Maintenance instructions for

Hydraulic Rock drill

1250 0025 58

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

Hydraulic Rock drill

1250 0025 58

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 war-
ning symbol (triangle) and a signal word, as shown below:

indicates hazards or hazardous procedures which COULD

WARNING result in serious or fatal injury if the warning is not observed.

indicates hazards or hazardous procedures which COULD

CAUTION 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-
tenance instructions for the drill rig and rock
drill before putting the rock drill to use. Always
follow the instructions given.
· Do not use or intervene in the rock drill unless
you have been trained to do so.
· The rock drill may only be used for the pre-
scribed purposes.
· Make sure that the drill rig has been maintai-
ned in accordance with the current instructions.
· Make sure that all safety labels remain in pla-
ce, and that they are kept clean and fully legib-
le. See the spare parts list for details of label
locations and part numbers.
· Always wear a safety helmet and ear protec-
tors during drilling. Any local regulations that
exist must also be observed.
· Before moving the drill rig or starting to drill,
make sure that there are no personnel in the
immediate vicinity of the drill rig.
· Use Atlas Copco genuine parts only. Any
damage or malfunction caused by the use of
unauthorized parts is not covered by Warranty
or Product Liability.
· Never attempt to carry out maintenance while
the drill rig is in operation.
· Those checks and adjustments that must be
made while the drill rig is in operation must be
carried out by at least two persons. One per-
son must man the control station and keep a
strict watch over the work.
· To prevent injury during service and mainte-
nance, all components that could possibly
move or drop must be supported safely on
blocks or trestles, or secured by means of
adequately dimensioned slings.
· Before starting work on any of the systems,
make sure that the hydraulic, air and water sys-
tems are without pressure, and that the electri-
cal system is dead.
· Check that the hoses used are of the right qua-
lity, and that all hose connections are in good
condition and properly tightened.

Contents Page

Safety regulations . . . . . . . . . . . . . . . . 2 Setting of ECL lubricating system . . . . . . . . 10

Action list . . . . . . . . . . . . . . . . . . . . . 3 Setting the damper pressure . . . . . . . . . . 11
Hose connections . . . . . . . . . . . . . . . . 4 Setting the extractor-unit pressure
Tightening torques . . . . . . . . . . . . . . . . 5 COP 2150EX / COP 2550EX) . . . . . . . . . 11
Accumulators . . . . . . . . . . . . . . . . . . 6 Removing the front head . . . . . . . . . . . . 12
– Charging the accumulators . . . . . . . . . . 6 Checking the front head . . . . . . . . . . . . 13
– Checks in the event of hose vibration . . . . . 7 Changing the flushing head and driver . . . . . 14
– Changing the accumulators . . . . . . . . . . 8 Mounting the front head . . . . . . . . . . . . 16
– Changing the return accumulator . . . . . . . 9 Slinging . . . . . . . . . . . . . . . . . . . . . 17
Changing the hydraulic motor . . . . . . . . . . 9 Long-term storage . . . . . . . . . . . . . . . 17
Filling with lubricating oil and bleeding the system 10 Recommended hydraulic oils and lubricants . . 18

2
 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
handling the drill bit. Mind your fingers!
· Keep your clothing away from rotating
machine parts.
Carelessness can lead to serious injury.
· Always use ear protectors during drilling.
High noise levels damage hearing.
· Never attempt maintenance or intervene
in the rock drill, connections or hoses whi-
le 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.
IMPORTANT
· Observe great cleanliness when interve-
ning in the rock drill or its hydraulic cir-
cuit.
· The following parts may be changed at the
worksite in accordance with the instruc-
tions given:
– shank adapter
– driver
– front head parts
– accumulators
– hydraulic motor
– screws
– connections.
Other repairs must be carried out in a sui-
table workshop in accordance with the
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
Every shift
· Check that air and lubricating oil come out
between the shank adapter and front guide
and also out of the hole in the front head . . 13
· Check that the damper-pressure gauge on
the drill rig shows the normal value. In case
of deviation, adjust the damper pressure . . . 11
· Check that the shank-adapter threads are
not damaged . . . . . . . . . . . . . . . . . 13
· Keep an eye on the hydraulic hoses. If they
vibrate too much, check the accumulators . . 7
· Check that there is no leakage from the rock
drill. If the flushing medium leaks out of the
overflow hole in the front head, change the
seals and O-rings . . . . . . . . . . . . . . . 13
· When changing the shank adapter or remov-
ing the front head, check the internal compo-
nents, including the visible parts of the piston,
driver and rotation chuck bushing . . . . . . . 13
In the event of defect, remove to a suitable
workshop for repair or replacement.
After the first shift when using a
new- or newly overhauled rock drill
· Tighten all threaded unions . . . . . . . . . 5
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.
3
Hose connections

550
1 2 150/2
8 7 COP

AIR
6

0EX
0E X/255
P 215
1250 0130 65

CO

4
3
2

1. Drainage 10
2. Rotation to the left 9
6
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

Connecting the hoses

CAUTION · Clean the hose connections on the rock drill be-
fore removing the protective plugs (or caps).
· Never attempt maintenance or intervene
in the rock drill, connections or hoses whi- · Never remove a protective plug until the hose is
le the hydraulic, lubrication or flushing ready to be connected.
systems are pressurized. · Always store the rock drill with all hose connec-
Air or oil can squirt out at high pressure tions plugged. Use suitable protective plugs or
and high temperature, with the risk of caps, and make sure that they are clean.
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 lay-
ers of spirally wound steel-wire reinforce-
ment). 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 instruc-
tions are not observed!

4
Tightening torques

50
1 50/25
6 COP 2
5 1
4

3A

14
13

X
2550E
9
0EX/
CO P 215
6
12
7 11
9 10
8 3B
1250 0130 66

15
13 16

COP 2150/2550 COP 2150EX/2550EX

3B

3A 2 2

N.B. Tighten item Nos. 1–3 in the prescribed order.

Ref.No. Qty. Check point Torque Instructions

Nm lbf.ft

1 2 Side bolts 300 220 Tighten the rear nuts

2 1 Front bolt 300 220 Tighten the front bolt
3 3 Side bolts (2550EX) 300 220 Tighten the front nuts
4 3 Back head 220 160 Tighten the screws alternately to full torque
(uppermost screw last)
5 1 Regulating plug 80 60
6 4 Accumulators 220 160 Tighten the screws alternately to full torque
7 4 Hydraulic motor 65 48 Tighten the nuts alternately
8 2 Clamping attachment,
return accumulator 30 22
9 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque
10 1 Plug 45 33
11 4 Valve covers 145 105 Tighten the screws alternately to full torque
12 2 Connection plate 120 90 Tighten the screws alternately to full torque
13 1 Flushing connection 300 220
14 4 Inlet, flushing medium 90 65 Tighten the screws alternately to full torque
15 1 Intake, extractor unit 120 90
16 1 Return, extractor unit 120 90

5
Accumulators

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

1250 0020 91
1. Damper accumulator
2. Intake accumulator = Must be charged with nitrogen only
3. Return accumulator
1250 0027 19

Charging the accumulators

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 instruc-
tions are not observed!
1. Remove the protective cap (4).
2. Open the valve nut (5) by 2–3 turns, and con-
nect 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 over-
charge the accumulators.
The return accumulator (3) must not be charged
5. Tighten the valve nut (5) and close the gas val-
ve (6).
6. Remove the gas hose and fit back the protective
cap (4) to the accumulator valve

6
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 ac-
cumulator is charged, the pin will stick out by
4.5 mm and give a firm resistance when pres-
sed 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 the-
re 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 re-
peatedly. The charging valve should therefore
be changed regularly.

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 accumula-
tor 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.
1250 0027 20

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
Changing the accumulators
1250 0041 44
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 instruc-
tions 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.
8
Mounting
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 intermedia-
te 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.
Changing the return accumulator Changing the hydraulic
1250 0027 22 motor

8 5
10

1250 0027 23
9
3
2

Removal Removal
Disconnect the hydraulic hoses (1).
CAUTION Remove the return accumulator (3).

· Before starting work on any of the sys- Remove the nuts (2) and take off the hydraulic mo-
tems, make sure that there is no pressure tor (3).
in the hydraulic, water and air systems. Pull out the coupling (4).
· 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 lay-
ers of spirally wound steel-wire reinforce-
ment). See spare parts list for drill rig.
For safety reasons, these hoses must not,
under any circumstances, be replaced Mounting
with hoses of a lower rating. Make sure that the circlip (5) is fitted into the coup-
There is a risk of injury if these instructions ling (4).
are not observed!
Grease the splines inside the coupling, and slide
the coupling on to the output shaft of the hydraulic
Disconnect the hydraulic hose (8) from the return motor (3).
accumulator (3).
Fit the hydraulic motor (3) with gasket (7) to the
Remove the return accumulator (3) by removing cylinder (6). Change the gasket if it is damaged.
the nuts (2) and screws.
Tighten the nuts (2) to a torque of 65 Nm (48 lbf.ft).
Pull off the clamp (5) and unscrew the accumulator
from the nipple (7 on surface drill rigs) or Connect the hydraulic hoses (1). Check that the
(9 on underground drill rigs). motor rotates in the correct direction.
Now send the accumulator to a workshop for
overhauling!

Mounting
Fit the return accumulator (3) to the nipple (7 or 9)
and tighten in such a way that the plug (10) is ac-
cessible for checking the accumulator diaphragm.
Slide the clamp (5) on to the accumulator, 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
· If the lubricating system has been empty of
CAUTION
· 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 pres-
sure and the recommended lubri-
cating oil.
Certain moving parts of the rock drill are
lubricated by means of oil-mixed compres-
sed air. It is important that these parts re-
ceive good lubrication.
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).

· Check the oil level in the lubricating-oil container

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

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). underground 10
3. Check the lubricating air pressure at the rock A
drill (11) using a pressure gauge (A). The pres-
3
R
sure should be 2–3 bar. If the pressure is too T1
low, clean the restrictor (9) or increase the dia- T2 B
G
meter of the restrictor.
2 1 B
Underground drill rigs
4. Check that the green light emitting diode (G)
Min.
B
indicates power on. oil level
5. Adjust the screw (T1) so that the light emitting 11
time of the yellow diode (R) is 0.5 seconds. 7 F 12
6. Observe the yellow diode (R) and adjust the
lubricating oil dosage to 60 pulses/min, by me-
ans of the screw (T2). 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 1. Lubricating-oil container A. Pressure gauge
and between the shank adapter and front guide. 2. Filler cap F. Light-emitting diode (LED)
3. Pulse relay G. Green LED
7. Cap, bleeding R. Yellow LED
8. Pressure gauge T1. Adjustment screw,
9. Restrictor light-emitting time
10. Plastic hose T2. Adjustment screw,
11. Lubricating-air connect. pulse frequency
12. Lubricating-air hose

10
 Surface
Setting of ECL lubricating system,
4
10 Surface drill rigs
A
6 B
5 C 1. Open the electrical cabinet.
3 1 2. Start the lubricating system (see the operator’s
C instructions for the drill rig).
2 Min.
oil level 3. Adjust the lubricating air pressure to 5 - 5.5 bar

1250 0149 04
using the pressure regulator (9). Check the
11 lubricating air pressure at the rock drill (11)
7
using a pressure gauge (A).
4. The pressure should be 3 bar. If the pressure is
F too high or too low, adjust the pressure regula-
+ - 12 tor (9).
Adjust to the correct lubricating oil dosage, 40
9
pulses/min, using the potentiometer (5). The
8
green LED (4) indicates the pulse frequency.
1. Lubricating oil container 9. Restrictor
2. Filler cap 10. Plastic hose 5. Check the LED (F) on the lubricating pump to
3. Pulse relay 11. Lubricating air
ensure that the right pulse frequency has been
connection obtained. Check also that oil comes out be-
4. Green LED.
12. Lubricating air hose tween the shank adapter and front guide (C).
5. Potentiometer
A. Pressure gauge Check that the ECL collection system is wor-
pulses/min
B. Lubricating air return
king (see the operator’s instructions for the drill
6. Potensiometer, rig.).
delay (not used) connection
7. Cap, bleeding C. Lubricating air output Setting the damper pressure
8. Pressure gauge F. LED
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).
1250 0040 48

3. Pressurize the damper circuit.

4. Check that the shank adapter is unloaded, and
that it has been pushed into the forward posi-
tion.
5. Adjust the constant-flow valve until the pressu-
re gauge (A) reads 30–35 bar.
6. Read off the pressure on the damper pressure
gauge on the drill rig.
If the pressure gauge later shows a different va-
lue, make a new pressure setting.
7. Disconnect the pressure gauge (A) and re-
connect the hose to the nipple (1).
Setting the extractor-unit
pressure (COP 2150EX / COP
2550EX)
1250 0040 49

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

11
 Removing the front head

CAUTION
· Never attempt maintenance work while the
drill rig is in operation.
· Before starting work on any of the sys-
tems, 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!

N.B. Always clean the outside of the rock drill befo-

re disassembly.
1250 0040 50

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).
Now pull out the shank adapter (4) from the front
head (1).
Check the internal components of the front head
1250 0040 51

when changing the shank adapter.

COP 2150EX / COP 2550EX

Remove the front side-bolt nuts (3) with their
washers (2).
Remove the front head (1) by tugging the shank
adapter (4) or by tapping the front head with a cop-
per hammer.
1250 0040 52

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
Checking the front head
1250 0130 67

6 13 3 4 3 3 A 5 2 9 6 11 13 11 11 3 3 3 3 4 5 A 9

12

8 14
8 14
7
7 3 C B 1
12
10 C B 2
COP 2150/2550 COP 2150EX/2550EX

3 3 4 3 3 11 10 11 11
1m 1 mm
1 m

COP 2150/2550 COP 2150EX/2550EX

5 3 3 4 3 3
2 mm

7 COP 2150EX/2550EX

m 2
6 1m D
53 mm

· Check that air and lubricating oil come out be-
tween the shank adapter (6) and front guide
(7), and also out of the hole (B).
· Blow clean the lubricating oil ducts (A) in the
front head (13) using compressed air, and check
that the restrictors (9) are open.
· 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 surfa-
ce 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.
· Look inside the gear housing and check the spli-
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 chip-
ped, or if the front or rear end surfaces of the
splines are worn.
· Check that the drill collar (8), which must be
used in upwards-directed drilling, is not dama-
ged and that it rotates with the shank adapter.

13
 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 hou-
sing (4) until it comes to a stop, i.e. until the spli-
ned part of the tool has passed the splines of the
driver (5).
Turn the disassembly tool clockwise a little.
Tap out the driver (5) and flushing head (6) by stri-
king with the impact hammer (B).
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 drillmet-
res (max!).
1250 0040 61

14
 Assembly
1250 0039 24

If the rotation chuck bushing (3) has been remo-

ved, 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.

Fit the O-rings (3) and seals (4) into the flushing
head (2).
1250 0040 62

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).
N.B. Before assembly, smear the threads with gre-
ase (type NEVER-SEEZ).
1250 0040 64

Check the tightening torques of the rear side-bolt

nuts and front side bolt (see 1–2, page 5).
Now tighten the nuts (3) alternately to a torque of
350 Nm (260 lbf.ft).

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

Fit the connection plate (1) to the front head using
the washers (6) and screws (3). Tighten the
1250 0040 65

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 coup-
ling 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
6 4 1
1250 0088 95

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 gre-
ase (type NEVER-SEEZ).
Tighten the nuts (3) alternately to a torque of
300 Nm (220 lbf.ft).
Connect the flushing hose to the nipple (7).
After assembly, check that air and lubricating
oil come out of the hole in the front head and
also between the shank adapter and the front
guide.

17
Slinging
1250 0088 96

Make sure that the rock drill is safely slung for

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

Rock drill weights, approx.

CAUTION COP 2150 / COP 2550 200kg (440lbs)
COP 2150EX / COP 2550EX 260 kg (576 lbs)
· 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 degre-
asing agent and hose down the rock drill with wa-
ter.
· Thoroughly clean the front head parts that are in
contact with the flushing medium, especially in
the case of high air humidity. After cleaning, oil
the parts with clean hydraulic oil.
· Release the gas from the accumulators (see in-
structions on page 8).
· Store the rock drill in a dry place.

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 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) Viscosity Viscosity

Normal operating temp. Min. starting temp. Max. temp. grade VG index VI
(viscosity 25–50 cSt) (viscosity min. 1000 cSt) (ISO 3448)
+50 to +70 (122 to 158) +5 (41) 80 (176) ISO VG 100 Min. 100
+45 to +60 (113 to 140) –5 (23) 75 (167) ISO VG 68 Min. 100
+35 to +50 (95 to 122) –10 (14) 65 (149) ISO VG 46 Min. 100
+25 to +40 (77 to 104) –15 (5) 55 (131) ISO VG 32 Min. 100

Air tool oil · Use a mineral based air tool oil.

Ambient temperature oC ( oF) Viscosity grade (ISO 3448)
–30 to 0 (–22 to +32) ISO VG 32–68
–10 to +20 (14 to 68) ISO VG 68–100
+10 to +50 (50 to 122) ISO VG 100–150

Printed in Sweden
Atlas Copco, 2005

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