Atlas Copco

Hydraulic Rock Drill

COP 1838 HD+
Version F
Maintenance instructions

PM no. 9852 2943 01b

2015-04
 SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.

Special attention must be paid

to information alongside
this symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

© Copyright 2015, Atlas Copco Rock Drills AB, Sweden

All product names in this publication are trademarks of Atlas Copco. Any unauthorised use or copying of the
contents or any part thereof is prohibited. Illustrations and photos may show equipment with optional extras.
No warranty is given regarding specifications or otherwise. Specifications and equipment are subject to
change without notice. Consult your Atlas Copco Customer Centre for specific information.

Translation of original instructions

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
 Table of Contents

Table of Contents
1. GENERAL .......................................................................................................... 3
1.1 Description of Manufacturing Number.......................................................................... 3
1.2 In the Event of Leakage Problems ............................................................................... 3
1.3 During Dismantling ....................................................................................................... 3
1.4 During Assembly .......................................................................................................... 3
1.5 Environment ................................................................................................................. 3
1.6 Safety Regulations ....................................................................................................... 4
1.6.1 Warning Boxes ....................................................................................................4
1.6.2 The Following General Safety Rules Must Be Observed ....................................4

2. TOOL LIST.......................................................................................................... 7
3. SERVICE INTERVAL ......................................................................................... 9
3.1 Overhaul Kits................................................................................................................ 9
3.2 Before Starting Up a New or Newly Overhauled Rock Drill.......................................... 9
3.3 After the First Shift With a New or Newly Overhauled Rock Drill ................................. 9
3.4 Before Each Shift ......................................................................................................... 9
3.5 After Every 40th Percussion-hour ................................................................................ 9
3.6 After Every 600th Percussion-hour .............................................................................. 9

4. HOSE CONNECTIONS .................................................................................... 11

4.1 General....................................................................................................................... 11
4.2 Connecting the Hoses ................................................................................................ 11

5. TIGHTENING TORQUES ................................................................................. 13

5.1 Bolted Joints............................................................................................................... 13
5.2 Nipples ....................................................................................................................... 14
5.3 Adjusting the Side Bolts ............................................................................................. 15
5.3.1 Tightening the Side Bolts ..................................................................................15
5.3.2 Retightening the Side Bolts ...............................................................................15

6. ACCUMULATORS ........................................................................................... 17
6.1 Safety Label Locations ............................................................................................... 17
6.2 Safety Label Meanings............................................................................................... 17
6.3 Charging the Accumulators ........................................................................................ 18
6.4 Pressure Checking the Accumulators ........................................................................ 20
6.4.1 Damper Accumulator and Intake Accumulator ..................................................20
6.4.2 Return Accumulator ..........................................................................................20
6.5 Replacing Intake and Damper Accumulator............................................................... 21
6.5.1 Dismantling .......................................................................................................21
6.5.2 Assembly ...........................................................................................................22
6.6 Replacing the Return Accumulator............................................................................. 23
6.6.1 General .............................................................................................................23
6.6.2 Dismantling .......................................................................................................23
6.6.3 Assembly ...........................................................................................................24

7. REPLACING THE HYDRAULIC MOTOR ........................................................ 25

7.1 Dismantling................................................................................................................. 25
7.2 Assembly.................................................................................................................... 25
7.3 Function and Condition Test of the Hydraulic Motor .................................................. 25
7.3.1 Function Test ....................................................................................................26
7.3.2 Belle Test ..........................................................................................................26
7.3.3 Half Belle Test ...................................................................................................27

1
Table of Contents

8. FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM ............. 29

9. SETTINGS ........................................................................................................ 31
9.1 Setting of ECL Lubricating System ............................................................................ 31
9.2 Setting Damper Pressure........................................................................................... 31

10. FRONT HEAD................................................................................................... 33

10.1 Dismantling .............................................................................................................. 33
10.2 Check....................................................................................................................... 35
10.3 Assembly ................................................................................................................. 38

11. DISMANTLING FROM CRADLE...................................................................... 41

11.1 Slinging .................................................................................................................... 41
11.2 Rock Drill Weights.................................................................................................... 41
11.3 Long-term Storage ................................................................................................... 41

12. LUBRICATION.................................................................................................. 43
12.1 Gear Housing........................................................................................................... 43

13. HYDRAULIC AND LUBRICANT RECOMMENDATIONS................................ 45

13.1 Hydraulic Fluid ......................................................................................................... 45
13.1.1 If the Viscosity is Too Low: .............................................................................45
13.1.2 If the Viscosity is Too High: .............................................................................45
13.1.3 The Hydraulic Fluid Must be Changed at Regular Intervals. ..........................45
13.2 Pneumatic Tool Oil................................................................................................... 46
13.3 Grease ..................................................................................................................... 46

2
 1. General

1. General
This instruction is intended as a guide when performing maintenance on your rock drill.

1.1 Description of Manufacturing Number

All rock drills are given a manufacturing number depending on place of manufacture, year, family and
version.
The manufacturing number is stamped-on and the location on the rock drill varies, depending on the model.

1. Factory code for manufacturing unit:

AVO= Atlas Copco Rock Drills AB 2 4
2. Year the product was produced.
3. Family letter identifying number series:
D = Hydraulic rock drill
P = Pneumatic rock drill
T = Rotation units
AVO 15 D 333B

1250 0404 84
4. Serial number in the "Family Group".
1 3 5
5. Version letter for the product. To show which
manual/spare parts list that is relevant.

1.2 In the Event of Leakage Problems

Check the source of the leakage before removing the rock drill from the rig.

1.3 During Dismantling

Always wash the rock drill externally using grease solvent before starting removal.
An assembly fixture must be used when dismantling the rock drill.

1.4 During Assembly

Pneumatic tool oil must be applied to the internal parts during all fitting unless otherwise stated.

1.5 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 environment.
Always collect oil residue, oil spill, oily waste and grease residue and spill. Treat according to appli-
cable local regulations.
Use biodegradable hydraulic fluid and lubrication oil wherever possible.

3
1. General

1.6 Safety Regulations

The Safety chapter contains important information for the prevention of accidents.

1.6.1 Warning Boxes

The manual contains 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.

1.6.2 The Following General Safety Rules Must Be Observed

r

Important!
Read through the maintenance instructions thoroughly before starting maintenance work. Follow
the instructions given and local regulations.
Do not use or intervene with 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.
Use approved lifting devices when handling the rock drill. Avoid lifting heavy weights yourself.
To prevent injury during service and maintenance, all components that could possibly move or drop
must be supported safely on blocks or trestles, or secured by means of adequately dimensioned
slings.
Check that the hoses used are of the right quality, and that all hose connections are in good condi-
tion 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.

Important!
Make sure that the rock drill has been maintained in accordance with the applicable instructions.
Before tramming the rig and rock drill or starting to drill, make sure that no personnel is in the imme-
diate 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 be present at the operating station and have a good view
of the work.
Always wear a helmet and earmuffs when drilling. Follow local regulations
Make sure that the place of work is well ventilated.
Make sure that the safety labels are fitted, clean and fully legible.
Particular attention must be paid to all warnings in the manual.
Exercise caution when jointing drill rods and with drill bit handling. Watch your fingers!
Make sure that clothes do not come too close to rotating machine parts.
Negligence could cause serious injury.

4
 1. General

Important!
A mining machine has many components and functions that are controlled by a hydraulic system,
directly or indirectly. Before working on or inspecting any part of the machine, it is important to know
how the machine moves and how its functions are controlled by the hydraulic system.
Prior to starting work or inspecting any part it must be physically locked/stopped from being able to
move and causing bodily injury. The mechanic must be careful to not place any body part where a
movement of the machine could cause injury if the hydraulic system fails or is disconnected.
There may be occasions where components and or vehicles start moving when trapped energy is
released. Where applicable, there must be confirmation that all measures to safeguard against
involuntary movement have been taken by releasing the energy and/or physically locking/stopping
the machine.
It is also incumbent on the individuals involved to ensure that all local, national and federal safety
regulations are followed, before and during the work or inspection.

5
1. General

6
 2. Tool List

2. Tool List

A1 A10 P

A4 A11
R
A12
A5 S
A13

A6 A14 V

1250 0378 70
A7 D PP

Letter Tools Part No.

A1 Plastic mallet
A4 U-ring spanners 10-32 mm, 46 mm
A5 Hexagon wrench 4-10 mm, 3/16"
A6 Crowbar
A7 Mandrel 2-10 mm, copper mandrel 20x250 mm
A10 Torque wrench 10-100 Nm 9106 1015 40
Torque wrench 75-400 Nm 9106 1015 41
A11 Socket wrench set with sockets 10-32 mm for external hexagon
Socket wrench set with sockets 4-10 mm for internal hexagon
Socket wrench set with socket 3/16" for internal hexagon
A12 Punch
A13 T-handle with 3/4" connection bracket, Power socket 32 mm
A14 Vernier calliper
D Mandrel 3115 1019 00
P Charging equipment for accumulators 3115 3425 80
R Pressure gauge inc. adapter 3115 3799 80
S Ring spanner 3115 2263 00
V Socket wrench 3115 1899 00
PP Removal tool for flushing head 3115 5255 00

7
2. Tool List

8
 3. Service Interval

3. Service Interval
3.1 Overhaul Kits
Overhaul kits are available for all types of Atlas Copco rock drills and rotation units, the kits are designed
to optimise the performance and service life of the rock drill/rotation unit. Information on the overhaul kits
is available in the spare parts catalogue for each rock drill/rotation unit. There you can find information on
what the kits contain and part numbers.

3.2 Before Starting Up a New or Newly Overhauled Rock Drill

Chapter
• Connect up the hoses ..........................................................................................................................4
• Charge the accumulators .....................................................................................................................6
• Select a suitable hydraulic oil and lubricant........................................................................................13
• Fill the lubricating system with oil .........................................................................................................8
• Adjust and set the lubricating system ...................................................................................................9
• Set the damper pressure ......................................................................................................................9

3.3 After the First Shift With a New or Newly Overhauled Rock Drill
• Tighten all threaded unions ..................................................................................................................5

3.4 Before Each Shift

• Check that air and lubricating oil escapes between the shank adapter and front guide, and also 
out of the hole in the front head. .......................................................................................................10
• Check that the drill rig’s damper pressure gauge is showing normal values while it is running at 
drilling speed. In the event of deviation, adjust the damper pressure ..................................................9
• Check that the shank adapter’s threads are not damaged.................................................................10
• Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulators .....................6
• Check that the machine does not leak. If the flushing medium leaks from the flushing head, 
replace the seals and O-rings.............................................................................................................10
• When replacing the shank adapter or removing the front head, check the internal components 
including piston, driver and the visible parts of the rotation chuck bushing ........................................10
• In the event of oil leakage from the front head: close percussion and only activate the damper 
in order to determine if the leakage is coming from the percussion or damper. .................................10

3.5 After Every 40th Percussion-hour

• Grease the gear .................................................................................................................................12
• Tighten all threaded unions ..................................................................................................................5
• Check the safety labels on the accumulators. Replace them if they are damaged or illegible.............6
• Check the accumulators .......................................................................................................................6

3.6 After Every 600th Percussion-hour

• Remove the rock drill from the drill rig. 
Transport the rock drill to a suitable workshop for inspection .............................................................11

Important!
Servicing should be carried out at appropriate 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 servicing.

Important!
Always function-test the rock drill after service.

9
3. Service Interval

10
 4. Hose Connections

4. Hose Connections
4.1 General

Caution!
Never attempt any maintenance or work on the rock drill, connections or hoses while the hydraulic,
lubrication or flushing pressure 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). See the rock drill’s spare parts list. 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!

8
7
1

6
5
1250 0380 49

2 3 4
1. Percussion drainage (HD)
2. Rotation, intake (RRL)
3. Rotation, return (RRR)
4. Percussion return (HT)
5. Percussion intake (HP)
6. Flushing (F)
7. Lubricating air (ECL)
8. Damper, intake (HDP)

4.2 Connecting the Hoses

• Clean the rock drill’s 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 connections plugged. Use suitable protective caps, and make
sure that they are clean.

11
4. Hose Connections

12
 5. Tightening Torques

5. Tightening Torques
5.1 Bolted Joints

1
4

14 13
12 6 16 9
5
8 10 17 15
9

7
11 9
1250 0380 50

3
2 9 16 6 15
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 alternately to full
torque
2 1 Front bolt 300 Tighten the front bolt
3 4 Side bolt 300 Tighten the front nuts alternately to full
torque
4 3 Back head 220 Tighten the bolts 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 bracket, return accu- 30
mulator
9 4 Rock drill mounting 250 Tighten the screws alternately to full
torque
10 1 Plug 45
11 4 Valve covers 145 Tighten the screws alternately to full
torque

13
5. Tightening Torques

Ref. Torque
Qty. Check point Instructions
No. Nm
12 2 Connecting plate 120 Tighten the screws alternately to full
torque
13 1 Flushing connector 300
14 2 Intake, flushing medium 220 Tighten the screws alternately to full
torque
15 2 Plug, accumulator 45
16 2 Filler nipple, accumulator 30
17 1 Pressure screw 170

5.2 Nipples

8
7
1

6
5
1250 0380 49

2 3 4

Ref. Torque
Def. Check point Instructions
No. Nm
1 HD Percussion, drain 70
2 RRL Rotation, intake 85
3 RRR Rotation, return 85
4 HT Percussion, return 170
5 HP Percussion, mechanism 170
6 F Flushing 300
7 ECL Lubricating air 70
8 HDP Damper, intake 70

14
 5. Tightening Torques

5.3 Adjusting the Side Bolts

5.3.1 Tightening the Side Bolts

1. Check whether the side bolts, dome nuts or

washers have cracks, scratches or rust. 1
Replace damaged side bolts, dome nuts and
washers.
2. Lubricate the threads and contact surfaces of
the side bolt, dome nuts and washers with
Never-Seez Regular Grade.

1250 0378 85
3. Tighten the rear dome nuts (1) alternately to
3
tightening torque. 2
4. Tighten the side bolt (2) to the tightening
torque.
5. Tighten the front dome nuts (3) alternately to
tightening torque.

5.3.2 Retightening the Side Bolts

1. Undo the front dome nuts (3) so that the

tension releases. 1
2. If the threads are seized, remove the dome
nuts, clean them and lubricate with Never-
Seez Regular Grade.
3. Tighten the front dome nuts (3) hand-tight.
4. Tighten the rear dome nuts (1) alternately to
1250 0378 85

tightening torque. 3
5. Tighten the side bolt (2) to the tightening 2
torque.
6. Tighten the front dome nuts (3) alternately to
tightening torque.

15
5. Tightening Torques

16
 6. Accumulators

6. Accumulators
Check the safety labels on the accumulators. Replace them if they are damaged or illegible.

6.1 Safety Label Locations

31. Damper accumulator

30. Intake accumulator
35. Return accumulator 31

1250 0380 51
30
35

6.2 Safety Label Meanings

1. Read the operator’s instructions carefully

before service or replacement of the accumu-
lator
2. Must only be charged with nitrogen gas
N2
1250 0187 04

1 2

17
6. Accumulators

6.3 Charging the Accumulators

Caution!
Charge the accumulators when they are assembled on the rock drill. There is a risk of injury if these
instructions are not observed!

Warning!
A gas other than N2 could cause an explosion.

1. Remove the charge valve’s protective cap (A).

1250 0345 16

2
A

18
 6. Accumulators

2. Fit the gas hose with the connection adapter

(3) on the new charging valve (2). Tighten the 31
connection adapter (3) using manual force.
3. Close the bleed valve (8) by turning the
control knob clockwise.
4. Close the pressure regulator (7) by turning the
control knob anticlockwise (-).
35 30
5. Open the bottle valve (9) slowly and check
that the high pressure gauge (4) gives
readings to full bottle pressure.

1250 0380 52
Notice! Charge at the bottom if possible rather 9
than too high.
5 3 2
6. Turn the pressure regulator control knob (7) 1
slowly clockwise (+) and set the desired filling 6
pressure on the low pressure gauge (6) or
high pressure manometer (5). N2
Damper accumulator (31): 20-25 bar 8
Return accumulator (35): must not be
charged with N2 4 7
Intake accumulator (30): 80-100 bar*
*Intake accumulator 30-40 bar below collaring
pressure. Normal 80-100 bar. Max. 100 bar.

7. In the event of the pressure being too high,

adjust the pressure regulator control knob (7)
anticlockwise (-). Evacuate the overpressure
carefully by turning the control knob for the
bleed valve (8) anticlockwise and then close
the bleed valve. Adjust the pressure regulator
(7) slowly to the correct accumulator pres-
sure.
8. Close the pressure regulator (7) by turning the
control knob anticlockwise (-).
9. Close the bottle valve (9).

10.Loosen the connection adapter (3) from the

charging valve (2). Notice! The gas in the
hose will hiss out. The accumulator is
switched off and will not release gas when the
1250 0345 16

adapter is removed.
11. Mount the protective cover (A) on the charge
valve, tighten using manual force.

2
A

19
6. Accumulators

6.4 Pressure Checking the Accumulators

Warning!
The hydraulic system must be depressurised before checking the accumulators.

6.4.1 Damper Accumulator and Intake Accumulator

1. Remove the charge valve’s protective cap (2).

2. Fit the pressure gauge (10) onto the charging
valve (1). Tighten using manual force.
3. Read the pressure gauge (10) and check that
the correct accumulator pressure is obtained.
Damper accumulator (31): 20-25 bar Intake 1
accumulator (30): 80-100 bar* *Intake
accumulator 30-40 bar below collaring pressure.
Normal 80-100 bar. Max. 100 bar.
4. Remove the pressure gauge (10) with
connection adapter (3).
5. If required, charge the accumulators with
30
nitrogen gas (N2). See chapter: Charging the
accumulators. 2
3
6. Refit the charge valve’s protective cap (2),
1250 0358 58

tighten using manual force.

10

6.4.2 Return Accumulator

1. Position the rock drill in horizontal position.

2. Remove the plug (11) with O-ring (12). If oil
escapes then the diaphragm is damaged or
the accumulator has been overcharged.
3. Replace the accumulator, diaphragm and/or
filler valve if they are not functioning properly.
4. If the diaphragm is resting against the outer
pipe, press the diaphragm with a cylindrical
(blunt) mandrel (7-9 mm).See Figure A. 35 11
11 12
Correct position for diaphragm, see Figure B.
5. Refit the plug (11) and O-ring (12).
6. Charge by means of admitting air at atmosp-
heric pressure into the accumulator.
A
1250 0378 71

20
 6. Accumulators

6.5 Replacing Intake and Damper Accumulator

Warning!
All gas must be released before removal, by means of removing the protective cap and fitting the
connection adapter (3).
There is a risk of injury if these instructions are not observed!

Caution!
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.

Important!
Use 65 mm long screws when using the HD accumulator.

6.5.1 Dismantling

1. Remove the charging valve’s (2) protective

cap (A).
2. Fit the connection adapter (3), and the
nitrogen gas (N2) in the accumulator is rele-
1250 0345 15

ased.
Notice! Align the connection adapter so that
there is no risk of personal injury.
3. Remove the connection adapter (3) and refit
the protective cap (A) of the charge valve (2),
tighten hand-tight.

2
3
A

4. Remove the accumulators (30 and 31) with

seal rings (350) by loosening the bolts (10). 30
5. Send the accumulators to a workshop for
overhauling!
10
350 31
10
1250 0378 72

350

21
6. Accumulators

6.5.2 Assembly

1. Position the seal rings (350) in the grooves on

the intermediate segment. 30
Notice! The seal rings (350) must be turned in
accordance with the figure.
2. Make sure that the seal rings (350) do not get
damaged during the assembly. 10
3. Mount the damper accumulator (31) on the left 350 31
side of the rock drill. 10
4. Intake accumulator (30) on the right side of

1250 0378 72
the rock drill (hose side). 350
5. Mount with undamaged original bolts. The
intake accumulator (30) must have two bolts
with a length of 65 mm. The damper accumu-
lator (31) must have two bolts with a length of
65 mm. Replace the bolts in pairs even if only
one bolt is corroded or damaged in some
other way.
6. Tighten the screws alternately to the tighte-
ning torque in accordance with the chapter
Tightening torques.
7. Charge the accumulators with nitrogen gas
(N2), see chapter Charging the accumulators.

22
 6. Accumulators

6.6 Replacing the Return Accumulator

6.6.1 General

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 not observed!

6.6.2 Dismantling

1. Remove the hydraulic hose from the return

accumulator (35).
2. Remove the return accumulator (35) by
removing the nuts (24), the bolts (23), the bolt
(1) and the holder (22). 1
3. Pull away the clip (21). 23
4. Unscrew the pressure screw (5) with O-ring
(6). 22
5. Detach the return accumulator (35) with O-
ring (7) from the cylinder. 11

1250 0378 73
6. Send the return accumulator (35) to a
workshop for reconditioning. 21 7

35 6
24 5

23
6. Accumulators

6.6.3 Assembly

1. Mount the pressure screw (5) with the O-ring

(6) on the return accumulator (35).
2. Fit the O-ring (7) in the groove on the pressure
screw (5).
3. Mount the return accumulator (35) on the 1
cylinder with the pressure screw (5) and O- 23
ring (7). Screw the pressure screw (5) loosely.
Notice! Carefully check that the O-ring (7) is
22
not damaged and that the plug (11) remains
accessible for checking the accumulator
11
membrane.

1250 0378 73
4. Thread on the clamp (21) and fit the holder 21 7
(22) with screws (1, 23) and nuts (24). Tighten
the screws and nuts to the tightening torque
according to chapter Tightening torques. 35 6
5. Tighten the pressure screw (5) to the tighte- 24 5
ning torque in accordance with the chapter
Tightening torques.
6. Connect the hydraulic hose to the return
accumulator (35).

24
 7. Replacing the Hydraulic Motor

7. Replacing the Hydraulic Motor

Caution!
Ensure that the hydraulic, water and air systems are depressurised before starting any work on the
systems.
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). See the rock drill’s spare parts list. 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!

7.1 Dismantling
Depending on the size of the hydraulic motor, the rock drill needs to be detached from the cradle.

1. Remove the hydraulic hoses.

2. Loosen the nuts (25) with a ring spanner (S)
S
and remove the hydraulic motor (20) and
gasket (24).
3. Pull out the coupling (21).

22 21
401 24
1250 0378 74

25 20

7.2 Assembly

1. Make sure that the groove ring (22) is fitted in

the coupling (21).
S
2. Lubricate the coupling’s splines with grease
and fit the coupling (21) on the hydraulic motor
(20).
3. Fit the gasket (24) and hydraulic motor (20)
onto the cylinder (401). Replace the gasket
(24) if it is damaged.
4. Tighten the nuts (25) alternately to the correct 22 21
401 24
1250 0378 74

tightening torque according to chapter Tighte-

ning torques with a ring spanner (S). 25 20
5. Connect the hydraulic hoses. Check that the
correct direction of rotation is obtained.

7.3 Function and Condition Test of the Hydraulic Motor

The following tests give an approximation of the present state of the motor.
The following items are required to conduct the tests:
• Apparatus for hydraulic flow and pressure.
• A pressure gauge.
• A flow meter in the 0-15 l/min range, preferably with an accuracy of at least 0.5 l/min
• Couplings and hoses to assemble the components.
• A fixture to lock the rotation of the rear axle.
• Oil grade HLP46 at 50 degrees and viscosity approx. 35 CST

25
7. Replacing the Hydraulic Motor

7.3.1 Function Test

1. Connect the hydraulic hoses P (Pressure) and

R (return) to the hydraulic motor.
2. Allow the motor to rotate for about 30 seconds
with a maximum flow of 10 l/min.
3. Make sure rotation is smooth and without
noise.
P

1250 0403 55
7.3.2 Belle Test
For motors with external drainage line only.
The test indicates the general state of the motor, including axial wear, condition of seals, valves, etc.
Replace the motor if the size of the leak exceeds table value.

Test procedure:
1. Plug port "B" with a suitable plug. B AA
2. Connect a flow meter to the motor’s drainage
line. T (drain)
3. Make sure the motor shaft can rotate freely.
4. Pressurise port "A" in accordance with the
following table. Make sure to use the correct
pressure for the current motor type!
P
5. Measure the flow from the drainage line.
Replace the motor if it exceeds the specified
1250 0403 56

value. R

Motor Type Pressure Port Permitted Flow

A in Drainage
Line

MS 210 bar 3,5 l/min

26
 7. Replacing the Hydraulic Motor

7.3.3 Half Belle Test

The following test indicates the condition of the gear wheel in the motor. It can be used for all motors.

Test procedure:
B
1. If the motor has a drainage line, couple it to
port "B" with a T-coupling. A
2. Couple the flow meter to port "B" on the motor. T (drain)
3. Secure the rear axle with suitable equipment.
It must not rotate.
4. This unit can be ordered for type MS motors. S
5. Pressurise port "A" in accordance with the P
following table. Make sure to use the correct
pressure for the current motor type!

1250 0403 57
R
6. Measure the flow from port "B" (if necessary in
combination with the drainage line). Replace
the motor if it exceeds the specified value.

Motor Type Pressure Port Permitted Flow

A in Drainage
Line

MS 80-160cc 140 bar 10 l/min

MS 200-315 110 bar 10 l/min
MS 400-475 70 bar 10 l/min

27
7. Replacing the Hydraulic Motor

28
 8. Filling with Lubricating Oil and Bleeding the System

8. Filling with Lubricating 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 important 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.
The lubricating oil tank holds 5 l. See chapter: Hydraulic oil and lubricant recommendations.
If the lubricating system has been empty of oil, it must be bled after filling. See the respective Rig manuals
for instructions.

29
8. Filling with Lubricating Oil and Bleeding the System

30
 9. Settings

9. Settings
9.1 Setting of ECL Lubricating System
ECL=Electric Controlled Lubrication
Rock drill lubrication must be set with regard to local conditions.
1. Start the lubricating system.
2. Check the lubricating air pressure at the rock drill using a pressure gauge. The pressure should be 2.5-
3 bar. If the pressure is too low, clean the restriction or increase the diameter of the restriction.
3. Set the correct lubricating oil dose:
Pump (3217 8667 50) - 35-40 pulses/min
Pump (3217 8667 52) - 20-25 pulses/min
4. After setting, check that the correct pulse frequency has been obtained and that oil is emerging from the
front head’s hole and between the shank adapter and front guide.

9.2 Setting Damper Pressure

Notice! The setting should take place at normal operating temperature for the hydraulic oil.

1. Fully close the constant flow valve (B) on the

drill rig.
1
2. Connect a pressure gauge (A), calibrated for
0-60 bar, between the hose and the damper
union (1).
3. Pressurise the damper circuit.
4. Check that the shank adapter is unloaded and
in the forward position.
5. Adjust the constant flow valve until the pres-
B
1250 0378 75

sure gauge (A) shows 35 bar (operator panel

shows 40 bar).
6. Disconnect the pressure gauge (A) and
connect the hose to the union (1).

31
9. Settings

32
 10. Front Head

10. Front Head

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

Caution!
The percussion mechanism must not be enabled, when the shank adapter is dismantled. Piston and
front piston guide can be damaged.

Notice! Always clean the outside of the rock drill before dismantling.

10.1 Dismantling

1. Remove the flushing hose.

2. Remove the connecting plate (186) by
undoing the bolts (188) with the washers
(189).
3. Remove the seal (194).

194
186

189
1250 0378 78

188

4. Remove the front nuts (10) with their washers

(11).
5. Remove the front head (172) by pulling the
shank adapter (1) or by tapping with a plastic
mallet.

191
172
1
1250 0378 79

11
10

33
10. Front Head

6. Remove the drill sleeve (5).

7. Pull the shank adapter (1) from the front head 1
(172). 181
172

1250 0378 80
8. Mount the tool (PP) in the cup seals (175)
through the flushing connection hole in the
front head.
9. Use a mandrel and a plastic mallet to tap out A1
the stop ring (185), washer (184) and flushing
head (174). PP

172

174

175
PP
184

1250 0378 77
185

10.If necessary, press the guide (177) out of the

front head (172). Use a mandrel (D) to remove
the guide.

177

172
1250 0378 86

34
 10. Front Head

10.2 Check
Overview illustration of the front head

1 5 177 172 174 184 185 152 260 202 261 360 430
1250 0378 81

178 175 192 175 192 176 195 193

Many of the position numbers in the instructions below are included in the figure above.

1. Check that air and lubricating oil escape

between the shank adapter (1) and front guide
(177), and also out of the hole (B)
2. Blow clean the lubricating air ducts with
compressed air and check that the restrictions
are open
1
1250 0380 55

3. Replace the guide (177) if the inside diameter

exceeds 39 mm. Notice! Max. dimension. 178
4. Check the lubricating channels on the guide.
5. Check that the wiper (178) is not worn or
damaged. Notice! The wiper (178) must be 177
turned in accordance with the figure.

39 mm
1250 0378 82

35
10. Front Head

6. Check the seal rings (192) and the cup seals

(175-176) if air is escaping from the hole (C) 192
in the front head. Replace the seal rings (192)
and cup seals (175-176) if they are worn or 176
damaged. 175
Notice! The cup seals must be turned in
accordance with the figure. 174
7. Replace the flushing head (174) if it is serio-
usly corroded, or if it contains cracks. 175
192

1250 0378 83
8. Replace the stop ring (185) if:
i

• any point within the wear surface (S) is worn

more than 1 mm, compare with a new stop
ring
• any cracks (signs of breakage) are found 1,0
• the wear surface (S) is uneven 193
M - Measuring point
S - Wearing surface 185
9. Check and replace the O-rings (193, 195) if 195 S
they are worn or damaged.
M
1250 0378 84

185

10.Look inside the gear housing and check the

splines on the driver (260). If the splines are 260
less than 2 mm in width, the driver (260) must
be replaced.
1250 0318 84

36
 10. Front Head

11. Send the rock drill to a workshop for inspec-

tion if: 1,0
261
• the rotation chuck bushing (261) is worn
more than 1 mm on the wear surface (S)
• after 600 percussion hours
• if the impact piston’s (430) impact surface is
damaged in any way
12.Also replace the rotation chuck bushing (261)
if marks (wave type) from splines are visible M
on the wear surface (S).
13.Notice! Fit the rotation chuck bushing so that
the lubricating grooves are directed towards
the damper piston (360).
M - Measuring point
S
S - Wearing surface

1250 0325 89
14.Replace the shank adapter (1) if:
• the thread is worn out
• the impact surface is crushed or chipped
• the front or rear end surfaces of the splines
are worn
1250 0318 87

15.Check that the drill sleeve (5), to be used with

upwards directed drilling, is not damaged and 5
rotates with the shank adapter (1).
1250 0380 53

37
10. Front Head

10.3 Assembly

Important!
Before fitting the parts must be lubricated with clean hydraulic oil.

1. Check that the lubricating duct (A) is open by

blowing with compressed air.
2. Press the guide (177) with wiper (178) into the A
front head (172). Use mandrel (D).
D

172

1250 0378 87
178
177

3. Fit the cup seals (175-176) in the flushing

head (174). Notice! The cup seals (175-176) 192
must be turned in accordance with the figure.
176
4. Fit the seal rings (192) on the flushing head.
175
174

175
192

1250 0378 83

38
 10. Front Head

5. Press in the flushing head (174) using the

mandrel (D) and the sleeve (V). Notice! The
flushing head must be turned so that the lubri-
cating grooves are upwards. See the figure.
6. Also make sure that the flushing hole in the D
flushing head is aligned with the hole (A) in the
front head (172).

172
174
A

1250 0378 93
7. Fit the washer (184) in the front head (172).
8. Fit the stop ring (185) with O-rings (193, 195) 193
in the front head. Tap with a plastic mallet. 185
195
184

172

1250 0378 94

9. Slide the shank adapter (1) into the front head

(172). 1
10.Fit the drill sleeve (5) on the shank adapter. 181
11. Check and replace the seal ring (181) if it is 172
worn or damaged.

5
1250 0378 80

39
10. Front Head

12.Make sure that the pin (191) is fitted in the

cover plate. Place the front head (172) on the
side bolts.
13.Lubricate the threads and contact surfaces for
the washers (11) and nuts (10) with thread
grease.
14.Fit the washers (11) and nuts (10). 191
15.Check the tightening torques on the rear side- 172
bolt nuts and the front side bolt. See chapter 1

1250 0378 79
Tightening torques. 11
10
16.Tighten the front nuts (10) alternately to the
tightening torque given in chapter Tightening
torques.

17.Fit the seal ring (194) into the flushing head.

18.Fit the connecting plate (186) on the front
head using washers (189) and screws (188).
Notice! Also make sure that the flushing hole
in the flushing head aligns with the hole in the
front head.
19.Tighten the screws (188) alternately to the
tightening torque in accordance with the
chapter Tightening torques. 194
20.Replace the seal washer if it is damaged. 186
21.Fit the nipple on the connecting plate. Tighten
to the tightening torque in accordance with the
chapter Tightening torques. 189
1250 0378 78

22.Connect the flushing hose and tighten the nut.

188
After assembly
Check that air and lubricating oil escape from the
holes (B and C) in the front head and between the
shank adapter and guide.

40
 11. Dismantling From Cradle

11. Dismantling From Cradle

11.1 Slinging

Caution!
Lifting devices and straps must be approved for lifting at least 500 kg.
Incorrect lifting devices could cause the rock drill to start moving or fall down.
Incorrect operation could cause crushing damage.

Make sure that the rock drill is safely slung for

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

1250 0380 54
11.2 Rock Drill Weights

COP 1838 HD+ 185 kg

11.3 Long-term Storage

If the rock drill is not going to be used for a long time, the following precautions should be taken.
1. Check that all connections, including the one for the flushing medium, are properly capped with protec-
tive caps of the right size
2. Clean the rock drill carefully. Use degreasing agent and rinse with water.
3. Clean thoroughly and oil in the front head components in contact with flushing medium (especially in
high humidity).
4. Fill grease in the nipples in the front.
5. Release gas from the accumulators.
6. Store the rock drill in a dry place.

41
11. Dismantling From Cradle

42
 12. Lubrication

12. Lubrication
12.1 Gear Housing

1. Unscrew the bleed plug (214) with gasket

(215). 215 214
2. Lubricate with heat-resistant grease through
the grease nipple (212) until grease escapes 3
through the hole (3) for the bleed plug.
3. Tighten the bleed plug (214) with gasket
(215).

1250 0319 01
212

43
12. Lubrication

44
 13. Hydraulic and Lubricant Recommendations

13. Hydraulic and Lubricant Recommendations

13.1 Hydraulic Fluid
Atlas Copco offers a range of hydraulic oils based on operational requirements and varying temperature
ranges. These oils provide superior protection against wear, rust and oxidation, as well as air and water
separation and good anti-foaming. All Atlas Copco hydraulic oils conform to standard ISO 11158 HM, DIN
51524 HLP/HVLP and ISO 15380 (for biodegradable options).
The diversity of Atlas Copco hydraulic oil helps fulfil all limit values for viscosity as required for different
operating conditions and ambient temperatures. It is important to have the viscosity grade suited for your
operating environment (please review the table below). There are different types of oils across these
ranges, varying from mineral to synthetic-based. These oils ensure high efficiency operation with superior
purity and excellent filtration.

Hydraulic oil Climate 20 Litres 209 Litres 1000 Litres

100 ISO VG 46 Normal 9106 2303 21 9106 2303 20 9106 2303 26
120 ISO VG 46 Normal Degradable 9106 2303 22 9106 2303 33
9106 2303 23
200 ISO VG 32 Arctic 9106 2303 27 9106 2303 28 9106 2303 29
300 ISO VG 68 Tropical 9106 2303 30 9106 2303 31 9106 2303 32

13.1.1 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 causing increasing fluid losses and
increasing energy requirements.

13.1.2 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 100ºC.

13.1.3 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-friendly manner and in
accordance with regulatory requirements.

45
13. Hydraulic and Lubricant Recommendations

13.2 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 ºC and +50 ºC.
COP OIL can be ordered with the following part numbers:

Quantity Part Number

1 can of 4 litres 3115 3125 02
1 can of 20 litres 3115 3125 01
24 cans of 20 litres 3115 3126 01
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 ºC Viscosity grade (ISO 3448)

-30 to 0 VG 32-68
-10 till +20 VG 68-100
+10 till +50 VG 100-150

• 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

13.3 Grease
Notice! 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
additives that protect against oxidation, corrosion and wear at high loads and with EP additive.

Operating
NLGI number Drop point Base oil viscosity
Temperature
2 260 ºC 220 cSt at 40 ºC -15 to +150 ºC

Atlas Copco recommends the use of Atlas Copco COP Grease, gear housing grease, which has been
specially developed for our hydraulic rock drills. COP Grease withstands temperatures between -40ºC to
+150ºC, and temperatures of up to 220ºC during shorter periods.
COP Grease can be ordered with the following part numbers:

Quantity Part Number

Tube 0.4 kg 3115 3422 00
Can 18 kg 3115 3423 00

46
www.atlascopco.com