Professional Documents
Culture Documents
Maintenance instructions
Hydraulic Rock drills
COP 1838HD
Contents
1. General............................................................................................................................. 5
Environment ....................................................................................................................................5
Safety regulations ............................................................................................................................5
Warning boxes............................................................................................................................. 5
The following general safety rules must be observed ................................................................. 6
2. Service interval ............................................................................................................... 9
Before starting a new or newly overhauled rock drill .......................................................................9
After each shift when using a new or newly overhauled rock drill ...................................................9
Before each shift ..............................................................................................................................9
After every 40th percussion hour .....................................................................................................9
Every 400th percussion-hour: ..........................................................................................................9
3. Hose connections ......................................................................................................... 10
Connecting the hoses ....................................................................................................................10
4. Tightening torques ....................................................................................................... 11
Adjusting the side bolts ..................................................................................................................12
Tightening the side bolts............................................................................................................ 12
Retightening the side bolts ........................................................................................................ 12
5. Accumulators ................................................................................................................ 13
Safety labels ..................................................................................................................................13
Location and meaning ............................................................................................................... 13
Charging the accumulators ............................................................................................................13
Checking the accumulators in the event of hose vibration ............................................................13
Damper accumulatorand intake accumulator ........................................................................... 13
Replacing intake and damper accumulator ...................................................................................14
Dismantling................................................................................................................................ 14
Assembly ................................................................................................................................... 14
Replacing the return accumulator ..................................................................................................15
Dismantling................................................................................................................................ 15
Assembly ................................................................................................................................... 15
6. Hydraulic motor ............................................................................................................ 16
Replacing the hydraulic motor .......................................................................................................16
Dismantling................................................................................................................................ 16
Assembly ................................................................................................................................... 16
7. Filling with lubricating oil and bleeding the system.................................................. 17
8. Settings.......................................................................................................................... 18
Setting of ECL lubricating system ..................................................................................................18
Setting the damper pressure .........................................................................................................18
9. Removing the front head.............................................................................................. 19
10. Checking the front head............................................................................................... 20
11. Mounting the front head............................................................................................... 21
12. Slinging, weights, storage and hose length ............................................................... 22
Slinging ..........................................................................................................................................22
Rock drill weights ...........................................................................................................................22
Long-term storage .........................................................................................................................22
13. Lubrication .................................................................................................................... 23
Lubrication of gear .........................................................................................................................23
14. Hydraulic and lubricant recommendations ................................................................ 24
Hydraulic fluid ................................................................................................................................24
Pneumatic tool oil ..........................................................................................................................25
Grease ...........................................................................................................................................25
3
Contents
4
General 1
Warning boxes
Environment The manual contains warnings.
Environmental regulations Warnings are preceded by a heading (Danger,
Warning and Caution).
Care for the environment!
Warning boxes
Leaking hydraulic couplings and grease are
hazardous to the environment.
Danger
Changing oils, hydraulic hoses and various Indicates an imminent risk of serious or fatal
types of filter can be hazardous to the environ- injury if the warning is not heeded.
ment.
5
General 1
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- Make sure that the safety labels are fitted, clean
nance, all components that could possibly move and fully legible.
or drop must be supported safely on blocks or Particular attention must be paid to all warnings
trestles, or secured by means of adequately in the manual.
dimensioned slings.
Exercise caution when jointing drill rods and
Check that the hoses used are of the right with drill bit handling. Watch your fingers!
quality, and that all hose connections are in
good condition and properly tightened. Hoses Make sure that clothes do not come too close to
that loosen could cause serious injury. rotating machine parts.
Use only Atlas Copco original parts. Any Negligence could cause serious injury.
damage or malfunction caused by the use of
non-original Atlas Copco parts is not covered by
warranty or product liability.
6
General 1
Important!
A mining machine has many components and
implements that are controlled by a hydraulic
system, either directly or indirectly. Before
working on or inspecting any part of a mining
machine, it is important that the individual
knows how the components move and are
controlled by the hydraulic system components
including the respective control circuits.
7
General 1
8
Service interval 2
2. Service interval
Part numbers for the repair kits are in the rock drill’s spare parts catalogue
After each shift when using a new or newly overhauled rock drill
• Tighten all threaded unions ..................................................................................................................4
Important!
Always function test the rock drill after service.
9
Hose connections 3
3. Hose connections
8
7
1250 0240 34
1
5
2 3 4
10
Tightening torques 4
4. Tightening torques
5 1
4
3
14 13
9
6
11 12
10
7 8
1250 0240 35
9
11
3 2 9 6
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
3 4 Side bolt 350 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 2 Intake, flushing medium 220 Tighten the screws alternately to full
torque
11
Tightening torques 4
1
1250 0240 36
3
2
12
Accumulators 5
• Tighten the valve nut (5) and close the gas valve
1250 0217 44
(6).
4
2 6
3 7
13
Accumulators 5
• Charge by means of admitting air at • Tighten the bolts (C and D) alternately to tighte-
atmospheric pressure into the accumulator. ning torque 220 Nm.
82
1250 0244 72
B
A
221
D
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.
14
Accumulators 5
1250 0240 39
1
8
2 7 Assembly
• Install new O-rings (8) and (9) in the return accu-
mulator (1).
Caution!
Ensure that the hydraulic, water and air • Loosely screw the return accumulator (1) onto
systems are depressurised before starting the rock drill using pressure screw (7).
work on the system. • Thread the clamp (6) onto the return accumu-
For reasons of safety, under no circumstance lator (1) and screw the clamp with the bolts (3)
may the pressure hoses be replaced with and the nuts (2) into place.
hoses of a lower quality. The hoses must be • Screw the bolt (4) into the rock drill.
high-pressure hoses with four layers of steel
reinforcement, quality SAE 100R9R. • Tighten the pressure screw (7).
There is a risk of injury if these instructions are • Connect the hydraulic hose to the return accu-
not observed! mulator (1).
15
Hydraulic motor 6
Dismantling
• Disconnect the hydraulic hoses (1).
16
Filling with lubricating oil and bleeding the system 7
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 lubri-
cation.
17
Settings 8
1250 0240 40
should be 2-3 bar. If the pressure is too low,
clean the restriction or increase the diameter of
the restriction.
• Set the correct lubricating oil dose. NB! The setting should take place at normal
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.
• After setting, check that the correct pulse • Connect a pressure gauge (A), calibrated for 0-
frequency has been obtained and that oil is 60 bar, between the hose and the damper union
emerging from the front head’s hole and (1).
between the shank adapter and front guide. • Pressurise the damper circuit.
18
Removing the front head 9
4
1
3
1250 0240 37
1
4
2
1250 0240 38
19
Checking the front head 10
8 7 3 A 3 3 1 5 6 2 9
C
4 B
12 14
1 1m 3 3 4 3 3
m
5
2 mm
m 2 7
1m D 6
R38
1250 0240 41
39 mm
T38
• Check that air and lubricating oil escape • Look inside the gear housing and check the
between the shank adapter (6) and front guide splines on the driver (5). If the splines are less
(7), and also out of the hole (B) than 2 mm in width, the driver must be changed.
Fit a new driver with the aid of a suitable
• Blow clean the lubricating air ducts (A) with mandrel and a copper hammer.
compressed air and check that the restrictions
(9) are open. • If the rotation chuck bushing (2) is worn by more
than 1 mm or is damaged in any other way then
• Replace the guide (7) if the inside diameter it must be replaced.
exceeds 39 mm. NB! Fit the rotation chuck bushing so that the
• Check the seal rings and flushing seals (3) if air lubricating grooves (D) are directed towards the
is escaping from the hole (C) in the front head. damper piston (14).
Replace the seal rings and flushing seals if they • Replace the shank adapter (6) if the thread is
are worn or damaged. worn out or the impact surface is warped or
• Replace the flushing head (4) if it is seriously chipped, or if the front or rear end surfaces of the
corroded, or if it contains cracks. splines are worn.
• Replace the stop ring (1) if it is worn by more • Check that the drill sleeve (8), to be used with
than 1 mm. upwards directed drilling, is not damaged and
rotates with the shank adapter.
20
Mounting the front head 11
6 5
1
4
2
1250 0244 31
• Fit the stop ring and shank adapter (4) into the
front head (1).
4
1
5
3
1250 0244 35
• Fit the seal ring (4) into the connecting plate (1).
• Fit the connecting plate (1) to the front head
using washers (3) and bolts (2). Tighten the
bolts (2) to a torque of 220 Nm.
• Replace the seal washer (5) if it is damaged.
21
Slinging, weights, storage and hose length 12
1250 0244 33
If the rock drill is not going to be used for a
long time, the following precautions should be
1250 0244 32 taken:
22
Lubrication 13
13. Lubrication
1250 0244 34
3
2
Lubrication of gear
• Unscrew the bleed plug with washer (1).
• Lubricate with heat-resistant grease through the
union (2) until grease escapes through the hole
(3).
• Tighten the bleed plug with washer (1).
23
Hydraulic and lubricant recommendations 14
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. ºC Viscosity grade VG
temp. ºC Max. temp. ºC 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
The hydraulic fluid must be changed at regular intervals. Factors influencing the interval between
changes are as follows:
• 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.
24
Hydraulic and lubricant recommendations 14
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:
• The oil must have an EP additive which covers the following load-bearing properties:
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
additives 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 ºC 400-600 mm2/s -40 to +150 ºC
at 40 ºC
25