PM No. 9852 1553 01h
2007-04
Atlas Copco
Boomer 281/282 with carrier DC15
Maintenance instructions
Atlas Copco Rock Drills AB
SE-70191 Örebro, Sweden
SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.
Special attention must be paid
to information alongside
this symbol.
Only use genuine Atlas Copco parts.
1250 0071 04
© Copyright 2007, Atlas Copco Rock Drills AB, Sweden
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
Safety
3
Safety
Reference................................................................................................................. 5
Safety
4
Safety
5
Reference
Note
Always read the safety information before operating the rig or beginning mainte-
nance work.
1250 0099 89
Safety

6
Maintenance instructions
7
Maintenance instructions
1. General ................................................................................................................... 17
Environment ................................................................................................. 17
Contact details ....................................................................................................... 18
Target group and objective .................................................................................... 21
Hydraulic systems ................................................................................................. 22
General.............................................................................................................. 22
Repairing hydraulic components ...................................................................... 22
Hydraulic workshops ........................................................................................ 23
Replacement of hydraulic hoses ....................................................................... 23
Welding.................................................................................................................. 23
Electrode recommendations.............................................................................. 24
Tightening torque in bolted joints. ........................................................................ 24
Markings and plates............................................................................................... 25
Dismantling and assembly..................................................................................... 26
Fault finding .......................................................................................................... 26
Starting with an auxiliary battery .......................................................................... 27
2. Lubricants, coolants and propellants...................................................................... 28
Introduction ........................................................................................................... 28
Hydraulic oil.......................................................................................................... 28
Hydraulic systems............................................................................................. 28
Lubrication oil ....................................................................................................... 29
Rock drill (ECL lubrication system)................................................................. 29
Diesel engine .................................................................................................... 29
Hydraulic transmission ..................................................................................... 30
Wheel axle centre and hub reduction gears ...................................................... 30

Compressor ....................................................................................................... 30
Reeling units ..................................................................................................... 31
Gears ............................................................................................................ 31
Lubrication grease ................................................................................................. 31
Rock drill .......................................................................................................... 31
Feeder ............................................................................................................... 31
Boom................................................................................................................. 31
Drill-steel support ............................................................................................. 32
Carrier ............................................................................................................... 32
Electrical system............................................................................................... 32
Propellants ............................................................................................................. 32
Diesel engine .................................................................................................... 32
Coolants................................................................................................................. 33
Diesel engine cooling system ........................................................................... 33
3. Feeder..................................................................................................................... 35
Safety..................................................................................................................... 35
2000-series............................................................................................................. 35
Technical data........................................................................................................ 37
Maintenance instructions
8
2000-series ........................................................................................................ 37
Mounting rock drill/rotation unit........................................................................... 37
Preparation ........................................................................................................ 37
Assembly .......................................................................................................... 38
Check after four hours ........................................................................................... 38
Rock drill hoses ..................................................................................................... 38
Location of hoses .............................................................................................. 38
Adjusting the hoses........................................................................................... 39
Haul and return ropes ............................................................................................ 40
Locations........................................................................................................... 40

Replacing the haul rope .................................................................................... 40
Adjusting haul and return ropes........................................................................ 41
Tension of return rope....................................................................................... 41
Adjusting the cradle on the feed beam .................................................................. 42
Adjusting the feed beam on the telescope feeder .................................................. 43
Replacing the slide pieces in the holder ................................................................ 44
Replacing slide rails............................................................................................... 45
Adjusting different drill steel lengths for the telescope feeder.............................. 46
Feed cylinder ......................................................................................................... 47
Dismantling the feed cylinder........................................................................... 47
Tension bushing for spacer ............................................................................... 49
Description ................................................................................................... 49
Dismantling .................................................................................................. 49
Assembly...................................................................................................... 49
Dismantling the lower feed cylinder on the telescope feeder........................... 50
Dismantling the upper feed beam ................................................................ 50
Dismantling the cylinder .............................................................................. 51
Long-term storage.................................................................................................. 52
4. Boom ...................................................................................................................... 53
BUT 28 G .............................................................................................................. 53
Technical data ........................................................................................................ 54
BUT 28 G.......................................................................................................... 54
Bolted joints........................................................................................................... 54
Tightening torques ............................................................................................ 54
Torque tightening retaining bolts on telescope tube flange .............................. 55
Starting to use a new boom.................................................................................... 56
Slinging and hoisting............................................................................................. 57
Safety ................................................................................................................ 57
Hoisting............................................................................................................. 57
Slinging............................................................................................................. 58

Dismantling the boom ........................................................................................... 59
Safety ................................................................................................................ 59
Dismantling the feeder...................................................................................... 59
Dismantling the boom body.............................................................................. 60
Expander shafts...................................................................................................... 60
Dismantling....................................................................................................... 60
Assembly .......................................................................................................... 61
Maintenance instructions
9
Boom telescope ..................................................................................................... 61
Dismantling the boom telescope....................................................................... 61
Checking the bushings in the bearing housing ................................................. 63
Checking the keys............................................................................................. 64
Checking the slide rails..................................................................................... 64
Rotation unit .......................................................................................................... 65
Changing the position of the stop point............................................................ 65
Adjusting the feed lookout cylinder ...................................................................... 66
Directional control - angle sensor.......................................................................... 67
5. Engine .................................................................................................................... 68
Engine Deutz 912W .............................................................................................. 68
Technical data........................................................................................................ 69
Safety..................................................................................................................... 70
Fuel system............................................................................................................ 70
Changing fuel filter........................................................................................... 70
Draining the fuel tank ....................................................................................... 71
Air system.............................................................................................................. 72
General.............................................................................................................. 72
Cleaning the oil bath air filter........................................................................... 72
Oil system.............................................................................................................. 74
Topping up with engine oil ............................................................................... 74

Changing oil...................................................................................................... 74
Checking oil level ............................................................................................. 75
Changing oil filter............................................................................................. 75
Belts....................................................................................................................... 77
Tension gauge ................................................................................................... 77
Tensioning belts ................................................................................................ 78
Generator belt............................................................................................... 78
Changing the cooling fan belt........................................................................... 78
Changing the generator belt.............................................................................. 79
Valve clearance...................................................................................................... 80
Alternating current generator ................................................................................ 82
Important........................................................................................................... 82
Lifting device......................................................................................................... 82
Fault finding .......................................................................................................... 83
Deutz instruction manual....................................................................................... 84
6. Transmission .......................................................................................................... 85
Locations ............................................................................................................... 85
Technical data........................................................................................................ 85
Wheels .............................................................................................................. 85
Steering ............................................................................................................. 85
Drive shafts....................................................................................................... 86
Transmission..................................................................................................... 86
Fitting tyres and rims............................................................................................. 86
Control system....................................................................................................... 86
Drive shafts............................................................................................................ 87
Maintenance instructions
10
Checking oil level in centre gear ...................................................................... 87
Changing oil in the final drive .......................................................................... 88
Checking oil level in hub gear .......................................................................... 89

Changing oil in hub gear................................................................................... 90
Hydraulic transmission .......................................................................................... 91
Safety ................................................................................................................ 91
Checking oil level ............................................................................................. 91
Changing filter and oil ...................................................................................... 92
Lubricating the chassis .......................................................................................... 93
Propeller shafts ................................................................................................. 93
Central lubrication of chassis............................................................................ 93
Towing ................................................................................................................... 94
Safety ................................................................................................................ 94
Before towing ................................................................................................... 94
Release the brakes............................................................................................. 95
Removing propeller shafts ................................................................................ 95
Disconnecting the steering cylinder.................................................................. 96
After towing...................................................................................................... 96
Steps to take ................................................................................................. 96
7. Brake system .......................................................................................................... 98
Safety ..................................................................................................................... 98
General................................................................................................................... 98
Technical data ........................................................................................................ 99
Brake system..................................................................................................... 99
Checking brake pressure........................................................................................ 99
Service brake pressure ...................................................................................... 99
Parking brake pressure.................................................................................... 100
Bleeding the brakes ............................................................................................. 101
Checking brake discs ........................................................................................... 101
Adjusting the brakes ............................................................................................ 102
Function check, parking brake............................................................................. 103
Function check, service brakes............................................................................ 103
Checking accumulator charge pressure ............................................................... 104

Checking brake pressure control valve................................................................ 105
Checking the accumulators.................................................................................. 105
Scrapping an accumulator ................................................................................... 108
8. Drill system .......................................................................................................... 109
DCS 12, DCS 14 and DCS 18 ............................................................................. 109
9. Hydraulic systems ................................................................................................ 110
Safety ................................................................................................................... 110
Technical data ...................................................................................................... 110
Hydraulic system DCS 12, DCS 14 and DCS 18 ........................................... 110
Filter..................................................................................................................... 112
Return oil filter................................................................................................ 112
General ....................................................................................................... 112
Maintenance instructions
11
Changing the return oil filter...................................................................... 112
Breather filter.................................................................................................. 113
General....................................................................................................... 113
Changing the breather filter ....................................................................... 114
Oil sampling ........................................................................................................ 115
Changing oil ........................................................................................................ 115
General............................................................................................................ 115
Draining .......................................................................................................... 116
Filling up......................................................................................................... 116
General....................................................................................................... 116
Filling manually ......................................................................................... 117
Electric filling, option ................................................................................ 117
Draining condensation from the hydraulic oil tank............................................. 118
Pumps .................................................................................................................. 120
Power unit pumps ........................................................................................... 120
Checking pump rotation direction .................................................................. 120

Starting a new or reconditioned pump............................................................ 121
Bleeding the pumps ........................................................................................ 121
Circulating the pump ...................................................................................... 122
Settings ................................................................................................................ 124
Safety .............................................................................................................. 124
Illustrations showing locations ....................................................................... 124
Pressure setting and adjustment of rotation speed.......................................... 124
Main pump...................................................................................................... 126
Stand-by pressure ....................................................................................... 126
Pump pressure (percussion pressure)......................................................... 127
Positioning pressure ................................................................................... 128
Positioning pressure ................................................................................... 129
Rotation pump ................................................................................................ 130
Small hole bit ............................................................................................. 130
Reaming hole bit, option............................................................................ 130
Percussion pressure for collaring.................................................................... 131
Percussion pressure for full drilling................................................................ 132
Percussion pressure for full drilling................................................................ 132
Rock drill damper pressure............................................................................. 133
Percussion return pressure (COP 1532).......................................................... 134
Feed pressure .................................................................................................. 135
Max. feed pressure ..................................................................................... 135
Feed pressure for collaring......................................................................... 137
Feed pressure for full drilling in a small hole ............................................ 137
Feed pressure for full drilling of reaming holes, option ............................ 138
Introduction................................................................................................ 139
Max. feed pressure (upper and lower cylinder) ......................................... 140
Pressure difference between upper and lower cylinder ............................. 141
Feed pressure for collaring and full drilling............................................... 141
Feed pressure, reverse................................................................................ 141

Anti-jamming protection ................................................................................ 142
Description................................................................................................. 142
Maintenance instructions
12
RPCF feed control...................................................................................... 142
Feed (rock drill) return movement ............................................................. 143
General ....................................................................................................... 143
Setting for DCS 12 ..................................................................................... 143
Setting for DCS 14/18................................................................................ 144
Setting the feed return movement .............................................................. 145
Setting for DCS 12 ..................................................................................... 146
Setting for DCS 14/18................................................................................ 147
Function check ........................................................................................... 149
FPCI, regulating the percussion pressure ....................................................... 150
Adjusting the ECL lubricating system............................................................ 150
Metering lubricating oil.............................................................................. 150
Lubrication oil level monitor, option ......................................................... 151
10. Compressor......................................................................................................... 153
Safety ................................................................................................................... 153
Compressor instructions ...................................................................................... 153
Compressor LE3 (LE22), LE5 (LE40), LE7 (LE55), LE10 (LE75) ............. 153
Changing air filter........................................................................................... 154
Oil level........................................................................................................... 154
11. Air and water systems ........................................................................................ 155
Technical data ...................................................................................................... 155
Hose dimensions ............................................................................................. 155
Safety ................................................................................................................... 156
Water pump.......................................................................................................... 156
General............................................................................................................ 156
Setting the flow switch. .................................................................................. 156

Compressor unloading and loading pressure....................................................... 158
Safety .............................................................................................................. 158
Adjusting the unloading and loading pressure................................................ 158
Adjusting the unloading pressure............................................................... 158
Adjusting the loading pressure................................................................... 159
Lubricating air pressure ....................................................................................... 159
Cleaning the water strainer .................................................................................. 160
Freeze prevention measures................................................................................. 161
Draining the water system .............................................................................. 161
Draining the air tank ....................................................................................... 163
12. Electrical system, IEC and Australia.................................................................. 164
Safety ................................................................................................................... 164
General................................................................................................................. 164
Safety standard................................................................................................ 164
Low-voltage circuit......................................................................................... 164
Extra low-voltage circuit ................................................................................ 165
Before starting................................................................................................. 165
Cable marking................................................................................................. 165
Replacement of components........................................................................... 165
Maintenance instructions
13
Electrical distribution cabinet, high-current ........................................................ 165
Indicator lamps ............................................................................................... 165
Voltmeter and ammeter................................................................................... 165
Hour counter ................................................................................................... 166
Electrical system protection ................................................................................ 167
Main switch .................................................................................................... 167
Phase sequence monitor.................................................................................. 167
Earth fault equipment ..................................................................................... 167
Motor protection ............................................................................................. 167

Fault finding ........................................................................................................ 168
13. Electrical system Canada, USA ......................................................................... 169
Safety................................................................................................................... 169
General ................................................................................................................ 169
Safety standard................................................................................................ 169
Low-voltage circuit......................................................................................... 169
Extra low-voltage circuit ................................................................................ 170
Before starting ................................................................................................ 170
Cable marking................................................................................................. 170
Replacement of components........................................................................... 170
Electrical distribution cabinet, high-current ........................................................ 171
Exterior ........................................................................................................... 171
Interior with Direct start ................................................................................. 172
Interior with Soft start..................................................................................... 173
Electrical system protection ................................................................................ 174
Main switch .................................................................................................... 174
General....................................................................................................... 174
Main circuit breaker short-circuit protection ............................................. 174
Phase sequence monitor.................................................................................. 174
Earth fault equipment ..................................................................................... 174
Motor protection ............................................................................................. 175
Thermal overload protection...................................................................... 175
Cabinet with Soft start .................................................................................... 175
Alignment form, Soft start ......................................................................... 175
Fault finding.................................................................................................... 177
14. Component locations.......................................................................................... 178
Valves .................................................................................................................. 178
Hydraulically controlled valves...................................................................... 178
Pressure gauges, test outlets and flow monitor ................................................... 179
15. Reeling units....................................................................................................... 180

General ................................................................................................................ 180
Introduction ......................................................................................................... 180
Reeling unit RAC 611 ......................................................................................... 182
Adjusting reeling unit drive chain .................................................................. 182
Reeling unit RAC 612/RAC 614......................................................................... 183
Reeling unit gear............................................................................................. 183
Maintenance instructions
14
Adjusting the reeling unit slip clutch.............................................................. 183
Adjusting the reeling unit speed .......................................................................... 184
Collector, cable reeling unit................................................................................. 184
Checking the collector .................................................................................... 184
Limit switch, option............................................................................................. 185
Adjusting......................................................................................................... 185
16. Exhaust filtering ................................................................................................. 187
Safety ................................................................................................................... 187
Scrubber............................................................................................................... 187
General............................................................................................................ 187
Fill up with water. ........................................................................................... 188
Freeze prevention measures............................................................................ 190
Draining...................................................................................................... 190
17. Fire fighting equipment...................................................................................... 191
Fire fighting systems ........................................................................................... 191
Description...................................................................................................... 191
Ansul............................................................................................................... 191
Forrex.............................................................................................................. 191
Locations ............................................................................................................. 192
Manual triggering ................................................................................................ 192
Maintenance of fire fighting system.................................................................... 193
Safety measures .............................................................................................. 193

Modification of the machine........................................................................... 193
Service ............................................................................................................ 193
Steps to take after a fire or activation of the fire fighting system................... 194
Fire fighting systems ........................................................................................... 194
General............................................................................................................ 194
Ansul manual .................................................................................................. 194
Description ................................................................................................. 194
Forrex manual ................................................................................................. 195
Description ................................................................................................. 195
Forrex Auto..................................................................................................... 195
Description ................................................................................................. 195
Central unit................................................................................................. 196
Heat detector .............................................................................................. 197
Ansul Auto...................................................................................................... 198
Description ................................................................................................. 198
Central unit................................................................................................. 199
Heat detector .............................................................................................. 201
Ansul Checkfire .............................................................................................. 201
Description ................................................................................................. 201
Central unit................................................................................................. 201
Fault finding ............................................................................................... 205
Heat detector .............................................................................................. 206
General information on safety, triggering and service ........................................ 206
Safety measures .............................................................................................. 206
Maintenance instructions
15
Modification of the machine........................................................................... 206
Manual triggering ........................................................................................... 206
Service ............................................................................................................ 207
Machine maintenance ..................................................................................... 207

Maintenance and checks ................................................................................. 207
Steps to take after a fire or activation of the fire fighting system................... 208
18. Automatic lubrication......................................................................................... 209
Introduction ......................................................................................................... 209
Lincoln Quicklub 203 lubrication pump ............................................................. 209
Safety valve ......................................................................................................... 210
Setting pause and running time ........................................................................... 210
Test function ........................................................................................................ 211
Filling lubrication grease..................................................................................... 211
Return connection................................................................................................ 212
Power supply ....................................................................................................... 212
Timer terminal ..................................................................................................... 213
Circuit diagram.................................................................................................... 214
19. Directional control ............................................................................................. 215
FAM..................................................................................................................... 215
Technical data...................................................................................................... 215
Directional control FAM................................................................................. 215
Menus .................................................................................................................. 216
Password.............................................................................................................. 216
Connections ......................................................................................................... 218
Single-boom and dual-boom systems............................................................. 218
Three-boom system ........................................................................................ 220
Sensor connections ......................................................................................... 222
Power supply circuit, 24 V DC....................................................................... 222
Sensor calibration ................................................................................................ 223
Conditions....................................................................................................... 223
Adjusting the lookout cylinder ....................................................................... 223
Feeder inclination sensor ................................................................................ 225
Calibration menu........................................................................................ 225
Adjusting inclination sensor....................................................................... 225

Resetting inclination sensor ....................................................................... 228
Setting coefficient for inclination sensor ................................................... 229
Rear and front side angles............................................................................... 229
Calibration menu........................................................................................ 229
Setting coefficient for rear and front side angles ....................................... 229
Resetting rear side angle ............................................................................ 230
Resetting front side angle........................................................................... 230
Rock drill position (option - hole depth measurement) .................................. 230
Replacement of components................................................................................ 231
Replacement of angle sensors......................................................................... 231
Replacement of inclination sensors ................................................................ 233
Replacement of length sensor......................................................................... 235
Maintenance instructions
16
Rock drill mode.......................................................................................... 235
Replacement of resolver module .................................................................... 235
Fault finding ........................................................................................................ 236
Fault indication ............................................................................................... 236
System........................................................................................................ 236
CAN communication ................................................................................. 236
Function check................................................................................................ 237
Fault-finding menus........................................................................................ 237
Angle sensors.................................................................................................. 238
Inclination sensor............................................................................................ 239
Length sensor, rock drill ................................................................................. 240
20. Air conditioning ................................................................................................. 241
Safety ................................................................................................................... 241
Technical data ...................................................................................................... 241
Adjusting compressor V-belts.............................................................................. 242
Fresh air filter ...................................................................................................... 243

Fault finding ........................................................................................................ 244
No heating....................................................................................................... 244
No cooling....................................................................................................... 244
Poor cooling.................................................................................................... 244
Uneven cooling ............................................................................................... 244
Abnormal noise............................................................................................... 244
21. Equipment for water mist................................................................................... 246
General................................................................................................................. 246
Equipment for water mist .................................................................................... 247
Technical data ...................................................................................................... 247
Settings ................................................................................................................ 248
Safety .............................................................................................................. 248
Checking and adjusting the water pump (CAT).............................................. 248
22. Soft starter .......................................................................................................... 249
Setting ABB soft start.......................................................................................... 249
Maintenance instructions
1. General
17
1. General
Environment
ENVIRONMENTAL DIRECTIONS
• Think of the environment!
• 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.
ENVIRONMENTAL DIRECTIONS
• Think of the environment!
• Engine exhausts are poisonous and
environmentally hazardous.
• Good ventilation is essential when the
diesel engine is running.
• Well-maintained air filters help to keep
down emission levels.
Maintenance instructions
1. General
18
Contact details
Table: Addresses, telephone numbers and fax numbers to Atlas Copco companies
ENVIRONMENTAL DIRECTIONS
• Think of the environment!
• Fuel spillage is environmentally
hazardous and a fire risk.
• Always collect fuel residue and spillage.
Treat in accordance with local
regulations.
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.
ENVIRONMENTAL DIRECTIONS
• Think of the environment!
• Chemicals such as flushing additives,
other additives and coolants can be
environmentally hazardous.
• Treat in accordance with local regulations
for both handling and waste disposal.
Country Address Phone and fax number
Argentina Juncal 2869
B1640 GRD Martinez, Buenos
Aires
Phone: +54 - (0)11 - 47 17 22 00
Fax: +54 - (0)11 - 47 17 02 27
Maintenance instructions
1. General
19
Australia P O Box 6134
Delivery Centre
Blacktown NSW 2148
Phone: +61 - (0)2 - 96 21 97 00
Fax: +61 - (0)2 - 96 21 98 13
Austria Postfach 108
A-1111 Vienna
Phone: + 43- (0)1 -76 01 20
Fax: + 43 - (0)1 - 769 56 72

Bolivia P O Box 290
Santa Cruz
Phone: + 591 (0)3-343 68 68
Fax: + 591 (0)3-343 69 69
Brazil P O Box 12737
Sao Paulo, SP
04744-970
Phone: + 55 - (0)11 - 247 88 00
Fax: + 55 - (0)11 - 541 76 71
Canada 200 Mumford Road
Walden Industrial Park
Lively, Ontario P3Y 1L2
Phone: + 1 - 705 673 67 11
Fax: + 1 - 705 692 31 01
Chile Panamericana Norte 5001 -
Conchali
Santiago, 6553935 Conchali
Phone: + 56 - (0)2-442 3600
Fax: +56 -(0)2 - 623 44 60
China / Hong
Kong
P O Box 1516 Shatin Central P
O
New Territories, Hong Kong
Phone: + 86 -(0)25 - 852 27 97 68 00
Fax: + 86 - (0)25 - 852 23 41 43 13
CMT
International
S-105 23 Stockholm Phone: + 46 - (0)8 - 743 80 00
Fax: + 46 - (0)8 - 702 21 29

Colombia A.A. 95310
Santafé de Bogotá, D.C.
Phone: +57 - (0)1 - 291 54 90
Fax: +57 - (0)1 - 430 65 14
Czech Republic Prumyslová 10
102 00 Praha 10.
Phone: + 420 - 225 434 000
Fax: + 420 - 225 434 222
Finland Tuupakankuja 1
SF-01740 Vantaa
Phone: + 358 - (0)9 - 296 64 41
Fax: + 358 - (0)9 - 29 64 21 8
France B.P. 27055 Saint Quen
l’Aumône
FR-95052 Cergy Pontoise
Cedex
Phone: + 33 - (0)1 33 09 30 00
Fax: + 33 - (0)1 - 39 09 30 49
Germany Postfach 10 02 25
D-45002 Essen
Phone: + 49 - (0)201 - 217 70
Fax: + 49 - (0)201 - 217 74 54
Ghana P O B 10071
Accra North
Phone: + 233 - 21 77 45 12
Fax: + 233 - 21 77 61 47
Great Britain P O Box 79
Hemel Hempstead
Herts HP2 7HA
Phone: +44 - (0)1442 - 22 21 00

Fax: + 44 - (0)1442 - 23 44 67
Greece 78, Kifissou Avenue
GR-182 33 Ag. I. Rentis
Phone: +30 - (0)1 - 349 96 00
Fax: +30 - (0)1 - 345 4783
Hong Kong P O Box 1516 Shantin Central P
O
New Territories, Hong Kong
Phone: + 852 - 27 97 68 00
Fax: + 852 - 23 41 43 13
Country Address Phone and fax number
Maintenance instructions
1. General
20
India Sveanagar
Bombay Pune Road
Dapodi
Pune 411 012
Phone: + 91- (0)20 -271 464 16 17, 271 444 17
Fax: + 91 - (0)20 - 271 459 48
Indonesia P O Box 7021/JKS CCE
Jakarta 12075
Phone: +62 - (0)21 - 780 10 08
Fax: +62 - (0)21 - 780 18 37
Iran PO Box 13145-1311
Tehran 13454
Phone: +98 - (0)21 - 693 77 11
Fax: +98 - (0)21 - 692 73 14
Ireland Kylemore Road
Bluebell

Dublin 12
Phone: +353 - (0)1 - 450 5978
Fax: +353 - (0)1 - 456 7686
Italy Casella Postale 77
I-20092 Cinisello Balsamo MI
Phone: + 39 - (0)2 - 61 79 91
Fax: + 39 - (0)2 - 61 79 95 20
Japan Shiba Bldg. 11F
13-4 Shiba 2-chome
Minato-ku Tokyo 105-0014
Phone: + 81 - (0)3 - 57 65 78 90
Fax: + 81 - (0)3 - 57 65 31 99
Kenya PO Box 400 90
Nairobi
Phone: + 254 - (0)2 - 82 52 65/6
Fax: + 254 - (0)2 - 82 52 15
Korea C-P.O. Box 8354
Seoul
Phone: + 82 - (0)2 - 29 89 40 00
Fax: + 82 - (0)2 - 522 82 39
Malaysia 26 Jalan Anggerik Mokara 31/47
Kota Kemuning, Seksyen 31
40460 Shah Alam
Selangor Darul Ehsan
Phone: + 60 - (0)3 - 51 23 88 88
Fax: + 60 - (0)3 - 51 23 89 49
Mexico Apartado Postal Box 104
Tlalnepantla
Edo. De Mexico
Phone: + 52 - 5 - 553 21 06 00

Fax: + 52 - 5 - 553 90 15 20
Morocco P O Box 13 844
20 300 Casablanca
Phone: + 212 - 2 - 600 040
Fax: + 212 - 2 - 60 05 22
Norway P O Box 334
N-1401 Ski
Phone: + 47 - 64 - 86 03 00
Fax: + 47 - 64 - 86 03 30
Peru Apartado 662
Lima 100
Phone: + 51 - 1 - 411 61 00 (Service)
Fax: + 51 - 1 - 224 77 12 (Service)
Philippines P.O. Box 1373
1200 Makati City
Phone: + 63 - (0)2 - 823 8178-80
Fax: + 63 - (0)2 - 823 84 59
Poland (Sales) ul. Katowicka 32
P-40-173 Katowice
(Service) ul. Krzywa 3,
59-100 Polkowice
Sales
Phone: + 48 -(0)32 - 209 57 74
Fax: + 48 -(0)32 - 209 57 76
Service
Phone: + 48 -(0)76 847 49 36
Portugal Apartado 14
P-2796-953 Linda-a-Velha
Phone: + 351 - (0)21- 416 85 00
Fax: + 351 - (0)21 - 416 01 66

Saudi Arabia P O Box 7330
Jeddah 21462
Phone: + 966 - (0)2 - 693 33 57
Fax: + 966 - (0)2 - 693 28 92
Country Address Phone and fax number
Maintenance instructions
1. General
21
Target group and objective
The maintenance instructions are intended for mechanics and personnel in mainte-
nance and service. The user should have undergone Atlas Copco's training courses
for the equipment concerned.
Singapore Jurong Point
P O Box 438
Singapore 639456
Phone: + 65 - 68 62 28 11
Fax: + 65 - 68 63 60 98 (Service)
South Africa P O Box 14110
Witfield 1467
Phone: + 27 - (0)11 - 821 90 00
Fax: + 27 - (0)11 - 821 91 83
Spain Apartado 24
E-28820 Coslada
Madrid
Phone: + 34 - (9)1 - 627 91 00
Fax: + 34 - (9)1 - 627 9239
Sweden S-10523 Stockholm Phone: + 46 - (0)8 - 743 80 00
Fax: + 46 - (0)8 - 743 92 47
Switzerland Büetigenstrasse 80
CH-2557 Studen/Biel

Phone: + 41 - (0)32 - 374 14 14
Fax: + 41 -(0)32 - 374 13 00
Taiwan P O Box 14-45, Chungli
Tao yuen Hsien
Taiwan,
R.O.C.
Phone: + 886 - (0)3 - 479 68 38
Fax: + 886 - (0)3 - 479 68 20
Thailand 1696 New Petchburi Road
Bangkapi
Huay Kwang
Bangkok 10320
Phone: + 66 - (0)2 - 652 90 06
Fax: + 66 - (0)2 - 652 81 94
Turkey Istasyon Arkasi
34940 Tuzla
Istanbul
Phone: + 90 - (0)216 - 395 24 60
Fax: + 90 - (0)216 - 395 23 01
USA-US PO Box 1159
Commerce City CO 80022
USA
Phone: + 1 - 303 - 287 88 22
Fax: + 1 - 303 - 217 28 39
Venezuela Apartado 76111
Caracas 1070-A
Phone: + 58 - (0)2 - 256 23 11
Fax: + 58 -(0)2 - 257 18 10
Vietnam No. 42, Street 37, Thao Dien
Ward

District 2
Ho Chi Minh City
Phone: + 84 - 8 - 898 96 38
Fax: + 84 - 8 - 898 96 37
Zambia P O Box 11291
Chingola
Phone: + 260 - (0)2 - 31 12 81, 31 30 15
Fax: + 260 - (0)2 - 31 38 77
Zimbabwe P.O. Box CY 935 Phone: + 263 - (0)4 - 62 17 61 5
Fax: + 263 - (0)4 - 62 17 94
Country Address Phone and fax number
Maintenance instructions
1. General
22
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.
Hydraulic systems
General
Hydraulic systems are sensitive to impurities and pollutants. The environment in
which rock drilling equipment usually works is generally unsuitable as a place for
repairing hydraulic components. Work on the hydraulic system at the worksite should
therefore be limited to what is absolutely essential. The components should then be
repaired in a suitable environment, see the section Hydraulic workshops .
Observe the following points to avoid breakdowns and interruptions in operation due
to fouled hydraulic oil:
• Keep the rig clean. Hose it down at regular intervals, preferably with a grease sol-

vent as an additive
• Before opening any connection, clean the area round it.
• Use clean tools and work with clean hands.
• Always plug hydraulic connections immediately after they have been detached.
• 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 indicate clogging.
Repairing hydraulic components
Repairing and/or reconditioning hydraulic components should be carried out by
expert personnel and in a suitable place. The following alternatives are possible:
• Suitable premises for hydraulic repairs to be arranged at the workplace. Repairs to
be carried out by your own specially trained personnel, the manufacturer's techni-
cians or Atlas Copco personnel.
• Components to be sent to the manufacturer's local agent for repair.
• Component repairs are carried out by Atlas Copco. Repair instructions are availa-
ble for the most important and most complicated hydraulic components.
Maintenance instructions
1. General
23
Hydraulic workshops
Workshops used for the repair of hydraulic components must:
• be separate from activities which generate dust and particles, such as welding,
grinding, the transportation of vehicles, etc.;
• have their own suitable washing equipment which is required for repairing the
components;
• have the necessary tools, both standard and special, and that are only used in the
hydraulic workshop.
• have a ventilation system that does not admit dust into the premises.

• have well-trained mechanics.
Replacement of hydraulic hoses
A high percussion pressure, vibration and other mechanical interference puts high
demands on the hydraulic hoses.
When replacing hydraulic hoses, check that they are replaced with hydraulic hoses:
• with the correct crimped couplings
• of the correct quality class
• with the correct dimension
All hydraulic pressure hoses have crimped couplings and should therefore be pur-
chased ready-made directly from Atlas Copco. Quality classes and hose dimensions
are specified in the spare parts catalogue for the relevant rig. Make also sure that hose
connections are clean, in good condition and well tightened.
Welding
Note
It is important to consult Atlas Copco for approval of welding and choice of elec-
trodes.
The following must be observed when welding:
• Turn off the supply of current to the unit.
• Disconnect the cables from the generator and battery.
• Grind off rust and paint from the area that is to be welded and carefully prepare the
joint.
• Weld in a dry area.
• Connect the welding earth cable to a clean surface as close as possible to the weld-
ing area. Avoid welding close to bearings and bushes. If these cannot be removed,
connect earth cables on both sides of the weld.
Maintenance instructions
1. General
24
• 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 compressed air 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
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
If in any doubt, contact Atlas Copco for advice.
Tightening torque in bolted joints.
All joints are tightened to the torque specified in Atlas Copco Standard 4369:01 K,
unless otherwise explicitly specified. In such a case, it is specified in the maintenance
instructions of the component in question.
Note
All bolted joints in the table below must be lubricated with Molycote 1000 or corre-
sponding thread lubricant with coefficient of friction 0.11
µ
.
ISO: 2560 E51 5B 120 20 H
SS: 14 3211 H10
DIN 1913: E51 55 B10
AWS: A/SFA 5.1 E 7018

SS: 14 3403 3423
DIN 8559: SG 2
AWS: A/SFA 5.18: ER 70 S-6
Maintenance instructions
1. General
25
Table: Atlas Copco Standard 4369:01 K.
Markings and plates
Signs are placed on the larger carrier components. Always quote the type designation
and serial number when ordering spares or enquiring about the carrier. The type des-
ignation and serial number are specified on a separate document, DRI (Drill Rig
Identification). Spares can always be ordered from Atlas Copco.
Size Strength
class
Torque in
Nm.
Tolerance
±
M6 8.8 9 1
M8 8.8 23 2
M10 8.8 44 5
M12 8.8 76 8
M14 8.8 120 12
M16 8.8 187 19
M20 8.8 365 37
M24 8.8 627 63
M12 x 1.25 10.9 114 6
M16 x 1.25 10.9 276 15
M18 x 1.25 10.9 460 20
M6 12.9 15 2

M8 12.9 38 4
M10 12.9 75 8
M12 12.9 128 13
M14 12.9 203 20
M16 12.9 315 32
M20 12.9 615 62
M24 12.9 1058 106