Atlas Copco

Maintenance instructions
Hydraulic Rock drills
COP 1840, 1840EX

Atlas Copco Rock Drills AB

rebro, Sweden
Atlas Copco Rock Drills AB, 2009, All rights reserved

No. 9852 1007 01k

 Copyright 2009, Atlas Copco Rock Drills AB, Sweden
Any unauthorised use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and draw-
ings.

Atlas Copco Rock Drills AB

SE-70191 rebro, Sweden
 CONTENTS

CONTENTS
1. GENERAL .......................................................................................................... 5
1.1 ENVIRONMENT.................................................................................................................. 5
1.2 SAFETY REGULATIONS.................................................................................................... 5
WARNING BOXES.............................................................................................................. 5
THE FOLLOWING GENERAL SAFETY RULES MUST BE OBSERVED .......................... 6

2. SERVICE INTERVAL.......................................................................................... 7
2.1 BEFORE STARTING A NEW OR NEWLY OVERHAULED ROCK DRILL ......................... 8
2.2 AFTER EACH SHIFT WHEN USING A NEW OR NEWLY OVERHAULED ROCK DRILL 8
2.3 FOR EACH SHIFT .............................................................................................................. 8
2.4 AFTER EVERY 40TH PERCUSSION-HOUR ..................................................................... 9
2.5 EVERY 400TH PERCUSSION-HOUR:............................................................................... 9

3. HOSE CONNECTIONS .................................................................................... 10

3.1 CONNECTING THE HOSES ............................................................................................ 10

4. TIGHTENING TORQUES ................................................................................. 11

4.1 TIGHTENING THE SIDE BOLTS...................................................................................... 12
4.2 RETIGHTENING THE SIDE BOLTS................................................................................. 12

5. ACCUMULATORS............................................................................................ 13
5.1 SAFETY LABEL LOCATION............................................................................................. 13
5.2 SAFETY LABEL INSTRUCTIONS .................................................................................... 13
5.3 CHARGING THE ACCUMULATORS................................................................................ 13
5.4 CHECKING THE ACCUMULATORS IN THE EVENT OF HOSE VIBRATION................. 14
INTAKE AND DAMPER ACCUMULATORS ..................................................................... 14
5.5 REPLACING INTAKE AND DAMPER ACCUMULATOR.................................................. 14
DISMANTLING.................................................................................................................. 15
ASSEMBLY ....................................................................................................................... 15
5.6 REPLACING THE RETURN ACCUMULATOR................................................................. 15
DISMANTLING.................................................................................................................. 15
ASSEMBLY ....................................................................................................................... 15

6. CHANGING THE HYDRAULIC MOTOR.......................................................... 16

DISMANTLING.................................................................................................................. 16
ASSEMBLY ....................................................................................................................... 16

7. FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM ............. 17

8. SETTINGS ........................................................................................................ 18
8.1 SETTING OF ECL LUBRICATING SYSTEM.................................................................... 18
8.2 SETTING DAMPER PRESSURE...................................................................................... 18
8.3 SETTING EXTRACTOR PRESSURE............................................................................... 19

9. REMOVING THE FRONT HEAD...................................................................... 20

9.1 EXTRACTOR FRONT HEAD............................................................................................ 20

10. CHECKING THE FRONT HEAD ...................................................................... 21

10.1 EXTRACTOR FRONT HEAD............................................................................................ 22

11. REPLACING THE FLUSHING HEAD AND DRIVER....................................... 23

DISMANTLING.................................................................................................................. 23
ASSEMBLY ....................................................................................................................... 23
11.1 EXTRACTOR FRONT HEAD............................................................................................ 24
DISMANTLING.................................................................................................................. 24
ASSEMBLY ....................................................................................................................... 24

3
CONTENTS

12. MOUNTING THE FRONT HEAD ..................................................................... 25

12.1 EXTRACTOR FRONT HEAD ........................................................................................... 25

13. SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING ............ 26

13.1 SLINGING ........................................................................................................................ 26
13.2 ROCK DRILL WEIGHTS .................................................................................................. 26
13.3 LONG-TERM STORAGE ................................................................................................. 26
13.4 STROKE LENGTH SETTING........................................................................................... 26
BASIC SETTING .............................................................................................................. 26

14. LUBRICATION ................................................................................................. 29

14.1 LUBRICATION OF GEAR ................................................................................................ 29

15. HYDRAULIC AND LUBRICANT RECOMMENDATIONS................................ 31

15.1 HYDRAULIC FLUID ......................................................................................................... 31
15.2 PNEUMATIC TOOL OIL ................................................................................................... 32
15.3 GREASE........................................................................................................................... 32

4

1. GENERAL
This instruction is intended as a guide when
performing maintenance on your rock drill.
1.1 ENVIRONMENT
ENVIRONMENTAL REGULATIONS
Care for the environment!
Leaking hydraulic couplings and grease are
hazardous to the environment.
Changing oils, hydraulic hoses and various
types of filter can be hazardous to the environ-
ment.
Always collect oil residues, oil spillage, oily
waste and residues and spilt grease. Deal with
according to local provisions.
Use biodegradable hydraulic and lubricating
oils where possible.
5
GENERAL 1
1.2 SAFETY REGULATIONS
The Safety chapter contains important information
for the prevention of accidents.
WARNING BOXES
The instructions include warnings.
Warnings are preceded by a heading (Danger,
Warning and Caution).
WARNING BOXES
Danger
Indicates an imminent risk of serious or fatal
injury if the warning is not heeded.
Warning
Indicates hazards or hazardous procedures
which could result in serious or fatal injury if the
warning is not heeded.
Caution
Indicates hazards or hazardous procedures
which could result in personal injury or
damage to property if the warning is not
heeded.
GENERAL 1

THE FOLLOWING GENERAL SAFETY RULES

MUST BE OBSERVED
IMPORTANT!
Read through the maintenance instructions
carefully before starting maintenance work.
Follow the instructions given and local regula-
tions.
Do not use or intervene in the rock drill unless
you have been trained to do so.
Never attempt to carry out maintenance while
the rock drill is in operation.
Ensure that the hydraulic, water and air systems
are depressurised and that the electrical system
is de-energised prior to removing the rock drill
or starting work on the system.
IMPORTANT!
Make sure that the rock drill has been main-
tained in accordance with the applicable instruc-
tions.
Before moving the rig and rock drill or starting to
drill, make sure that there are no personnel in
the immediate vicinity of the drill rig.
Checks and adjustments that are necessary
when the rock drill is in operation must be
carried out by at least two persons. One person
must then be present at the operating station
and have a good view of the work.
Always wear a helmet and earmuffs when dril-
ling. Follow local regulations

Use approved lifting devices when handling the Make sure that the place of work is well venti-
rock drill. Avoid lifting heavy weights yourself. lated.

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.
Make sure that the safety labels are fitted, clean
and fully legible.
Particular attention must be paid to all warnings
in the instructions.

Check that the hoses used are of the right

quality, and that all hose connections are in
good condition and properly tightened. Hoses
that loosen could cause serious injury.

Use only Atlas Copco original parts. Any

damage or malfunction caused by the use of
non-original Atlas Copco parts is not covered by
warranty or product liability.

6
 SERVICE INTERVAL 2

2. SERVICE INTERVAL
Read all safety regulations before starting to work IMPORTANT!
on the machine. Observe great cleanliness when intervening in
the rock drill or its hydraulic circuit.
Order numbers for the repair kits are in the
rock drills spare parts catalogue. The following parts may be changed at the
work site in accordance with the instructions
WARNING! given:

Before starting any maintenance work, make shank adapter

sure that the electrical system is dead. driver
front head parts
There is a risk of injury if these instructions are accumulators
not observed! hydraulic motor
screws
CAUTION! connections
Exercise caution when jointing drill rods and Other repairs must be carried out in a suitable
with drill bit handling. Watch your fingers! workshop in accordance with the repair
instructions for the rock drill.
Make sure that clothes do not come too close
to rotating machine parts.
IMPORTANT!
Negligence could cause serious injury. Ensure bolted joints are tightened to the
correct tightening torques after every 40
Always use hearing protection when drilling.
percussion hours and when reconditioning the
High noise levels damage the hearing.
rock drill.
Never attempt maintenance or intervene in the
rock drill, connections or hoses while the
hydraulic, lubrication or flushing systems are
pressurised. Air or oil can spray out at high IMPORTANT!
pressure and high temperature. There is a risk Servicing should be carried out at appropriate
of serious injury to the eyes and skin. time intervals based on local conditions. The
condition of the rock has a major affect on the
amount wear and with that the need of servi-
cing.

7
SERVICE INTERVAL 2

IMPORTANT!
Any defect must be rectified in the designated workshop

2.1 BEFORE STARTING A NEW OR

NEWLY OVERHAULED ROCK
DRILL

Action Chapter
Connect up the hoses 3
Charge the accumulators 5
Select a suitable hydraulic oil and lubricant 15
Fill the lubricating system with oil 7
Adjust and set the lubricating system 8
Set the damper pressure 8
Set the extractor unit pressure 8

2.2 AFTER EACH SHIFT WHEN USING

A NEW OR NEWLY OVERHAULED
ROCK DRILL

Action Chapter
Tighten all threaded unions 4

2.3 FOR EACH SHIFT

Action Chapter
Check that air and lubricating oil escape from the hole in the front head 10
Check that the drill rigs damper pressure gauge is showing normal values. Check 8
that the drill rigs damper pressure gauge is showing normal values. In the event of
deviation, adjust the damper pressure.
Check that the shank adapter threads are not damaged 10
Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumula- 5
tors
Check that the machine does not leak. If the flushing medium leaks from the flushing 10
head, replace the seals and O-rings
When replacing the shank adapter or removing the front head, check the internal 10
components including piston, driver and the visible parts of the rotation chuck bushi-
ng
In the event of oil leakage from the front head: close percussion and only activate 10
the damper in order to determine if the leakage is coming from the percussion or
damper.

8
 SERVICE INTERVAL 2

2.4 AFTER EVERY 40TH PERCUS-

SION-HOUR

Action Chapter
Grease the gear 14
Tighten all threaded unions 4
Check the safety labels on the accumulators. Replace them if they are damaged or 5
illegible
Check the accumulators 5

2.5 EVERY 400TH PERCUSSION-

HOUR:

Action Chapter
Dismantle the rock drill from the drill rig. Transport the rock drill to an appropriate 13
workshop for servicing

IMPORTANT!
Always function test the rock drill after service.

9
HOSE CONNECTIONS 3

3. HOSE CONNECTIONS
3.1 CONNECTING THE HOSES
Clean the rock drills hose connections before
undoing the protective caps.
Never remove a protective cap until the hose is
ready to be connected.
Always store the rock drill with all hose connec-
tions plugged. Use suitable protective caps, and
make sure that they are clean.
CAUTION!
Never attempt maintenance or any work in the
rock drill, connections or hoses while the
hydraulic, lubrication or flushing systems are
pressurised. Air or oil can spray out at high
pressure and high temperature. There is a risk
of serious injury to the eyes and skin.
Pressure hoses with an internal diameter of 19
mm (3/4") or greater are of the quality SAE 100
R9R (high-pressure hose with four layers of
steel reinforcement). For reasons of safety,
under no circumstance may these hoses be
replaced with hoses of a lower quality. There is
a risk of injury if these instructions are not
observed!

7
8
1

6
1250 0210 53

5
4
3
2

9 10
6

1. Drainage 6. Flushing air/water

2. Rotation left 7. Lubricating air
3. Rotation right 8. Damper, intake
4. Percussion return 9. Extractor unit, return
5. Inlet impact mechanism 10.Extractor unit, intake

10
 TIGHTENING TORQUES 4

4. TIGHTENING TORQUES

6
5 1
4

3A 3A 2
14
9
13
6
12
7 11 3B
8 9 10 15
16
1250 0210 54

2
13

Lubricate the nuts threads and the washers

contact surfaces with Never-Seez Regular Grade.

Ref. Torque
Qty. Check point Instructions
No. Nm
1 2 Side bolts 300 Tighten the rear nuts
2 1 Front bolt 300 Tighten the front bolt
3A 2 Side bolt 350 Tighten the front nuts
3B 3 Side bolts EX 300 Tighten the front nuts
4 3 Back head 220 Tighten the screws alternately to full
torque, top bolt last
5 1 Regulating plug 80
6 4 Accumulator 220 Tighten the screws alternately to full
torque
7 4 Hydraulic motor 65 Tighten the nuts alternately
8 2 Clamping attachment, return 30
accumulator
9 4 Rock drill mounting 250 Tighten the screws alternately to full
torque
10 1 Plug 45
11 4 Valve end plates 145 Tighten the screws alternately to full
torque
12 2 Connecting plate 120 Tighten the screws alternately to full
torque
13 1 Flushing connector 300
14 4 Intake, flushing medium 90 Tighten the screws alternately to full
torque
15 1 Intake, extractor unit 120
16 1 Return, extractor unit 120

11
TIGHTENING TORQUES 4

4.1 TIGHTENING THE SIDE BOLTS 4.2 RETIGHTENING THE SIDE BOLTS
Not extractor unit version
Undo the front nuts (3A) so that the tension rele-
1 ases.

If the threads are seized, remove the nuts and

clean and lubricate them with Never-Seez
1250 0219 79

Regular Grade.
2 3B
Tighten the front nuts (3A) manually.
Both versions
Tighten the rear nuts (1) to the tightening torque.

Tighten the side bolt (2) to the tightening torque.

Tighten the front bolts (3A or 3B) to the tighte-

2 3A
ning torque.
Check whether the side bolts, nuts or washers
have cracks, scratches or rust. Replace
damaged side bolts, nuts and washers.

Lubricate the threads and contact surfaces of

the side bolt (2), nuts and washers with Never-
Seez Regular Grade.

Tighten the rear nuts (1) to the tightening torque.

Tighten the side bolt (2) to the tightening torque.

Tighten the front bolts (3A or 3B) to the tighte-

ning torque.

12
 ACCUMULATORS 5

5. ACCUMULATORS 5.3 CHARGING THE ACCUMULATORS

Check the safety labels on the accumulators.

Replace them if they are damaged or illegible.

5.1 SAFETY LABEL LOCATION

1250 0210 55

221

CAUTION!
231 211 Charge the accumulators when assembled on
the rock drill. There is a risk of injury if these
instructions are not observed!
221.Damper accumulator
211.Intake accumulator
231.Return accumulator
WARNING!
A gas other than N 2 could cause an explo-
5.2 SAFETY LABEL INSTRUCTIONS sion.

Remove the protective cap (A).

Open the valve nut (B) by 2-3 turns, and connect

the gas hose.
1250 0210 56

Open the gas valve (C).

Charge the accumulators with nitrogen gas (N 2)

2 to the correct pressure in accordance with the
1
following:
NB! Charge at the bottom if possible rather than
1. Read the operators instructions carefully before
too high.
service or replacement of the accumulator.
2. Must be charged with nitrogen only
Damper 20-25 bar
accumulator (221)
Intake 30-40 bar
accumulator (211) (80-100 bar)*
Return Must not be
accumulator (231) charged with N2
*Intake accumulator 30-40 bar under collaring pressure.
Normal 80-100 bar. Max. 100 bar.

Tighten the valve nut (B) and close the gas valve
(C).

Remove the gas hose and screw in the protec-

tive cap (A) to the accumulator valve.

13
ACCUMULATORS 5

5.4 CHECKING THE ACCUMULATORS RETURN ACCUMULATOR

IN THE EVENT OF HOSE VIBRA-
TION C

INTAKE AND DAMPER ACCUMULATORS

A
A

1250 0210 59
B 231 C
1250 0210 58

Position the rock drill in horizontal position.

211 221 Remove the stopper with O-ring (C). If oil

Push in the control valves pin (A). If the accu-
mulator is charged, the pin protrudes 4.5 mm
and is hard to push in.
If the pin is easy to press in then the gas pres-
sure has disappeared (broken diaphragm or
defective filler valve). NB! The damper accumu-
lators pin is slightly easier to press in.
Replace the accumulator, diaphragm and/or
filler valve if they are damaged.
Charge the new accumulator after replacement.
.......... NB! The seat of the filler valve is easily
deformed by repeated opening/closing. The
filler valve must be replaced frequently.
escapes then the diaphragm is damaged.
Replace the accumulator and/or diaphragm if
they are damaged.
If the diaphragm is in contact against the outer
tube, press diaphragm with a cylindrical (blunt)
mandrel (7-9 mm). See Figure A. The correct
position for the diaphragm is, see Figure B.
Refit the stopper and O-ring (C).
Charge by means of admitting air at atmos-
pheric pressure into the accumulator.
5.5 REPLACING INTAKE AND
DAMPER ACCUMULATOR

D BA
221
82
53

211 82
1250 0210 60

BA
C

WARNING!
All gas must be released prior to fitting by
means of removing the protective cap (A),
undoing the valve nut (B) and opening it 2-3
turns.

There is a risk of injury if these instructions are

not observed

14
 ACCUMULATORS 5

CAUTION! 5.6 REPLACING THE RETURN ACCU-

Defective bolts may lead to dangerous oil
leakage or the accumulator working loose. Oil
spray can injure the eyes and skin.
Parts that come loose can cause serious injury.
DISMANTLING
Remove the accumulators (221, and 211) with
the sealing rings (82) by undoing the bolts (C
and D). Send the accumulators to a workshop
for reconditioning!
MULATOR
CAUTION!
Ensure that the hydraulic, water and air
systems are depressurised before starting
work on the system.
For reasons of safety, under no circumstance
may the pressure hoses be replaced with
hoses of a lower quality. The hoses must be
high-pressure hoses with four layers of steel
reinforcement, quality SAE 100R9R.

There is a risk of injury if these instructions are

ASSEMBLY
not observed!
Locate the sealing rings (82) in the grooves on
the intermediate section (53).

Make sure that the sealing rings (82) do not get

damaged during the assembly.
23

1250 0210 61
Fit the damper accumulator (221) on the rock
drills left-hand side and the intake accumulator
(211) on the rock drills right-hand side (hose A 21 11
side). Fit with undamaged original bolts (D)
length of 70 mm and (C) length 100 mm. B
Replace the bolts in pairs even if only one bolt is 25
corroded or damaged in some other way. 24 231
Tighten the bolts (C and D) alternately to tighte-
ning torque 220 Nm.
DISMANTLING
Charge the accumulators with nitrogen gas (N Remove the hydraulic hose (A) from the return
2). accumulator (231).

Remove the return accumulator (231) by remo-

ving the nuts (24) and the bolts (23).

Pull away the clamp (21) and unscrew the accu-

mulator from the nipple (B).

Send the return accumulator to a workshop for

overhauling.

ASSEMBLY
Screw in the return accumulator (231) onto the
nipple (B) in such a way that the stopper (11) is
accessible for checking the accumulators
diaphragm.

Fit the clamp (21) onto the return accumulator.

Fit the rock drills with the bolts (23) and the nuts
(24).

Connect the hydraulic hose (A) to the return

accumulator (231).

15
CHANGING THE HYDRAULIC MOTOR 6

6. CHANGING THE ASSEMBLY

Make sure that the groove ring (130) is fitted in
HYDRAULIC MOTOR the coupling (249).

Lubricate the couplings splines with grease and

fit the coupling (249) on the hydraulic motor
3 (241).
A 241 248
Replace the gasket (248) if it is damaged.

Fit the gasket (248) and the hydraulic motor

(241) on the cylinder (3). Tighten the nuts (246)
to tightening torque 65 Nm.
1250 0210 62

Connect the hydraulic hoses (A). Check that the

246 249 130 correct direction of rotation is obtained.

DISMANTLING
Detach the hydraulic hoses (A).

Undo the nuts (246) and remove the hydraulic

motor (241).

Pull out the coupling (249).

16
 FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM 7

7. FILLING WITH LUBRICA-

TING OIL AND BLEEDING
THE SYSTEM
CAUTION!
Never work on the lubrication system when it is
pressurised.

Lubricating oil could spray out.

There is a risk of serious injury to the eyes and

skin.

IMPORTANT!
Use the recommended lubrication air pressure
and recommended lubrication oil. Some
moving parts on the rock drill are lubricated
with oil mixed with compressed air. Is impor-
tant that these parts receive good lubrication.

Check the level in the lubricating oil tank for every

shift. Exercise cleanliness and fill with the right
grade oil.

NB! If the lubricating system has been empty of

oil, it must be bled after filling.

17
SETTINGS 8

8. SETTINGS 8.2 SETTING DAMPER PRESSURE

A
8.1 SETTING OF ECL LUBRICATING
SYSTEM 1
ECL=Electric Controlled Lubrication
Rock drill lubrication must be set with regard to the
local conditions.

Start the lubricating system.

Check the lubricating air pressure at the rock

1250 0210 72
drill using a pressure gauge. The pressure B
should be 2-3 bar. If the pressure is too low,
clean the restriction or increase the diameter of
the restriction.
NB! The setting should take place at normal
Set the correct lubricating oil dose.
operating temperature for the hydraulic oil.

Pump (3217 8667 50) 35-40 pulses/minute Fully close the constant flow valve (B) on the drill
Pump (3217 8667 52) 20-25 pulses/minute rig.

Connect a pressure gauge (A), calibrated for 0-

After setting, check that the correct pulse 60 bar, between the hose and the damper union
frequency has been obtained and that oil is (1).
emerging from the front heads hole and
between the shank adapter and front guide. Pressurise the damper circuit.

Check that the shank adapter is unloaded and in

the forward position.

Adjust the constant flow valve until the pressure

gauge (A) shows 30-35 bar at the rock drill
(operator panel shows 10-15 bar higher value).

Read off the drill rigs damper pressure gauge. If

this pressure gauge later shows another value,
make a new pressure setting.

Disconnect the pressure gauge (A) and connect

the hose to the union (1).

18
 SETTINGS 8

8.3 SETTING EXTRACTOR PRES-

SURE
A

P
1250 0210 73

Fully close the constant flow valve (B) on the drill

rig.

Connect a pressure gauge (A), calibrated for 0-

60 bar, between the hose and the extractor
units intake union (P).

Connect the extractor unit circuit by activating

the return feed and running the cradle against
the stop. Let the lever remain in this position.

Adjust the constant flow valve (B) until the pres-

sure gauge (A) shows 20-25 bar.

Disconnect the pressure gauge (A) and connect

the hose to the union (P).

19
REMOVING THE FRONT HEAD 9

9. REMOVING THE FRONT

HEAD
CAUTION! 172
Never attempt to carry out maintenance while
the drill rig is in operation.

Ensure that the hydraulic and air systems are

depressurised before starting any work.

1250 0210 76
There is a risk of injury if these instructions are 300
not observed!
252 251
NB! Always clean the outside of the rock drill
before disassembly.
Remove the front side-bolt nuts (251) with their
washers (252).

Remove the front head (172) by pulling the

shank adapter (300).

Then pull the shank adapter from the front head.

180 Always check the internal components, also

when replacing the shank adapter.
1250 0210 75

179
178 9.1 EXTRACTOR FRONT HEAD
A 173 177

Remove the flushing hose (A). 162

Remove the connecting plate (177) and nipple
(173) by removing the bolts (178) and washers
(179).

Remove the cup seal (180).

1250 0210 77

300
252 251

Remove the front side-bolt nuts (251) with their

washers (252).

Remove the front head (162) by pulling the

shank adapter (300) or by tapping with a copper
hammer.

Then pull the shank adapter from the front head.

Always check the internal components, also

when replacing the shank adapter.

20
 CHECKING THE FRONT HEAD 10

10. CHECKING THE FRONT

HEAD

192
300 172 190 174 191 176 A 131 132 E

F
1250 0210 74

173 175 C B 185

21 86
131 192 176
185 1m 175 190 174 191 175
m
2 mm

m 132
173 1m
53 mm
D
Check that air and lubricating oil escape
between the shank adapter (300) and front
guide (173), and also out of the hole (B)
Blow clean the lubricating air ducts (A) in the
front head (172) with compressed air and check
that the restrictions (E) are open.
Replace the guide (173) if the inside diameter
exceeds 53 mm.
Check the O-rings (190-192) and flushing seals
(175,176) if air is escaping from the hole (C) in
the front head. Replace the O-rings and flushing
seals if they are worn or damaged.
300
If the rotation chuck bushing (132) is worn more
than 1 mm or the piston (21) impact surface is
damaged in any way then the rock drill must be
sent to a workshop for inspection. NB! Fit the
rotation chuck bushing so that the lubricating
grooves (D) are aligned towards the damper
piston (86).
Replace the shank adapter (300) if the thread is
worn out or the impact surface is warped or
chipped, or if the front or rear end surfaces of the
splines are worn.

Replace the flushing head (174) if it is seriously

corroded, or if it contains cracks.

Replace the stop ring (185) if it is worn by more

than 1 mm.

Look inside the gear housing and check the

splines on the driver (131). If the splines are less
than 2 mm in width, the driver must be changed.
Fit a new driver with the aid of a suitable
mandrel and a copper hammer.

21
CHECKING THE FRONT HEAD 10

10.1 EXTRACTOR FRONT HEAD

185
194
185

196
172 168
170
169

185

185
167

171 193

195

131
300

162

E
182
21

F
163
1250 0210 88

181 C B 132

131 194 196

m 132 193 185 182 185 195
1m
2 mm

300 163 169 167 181 170 168 171,172

1 mm
53 mm

Check that air and lubricating oil escape
between the shank adapter (300) and front
guide (163), and also out of the hole (B)
Blow clean the lubricating air ducts (A) in the
front head (162) with compressed air and check
that the restrictions (E) are open.
Replace the guide (163) if the inside diameter
exceeds 53 mm.
Check the O-rings (193-195) and flushing seals
(185) if air is escaping from the hole (C) in the
front head. Replace the O-rings and flushing
seals if they are worn or damaged.
Replace the flushing head (182) if it is seriously
corroded, or if it contains cracks.
Look inside the gear housing and check the
splines on the driver (131). If the splines are less
than 2 mm in width, the driver must be changed.
Fit a new driver with the aid of a suitable
mandrel and a copper hammer.
grooves (D) are aligned towards the damper
piston (86).
Replace the shank adapter (300) if the thread is
worn out or the impact surface is warped or
chipped, or if the front or rear end surfaces of the
splines are worn.
Check that the drill sleeve (F), to be used with
upwards directed drilling, is not damaged and
rotates with the shank adapter.
Replace the extractor units piston (181) if the
surface against the shank adapter has worn
more than 1 mm. When replacing the extractor
units piston check the seals (167,168) and O-
rings (169-172). Replace the seals and O-rings
if they are worn or damaged.

If the rotation chuck bushing (132) is worn more

than 1 mm or the piston (21) impact surface is
damaged in any way then the rock drill must be
sent to a workshop for inspection. NB! Fit the
rotation chuck bushing so that the lubricating

22
 REPLACING THE FLUSHING HEAD AND DRIVER 11

11. REPLACING THE ASSEMBLY

FLUSHING HEAD AND
DRIVER D

V
CAUTION!
Exercise care when dismantling flushing head
and the driver. Watch your fingers! 174

DISMANTLING A

1250 0210 50
D
Press the flushing head (174) into the front head
V using a mandrel and sleeve.
NB! The flushing head must be reversed so that
173 the lubricating grooves are turned upwards.
174 Make sure that the flushing hole in the flushing
head (174) aligns with the hole in the front head.
1250 0210 89

185

Use a mandrel and suitable sleeve to push out

the guide (185), the flushing head (174) and the
stop ring (173) from the front head. D

131
C
1250 0210 51

117

131
1250 0210 49

B A Use a mandrel and plastic hammer to fit the

driver (131) in the drill sleeve (117).

The driver (131) is pulled out manually or with an

extractor (C) and an expander 37-46 mm, alter-
natively with dismantling tool (A)(3115 2724 80).

23
REPLACING THE FLUSHING HEAD AND DRIVER 11

11.1 EXTRACTOR FRONT HEAD Tap in the rotation chuck bushing (132) with a
suitable copper mandrel.

CAUTION! Tap the driver (131) into the drill sleeve in the
gear housing (103) using a mandrel (A) and a
Exercise care when dismantling flushing head copper hammer.
and the driver. Watch your fingers!

DISMANTLING

185
153

185

196
195
194

182
193
131
B A 182 132
198
197

1250 0210 83
184
1250 0210 81

183 183
263
103 AB
263
C Fit the O-rings (193-196) and the seals (185) in
the flushing head (182).
Remove the flushing hose (C) from the nipple
Important! The seals (185) must be turned in
(263).
accordance with the illustration.
Remove the nipple (183) and its O-rings and
Fit the flushing head (182) in the cover plate
support ring.
(153) and tap it in with a copper hammer. Check
Press the removal tool (A) (3115 2724 80) into carefully that the flushing intake in the cover is
the gear housing (103) until the tool moves to aligned with the hole in the flushing head.
the stop, i.e. the tools splines-equipped section
Fit the O-rings (197,198) and the support ring
has then passed the drivers (131) splines.
(184) on the nipple (183).
Turn the removal tool clockwise slightly.
Fit the nipples (183,263 and B) and the nut (A).
Tap out the driver (131) and flushing head (182)
Torque tighten the nipple (183) to 300 Nm and
using the sliding hammer (B).
the nipple (263) to 180 Nm.
Normally the rotation chuck bushing (132)
follows as well when removing the driver. If this
is not the case, then remove the rotation chuck
bushing using a puller and an expander.

ASSEMBLY
1250 0210 8

103 131 A

132

Fit the rotation chuck bushing (132) so that the

lubricating grooves are aligned towards the
damper piston.

24
 MOUNTING THE FRONT HEAD 12

12. MOUNTING THE FRONT After assembly

Check that air and lubricating oil escapes out of
HEAD the hole in the front head and between the shank
adapter and front guide.

162
172 12.1 EXTRACTOR FRONT HEAD

1250 0210 8
186 300 162
1250 0210 78

300 263 188 252 251

252 251
161
Fit the stop ring and shank adapter (300) in the
front head (172).
Make sure that the pin (162) is fitted in the cover
plate. Position the front head (172) on the side
bolts (161).
Apply grease, type Never Seez, onto the
threads of the side bolts (161).
Fit the washers (252) and nuts (251).
Check the tightening torques on the rear side-
bolt nuts and the front side bolt.
Following which, tighten the nuts (251) alterna-
tely to a torque of 350 Nm.
Fit the shank adapter (300) in the extractor units
front head (162).
Fit the cylindrical pin (188).
Fit the front head (162) on the side bolts (186).
Apply grease, type Never Seez, onto the
threads of the side bolts (186).
Fit the washers (252) and nuts (251).
Check the tightening torques on the rear side-
bolt nuts and the front side bolt.
Following which, tighten the nuts (251) alterna-
tely to a torque of 300 Nm.
Connect the flushing hose to the nipple (263).
After assembly
Check that air and lubricating oil escapes out of
the hole in the front head and between the shank
adapter and front guide.

180
1250 0210 79

179
178
A 173 177

Fit the cup seal (180) into the flushing head.

Fit the connecting plate (177) to the front head

using the washers (179) and bolts (178). Tighten
the bolts to a torque of 90 Nm.
Fit the nipple (173) on the connecting plate.
Tighten the nipple to tightening torque 300 Nm.
Fit the flushing hose (A) and tighten the nut.

25
SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING 13

13. SLINGING, WEIGHT, 13.2 ROCK DRILL WEIGHTS

STORAGE AND STROKE
COP 1840 184 kg
LENGTH SETTING
COP 1840EX 247 kg
13.1 SLINGING
13.3 LONG-TERM STORAGE

1250 0184 87
1250 0184 84

Make sure that the rock drill is safely slung for If the rock drill is not going to be used for a
lifting. Make sure that the rock drill is securely long time, the following precautions should be
anchored for transportation. taken.

Check that all connections, including the one for

caution!
Lifting devices and straps must be approved
for lifting 500 kg.
Incorrect lifting devices could cause the rock
drill to start moving or fall down.
Incorrect operation could cause crushing
damage.
the flushing medium, are properly capped with
protective caps of the right size.
Clean the rock drill carefully. Use degreasing
agent and rinse with water.
Clean thoroughly and oil in the front head
components in contact with flushing medium
(especially in high air humidity).
Release gas from the accumulators.
Store the rock drill in a dry place.

13.4 STROKE LENGTH SETTING

63

66
1250 0210 52

BASIC SETTING
On cylinder (66) there is a plug (63). Turning the
plug changes the stroke length of the piston.
There are two different positions. They are
shown on the plug (63) by punched dots. For

26
 SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING 13

example, when two dots are shown upward the

setting is 2

27
SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING 13

28
 LUBRICATION 14

14. LUBRICATION

1
3
1250 0210 87

14.1 LUBRICATION OF GEAR

Unscrew the bleed plug (1).
Lubricate with heat-resistant grease through the
nipple (2) until new grease escapes through the
hole (3).
Tighten the plug (1).

29
LUBRICATION 14

30
 HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15

15. HYDRAULIC AND LUBRICANT RECOMMENDATIONS

15.1 HYDRAULIC FLUID
A good hydraulic fluid provides superior protection against wear, rust and oxidisation as well as good anti-
foaming and air and water separation properties.
In order to ensure a lowest level on these properties the mineral oil based and synthetic (polyalphaolefin)
hydraulic fluids must conform to the standard ISO 11158 HM/HV or DIN 51524 HLP/HVLP.

Environmentally friendly hydraulic fluids must fulfil ISO 15380

It is essential to chose a hydraulic fluid of a suitable viscosity for the operating temperature of the drill rig.
Select a viscosity grade (VG) and viscosity index (VI) as specified in the following table. A high viscosity
index reduces the effect of temperature on the hydraulic fluid.

Normal operating
Min start temp. C Viscosity grade VG
temp. C Max temp. C Viscosity index VI
(Viscosity min. 1000 cSt) (ISO 3448)
Viscosity 25-50 cSt
+50 to +70 +5 80 ISO VG 100 Min. 100
+45 to +60 -5 75 ISO VG 68 Min. 100
+35 to +50 -10 65 ISO VG 46 Min. 100
+25 to +40 -15 55 ISO VG 32 Min. 100
+10 to +25 -25 35 ISO VG 15 Min. 100

IF THE VISCOSITY IS TOO LOW:

The hydraulic fluid may not form a lubricating layer between surfaces, thus increasing the risk of wear.
The hydraulic fluid can leak past seals more easily in the rock drill thus increasing fluid losses and incre-
asing energy requirements.

IF THE VISCOSITY IS TOO HIGH:

Flow losses in the hydraulic lines will be high increasing energy consumption and pressure levels, putting
increased strain on seals.
The risk of cavitation will increase, thus also the risk of damage to the rock drill and hydraulic pumps.

The hydraulic fluid must be filtered to a purity of 20/18/15 in accordance to ISO 4406.
The viscosity will change during the period that the hydraulic fluid is used. In general viscosity will drop with
increased operating hours. To ensure that the viscosity of the fluid does not drop to a critical level before
the recommended service interval, a hydraulic fluid of sufficient stability must be used. The viscosity in cSt
of suitable hydraulic fluids shall drop a maximum of 25% when tested for shear stability in accordance with
DIN 51350-6 at 100 C.

THE HYDRAULIC FLUID MUST BE CHANGED AT REGULAR INTERVALS. FACTORS INFLUENCING

THE INTERVAL BETWEEN CHANGES:
The viscous stability of the hydraulic fluid as specified above. The hydraulic fluid must be changed before
the viscosity drops to a critical level.
Contamination with water. If the hydraulic fluid becomes cloudy and light grey, the water content has
become such that the hydraulic fluid must be changed.
Deterioration of properties such as oxidation inhibition and anti-foaming.

ENVIRONMENT!
Excess and/or waste hydraulic fluid must be disposed of in an environmentally suitable manner and in
accordance with regulatory requirements.

31
HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15

15.2 PNEUMATIC TOOL OIL

Atlas Copco recommends the use of Atlas Copco COP OIL which has been specially developed for our
hydraulic rock drills. COP OIL is an environmentally friendly, degradable oil which can be used in ambient
temperatures between -25 C and +50 C.
COP OIL can be ordered with the following part numbers:

Quantity Part number

1 can of 10 litres 3115 3125 00
48 cans of 10 litres 3115 3126 00
1 barrel of 208 litres 3115 3127 00

If COP OIL is not available then the oil should have the following properties:
Use an oil with good lubricating properties intended for compressed air tools.
The oil must have good adhesion capacity.
The oil must have additives that prevent foam formation.
Depending on ambient temperature, the oil should have the following viscosity grades if the viscosity
index (VI) is about 100:

Ambient temperature C Viscosity grade (ISO 3448)

-25 to 0 VG 15-32
-10 to +20 VG 32-46
+10 to +50 VG 46-68

The oil must have an EP additive which covers the following load-bearing properties:

ASTM D 2783 Min. 250 kg

ASTM D 4172 (40 kg) Max. 0.5 mm

15.3 GREASE
NB! Because of the operating temperature in the rock drill gear housing, always use a high-temperature
grease with lithium complex soap based on a synthetic base fluid (polyalphaolefin/synthetic ester) with addi-
tives that protect against oxidation, corrosion and wear at high loads and with EP additive.

Operating
NLGI number Drop point Base oil viscosity
Temperature
1.5 250 C 400-600 mm2/s -40 to +150 C
at 40 C

32
HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15

33