - (0)2 - 823 9139
Poland (Sales) ul. Katowicka 32 Sales
P-40-173 Katowice Phone: +48 - (0)32 - 209 5774
(Service) ul.Krzywa 3, Fax: + 48 -(0)32 - 209 5776
59-100 Polkowice Service
Phone: +48 76 8474 935
13
1. General

Portugal Apartado 14 Phone: +351 - (0)1- 416 85 00
P-2796 Linda-a-Velha Fax: +351 - (0)1 - 418 0782 Service
Codex
Saudi Arabia P.O. Box 7330 Phone: +966 - (0)2 - 663 42 22
Jeddah 21462 Fax: +966 - (0)2 - 660 37 23
Singapore Jurong Point Phone: +65 - (8)62 - 28 11
P.O. Box 438 Fax: +65 - (8)62 - 5 62 8S Service
Singapore 916415
South Africa P.O. Box 14110 Phone: +27 - (0)11 - 821 90 00
Witfield 1467 Fax: +27 - (0)11 - 821 92 02
Spain Apartado 24 Phone: +34 - (9)1 - 627 91 00
E-28820 Coslada Fax: +34 - (9)1 - 627 9239
Madrid
Sweden S-105 23 Stockholm Phone: +46 - (0)8 - 743 92 30
Fax: +46 - (0)8 - 743 92 46
Switzerland Büetigenstrasse 80 Phone: +41 - (0)32 - 374 15 00
CH-2557 Studen/Biel Fax: +41 -(0)32 - 374 15 15
Taiwan No. 16-11, Wu Lin Phone: +886 - (0)3 - 4 79 31 64
Wu Lin Village Fax: +886 - (0)3 - 479 6820
Lung Tan
Tao Yuan Hsien
Thailand 1696 New Petchburi Road Phone: +66 - (0)2 - 652 90 06
Bangkapi Fax: +66 - (0)2 - 652 81 94
Huay Kwang
Bangkok 10320
Turkey Istasyon Arkasi Phone: +90 - (0)216 - 395 24 60
81700 Tuzla Fax: +90 - (0)216 - 395 23 01
Istanbul
Venezuela Apartado 76111 Phone: +58 - (0)2 - 256 23 11
Caracas 1070-A Fax: +58 -(0)2 - 271 13 93
Vietnam 24, Ly Tu Trong Street Phone: +84 - 8 - 822 2914
District 1 Fax: +84 - 8 - 822 2884
Ho Chi Minh City
Zambia P.O. Box 70267 Phone: +260 - (0)2 - 65 14 47/ 51
Ndola Fax: + + 260 - (0)2 - 65 11 57
Zimbabwe P.O. Box CY 935 Phone: +263 - (0)4 - 62 17 61-5
Fax: +263 - (0)4 - 62 17 94
14
1. General
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 sepa-
rate 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 dis-
mantle the drill rig. Observe the following when dismantling, lifting and assembling:
• Before dismantling, hose the entire rig clean with water and/or detergent contain-
ing 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.
15
1. General
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, e.g. used filters
• Rest fuel and fuel spill
• Rest grease and grease spill
• Batteries
• Discarded refrigerant, air conditioning
• Chemicals, e.g. washer 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, e.g. cables, electronic components
Tightening torques for 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.

Size Strength Torque in Tolerance
class Nm. ±
M6 8.8 8 2
M8 8.8 20 5
M10 8.8 41 10
M12 8.8 73 18
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 6
M16 x 1,25 10.9 315 15
M18 x 1,25 10.9 460 20
M6 12.9 14 3
M8 12.9 34 8
M10 12.9 70 17
M12 12.9 120 30
M14 12.9 195 45
M16 12.9 315 75
16
1. General
Size Strength Torque in Tolerance

class Nm. ±
M20 12.9 600 150
M24 12.9 1020 250
Welding
• Applies to drill rigs equipped with one of the following engines:
- CAT 3176
- CAT6.6
- CAT 3196
- 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 elec-
trodes.
The following must be observed when welding:

• Disconnect the cables from the generator, the battery and the engine's electronic
module (A).
1250 0097 60
Figure:
• Grind off rust and paint from the area that is to be welded and carefully prepare the
joint.
17
1. General
• Weld in a dry area.

• Connect the welding earth cable to a clean surface as close as possible to the weld-
ing 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 do any welding on the hydraulic oil reservoir, valve block, compressed
air receiver or delivery lines.
• Always keep a fire extinguisher for oil fires near at hand during all types of weld-
ing, cutting and grinding. Screen off the work area from flammable materials.
• Always protect hoses, cables and electric 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 gener-
ally recommended type of electrode is ESAB OK 48.00, ESAB OK 48.30 or the
equivalent in accordance with the standard below:
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 recom-
mended type of electrode is ESAB-OK Autorod 12.51 or the equivalent in accord-
ance 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 quickly as possible.
Always try to investigate the location of the fault in order to limit fault finding to a
certain system or function.
18
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.
Battery charging
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 dis-
charged 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.
19
1. General
Explosive oxyhydrogen gas is produced during charging. A short circuit, naked flame
or spark close to the battery could cause a powerful explosion. Provide adequate ven-
tilation. Always switch off the charger before disconnecting the battery clamps. If the
density of the electrolyte does not change significantly, despite many hours of charg-
ing, the battery has most likely reached the end of its life.
Quick charging, performed correctly, will not damage the battery. Quick charging
should however not be used regularly and is not recommended for older 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 of a similar age since the charge current required for the bat-
tery to reach a certain voltage alters with age.
• Uneven loads should be avoided.
• Serial connection means the capacity remains the same but the voltage increases
(doubles). Connecting 2 x 12V 60Ah batteries produces a voltage of 24V while
the capacity remains 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)

Procedure prior to 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 cable of the battery charger to the positive terminal of G1A.
4. Connect the negative cable of the battery charger to the negative terminal of G1B.
5. Start the battery charger.
Procedures 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.
20
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)

Procedure prior to 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 cable of the battery charger to the positive terminal of 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.
Procedures 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:
21
1. General
1. Check that the auxiliary starting batteries (1) have the same voltage as the batter-
ies on the chassis.
1250 0064 41
Figure: Boost starting

1 Auxiliary batteries
2 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.
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 mounting

• Occurrence of strand breaks
• Concentrations of wire breaks
• Effects of heat
• Occurrence of wire breaks due to operating time.
• Reduced elasticity
• Decreased cable diameter
22
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 mounting

Broken wires at cable ends indicate that they have been heavily loaded and can be
caused by faulty end mountings.
Shorten the cable and reattach it. However, the remaining cable length must be suffi-
cient.
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 estab-
lished through annealing colour.
Occurrence of wire breaks due to operating time.

Wire breaks occur first after a certain operating time depending on operating condi-
tions 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 foreseea-
ble time point for scrapping.
Reduced elasticity
Under certain conditions, the cable loses its elasticity.
23
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 indi-
vidual 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 follow-
ing 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
24
1. General
Table:
Number of load-bearing Number of visible wire breaks 2 that require
1
wires in the outer strand scrapping
Machine groups M1 and M2
Cross lay Equal lay
n
Over a length of Over a length of
6d 30d 6d 30d
201 - 220 9 18 4 9
221 - 240 10 19 5 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 examina-
tion.
Inner corrosion: Inner corrosion is more difficult to detect. Inner corrosion is char-
acterised by the following:
• Absence of gap between the strands in the outer layer of the cable, often in combi-
nation 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.
25
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
26
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
d 1 > 4d/3
d = Cable's nominal diameter
d 1 = 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
27
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.
28
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.
2 3
1
A
4
1250 0117 37
Figure: Crawler track
29
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.
30
1. General
Environmental issues regarding refrigerant handling

• 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 B
e b
d
e
a c
Figure: Filter - air conditioning.
• Undo the bolts around the covers (a, b).

• Open the covers (a, b) and lift out the filters.
31
1. General
• Install the new filters and screw back on the covers (a, b).
Fault finding
No cooling
Check the following points:
• Fuses, electric connections, compressor earth, electromagnets, switches and pres-

sure 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
Abnormal noise
• That the multi-V-belt to the compressor is thoroughly tightened and that the com-
pressor 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
32
1. General
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.
33
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
34
Make sure the chassis is not damaged when you position the feed in the transport/
hoisting position.
• Move the rotation unit 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 support leg is retracted.
• Track oscillation cylinders to LOCKED position. Switch (S445), position (c).
c
b c
a d
1250 0166 46
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.
35
Transport
WARNING
• Risk of tipping
damage to property
• Lock the track oscillation cylinders
before the drill rig is raised
• Transportation equipment must be
adapted for the dimensions and weight of
the drill rig
Figure: Tramming position, alternative 1.

1250 0129 09
Figure: Tramming position, alternative 2.
Before loading the drill rig onto the transport vehicle.

• Run the rotation unit/rock drill to its lowest position.
Use the boom and feed controls alternately to bring the feed down into the trans-
port position and firmly down on its jack (A).
36
Once the drill rig is loaded onto the transport vehicle.

• Lower the hydraulic jacks (extra equipment).
• Track oscillation cylinders to LOCKED position. Switch (S445), position (c).
c
b c
a d
1250 0166 46
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.
37
Towing
WARNING
• Danger of moving parts
damage to property
• Place a wedge under both of the track
frames, before dismantling 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:
38
3. Refit the cover plate by means of the two M8 bolts.
1250 0131 34
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.
39
3. Drilling system
3. Drilling system
Adjusting damper pressure
WARNING
• 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
200
100 300
2
0 400
bar
x 100 kPa
100 150
50 200
3 QDS-O 8a
0
bar
x 100 kPa
250
8b
100 150
4
50 200
0 bar 250
QDS-I
5
100 150
50 200
bar 250
QDS-A
QDS-J
8
6 10
2
0 bar 16
12
14
6
20
1250 0167 37
10 30
0
bar
40 7
40
60
20
80
Figure: Pressure gauge panel and logic block for percussion
The rock drill's damper circuit is supplied with oil via a constant flow valve inte-
grated into the logic block for percussion. The desired flow value through the damper
circuit is equivalent to the pressure when the damper piston is unloaded, i.e. the rock
drill's percussion rod is in its front position. Damper pressure adjustment must always
be made without pipes connected to the adapter and with the rock drill in vertical
position. Damper pressure must only be adjusted once the hydraulic oil has reached
working temperature, normally 40ºC (104ºF).
40
3. Drilling system
1. Connect a pressure gauge between the damper pressure connection and the
damper pressure hose on the rock drill.
2. Start the diesel engine and let it run at 1500 rpm.
3. Make sure the rock drill's percussion rod/shank adapter is in its front end position.
4. Turn the Drilling/Tramming/Preheating switch on the drill panel in the cab to

Drilling position.
5. Undo the lock screw (8b) and adjust the damper pressure by turning the knob (8a)
clockwise to lower the pressure or anticlockwise to increase it. The pressure
shown on the rock drill pressure gauge should read 35 bar and in the cab it should
read 45 bar.
6. Tighten the locking screw (8b) once the setting is correct.
For detailed information on rock drill pressure settings, refer to separate instruc-
tions “How to use the COP XXXX” for the relevant rock drill.
Note
The percussion should stop automatically if the damper pressure exceeds 120 bar,
falls below 45 bar or if drill feed is not activated.
Incorrect damper pressure can lead to damage to the rock drill, drill rig and drill
string. Damper pressure should only be adjusted by trained Atlas Copco personnel.
DPCI system
Function
The DPCI system controls the percussion function by sensing the damper pressure
during drilling. Depending on the damper pressure, activation of percussion may be
permitted, stopped or switched between high and low percussion pressure. This is
takes place by means of a number of sequence valves, so-called QDS valves, in the
rig's pilot-hydraulic system.
• QDS-I prevents the activation of percussion if the damper pressure is below 45 bar
or stops percussion if the damper pressure falls below 45 bar in the event of hose
ruptures or valve malfunctions for example.
• QDS-J switches off percussion if the damper pressure exceeds 120 bar, in the
event of the feed pressure being abnormally high or if a mechanical fault arises in
the damper for example.
• QDS-A. Permits high percussion pressure when the damper pressure exceeds 50
bar.
• QDS-O. Permits percussion activation when a certain drill feed pressure has been
reached or switches off percussion with reverse feed and hollows in the rock.
41
3. Drilling system
Adjustment
CAUTION
• Incorrect settings can lead to damage to
the rock drill, drill rig and drill string
• Settings should only be made by Atlas
Copco service technicians
The DPCI system can either be adjusted in the workshop or at the drilling site.
Adjustment in the workshop generally produces more precise values for the settings.
Adjustment at the drilling site produces settings which are well adapted to the rock
conditions and the other settings of the rig.
In general it is important that both QDS-I and QDS-O have values set as high as pos-
sible without making percussion difficult to start.
Table: Guide values for QDS valves (optimum values can be higher)
QDS-I QDS-J QDS-A QDS-O (feed pressure)
45 bar 120 bar 50 bar 50-55 bar
(2-5 bar under low feed
pressure)
42
3. Drilling system
200
100 300
2
0 400
bar
x 100 kPa
100 150
50 200
3 QDS-O
8a
0
bar
x 100 kPa
250
8b
100 150
4
50 200
0 bar 250
QDS-I
5
100 150
50 200
bar 250
QDS-A
QDS-
8
6 10
4
2
0 bar 16
12
14
6
20
1250 0167 37
10 30
0
bar
40 7
40
60
20
80
Figure: Pressure gauge panel and logic block for percussion
Settings during drilling

QDS-I Adjustment during drilling
1. Check that the damper pressure is set in accordance with "Adjustment of damper
pressure".
2. Disconnect QDS-O by turning its adjusting screw anticlockwise 3-4 turns. If this
is not done then percussion will be switched off due to too low feed pressure dur-
ing setting of QDS-I.
3. Start drilling with low percussion pressure and collaring feed pressure.
4. Lower the feed pressure slowly to 0 while observing the damper pressure gauge
(2).
5. When the damper pressure falls below 45 bar, due to the lower feed pressure, per-
cussion will be switched off automatically.
6. If necessary, adjust QDS-I clockwise to raise the setting or anticlockwise to lower

it.
7. Verify that percussion cannot be activated without the drill bit being pressed
against the ground as well as that percussion can be activated when the bit is
pressed against the ground with collaring feed pressure.
43
3. Drilling system
8. Re-adjust QDS-O by turning its adjusting screw clockwise as many turns as it was
turned anticlockwise in step 1, or in accordance with instructions.
9. Test the function by accessing the engine display and increasing the value for per-
cussion stop by 0.5 m. In practice, the automatic percussion stop is then deacti-
vated. Note down the original value!
1250 0167 96
Figure: Menu sequence for changing percussion stop
When the rock drill cradle stops against the mechanical end stop the percussion
must be switched off immediately. If not, the setting for QDS-I must be raised.
10. Reset the value for percussion stop to its original value.
NOTE: The QDS-I setting must be the highest possible without making it difficult
to start percussion. This means that high percussion pressure and damper pressure
during collaring require a higher QDS-I setting.
NOTE: Drilling with too low percussion pressure can cause damage to COPROD
sections and the rock drill.
QDS-O Adjustment during drilling

1. Start drilling with low percussion pressure and current collaring feed pressure.
2. Adjust QDS-O clockwise until percussion is switched off and then anticlockwise
until it restarts.
3. Reverse the rock drill. Percussion should be switched off immediately without idle
stroke.
44
3. Drilling system
4. Start drilling again and check that percussion starts without problems. Otherwise
QDS-O may need to be lowered slightly.
NOTE: The QDS-O setting must be the highest possible without making it difficult
to start percussion. This means that high feed pressure during collaring requires a
higher QDS-O setting.
QDS-A Adjustment during drilling

pressure".
2. Start drilling. Perform a thorough collaring and then activate high percussion pres-
sure.
3. Lower the feed pressure slowly while observing the damper pressure gauge (2).
4. When damper pressure falls below 50 bar the percussion pressure shall change to
low percussion pressure.
5. If necessary: adjust QDS-A anticlockwise to lower the setting and clockwise to

raise it.
QDS-J Adjustment during drilling

pressure".
2. Start drilling. Perform a thorough collaring and then activate high percussion pres-
sure.
3. Increase the feed pressure slowly to maximum while observing the damper pres-
sure gauge (2).
4. When the damper pressure exceeds 120 bar percussion shall be switched off auto-
matically.
5. If necessary, adjust QDS-J anticlockwise to lower the setting and clockwise to

raise it.
NOTE: This setting procedure involves an increased risk of jamming during setting
due to the increased feed pressure.
NOTE: In softer rock conditions it may be difficult to force damper pressure suffi-
ciently high. The setting can be made by temporarily setting the damper pressure reg-
ulator at 120 bar.
45
3. Drilling system
Settings in the workshop

QDS-I Adjustment in the workshop
1. Detach and plug the percussion delivery hose at the rock drill.
2. Start the diesel engine, run it to 1500 rpm and select drill position on the switch,
Drilling/Tramming/Preheating.
3. Adjust damper pressure to 45 bar, read off on the damper pressure gauge in the cab
(2).
4. Activate forward drill feed. This is necessary to enable the start of percussion on
COPROD rigs (QDS-O). When the rock drill reaches its lower end position, per-
cussion is prohibited by limit sensor B121. This can be avoided by increasing the
value for percussion stop by 0.5 m in the engine display. Note down the original
value!
5. Activate low percussion pressure. Check that low percussion pressure shows on
the percussion pressure gauge in the cab (1).
6. Adjust QDS-I slowly forward and back to find the change-over point where the
percussion pressure disappears from the pressure gauge. Clockwise raises the
change-over point and anticlockwise lowers it. Following which, slowly screw
anticlockwise until the percussion pressure is visible again on the pressure gauge.
7. Check: Increase and decrease damper pressure several times to make sure that per-
cussion is switched off when the damper pressure falls below 45 bar.
8. Deactivate percussion and feed, and switch off the diesel engine.
9. Tighten the lock nut on QDS-I, reset the value for percussion stop to its original
value and reconnect the percussion's pressure hose.
10. Adjust damper pressure in accordance with "Adjusting damper pressure". By

means of test drilling, verify that percussion cannot be started without the drill
bit being pressed against the ground as well as that percussion can be activated
when the drill bit is pressed against the ground with collaring feed pressure.
QDS-O Adjustment in the workshop

3. Adjust the damper pressure to approx. 50 bar in order to disengage QDS-I (permit
percussion activation without the drill bit being pressed against the ground).
46
3. Drilling system
4. Activate forward drill feed. This is necessary to enable percussion on COPROD

rigs (QDS-O). When the rock drill reaches its lower end position, percussion is
prohibited by limit sensor B121. This can be avoided by increasing the value for
percussion stop by 0.5 m in the engine display. Note down the original value!
5. Activate low percussion pressure. Check the pressure on the percussion pressure
gauge in the cab (1).
6. Adjust the low drill feed pressure to 2-5 bar lower than the normal setting, e.g. 45
bar.
7. Adjust QDS-O slowly forward and back to find the change-over point where the
change-over point and anticlockwise lowers it.
8. Check: Increase and decrease collaring feed pressure to make sure that percussion
is switched off at the set value.
10. Tighten the lock nut on QDS-O without changing the setting, reset the value for
percussion stop to its original value and reconnect the percussion's pressure hose.

means of test drilling, verify that percussion stops immediately when the drill feed
is switched off or if reverse feed is activated.
QDS-A Adjustment in the workshop

3. Adjust damper pressure to 50 bar, read off on the damper pressure gauge in the cab
(2).
value!
5. Activate drill rotation.
6. Activate high percussion pressure. Check that high percussion pressure shows on
47
3. Drilling system
7. Adjust QDS-A slowly forward and back to find the change-over point where the
percussion pressure switches between high and low. Clockwise raises the change-
over point and anticlockwise lowers it. Following which, slowly screw clockwise
until the percussion pressure switches to low.
8. Check: Increase and decrease damper pressure several times to make sure that the
percussion pressure changes when the damper pressure passes 50 bar.
9. Deactivate percussion, feed and rotation, and switch off the diesel engine.
10. Tighten the lock nut on QDS-A, reset the value for percussion stop to its original
value and reconnect the percussion's pressure hose.
11. Adjust damper pressure in accordance with "Adjusting damper pressure”. By

means of test drilling, verify that percussion switches from high to low if the
damper pressure falls below 50 bar when the feed pressure is decreased.
QDS-J Adjustment in the workshop

3. Adjust damper pressure to 120 bar, read off on the damper pressure gauge in the
cab (2).
value!
5. Activate low percussion pressure. Check that low percussion pressure shows on
6. Adjust QDS-J slowly forward and back to find the change-over point where the
change-over point and anticlockwise lowers it. Following which, slowly screw
clockwise until the percussion pressure disappears.
7. Check: Increase and decrease damper pressure several times to make sure that per-
cussion is switched off when the damper pressure exceeds 120 bar.
9. Tighten the lock nut on QDS-J without changing the setting, reset the value for
percussion stop to its original value and reconnect the percussion's pressure hose.
48
3. Drilling system

means of test drilling, verify that percussion is switched off when the damper pres-
sure exceeds 120 bar when the feed pressure is increased to the maximum.
Adjusting percussion pressure

General
Note
Percussion pressure should only be set during drilling and the hydraulic oil must
have reached operating temperature, normally 40° C (104°F).
Percussion pressure can be checked on the pressure gauge Percussion pressure (1,
see illustration: Pressure gauge panel).
200
2
100 300
0 400
bar
x 100 kPa
100 150
50 200
3
0 250
bar
x 100 kPa
100 150
4
50 200
0 bar 250
5
100 150
50 200
bar 250
6
6 10
4 12
2 14
0 bar 16
20
10 30
0
bar
40 7
40
60
1250 0127 74
20
80
Figure: Pressure gauge panel
Note
Valves Percussion pressure (7 and 8) are located inside the cab (on the right-hand
side).
49
3. Drilling system
2
2b
3 1
3b 1b
4
4b
5
5b
6
6b
7
7b
Figure: Control panel for pressure
Low percussion pressure

Settings must be made 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. Slacken lock nut (6b, see illustration: Control panel for pressure).
2. Turn the adjusting screw (6, see illustration: Control panel for pressure) clockwise
to increase the low percussion pressure.
3. Turn the adjusting screw (6, see illustration: Control panel for pressure) anticlock-
wise to decrease the low percussion pressure.
4. Tighten the lock nut (6b, see illustration: Control panel for pressure).
High percussion pressure

Settings must be made while drilling.
Note
Pressure ex works is 200 bar (factory setting).
50
3. Drilling system
The switch on the drill lever must be in position HIGH PERCUSSION PRESSURE.
1. Slacken lock nut (7b, see illustration: Control panel for pressure).
2. Turn the adjusting screw (7, see illustration: Control panel for pressure) clockwise
to increase the high percussion pressure.
3. Turn the adjusting screw (7, see illustration: Control panel for pressure) anticlock-
wise to decrease the high percussion pressure.
4. Tighten the lock nut (7b, see illustration: Control panel for pressure).
Percussion mode selection on COP 4050

Percussion mode on COP 4050/4050CR is controlled by switch S400 on the rod/pipe
handling panel.
S119 S187 S113 S182

a
S167
a
S111 f
d b e
S100
c
1250 0166 47
S451
S400 S181
Figure: Rod handling panel
There are two alternatives:
1. Long percussion mode (a).
2. Short percussion mode (c).
51
3. Drilling system
The mode to use depends on the rock conditions. When drilling in loose rock forma-
tions, long percussion will contain more energy than can be absorbed by the rock. In
this case, it may be better to use short percussion only.
Adjusting drill feed pressure

General
Note
Feed pressure should only be adjusted during drilling.
The hydraulic oil should have a normal working temperature of 40°C (104°F).
Valves Drill feed pressure (2 and 3) are located inside the cab (on right-hand side).
2
2b
3 1
3b 1b
4
4b
5
5b
6
6b
7
7b
Drill feed pressure can be checked on pressure gauge Drill feed pressure (3)
52
3. Drilling system
200
2
100 300
0 400
bar
x 100 kPa
100 150
50 200
3
0 250
bar
x 100 kPa
100 150
4
50 200
0 bar 250
5
100 150
50 200
bar 250
6
6 10
4 12
2 14
0 bar 16
20
10 30
0
bar
40 7
40
60
1250 0127 74
20
80
Figure: Pressure gauge panel
Select low or high drill feed pressure using the drilling lever.
2
1
4
3 6
5
Figure: Drill lever
53
3. Drilling system
Low drill feed pressure

Note
Factory setting is 45 bar.
The drilling lever must be in position (a), feed and rotation clockwise, as well as
reduced percussion pressure, button (5). The indicator lamp (2) should then flash and
indicator lamp (5) should illuminate.
1. Slacken the lock nut (2b).
2. Turn adjusting screw (2) clockwise to increase drill feed pressure.
3. Turn adjusting screw (2) anticlockwise to decrease drill feed pressure.
4. Tighten the lock nut (2b).
See illustration “Control panel for pressure” for the location of adjusting screws.
High drill feed pressure

Note
The drilling lever must be in position (a), feed and rotation clockwise, as well as full
percussion pressure, button (6). The indicator lamp (2) and indicator lamp (5) should
illuminate.
1. Slacken the lock nut (3b).
2. Turn adjusting screw (3) clockwise to increase drill feed pressure.
3. Turn adjusting screw (3) anticlockwise to decrease drill feed pressure.
See illustration “Control panel for pressure” for the location of adjusting screws.
Adjusting rotation speed

The valve for Rotation speed (1) is located inside the cab (on the right).
54
3. Drilling system
2
2b
3 1
3b 1b
4
4b
5
5b
6
6b
7
7b
• Loosen the knob (1b, see illustration: 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 (1b).
Note
Rotation speed can be set without drilling taking place.
The hydraulic oil should have a normal working temperature of 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 proper-
ties of the rock with the diesel engine running at maximum revs.
Observe the following guidelines:
Table: Normal setting for ordinary button drill bits

Size of drill 105 110 115 127 140 152 165
bit, mm
Size of drill 4 1/8 4 5/16 4 1/2 5 5 1/2 6 6 1/2
bit, inches
Rotation 80 - 75 - 95 70 - 90 60 - 80 70 - 90 65 - 85 60 - 80
speed 100
• Type of drill bit
55
3. Drilling system
- 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.
• 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.
Adjusting feed speed for threading and

unthreading
Feed speed in auto-drilling may require occasional adjustment depending on varia-
tions in friction in feed beam and pipe gripper.
The friction can vary due to the degree of wear and adjustment of the slide pieces, as
well as whether or not these are lubricated. There is also a difference between thread-
ing and unthreading with or without a drill rod due to the difference in weight. The
setting must be adjusted to the higher load, for example: threading a drill rod in the
rod grippers and unthreading a rod in the rod grippers.
56
3. Drilling system
2
2b
3 1
3b 1b
4
4b
5
5b
6
6b
7
7b
Figure: Pressure panel.
The drilling lever must be in rapid feed/jointing position. Change with button 3.
Lamp 1 should be off.
2
1
4
3 6
5
Figure: Drill lever
Threading
1. Undo the lock nut (4b) on the adjustment valve (4) for pipe threading.
2. Activate jointing by moving the drilling lever to position (b), jointing.
57
3. Drilling system
3. Turn the adjustment valve (4) for pipe coupling pressure clockwise/anticlockwise
to increase/decrease the feed pressure and feed speed. In general, the setting
should be the lowest possible for the cradle to move smoothly on the feed beam
with a pipe in drill centre and the grippers in guide position.
4. Tighten the lock nut on the adjustment valve.
Unthreading
1. Undo the lock nut (5b) on the adjustment valve (5) for pipe unthreading.
2. Activate jointing by moving the drilling lever to position (b), jointing.
3. Turn the adjustment valve clockwise/anticlockwise to increase/decrease the feed

pressure and feed speed. In general, the setting should be the lowest possible for
the cradle to move smoothly on the feed beam with a pipe in drill centre and the
grippers in guide position.
4. Tighten the lock nut on the adjustment valve.
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 set-
ting but a lower pressure. For a more detailed description, refer to the rock drill's
“How to use” instructions.
Adjustment
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 40ºC
(104ºF). In order to be able to make a good setting, the rock should be reasonably
homogenous so that a stable rotation pressure is obtained.
58
3. Drilling system
3
3b
1
4
4b 1b
5
5b
6
6b
7
7b
8
8b 2
1250 0131 65
2b
Figure: Control panel for pressure.
1. Undo the lock nut (2b) and turn the adjuster screw (2) clockwise to its end position
in order to disengage the function. Oil can trickle out around the adjuster screw
while it is being adjusted.
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.
59
3. Drilling system
3. Once an even and stable rotation pressure is achieved (pressure gauge 4), the
RPCF valve adjuster screw must be turned anticlockwise until the feed pressure
(pressure gauge 3) starts to drop.
200
2
100 300
0 400
bar
x 100 kPa
100 150
50 200
3
0 250
bar
x 100 kPa
100 150
4
50 200
0 bar 250
5
100 150
50 200
bar 250
6
6 10
4 12
2 14
0 bar 16
20
10 30
0
bar
40 7
40
60
1250 0127 74
20
80
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.
60
3. Drilling system
Pressure regulator adjustment
1 3
2 4
Figure:
1 Regulator knob
2 Locking the regulator knob
3 Pressure gauge, compressor pressure
4 Temperature switch
Table: Max. discharge pressure

ROC L7CR 10.5 bar 120ºC
ROC L7 10.5 bar 120ºC
Set the compressor discharge pressure according to the table above by turning the
regulator knob (1) clockwise/anticlockwise to increase/decrease the discharge pres-
sure. The pressure can be read on the pressure gauge (3).
In good rock conditions, the compressor can occasionally be run at a lower pressure
with maintained flushing air function. This will help to lower fuel consumption.
61
3. Drilling system
Flushing air
Adjusting reduced flushing air
1250 0167 97
FLUSH AIR
1 a
FULL REDUCED
Y115 Y116
b
2
c
3
Figure: Valves and rod/pipe handling panel.
Flushing air is regulated with two solenoid valves, Y115 (1) and Y116 (2). When full
flushing air is activated, both valves will be open and when reduced flushing air is
activated, only Y116 will be open.
On occasions when low flushing air pressure and flow are required, e.g. when collar-
ing, the flushing air can be run at reduced rate by setting switch S100 to position (b).
In this case, only Y116 is active and flushing air flow can then be set by opening or
closing the valve (3) until the desired flow is attained.
While the system is being run with full flushing air, the compressor discharge pres-
sure will limit the flushing air pressure. Full flushing air is consequently adjusted by
adjusting the compressor discharge pressure.
Anti-jamming protection
The drill rig is equipped 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.
62
3. Drilling system
Air flow switch, B142

The air flow switch is connected after the flushing air valves and detects a drop in
pressure through a restriction in the flushing air line. A reduced or non-existent air-
flow, e.g. if the drill bit is clogged, means the drop in pressure will be reduced or dis-
appear completely. The rock drill will then reverse automatically until the pressure
drop/flow returns to normal.
Adjusting air flow switch

The airflow guard can be adjusted only while drilling and only with full flushing air
flow active.
1250 0132 97
Figure: Air flow switch.
b
1250 0167 98
c
Figure: Rod/pipe handling panel with switch S100
1. Remove the flow switch cover.
2. Drill almost down to the greatest depth that will be drilled at the current position.
Make sure that full flushing air is activated. Switch S100, position a.
63
3. Drilling system
3. Turn the flow switch adjuster screw (1) anticlockwise until the rock drill starts to
reverse. The higher the numerical value on the adjuster screw graduation, the
more sensitive the flow switch is. Factory setting is 30 mbar.
4. Screw back the adjuster screw until the rock drill starts moving down again.
5. Drill another hole to check that the anti-jamming protection is not activated inad-
vertently due to the setting being too sensitive. If this is the case, screw back the
adjuster screw a little more.
6. Fit the flow switch cover.
When changing drill bit or drill steel dimension, or when changing the drill depth, it
may be necessary to readjust the flow switch to maintain satisfactory anti-jamming
protection.
Rotation pressure switch, B134

The rotation pressure switch B134 detects the drill rotation pressure during drilling.
A considerable increase in rotation pressure indicates that the drill is becoming
jammed. If the rotation pressure exceeds the pressure set, the rotation pressure switch
will receive a signal and the rock drill will reverse automatically. The reverse feed
will continue until the pressure drops below the set value again.
Note
64
3. Drilling system
Adjusting activation pressure
3
3b
1
4
4b 1b
5
5b
6
6b
7
7b
8
8b 2
1250 0131 65
2b
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 activation pressure of the anti-jamming protection must be adjusted on valve

B134. The activation pressure can be difficult to adjust during drilling as it is often
difficult to force the rotation pressure sufficiently high. For this reason, a simulation
can be carried out.
1. Turn the rotation speed adjusting knob (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 sup-
port. Close the drill-steel support to secure the sleeve.
3. Activate drill rotation.
4. Activate drill feed.
65
3. Drilling system
5. Slowly screw the adjusting knob clockwise while observing the rotation pressure
gauge. When the pressure exceeds the rotation pressure switch setting, the feed
direction will reverse. This can be seen by the pressure gauge reading falling to 0
and the rock drill attempting to pull loose from the drill-steel support.
6. Screw the adjuster knob anticlockwise to lower the rotation pressure and allow the
feed to start going down once 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. Reset the rotation speed to normal.
Lubrication settings
Lubrication settings are made in the display for the engine and directional instru-
ments. See Operator's instructions.
Bleeding (ECL and HECL)
Figure: Lubricating oil tank with HECL pump.
If the lubricating oil tank has run dry, the system may need to be bled in order to pre-
vent air pockets forming in the lines and the pump.
66
3. Drilling system
This can be done by pumping the lubricating oil through the hoses. Set the pulse relay
to the maximum number of pulses/minute to reduce the time it takes to bleed the sys-
tem.
The diesel engine must be running when bleeding HECL since the pump is hydrauli-
cally driven. This is not necessary when bleeding ECL since the pump is electrically
driven.
1. Detach the ECL hose from the rock drill and the HECL hose from its connection
on the flushing air line.
2. Undo the plug on the bleed hose leading from the ECL pressure gauge in the cab.
The hose is sticking out through the open bottom of the pressure gauge panel.
3. Open the bleed plugs on the ECL and HECL pumps (A).
4. Start the diesel engine and set the Drilling/Tramming/Preheating knob (S130) to
drilling.
5. Make sure the flushing air switch (S100) is turned on.
6. Activate ECL and HECL by pressing the percussion button to the left for 0.5 sec-
onds.
7. First tighten the bleed plugs on the pumps and then the pressure gauge bleed plug
once pure oil runs out without air bubbles.
8. Refit the ECL and HECL hoses once pure oil without air bubbles runs out of them.
The ECL hose has a narrow inner capillary tube and is therefore quicker to bleed
than the HECL hose.
67
4. Hydraulic systems
Environmental considerations when handling

oils

• 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 environ-
ment.
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.
68
• Always plug hydraulic connections immediately after they have been detached.
• Use clean protective plugs.
• Hydraulic components like hoses, valves, motors, etc. must always be stored with
suitable protective plugs fitted in place.
• Spare parts for hydraulic components must always be kept in sealed plastic bags.
• Change filter cartridges as soon as the filters show signs of 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 arranged at the workplace. Repairs can be
carried out by your own specially trained personnel, the manufacturer's techni-
cians or Atlas Copco personnel.
• Components sent to the manufacturer's local agent for repair.
• Component repairs 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, that are only used in the
hydraulic workshop.
• Have a ventilation system that does not admit dust into the premises.
• Have well-trained mechanics.
69
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 contain-
ing three filter inserts. The tubes are mounted inside the hydraulic oil reservoir.
The filter inserts must be replaced in accordance with 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 replaced immediately.
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.
1. Clean on and around the filter cap and unscrew the nuts (A).
A
B
D
1250 0097 64
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 anticlock-
wise.
70
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.
71
5. Feeder
5. Feeder
Cables
Feeder cables
Min 10 mm
A B
Figure: Feeder with cradle in upper end position

1 Cradle
2 Drum cradle
3 Haul cable
4 Return cable
5 Drum cradle haul cable
6 Drum cradle return cable
Figure: Feeder with cradle in lower end position
Elongation of cables
Tools: U-wrench 36 mm, U-wrench 19 mm, U-wrench 16 mm
Note
The cables must not rotate during elongation and slackening. Counterhold the turn-
ing with a 19 mm wrench on the flat part of the cable end.
1. Run the drill cradle to stop in the upper end position.
72
5. Feeder
2. Remove the protective covers over the cable ends A and B.
3. Adjust the cable ends A and B so that the measurement between the drum cradle
and stop lug is obtained in accordance with the figure above. If the distance needs
to be increased then cable B is slackened and cable A is elongated. Cable C may
also require slackening in order to increase the distance. To reduce the distance,
cable A is slackened and cable B is elongated.
4. Tension cable A.
5. Run the drill cradle to stop in the lower end position. Load the cylinder (150 bar
feed pressure) and check that cable B does not slacken during loading. If the cable
slackens the cradle is run up to upper end position and cable A is tensioned further.
6. The drum cradle haul cable is adjusted so that the slack is greater than that of the
hydraulic hoses.
7. The drum cradle return cable is adjusted so that it is not tensioned more that the
drill cradle return cable.
Replacing the haul cable

Tools: U-wrenches: 36 mm, 24 mm, 19 mm, 18 mm, 16 mm
Other tools: slide hammer, 18 and 12 mm sockets or block wrenches, 185 mm spacer
or straps (in the event of cable breakage).
The haul cable is threaded at one end and has an eyelet in the other end.
1. Unscrew the protective covers.
2. Run the hydraulic cylinder until the pulley wheel assembly is in the hole on the
left-hand side of the feeder (C).
Figure: Pulley wheel assembly
73
5. Feeder
3. Insert a 185 mm long spacer block between the cradles when the hose drum is in
its top position.
Figure: Spacer block
4. If the cable shall be replaced due to breakage then the cradles need to be pulled
apart with straps to facilitate fitting the new cable, see the illustration to the right.
The drill cradle must be pulled with the strap in the feed direction.
Figure: Straps
5. Undo the cable's threaded end. Remove pulley wheel C by removing the wheel
axle's stop washer, and screw the slide hammer into the centre hole. Then pull the
axle out and loosen the wheel via hole B. In addition, remove pulley wheel D in
the same way. First pull out the lubricating hose and remove the grease nipple
located in the centre hole (F) of the pulley wheel.
6. Pull out the cable's threaded end.
7. Go to the cable mounting on the cradle and undo the eight bolts holding plate A, in
which the other end of the cable is mounted. Turn the plate and pull it out in the
direction of the cable. Undo the bolt holding the cable's eyelet B and undo the
cable from the plate.
74
5. Feeder
Secure the new cable's eyelet in the plate. Then move the plate back to the correct
position and screw in the eight bolts.
Figure: Cable mounting on a cradle
8. Move the threaded end of the cable back to where the front wheel should be
located (A in the illustration below) and up through the hole (B in the illustration
below)
Figure: Cable guide
9. Secure the stop nut, washers and spacer sleeve, then insert the threaded end of the
cable in the hole (see illustration of pulley wheel assembly, A).
Refit the pulley wheel (see illustration of pulley wheel assembly, B) and screw in
the first nut and lock nut on the end of the cable.
10. Tension the cable and remove the spacer or strap. Check that the cables are cor-
rectly tensioned in accordance with the instructions.
75
5. Feeder
Replacing the return cable

Tools: U-wrenches: 36 mm, 24 mm, 19 mm, 18 mm, 16 mm. Other tools: slide ham-
mer, 18 mm socket or block wrench, 185 mm spacer or straps (in the event of cable
breakage).
The return cable is threaded at one end and has an eyelet in the other end.
1. Unscrew the protective covers.
2. Run the rock drill cradle forward/down until the drum cradle is almost in end posi-
tion in accordance with the illustration, Drum cradle.
Figure: Drum cradle

3. Undo and remove the stop nut at the cable's mounting (illustration, Drum cradle,
A). Then unscrew the other nut until the threaded end of the cable has been
released.
4. Pull out the threaded end of the cable through hole B in the illustration, Drum cra-
dle.
5. Undo the eight bolts holding the mounting for the cable's mounting eyelet on the
cradle. Then undo the eyelet from the plate.
76
5. Feeder
6. Then run the cradle to the lower end position so that the wheel axle A is visible
through the hole in accordance with the illustration, Wheel axle.
Figure: Wheel axle
7. Loosen the wheel by first unscrewing the axle's lock washer and then pull out the
axle with the slide hammer.
8. Now pull the cable's threaded end until the eyelet comes out through the hole (B in
the illustration, Drum cradle).
9. Insert the new cable with the eyelet end first and push it until it comes out from the
beam at the upper pulley wheel. Route the cable around the pulley wheel and
secure the eyelet in the plate. Screw in the plate using the eight bolts.
Figure: Upper pulley wheel
77
5. Feeder
10. Run the cradle into position in accordance with the illustration, Drum cradle.
Secure the stop nut with washers on the threaded end of the cable, insert the end of
the cable into the mounting hole and secure the washers, nut and lock nut.
11. Tension the cables in accordance with the instructions.
Replacing the drum cradle haul cable

Tools: 36 mm and 19 mm U-wrenches
The drum cradle haul cable is threaded at both ends.
1. Undo the nuts on the two threaded ends of the haul cable.
2. Undo the cable and secure the new cable.
3. Tension the cable in accordance with the instructions.
Replacing the drum cradle return cable

Tools: U-wrenches: 36 mm, 30 mm, 19 mm, 16 mm
The drum cradle return cable is threaded at one end and has an eyelet in the other end.
1. Run the drill cradle down to the stop.
2. Undo the threaded end of the cable from the cradle.
3. Unscrew the protective cover over the hole for the cable eyelet mounting. Then
unscrew the bolt from the eyelet.
Figure: Cable eyelet
78
5. Feeder
4. Pull the cable out from the beam from the rear pulley wheel.
5. Guide the eyelet section of the new cable into the mounting and screw in the eye-
let.
6. Secure the stop nut and stop washer on the threaded section. Then secure the
threaded section of the cable in the drum cradle and tighten the nut and the stop
nut.
7. Tension the cables in accordance with the instructions
Replacing the slide pieces in the holder

Each holder has a replaceable slide piece. 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 change 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 a new slide piece into the holder track and fit the new keys.
3. Make sure the holders are refitted correctly in the cradle and are adjusted accord-
ing to the directions.
Replacing slide rails

Slide rails should be replaced if they are worn or severely scratched.
79
5. Feeder
A
1250 0020 11
Figure: Replacing slide rails

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!
80
5. Feeder
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.
81
5. Feeder
5. Undo bolts C and D on cradle plates E and F.
C
E
SP
D
G H
N
F
A
K
M
L I
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.
82
5. Feeder
1250 0065 30
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.
83
6. Dust collector (DCT)
Filter test, dust collector (DCT)

1250 0106 33
Figure: Measurement points for dust collector filter.
To check the filters in the dust collector. Unscrew the plugs (a) and connect a pres-
sure drop gauge to the two holes.
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 spanner to unscrew the filters. Turn the nut on the underside of the filter anti-
clockwise.
84
1250 0116 41
b
Figure: Dust collector.
85
7. Radiator
7. Radiator
Coolant
WARNING
• Danger of scalding and pressure
• Can cause serious personal injury
• Release the pressure in the radiator
before removing the radiator cap
The drill rig has two radiators. The left-hand radiator is for the compressor oil and the
right-hand radiator is for engine coolant.
Checking and filling coolant takes place in a separate expansion tank.
86
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.
87
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 (3) if the oil level is below or level with the lower mark on the dipstick (see
table “Recommended hydraulic oil and lubricants”).
1. Check that the oil level is between the upper and lower marks on the dipstick (1).
2
1250 0167 38
1
Figure: Diesel engine
1. Dipstick
2. Filling up
2. Top up (2) if the oil level is below or level with the lower mark on the dipstick (see
table “Recommended hydraulic oil and lubricants”).
Maintenance of engine components
Air filter, service interval

The air filter comprises filter housings, 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.
88
8. Diesel engine
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 on the engine control panel in the cab.
RCS
ESC
RIG CONTROL SYSTEM

1250 0130 19
Figure: Warning lamp for clogged air filter
The filter cartridges, therefore, do not require service until the indicators warn other-
wise. The cartridges should, however, be checked for damage to the filter material at
the specified intervals.
If correct cleaning of the main cartridge cannot be ensured, a new cartridge should be
installed on each service occasion.
Table: Example
Hours 0 250 500 750 1000
Main cartridge service New Cleaning/ Cleaning/ Cleaning/ Changi
Changing Changing Changing 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.
When a drain valve is damaged, change it.
If the indicator lamp for clogged air filter remains on, the safety cartridge must also
be changed.
89
8. Diesel engine
1. Undo clamps (1) and remove the cover (2).
1
2
3
4
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 hous-
ing 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.
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!
90
8. Diesel engine
For further information, see the diesel engine's maintenance manual.
Checking air filter switches
6
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
The diesel engine has two fuel filters: diesel filter and prefilter. The prefilter has a
removable insert that must be cleaned once a month. If the prefilter insert is damaged,
change it.
The fine-grade diesel filter cannot be cleaned and must be changed.
Prefilter
The prefilter is mounted on the left of the engine.
91
8. Diesel engine
a
c
b
Figure: Prefilter
Draining
• Drain the water from the prefilter container daily by closing the fuel cock (a) and
opening the drain cock (b).
Changing fuel filter:
• Remove the filter bowl (d) and clean it with pure diesel fuel.
• Remove the fuel filter (c) 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 fur-
ther three quarters of a turn by hand. Do not tighten the filter too hard.
• Screw the clean filter bowl (c) back in place.
92
8. Diesel engine
Fine filter
1. Close the fuel cock to the prefilter. See previous section on prefilter.
CAT
a
Figure: Fine filter.
2. Unscrew the fuel filter (a) with a suitable tool and detach it.
3. Collect any residual fuel.
Figure: Changing fuel filter

4. Clean the filter holder sealing surface.
5. Lightly oil the new fuel filter rubber seal.
93
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.
Treat in accordance with local regulations
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 unscrew-
ing 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.
94
8. Diesel engine
Belts
Tension gauge
Check the belt tension with a tension gauge.
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
95
8. Diesel engine
2. Undo the nut for the generator mounting.(1)
2
1
3
1250 0001 93
Figure: Generator.
3. Relieve the tension of the belts by screwing the upper adjuster arm nut away from
the stop (2).
4. Loosen and pull out the four bolts in the shaft coupling until there is some clear-
ance (4).
1250 0105 03
4
Figure: Undo the bolts.
96
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 instruction refer to the separate instructions for

the diesel engine.
97
9. Oils and fuel
9. Oils and fuel
Environmental issues when handling fuel

• Fuel spillage is environmentally
hazardous and a health risk.
• Always collect fuel residue and spillage.
Treat in accordance with local regulations
in force.
Refuelling
Switch off the engine before topping up the fuel. Do not handle fuel in the vicinity of
hot surfaces, sparks or naked flames.
Figure: Refuelling.
1 Location of fuel filler orifice.
98
9. Oils and fuel
Use fuel with specifications complying with the engine manufacturer's recommenda-
tions.
99
9. Oils and fuel
Environmental considerations when handling

oils

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.
100
9. Oils and fuel
The compressor oil level can be read in the sight glass on the front of the air tank.
2
1250 0168 18
Figure: Compressor tank
1. Check that the engine is not running and that the sight glass (2) is half full.
2. Depressurise the system by opening the extra outlet valve located on the right-
hand side of the drill rig.
3. Top up (1, see illustration: Compressor tank) if necessary. Unscrew the filler plug
when topping up (see table “Recommended hydraulic oil and lubricants”.
Oil sampling
An oil sample gives a good indication of how well the hydraulic system has been
maintained.
101
9. Oils and fuel
Hydraulic oil
CAUTION
• Protect your eyes from hydraulic oil
Note
Do not fill up with too much hydraulic oil as it might then clog the ventilation filter.
The hydraulic oil level can be read in the sight glass on the front of the hydraulic oil
reservoir. The lower sight glass (2) should be full and the upper sight glass (1) should
be half full.
• Check the hydraulic oil level (1 and 2)

• Fill as needed with the hand pump (3) (See the table “Recommendations for
hydraulic oil and lubricant”)
1250 0167 46
1
2
Figure: Hydraulic oil reservoir
For engine oil see section “Diesel engine”
102

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9852 1880 01 Maintenance Instructions ROC L7CR II

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Atlas Copco

PM No. 9852 1880 01

Special attention must be paid

Only use genuine Atlas Copco parts.

© Copyright 2006, Atlas Copco Rock Drills AB, Sweden

Atlas Copco Rock Drills AB

Changing air filter ............................................................................................. 31

3. Drilling system ....................................................................................................... 40

Anti-jamming protection ....................................................................................... 62

4. Hydraulic systems .................................................................................................. 68

6. Dust collector (DCT).............................................................................................. 84

8. Diesel engine .......................................................................................................... 87

Air filter, service interval .................................................................................. 88

9. Oils and fuel ........................................................................................................... 98

• Never perform service or maintenance work while the rig is running

Target group and objective

The objective of these maintenance instructions is to detect and rectify faults at an

Country Address Phone and fax number

Country Address Phone and fax number

Signs for outsourced components

Dismantling and assembly

• Rest oil and oil spill

Tightening torques for bolted joints

Table: Atlas Copco Standard torques.

Size Strength Torque in Tolerance

The following must be observed when welding:

• Weld in a dry area.

Table: Electrode recommendations

Table: MIG electrodes

If in any doubt, contact Atlas Copco for advice.

Environmental considerations regarding batteries

• Think of the environment!

• The batteries must have the same capacity (Ah).

Proceed as follows (24V charger)

5. Start the battery charger.

Procedures after charging

5. Activate battery switch S300.

Proceed as follows (12V charger)

5. Start the battery charger.

10. Repeat steps 3-8 on G1B.

Procedures after charging

4. Activate battery switch S300.

Starting with an auxiliary battery

For this reason, proceed as follows:

Figure: Boost starting

Scrapping guidelines for steel cables

• Wire break at mounting

• Certain number and type of wire breaks

Wire break at cable mounting

Occurrence of strand breaks

Concentrations of wire breaks

If such concentrations occur within a length less than 60 cm or on an individual

Occurrence of wire breaks due to operating time.

Reduced elasticity is difficult to detect. If in doubt, consult a specialist.

• Decrease in cable diameter

Decrease in cable diameter

• Inner surface wear and surface wear nicks

It should then be scrapped even if no wire breaks have been detected.

Certain number and type of wire breaks

On 6 and 8-strand cables, wire breaks are primarily superficial.

1 = Filler wire is not considered load-bearing.

Severe corrosion can reduce elasticity.

Surface wear is increased through faulty or no lubrication, thereby increasing the

It should then be scrapped even if no wire breaks have been detected.