Reg.

code
AIB TAB 43
COP 1532
2003–02

Maintenance instructions for

Hydraulic
Rock drill COP 1532
1250 0027 80

ATLAS COPCO ROCK DRILLS AB

ÖREBRO • SWEDEN
© Atlas Copco Rock Drills AB, 2003. All rights reserved.

No. 9852 1398 01a

 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:
WARNING
CAUTION
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.
Contents Page
Safety regulations . . . . . . . . . . . . . . .
Action list . . . . . . . . . . . . . . . . . . .
Hose connections . . . . . . . . . . . . . . .
Tightening torques . . . . . . . . . . . . . . .
Accumulators . . . . . . . . . . . . . . . . .
– Charging the accumulators . . . . . . . . .
– Checks in the event of hose vibration . . . .
– Changing the accumulators . . . . . . . . .
Lubrication of gear . . . . . . . . . . . . . . .
Shutting off the lubricating air to the
parting surfaces . . . . . . . . . . . . . . . . . 9
2
indicates hazards or hazardous procedures which COULD
result in serious or fatal injury if the warning is not observed.
indicates hazards or hazardous procedures which COULD
result in injury or damage to equipment if the warning is not
observed.
• Use Atlas Copco genuine parts only. Any
damage or malfunction caused by the use of
unauthorized parts is not covered by Warranty
or Product Liability.
• Never attempt to carry out maintenance while
the drill rig is in operation.
• Those checks and adjustments that must be
made while the drill rig is in operation must be
carried out by at least two persons. One per-
son must man the control station and keep a
strict watch over the work.
• To prevent injury during service and mainte-
nance, all components that could possibly
move or drop must be supported safely on
blocks or trestles, or secured by means of
adequately dimensioned slings.
• Before starting work on any of the systems,
make sure that the hydraulic, air and water
systems are without pressure, and that the
electrical 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.
. 2 Setting the damper pressure . . . . . . . . . . 9
. 3 Filling with lubricating oil and bleeding the system 10
. 4 Setting of ECL lubricating system . . . . . . . . . 11
. 5 Removing the front head . . . . . . . . . . . . 12
. 6 Checking the front head . . . . . . . . . . . . . 13
. 6 Changing the driver . . . . . . . . . . . . . . . 14
. 7 Mounting the front head . . . . . . . . . . . . . 15
. 8 Changing the rotation chuck bushing . . . . . . 15
. 9 Slinging . . . . . . . . . . . . . . . . . . . . . 16
Long-term storage . . . . . . . . . . . . . . . . 16
Recommended hydraulic oils and lubricants . . 16
 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
– rotation chuck bushing
– screws
– connections.
Other repairs must be carried out in a sui-
table workshop in accordance with the
overhauling instructions for the rock drill.
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 . 9
• Fill the lubricating system with oil . . . . . . . 10
• Adjust and set the lubricating system . . . . 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 cover . . . . . 13
• 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 piston, driver and the
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
• Grease the gear . . . . . . . . . . . . . . . 9
• Tighten all threaded unions . . . . . . . . . 5
• Check the safety labels on the accumulators.
Replace them if they are damaged or illegible . 6
Every 400th percussion-hour:
• Remove the rock drill from the drill rig and
send it to a suitable workshop for over-
hauling*.
* The rock drill should be overhauled at suitable intervals,
based on local conditions. The characteristics of the rock will
have a great influence on the rate of wear, and thus on the
required frequency of overhauling.
3
Hose connections

5
1250 0115 53

8
6 1. Rotation to the left
7
2. Rotation to the right
2 3. Percussion mechanism, return
1
4. Percussion mechanism, intake
3 5. Flushing air/water
4 6. Lubrication air
7. Damper, return
8. Damper, intake

CAUTION
Connecting the hoses
• Never attempt maintenance or intervene • Clean the hose connections on the rock drill be-
in the rock drill, connections or hoses whi- fore removing the protective plugs (or caps).
le the hydraulic, lubrication or flushing
systems are pressurized. • Never remove a protective plug until the hose is
Air or oil can squirt out at high pressure ready to be connected.
and high temperature, with the risk of • Always store the rock drill with all hose connec-
serious injury to the eyes and skin. tions plugged. Use suitable protective plugs or
caps, and make sure that they are clean.
• 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

4 5

5
5
8

3
5
1
6

7
1250 0115 54

3
2 10
9

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 2 Front bolts 220 160 Tighten the front bolts
3 2 Side bolts 350 260 Tighten the front nuts
4 6 Back head 220 160 Tighten the screws alternately to full torque
5 6 Accumulators 220 160 Tighten the screws alternately to full torque
6 4 Hydraulic motor 60 44 Tighten the screws alternately to full torque
7 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque
8 6 Valve covers 220 160 Tighten the screws alternately to full torque
9 1 Flushing connection 300 220
10 1 Flushing plug 300 220

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

3 1
1250 0029 34

Charging the accumulators

N.B. In order to avoid the risk of leakage, it is
recommended that the charging nipples be replaced
after they have been opened/closed 3 times.
All stated pressures must be read at the rock drill
when the hydraulic oil is at operating temperature.
1. Remove the protective cap (A).
2. Loosen the valve nut (B) by 2–3 turns.
3. Fit the bottle regulator (Q or GG) and charging
hose (P) as shown in the figure.
4. Adjust the regulator (Q or GG) to the lowest pos-
sible pressure.
5. Open the gas valve (C).

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!
➪
6. Charge the respective accumulators to the fol-
lowing pressures by adjusting the output pres-
sure of the bottle regulator (Q or GG) as ne-
cessary:
• damper accumulator (91): 20 - 25 bar
• intake accumulator (67): 30 - 40 bar below the
collaring pressure.
N.B. It is better to undercharge rather than
overcharge the accumulators.
• return accumulator (92) - to half the value of
the percussion return pressure.
7. Tighten the valve nut (B) and shut the gas valve
(C).
8. Remove the charging hose (P) and fit back the
protective cap (A).
N.B. The reading on the pressure gauge in the
cab (or on the panel) is approx. 5 bar higher
than the reading obtained at the rock drill, de-
pending on the lengths of the hoses and the ty-
pes of valves that may be fitted between the
cab/panel and the rock drill.

6
Checking the accumulators in the event of hose vibration
1. Press in the pin on the test valve (4). If the
accumulator is charged, the pin will stick out
by 4.5 mm and give a firm resistance when
pressed in.
N.B. The damper-accumulator pin is somewhat
easier to press in.
If it is easy to press in the pin, it means that the-
re is no gas pressure (diaphragm damaged).
2. If the diaphragm is damaged or if the hoses con-
tinue to vibrate abnormally, change the
accumulator (see page 8).
3. Charge the new accumulator after fitting it to
the rock drill.
Fault finding
Damaged diaphragms with obvious circles on
the underside indicate that the accumulator
might have been charged with too high a pres-
sure.

92
67
91

A
P
C
1250 0115 56

1. Damper accumulator
4 2. Intake accumulator
3. Return accumulator
4. Test valve
N2 GG For accumulator 3
A. Protective cap
Q For accumulators 1 and 2 B. Valve nut
C. Gas valve
P. Charging hose
Q and GG Bottle regulators

7
Changing the accumulators

5
A B 2

7
4 5
5
1

5
4
4
5

1250 0115 58
5
3
6

Removal Mounting

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, 2 and 3) together
with the sealrings (4) by removing the screws (5).
Now send the accumulators to a workshop for
overhauling!
CAUTION
• Mount the accumulators to the rock drill
using undamaged original screws.
Each accumulator 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 sealrings (4) to the three accumulators

(1, 2 and 3).
Then fit the damper accumulator (1) to the interme-
diate part (6), the intake accumulator (2) to
the left-hand side of the cylinder (7) and the
return accumulator (3) to the right-hand side of
the cylinder (7).
Tighten the screws (5) alternately to a torque of
220 Nm (160 lbf.ft).
Now charge the accumulators with nitrogen (N2).
See page 6.

8
 Lubrication of gear
4 1
1. Unscrew and remove the bleeder plug (1) with
its washer (4).
2. Grease the gear through the nipple (2) until gre-
ase comes out of the hole (3). Use heat-
resistant grease (see "Recommended hydraulic
oils and lubricants").
3
3. Run the rotation motor without the bleeder plug
(1) to allow excess grease to be pressed out.
1250 0021 22

2 4. Fit back the plug (1) and washer (4), and

tighten.

Shutting off the

lubricating air to the
A
parting surfaces

If the supply of lubricating air to the parting surfa-

B ces is not required, it can be shut off as follows:
1250 0115 49

1. Remove the plug 0686 3718 01.

2. Replace the plug with the shut-off plug (B) 3115
3119 00 and two O-rings (A) 0663 2114 00.

Setting the damper

pressure

1. Close the constant-flow valve (B) on the rock

drill completely.
2. Connect a pressure gauge (A) between the
1250 0115 50

hose and the damper nipple (1).

3. Pressurize the damper circuit.
4. Check that the shank adapter is unloaded and in
1
the forward float position.
5. Adjust the constant-flow valve until a reading of
approximately 30 bar is obtained on the pressure
gauge. This corresponds to a damper flow of app-
roximately 7 l/min.
B A
6. Disconnect the pressure gauge (A) and re-con-
nect the hose to the nipple (1).

9
Filling with lubricating oil and bleeding the system
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.
• 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 9). The lubricating-oil container holds 5
litres.
• If the lubricating system has been empty of
oil, it must be bled after filling.
This is done as follows:
– Loosen the cap (7) and let the lubricating oil
escape until all air has been discharged from
the lubricating oil pump. Now tighten the cap.
– Start the lubricating system and loosen the
hose connection at pressure gauge (8), so that
all air is released from the system. Now
tighten the hose connection.
– Disconnect the lubricating-air hose (12) from
the nipple (11) on the rock drill.
– Start the lubricating pump and let it pump until
oil comes out of the plastic hose (10).
When re-starting (after standstill), oil must
come out of the plastic hose directly when the
lubricating pump is started.
– Check that the plastic hose (10) for lubricating
oil is not too long. It should not stick out by any
more than max. 20 mm.
– Re-connect the lubricating-air hose (12).

underground drill rigs surface drill rigs

underjordsaggregat ovanjordsaggregat
3 A 4 6
R
2 5
T1 T2 1

G
Min. oil level
Min. oljenivå

➪
1250 0115 51

11
F
12
10

ma
x.
20
24 V mm

8
9

10
Setting of ECL lubricating system
1. Open the electrical cabinet.
2. Start the lubricating system (see the operator’s
instructions for the drill rig).
3. Check the lubricating air pressure at the rock
drill (11) using a pressure gauge (A). The pres-
sure should be 2–3 bar. If the pressure is too
low, clean the restrictor (9) or increase the dia-
meter of the restrictor.
Underground drill rigs
4. Check that the green light emitting diode (G)
indicates power on.
5. Adjust the screw (T1) so that the light emitting
time of the yellow diode (R) is 0.5 seconds.
6. Observe the yellow diode (R) and adjust the
lubricating oil dosage to 35–40 pulses/min, by
means of the screw (T2).
Surface drill rigs
4. Observe the relay window (5) and adjust the
lubricating oil dosage to 40–50 pulses/min, by
means of the potentiometer (6).
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 air and lubricating oil comes out of the hole in
the front head and between the shank adapter and
front guide.

1. Lubricating-oil container
2. Filler cap
3. Pulse relay
4. Pulse relay
5. Relay window
6. Potentiometer
7. Cap, bleeding
8. Pressure gauge
9. Restrictor
10. Plastic hose
11. Lubricating-air connection
12. Lubricating-air hose

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

11
 Removing the front head

CAUTION
• Never attempt maintenance work while the
drill rig is in operation.
• Before intervening in the hydraulic, water
or air systems, make sure that there is no
pressure in the systems.
There is a risk of injury if these instructions
are not observed!

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

re disassembly.
1250 0021 24

Remove the flushing hose (3).

If the flushing head is to be changed, remove the
flushing connection (1) and flushing plug (2).
1
3

Remove the front side-bolt nuts (4) with their

washers (5).
Remove the front head (6) by tapping it with a
copper hammer.
6 Now pull out the shank adapter (7) from the front
7 head.
If the front guide (8) or flushing head are to be
changed, this may be done in a suitable workshop
only.
8 N.B. The flushing seals can be changed without
1250 0021 25

removing the flushing head.

5 Check the internal components of the front head

when changing the shank adapter.
4

12
Checking the front head
7
A 8
Ø 38
7
7
Ø 55

7
1 3 10
9 8
C 7
7
B 6

1 mm
A 5

A m
2m

Fas / Chamfer
1250 0000 03

R32
R32E
Ø 38 R38
R38E
T38
3 T38E

Ø 55 R32F
R38F

• Check that air and lubricating oil come out be- • Look inside the gear housing and check the spli-
tween the shank adapter (3) and front guide nes of the driver (4). If the splines are less than
(6), and also out of the hole (B). 2 mm in width, the driver must be changed (see
• Blow clean the lubricating oil ducts (A) using page 14).
compressed air.
• If the striking surface of the piston (1) is dama-
• Change the guide (6) if its internal diameter is ged in any way, the rock drill must be sent to a
greater than 39 mm or 56 mm. suitable workshop for overhauling. See the re-
• Check the O-rings and flushing seals (7) if pair instructions.
air/water is escaping from the hole (C) in the
front head. Change the O-rings and flushing • Change the shank adapter (3) if the thread is
seals if they are worn or damaged. worn out or the impact surface is upset or chip-
ped, or if the front or rear end surfaces of the
• Change the flushing head (8) and the ring (10) if splines are worn.
they are severely corroded or have cracks.
• Change the stop ring (5) if it is worn by more • Check that the drill collar (9), which must be
than 1 mm. used in upwards-directed drilling, is not dama-
ged and that it rotates with the shank adapter.
• Change the rotation chuck bushing (2) if the cham-
fer on its impact surface (see fig. A) is damaged or
worn down.
When the chamfer shown in fig. A has worn down,
it corresponds to approx. 1.5 mm of wear.
• When changing the damper piston, also change
the damper seals in the intermediate part. The
damper piston must be changed in a workshop.
See the overhauling instructions.

13
 Changing the driver

Disassembly

CAUTION
• Take care when removing the driver.
Mind your fingers!

Press the disassembly tool (A) into the gear hou-

sing (1) until it comes to a stop, i.e. until the spli-
ned part of the tool has passed the splines of the
driver (2).
1 Turn the disassembly tool clockwise a little.
Tap out the driver (2) by striking with the impact
hammer (B).
1250 0000 34

2
B

Assembly
Tap the driver (2) into the rotation chuck in the
1 gear housing (1) with the aid of a mandrel (A) and
a copper hammer.

A
1250 0021 28

14
 Changing the rotation
chuck bushing
The rotation chuck bushing (1) is accessible when
the front head (3) and the driver (2) are removed.
1250 0115 55

1
2
3

6
5 Mounting the front head
9
8

Fit the shank adapter (4) together with the sleeve

(9) as shown in the figure.
1 N.B. R38 shank adapters require a one-piece Ø
38 mm stop ring, i.e. not the split stop ring.
4
Check that the pin (6) is fitted into the cover and
9 2 that the O-ring (8) is fitted in the front head. Fit the
3 front head (1) to the side bolts (5).

Fit the washers (2) and nuts (3).

N.B. Before assembly, smear the threads with gre-
7 Ø 38
ase (type NEVER-SEEZ).
Check the tightening torques of the rear side-bolt
1250 0055 64

nuts and front side bolts (see 1–2, page 5).

Now tighten the nuts (3) alternately to a torque of
350 Nm (260 lbf.ft).

Fit the flushing connection (10) and flushing plug

(11), and tighten both to a torque of 300 Nm.

11
1250 0021 30

10

15
Slinging
1250 0000 30

Make sure that the rock drill is safely slung for
lifting. Make sure that the rock drill is securely
anchored for transportation.
CAUTION
• Lifting gear and slings must be approved
for a weight of 250 kg (550 lbs).
Faulty lifting gear can cause the rock drill
to move unpredictably or drop.
Incorrect handling can result in crush
injuries.
Rock drill weight, approx.
COP 1532 . . . . . 180 kg (400 lbs)
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.

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
+10 to +25 (50 to 77) –25 (–13) 35 (95) ISO VG 15 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

Grease • IMPORTANT! Because of the operating temperature in the rock drill gear housing (see "Lubrication of gear"),
always use a high-temperature grease containing an ashless thickening agent and additives that give
Atlas Copco, 2003
Printed in Sweden

resistance to oxidation and rust. The grease should also have good resistance to water.
Grease properties NLGI-number 2 Base oil viscosity 110 cSt at 40 oC (104 oF)
Dropping point 250 oC (480 oF) Operating temp. –20 to +150 oC (–4 to 300 oF)

16
 Maintenance instructions for

Hydraulic
Rock drill COP 1532
1250 0027 80

No. 9852 1398 01a

18