9852 1302 01e Maintenance Instruction Cop 2150-2550 -2150ex -2550ex

Maintenance instructions for

1250 0025 58

Hydraulic Rock drill

COP 2150 / COP 2550 COP 2150EX / COP 2550EX

No. 9852 1302 01e

Reg. code AIB TAB 43 COP 2150/2550 COP 2150EX/2550EX 2005–01

Maintenance instructions for

1250 0025 58

Hydraulic Rock drill

COP 2150 / COP 2550 COP 2150EX / COP 2550EX

ATLAS COPCO ROCK DRILLS AB ÖREBRO · SWEDEN © Atlas Copco Rock Drills AB, 2005. All rights reserved.

No. 9852 1302 01e

SAFETY REGULATIONS · Important safety information is given at various points in these instructions. · Special attention must be paid to the safety information contained in frames and accompanied by a warning symbol (triangle) and a signal word, as shown below:

WARNING

indicates hazards or hazardous procedures which COULD result in serious or fatal injury if the warning is not observed.

CAUTION

indicates hazards or hazardous procedures which COULD result in injury or damage to equipment if the warning is not observed.

The following safety rules must also be observed:

· Carefully read through all operating- and main-

· Use Atlas Copco genuine parts only. Any

· Do not use or intervene in the rock drill unless

·

tenance instructions for the drill rig and rock drill before putting the rock drill to use. Always follow the instructions given. you have been trained to do so.

·

· The rock drill may only be used for the prescribed purposes.

· Make sure that the drill rig has been maintai-

ned in accordance with the current instructions.

· Make sure that all safety labels remain in pla-

·

ce, and that they are kept clean and fully legible. See the spare parts list for details of label locations and part numbers.

· Always wear a safety helmet and ear protec-

·

· Before moving the drill rig or starting to drill,

·

tors during drilling. Any local regulations that exist must also be observed.

make sure that there are no personnel in the immediate vicinity of the drill rig.

Contents

Page

Safety regulations . . . . . . . . . . . . . . . Action list . . . . . . . . . . . . . . . . . . . . Hose connections . . . . . . . . . . . . . . . Tightening torques . . . . . . . . . . . . . . . Accumulators . . . . . . . . . . . . . . . . . – Charging the accumulators . . . . . . . . . – Checks in the event of hose vibration . . . . – Changing the accumulators . . . . . . . . . – Changing the return accumulator . . . . . . Changing the hydraulic motor . . . . . . . . . Filling with lubricating oil and bleeding the system

2

damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. Never attempt to carry out maintenance while the drill rig is in operation. Those checks and adjustments that must be made while the drill rig is in operation must be carried out by at least two persons. One person must man the control station and keep a strict watch over the work. To prevent injury during service and maintenance, all components that could possibly move or drop must be supported safely on blocks or trestles, or secured by means of adequately dimensioned slings. Before starting work on any of the systems, make sure that the hydraulic, air and water systems are without pressure, and that the electrical system is dead. Check that the hoses used are of the right quality, and that all hose connections are in good condition and properly tightened.

. . . . . . . . . .

2 3 4 5 6 6 7 8 9 9 10

Setting of ECL lubricating system . . . . . . Setting the damper pressure . . . . . . . . Setting the extractor-unit pressure COP 2150EX / COP 2550EX) . . . . . . . Removing the front head . . . . . . . . . . Checking the front head . . . . . . . . . . Changing the flushing head and driver . . . Mounting the front head . . . . . . . . . . Slinging . . . . . . . . . . . . . . . . . . . Long-term storage . . . . . . . . . . . . . Recommended hydraulic oils and lubricants

. . 10 . . 11 . . . . . . . .

. . . . . . . .

11 12 13 14 16 17 17 18

WARNING · Before starting any maintenance work, make sure that the electrical system is dead.

There is a risk of injury if these instructions are not observed!

CAUTION · Take care during rod jointing and when

Action list Before starting up a new- or newly overhauled rock drill Page · Connect up the hoses . . . . . . . . . . . . 4 · Charge the accumulators . . . . . . . . . . . 6 · Select a suitable hydraulic oil and lubricant . 19 · Fill the lubricating system with oil . . . . . . . 10 · Adjust and set the lubricating system . . . . 10 · Set the damper pressure . . . . . . . . . . . 11 · Set the extractor-unit pressure (COP 2150EX - COP 2550EX) . . . . . . . . 11

handling the drill bit. Mind your fingers!

· Keep your clothing away from rotating machine parts.

Carelessness can lead to serious injury.

Every shift · Check that air and lubricating oil come out

· Always use ear protectors during drilling. High noise levels damage hearing.

· Never attempt maintenance or intervene

in the rock drill, connections or hoses while the hydraulic, lubrication or flushing systems are pressurized. Air or oil can squirt out at high pressure and high temperature, with the risk of serious injury to the eyes and skin.

· · · ·

·

between the shank adapter and front guide and also out of the hole in the front head . . Check that the damper-pressure gauge on the drill rig shows the normal value. In case of deviation, adjust the damper pressure . . . Check that the shank-adapter threads are not damaged . . . . . . . . . . . . . . . . . Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulators . . Check that there is no leakage from the rock drill. If the flushing medium leaks out of the overflow hole in the front head, change the seals and O-rings . . . . . . . . . . . . . . . When changing the shank adapter or removing the front head, check the internal components, including the visible parts of the piston, driver and rotation chuck bushing . . . . . . . In the event of defect, remove to a suitable workshop for repair or replacement.

13 11 13 7

13

13

After the first shift when using a new- or newly overhauled rock drill · Tighten all threaded unions . . . . . . . . . 5

IMPORTANT · Observe great cleanliness when intervening in the rock drill or its hydraulic circuit.

· The following parts may be changed at the worksite in accordance with the instructions given: – shank adapter – driver – front head parts – accumulators – hydraulic motor – screws – connections.

After every 40th percussion-hour · Tighten all threaded unions . . . . . . . . . 5 · Check the safety labels on the accumulators. ·

Replace them if they are damaged or illegible . 6 Check the return accumulator . . . . . . . . 7

Every 400th percussion-hour · Remove the front head of the rock drill and check the internal components.

* The rock drill should be overhauled at suitable intervals, based on local conditions. The characteristics of the rock will have a great influence on the rate of wear, and thus on the required frequency of overhauling.

Other repairs must be carried out in a suitable workshop in accordance with the

3

Hose connections 8

1

7

550

150/2

2 COP

AIR

6 0EX

X/255

1250 0130 65

0E P 215

CO

5

2

3

4

1. Drainage 2. Rotation to the left 3. Rotation to the right 4. Percussion mechanism, return 5. Percussion mechanism, intake 6. Flushing air/water 7. Lubricating air 8. Damper, intake 9. Extractor unit, return 10. Extractor unit, intake

CAUTION · Never attempt maintenance or intervene

in the rock drill, connections or hoses while the hydraulic, lubrication or flushing systems are pressurized. Air or oil can squirt out at high pressure and high temperature, with the risk of serious injury to the eyes and skin.

· Pressure hoses with an internal diameter

of 19 mm (3/4") or more are rated SAE 100 R9R (i.e. high-pressure hose with four layers of spirally wound steel-wire reinforcement). See spare parts list for drill rig. For safety reasons, these hoses must not, under any circumstances, be replaced with hoses of a lower rating. There is a risk of injury if these instructions are not observed!

4

6

9

10

Connecting the hoses · Clean the hose connections on the rock drill before removing the protective plugs (or caps).

· Never remove a protective plug until the hose is ready to be connected.

· Always store the rock drill with all hose connections plugged. Use suitable protective plugs or caps, and make sure that they are clean.

Tightening torques

5

6

1

50

50/25

1 COP 2

4

3A 14 13

0EX/ P 215

CO

6

12

X

2550E

9

11

7 9

3B

1250 0130 66

8

10

13

COP 2150/2550

16

15

COP 2150EX/2550EX

3B

3A

2

2

N.B. Tighten item Nos. 1–3 in the prescribed order. Ref.No.

Qty.

Check point

Torque Nm lbf.ft

Instructions Tighten the rear nuts Tighten the front bolt Tighten the front nuts Tighten the screws alternately to full torque (uppermost screw last)

1 2 3 4

2 1 3 3

Side bolts Front bolt Side bolts (2550EX) Back head

300 300 300 220

220 220 220 160

5 6 7 8

1 4 4 2

80 220 65

60 160 48

9 10 11 12 13 14 15 16

4 1 4 2 1 4 1 1

Regulating plug Accumulators Hydraulic motor Clamping attachment, return accumulator Rock drill mounting Plug Valve covers Connection plate Flushing connection Inlet, flushing medium Intake, extractor unit Return, extractor unit

30 250 45 145 120 300 90 120 120

22 185 33 105 90 220 65 90 90

Tighten the screws alternately to full torque Tighten the nuts alternately Tighten the screws alternately to full torque Tighten the screws alternately to full torque Tighten the screws alternately to full torque Tighten the screws alternately to full torque

5

Accumulators The accumulators are fitted with safety labels as shown in the figure below. 1250 0020 91

= Must be charged with nitrogen only

1250 0027 19

1. Damper accumulator 2. Intake accumulator 3. Return accumulator

= Read the instruction book carefully before servicing or changing

Charging the accumulators 1. Remove the protective cap (4).

WARNING · The accumulators must be charged with nitrogen (N2) only! Other gases can cause an explosion.

CAUTION · Do NOT charge the accumulators until

they have been fitted to the rock drill. There is a risk of injury if these instructions are not observed!

6

2. Open the valve nut (5) by 2–3 turns, and connect the gas hose. 3. Open the gas valve (6). 4. Charge the accumulators to the correct pressure, as follows: – Damper accumulator (1): 20–25 bar (290–360 psi) – Intake accumulator (2): 30 - 40 bar below the collaring pressure (435- 580 psi) NB. It is better to undercharge rather than overcharge the accumulators. The return accumulator (3) must not be charged 5. Tighten the valve nut (5) and close the gas valve (6). 6. Remove the gas hose and fit back the protective cap (4) to the accumulator valve

Checking the accumulators in the event of hose vibration Damper accumulator (1) and Intake accumulator (2) 1. Press in the pin on the test valve (7). If the accumulator is charged, the pin will stick out by 4.5 mm and give a firm resistance when pressed in. N.B. The damper-accumulator pin is somewhat easier to press in. If it is easy to press in the pin, it means that there is no gas pressure (diaphragm damaged or defektive charging valve). 2. Change the accumulator if it is not functioning properly (see page 8). 3. After fitting a new accumulator, charge it with nitrogen. N.B. The seat of the charging valve can easily become deformed when opened and closed repeatedly. The charging valve should therefore be changed regularly.

1250 0027 20

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

1. Damper accumulator 2. Intake accumulator 3. Return accumulator 4. Protective cap 5. Valve nut 6. Gas valve 7. Test valve 8. Plug with O-ring

7

1250 0041 44

Changing the accumulators

Mounting

Removal

CAUTION · Release all gas before removing the ac-

cumulators from the rock drill. To do this, remove the protective cap (A), loosen the valve nut (B) and open it by 2–3 turns. There is a risk of injury if these instructions are not observed!

Remove the accumulators (1 and 2) together with the seals (3) by removing the screws (4 and 5). Now send the accumulators to a workshop for overhauling!

Mounting

CAUTION · Do not fit the seals on the accumulator.

CAUTION · Mount the accumulators to the rock drill

using undamaged original screws. The intake accumulator (2) must have two screws (4) of length 100 mm. The damper accumulator (1) must have two screws (5) of length 70 mm. Change both screws at the same time, even if only one of them is corroded (or damaged in some other way). Defective screws can cause dangerous oil leakage, or can cause the accumulator to be blown off. Squirting oil can seriously injure the eyes and skin. Parts that come loose can cause serious injury.

Fit the sealings (3) into the grove in the intermediate part (7) and then fit the accumulators (1 or 2) to the intermediate part (7) Make sure that the sealings dont get damaged during the assembly. Fit the damper accumulator (1) to the left-hand side of the rock drill. Fit the intake accumulator (2) to the right-hand side of the rock drill, i.e. the hose side. Tighten the screws (4 and 5) alternately to a torque of 220 Nm (160 lbf.ft). Now charge the accumulators with nitrogen (N2). See page 6.

8

1250 0027 22

Changing the return accumulator

Changing the hydraulic motor

1 5

10 7 9 2

3

Removal

1250 0027 23

8

Removal Disconnect the hydraulic hoses (1).

CAUTION · Before starting work on any of the sys-

tems, make sure that there is no pressure in the hydraulic, water and air systems.

· Pressure hoses with an internal diameter

of 19 mm (3/4") or more are rated SAE 100 R9R (i.e. high-pressure hose with four layers of spirally wound steel-wire reinforcement). See spare parts list for drill rig. For safety reasons, these hoses must not, under any circumstances, be replaced with hoses of a lower rating.

There is a risk of injury if these instructions are not observed! Disconnect the hydraulic hose (8) from the return accumulator (3). Remove the return accumulator (3) by removing the nuts (2) and screws. Pull off the clamp (5) and unscrew the accumulator from the nipple (7 on surface drill rigs) or (9 on underground drill rigs).

Remove the return accumulator (3). Remove the nuts (2) and take off the hydraulic motor (3). Pull out the coupling (4).

Mounting Make sure that the circlip (5) is fitted into the coupling (4). Grease the splines inside the coupling, and slide the coupling on to the output shaft of the hydraulic motor (3). Fit the hydraulic motor (3) with gasket (7) to the cylinder (6). Change the gasket if it is damaged. Tighten the nuts (2) to a torque of 65 Nm (48 lbf.ft). Connect the hydraulic hoses (1). Check that the motor rotates in the correct direction.

Now send the accumulator to a workshop for overhauling!

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

9

Filling with lubricating oil and bleeding the system CAUTION

· If the lubricating system has been empty of

oil, it must be bled after filling. This is done as follows: – Loosen the cap (7) and let the lubricating oil escape until all air has been discharged from the lubricating oil pump. Now tighten the cap. – Start the lubricating system and loosen the hose connection at pressure gauge (8), so that all air is released from the system. Now tighten the hose connection. – Disconnect the lubricating-air hose (12) from the nipple (11) on the rock drill. – Start the lubricating pump and let it pump until oil comes out of the plastic hose (10). When re-starting (after standstill), oil must come out of the plastic hose directly when the lubricating pump is started. – Check that the plastic hose (10) for lubricating oil not extends into the machine. – Re-connect the lubricating-air hose (12).

· Never intervene in the lubricating system while it is pressurized. Lubricating oil can squirt out, with the risk of injury to the eyes and skin.

IMPORTANT · Use the recommended lubricating-air pressure and the recommended lubricating oil. Certain moving parts of the rock drill are lubricated by means of oil-mixed compressed air. It is important that these parts receive good lubrication.

· Check the oil level in the lubricating-oil container (1) once a shift. Observe a high standard of cleanliness and fill with oil of the right quality (see page 19). The lubricating-oil container holds 5 litres.

Setting of ECL lubricating system - Underground drill rigs 1. Open the electrical cabinet. 2. Start the lubricating system (see the operator’s instructions for the drill rig). 3. Check the lubricating air pressure at the rock drill (11) using a pressure gauge (A). The pressure should be 2–3 bar. If the pressure is too low, clean the restrictor (9) or increase the diameter of the restrictor. Underground drill rigs 4. Check that the green light emitting diode (G) indicates power on. 5. Adjust the screw (T1) so that the light emitting time of the yellow diode (R) is 0.5 seconds. 6. Observe the yellow diode (R) and adjust the lubricating oil dosage to 60 pulses/min, by means of the screw (T2).

underground

3 T1 G

10 A

R T2

B B

2 1 Min. oil level 7 F

+

12

B 11

9

8

After making the respective setting, check the LED (F) on the lubricating pump to ensure that the right pulse frequency has been obtained. Check also that oil comes out of the hole (B) in the front head and between the shank adapter and front guide.

10

1. Lubricating-oil container 2. Filler cap 3. Pulse relay 7. Cap, bleeding 8. Pressure gauge 9. Restrictor 10. Plastic hose 11. Lubricating-air connect. 12. Lubricating-air hose

A. Pressure gauge F. Light-emitting diode (LED) G. Green LED R. Yellow LED T1. Adjustment screw, light-emitting time T2. Adjustment screw, pulse frequency

Surface

Setting of ECL lubricating system, Surface drill rigs

10 4 6 5 3

A

B

1. Open the electrical cabinet. 2. Start the lubricating system (see the operator’s instructions for the drill rig). 3. Adjust the lubricating air pressure to 5 - 5.5 bar using the pressure regulator (9). Check the lubricating air pressure at the rock drill (11) using a pressure gauge (A).

C 1

C

Min. oil level 11

7

1250 0149 04

2

F +

-

12 9 8

1250 0040 48

1. Lubricating oil container 2. Filler cap 3. Pulse relay 4. Green LED. 5. Potentiometer pulses/min 6. Potensiometer, delay (not used) 7. Cap, bleeding 8. Pressure gauge

9. Restrictor 10. Plastic hose 11. Lubricating air connection 12. Lubricating air hose A. Pressure gauge B. Lubricating air return connection C. Lubricating air output F. LED

4. The pressure should be 3 bar. If the pressure is too high or too low, adjust the pressure regulator (9). Adjust to the correct lubricating oil dosage, 40 pulses/min, using the potentiometer (5). The green LED (4) indicates the pulse frequency. 5. Check the LED (F) on the lubricating pump to ensure that the right pulse frequency has been obtained. Check also that oil comes out between the shank adapter and front guide (C). Check that the ECL collection system is working (see the operator’s instructions for the drill rig.).

Setting the damper pressure 1. Shut completely the constant-flow valve (B) on the drill rig. 2. Connect a pressure gauge (A) [calibrated from 0 to 60 bar] between the hose and the damper nipple (1). 3. Pressurize the damper circuit. 4. Check that the shank adapter is unloaded, and that it has been pushed into the forward position. 5. Adjust the constant-flow valve until the pressure gauge (A) reads 30–35 bar. 6. Read off the pressure on the damper pressure gauge on the drill rig. If the pressure gauge later shows a different value, make a new pressure setting. 7. Disconnect the pressure gauge (A) and reconnect the hose to the nipple (1).

1250 0040 49

Setting the extractor-unit pressure (COP 2150EX / COP 2550EX) 1. Close the constant-flow valve (B) on the drill rig completely. 2. Connect a pressure gauge (A) [calibrated from 0 to 60 bar] between the hydraulic hose and the extractor-unit intake nipple (P). 3. Connect the circuit for the extractor unit by activating feed reverse and running the cradle to the stop at the rear end of the feed beam. Hold the feed lever in the "feed-reverse" position. 4. Adjust the constant-flow valve (B) until the pressure gauge (A) reads 20–25 bar. 5. Disconnect the pressure gauge (A) and reconnect the hydraulic hose to the extractor-unit intake nipple (P).

11

Removing the front head CAUTION · Never attempt maintenance work while the ·

drill rig is in operation. Before starting work on any of the systems, make sure that there is no pressure in the hydraulic, water and air systems.

There is a risk of injury if these instructions are not observed!

1250 0040 50

N.B. Always clean the outside of the rock drill before disassembly.

COP 2150/2550 Remove the flushing hose (5). Remove the connection plate (1) and nipple (2) by removing the screws (3) and washers (6). Remove the cup seal (4).

Remove the front side-bolt nuts (3) with their washers (2). Remove the front head (1) by tugging the shank adapter (4).

1250 0040 51

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

COP 2150EX / COP 2550EX Remove the front side-bolt nuts (3) with their washers (2).

1250 0040 52

Remove the front head (1) by tugging the shank adapter (4) or by tapping the front head with a copper hammer. Now pull out the shank adapter (4) from the front head (1). Check the internal components of the front head when changing the shank adapter.

12

1250 0130 67

Checking the front head

6

13

3

4

3

3

A

5

9

2

6

11

13 11 11 3 3 3

3

4

5

A

9

12

14

8

14

8 7

7

3

C

B

1

12

10 COP 2150EX/2550EX

COP 2150/2550 3

3

4

3

3

11

10

2

11

11

1 mm

1m

m

1

B

C

COP 2150EX/2550EX

COP 2150/2550 5

3

3

3

4

3

2 mm

COP 2150EX/2550EX

7

m

1m

6 53 mm

· Check that air and lubricating oil come out between the shank adapter (6) and front guide (7), and also out of the hole (B).

· Change the guide (7) if its internal diameter is

·

greater than 53 mm.

· Check the O-rings and flushing seals (3) if

air/water is escaping from the hole (C) in the front head. Change the O-rings and flushing seals if they are worn or damaged.

· Change the flushing head (4) if it is seriously cor·

roded, or if it contains cracks. Change the stop ring (7) if it is worn by more than 1 mm.

· Change the extractor-unit piston (10) if the surface toward the shank adapter has worn by more than 1 mm. When changing the extractor-unit piston, check the seals and O-rings (11). Change them if they are worn or damaged.

D

· Look inside the gear housing and check the spli-

· Blow clean the lubricating oil ducts (A) in the

front head (13) using compressed air, and check that the restrictors (9) are open.

2

·

·

nes of the driver (5). If the splines are less than 2 mm in width, the driver must be changed (see page 14). Fit a new driver with the aid of a suitable mandrel and a copper hammer. If the rotation chuck bushing (2) is worn by more than 1 mm, or if it is damaged, it must be changed. N.B. Fit the rotation chuck bushing so that the lubrication grooves (D) face the damper piston (14). Change the rotation chuck bushing every 15,000 drillmetres (max!). See page 14. Change the shank adapter (6) if the thread is worn out or the impact surface is upset or chipped, or if the front or rear end surfaces of the splines are worn. Check that the drill collar (8), which must be used in upwards-directed drilling, is not damaged and that it rotates with the shank adapter.

13

Changing the flushing head and driver Disassembly

CAUTION · Take care when removing the flushing head and driver. Mind your fingers!

Remove the flushing hose (1) from the nipple (2). Remove the nipple (3) and its O-rings. Press the disassembly tool (A) into the gear housing (4) until it comes to a stop, i.e. until the splined part of the tool has passed the splines of the driver (5). Turn the disassembly tool clockwise a little. Tap out the driver (5) and flushing head (6) by striking with the impact hammer (B).

1250 0040 61

The rotation chuck bushing (7) usually comes out as well when the driver is removed. If this does not happen, remove the rotation chuck bushing with the aid of an extractor and expander. N.B. Change the bushing every 15,000 drillmetres (max!).

14

1250 0039 24

Assembly

If the rotation chuck bushing (3) has been removed, fit it back and tap into place with the aid of a suitable copper mandrel. Tap the driver (2) into the rotation chuck in the gear housing (1) with the aid of a mandrel (A) and a copper hammer.

1250 0040 62

Fit the O-rings (3) and seals (4) into the flushing head (2). IMPORTANT! The seals (4) must be turned as shown in the figure opposite. Place the flushing head (2) into the cover (1) and tap it in using a copper hammer. Check carefully that the flushing intake in the cover lines up with the hole in the flushing head. Fit the O-rings (5 and 6) and back-up ring (7) on to the nipple (8). Fit the nipples (8, 9 and 10) and the nut (11). Tighten the nipple (8) to a torque of 300 Nm (220 lbf.ft) and the nipple (9) to a torque of 180 Nm (130 lbf.ft).

15

Mounting the front head COP 2150/2550 Fit the stop ring and shank adapter (4) into the front head (1). Check that the pin (6) is fitted into the cover. Fit the front head (1) on to the side bolts (5). Fit the washers (2) and nuts (3).

1250 0040 64

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

1250 0040 65

Fit the cup seal (4) into the flushing head. Fit the connection plate (1) to the front head using the washers (6) and screws (3). Tighten the screws (3) to a torque of 90 Nm (65 lbf.ft). Change the seal washer (7) if it is damaged. Fit the nipple (2) to the connection plate, and tighten to a torque of 300 Nm (220 lbf.ft). Connect the flushing hose (5) and tighten the coupling nut. After assembly, check that air and lubricating oil come out of the hole in the front head and also between the shank adapter and the front guide.

16

Mounting the front head COP 2150EX / COP 2550EX 4

1

1250 0088 95

6

7

5

2

3

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

17

1250 0088 96

Slinging

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

CAUTION · Lifting gear and slings must be approved for a weight of 500 kg (1100 lbs).

Faulty lifting gear can cause the rock drill to move unpredictably or drop. Incorrect handling can result in crush injuries.

Long-term storage If the rock drill is not going to be used for a long time, the following precautions should be taken:

· Check that all connections, including the one for

· ·

· ·

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

18

Rock drill weights, approx. COP 2150 / COP 2550 200kg (440lbs) COP 2150EX / COP 2550EX 260 kg (576 lbs)

Recommended hydraulic oils and lubricants Lubricant

Recommendation

Hydraulic oil

· Use a mineral-base or synthetic (polyalpha-olefin or diester based) hydraulic oil with good anti-wear, anti-rust, anti-oxidation and foam inhibiting properties, and with good air and water separation characteristics. Choose an oil with viscosity grade (VG) and viscosity index (VI), in accordance with the table below. An oil with a high viscosity index is less sensitive to the effects of temperature.

Hydraulic oil temperature in tank oC ( oF) Normal operating temp. Min. starting temp. (viscosity 25–50 cSt) (viscosity min. 1000 cSt) +50 to +70 (122 to 158) +5 (41) +45 to +60 (113 to 140) –5 (23) +35 to +50 (95 to 122) –10 (14) +25 to +40 (77 to 104) –15 (5)

Air tool oil

· Use a mineral based air tool oil. Ambient temperature oC ( oF) –30 to 0 (–22 to +32) –10 to +20 (14 to 68) +10 to +50 (50 to 122)

Max. temp. 80 (176) 75 (167) 65 (149) 55 (131)

Viscosity grade VG (ISO 3448) ISO VG 100 ISO VG 68 ISO VG 46 ISO VG 32

Viscosity index VI Min. 100 Min. 100 Min. 100 Min. 100

Viscosity grade (ISO 3448) ISO VG 32–68 ISO VG 68–100 ISO VG 100–150

Printed in Sweden Atlas Copco, 2005

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