9853 1345 01 Manual Mantenimiento Cop MD20

Overhaul
COP MD20 Ver.A

Hydraulic Rock Drill
Original Instructions
2021-04-08 | No: 9853 1345 01i. en-US
COP MD20 Ver.A Table of Contents
Table of Contents
1 Introduction ............................................................................................................ 7
1.1 Safety first ................................................................................................................................. 7
1.2 The Purpose of This Publication ............................................................................................. 7
1.3 Target Group ............................................................................................................................. 8
1.4 Feedback and Contact Information ......................................................................................... 8
2 General Information............................................................................................... 9
2.1 Component Replacement......................................................................................................... 9
2.2 Manufacturing Number............................................................................................................. 9
2.3 Cleaning ................................................................................................................................... 10
2.3.1 Safety Precautions Before Cleaning..................................................................................... 10
2.3.2 Cleaning ............................................................................................................................... 10
2.3.3 Hydraulic Hoses ................................................................................................................... 10
2.4 Hydraulic Components........................................................................................................... 11
2.4.1 General................................................................................................................................. 11
2.4.2 Hydraulic Workshops............................................................................................................ 11
2.4.3 Hydraulic Hose Replacement ............................................................................................... 12
2.5 Welding .................................................................................................................................... 12
2.6 Prepare for Long Period of Storage or Marine Transportation .......................................... 12
2.7 After Long Period of Storage ................................................................................................. 13
3 Lift Rock Drill ....................................................................................................... 15
4 Tools ..................................................................................................................... 17
4.1 Standard Tools ........................................................................................................................ 17
4.2 Special Tools ........................................................................................................................... 18
5 Tightening Torques ............................................................................................. 21

5.1 Tighten All Threaded Unions ................................................................................................. 21
5.2 Tighten Nipples ....................................................................................................................... 22
6 Main Parts............................................................................................................. 25
7 Disassemble Rock Drill ....................................................................................... 27

7.1 Secure Rock Drill to Work Surface........................................................................................ 27
7.2 Discharge Accumulators........................................................................................................ 28
7.3 Front Head ............................................................................................................................... 28
7.3.1 Disassemble Front Head ...................................................................................................... 28
7.3.2 Disassemble Front Head Parts Seals and O-Rings ............................................................. 31
7.4 Gear Housing .......................................................................................................................... 33
7.4.1 Disassemble Gear Housing.................................................................................................. 33
7.4.2 Disassemble Gear Housing Parts, Seals, and O-Rings ....................................................... 37
7.5 Cylinder, Liner, and Impact Piston ........................................................................................ 38
7.5.1 Disassemble Cylinder, Liner, and Impact Piston .................................................................. 38
7.5.2 Disassemble Cylinder Parts, Seals, and O-Rings ................................................................ 43
7.6 Accumulators .......................................................................................................................... 45
7.6.1 Disassemble Intake and Return Accumulator ...................................................................... 45
8 Inspection Rock Drill Parts ................................................................................. 49

8.1 Front Head ............................................................................................................................... 49
iii No: 9853 1345 01i. en-US

8.1.1 Inspect Channels, Restrictions, and Plugs ........................................................................... 49

8.1.2 Inspect and Replace Front Head Parts ................................................................................ 50
8.2 Gear Housing .......................................................................................................................... 51
8.2.2 Inspect and Replace Parts in Gear Housing ........................................................................ 53
8.3.2 Inspect and Replace Cylinder, Liner, and Impact Piston Parts ............................................ 58
8.4 Accumulators .......................................................................................................................... 60
8.4.1 Inspect and Replace Parts Intake and Return Accumulator................................................. 60
9 Assemble Rock Drill ............................................................................................ 63

9.1 Accumulators .......................................................................................................................... 63
9.1.1 Assemble Intake and Return Accumulator ........................................................................... 63
9.2 Front Head ............................................................................................................................... 66
9.2.1 Assemble Seals and O-Rings............................................................................................... 66
9.2.2 Assemble Front Head........................................................................................................... 68
9.3 Gear Housing .......................................................................................................................... 70
9.3.1 Assemble Gear Housing Seals and O-Rings ....................................................................... 70
9.3.2 Assemble Gear Housing....................................................................................................... 73
9.4.1 Assemble Seals and O-Rings............................................................................................... 81
9.4.2 Assemble Cylinder, Valve Piston, Cover, and Impact Piston Guide..................................... 83
9.5 Rock Drill ................................................................................................................................. 89
9.5.1 Assemble Rock Drill ............................................................................................................. 89
10 Warning Signs...................................................................................................... 91
10.1 General..................................................................................................................................... 91
10.2 Warning Signs Accumulators ................................................................................................ 91
10.3 Warning Sign Location Accumulators .................................................................................. 91
11 Charge Accumulators ......................................................................................... 93

11.1 Connect Accumulator Charger to Gas Cylinder .................................................................. 93
11.2 Connect Accumulator Charger to Accumulator .................................................................. 94
11.3 Charge Accumulator............................................................................................................... 95
11.4 Disconnect Accumulator Charger ......................................................................................... 96
12 Function Tests ..................................................................................................... 97

12.1 Hydraulic Motor....................................................................................................................... 97
12.1.1 Function and Condition Test Hydraulic Motor ...................................................................... 97
12.1.2 Perform Hydraulic Motor Test............................................................................................... 98
12.1.3 Perform Half Belle Test ........................................................................................................ 99
12.2 Leakage Test ......................................................................................................................... 100
12.2.1 Prepare for Leakage Test................................................................................................... 100
12.2.2 Perform Leakage Test ........................................................................................................ 100
12.3 Percussion Test .................................................................................................................... 101
12.3.1 Prepare for Percussion Test............................................................................................... 101
12.3.2 Perform Percussion Test .................................................................................................... 101
12.4 Rotation Test ......................................................................................................................... 102
12.4.1 Prepare for Rotation Test ................................................................................................... 102
12.4.2 Perform Rotation Test ........................................................................................................ 103
13 Lubrication ......................................................................................................... 105
13.1 Hydraulic and Lubricant Recommendations...................................................................... 105
iv No: 9853 1345 01i. en-US

13.1.1 Hydraulic Fluid.................................................................................................................... 105

13.1.2 Pneumatic Tool Oil ............................................................................................................. 106
13.1.3 Grease................................................................................................................................ 107
v No: 9853 1345 01i. en-US

vi No: 9853 1345 01i. en-US

COP MD20 Ver.A 1 Introduction
1 Introduction
1.1 Safety first
WARNING
Serious injury
Risk of personal injury!
u Never operate the Rock Drill in any explosive environment.
u Always read the machine Safety Manual before start maintenance work on the Rock
Drill.
u Always observe local regulations.
u Always let the Rock Drill to cool down before maintenance work.
u Always carry out a documented risk analysis and take the necessary precautions be-
fore maintenance work.
u Only use clean, calibrated tools in good condition.
u Only use approved handling and working equipment in good condition.
u Always use personal protective equipment.
u During maintenance work, the equipment should be shut down, in service mode, and
the main switch turned off and locked.
u Attach WORK IN PROGRESS signs according to local regulations, or at least at the
main switch and operator's station.
WARNING
Serious injury or death
Serious danger when working on the hydraulic system!
u Ensure that the air, water and hydraulic system is depressurised before starting work.
u Adjacent moving units should always be anchored before working on a system part.
u Always stop work if there is an unforeseen or suspected risk.
1.2 The Purpose of This Publication

The objective of these instructions is to detect and rectify faults at an early stage so that
breakdowns, costly secondary damage and accidents can be prevented. Regular mainte-
nance is a precondition for planning necessary interruptions in operation such as recondi-
tioning and repairs. This allows work to be carried out when it's most suitable with regard to
production instead of causing complete breakdown.
7 No: 9853 1345 01i. en-US

COP MD20 Ver.A 1 Introduction
1.3 Target Group
! NOTE: This instruction is an example of workflow during maintenance.
The maintenance instructions are intended for use by maintenance and service personnel.
Persons working to these instructions must have completed relevant Epiroc training for the
Rock Drill.
1.4 Feedback and Contact Information

Epiroc works actively to develop and continuously improve its products and associated
documentation. Provide your feedback on products and documentation by contacting your
local supplier at http://www.epiroc.com, under 'CONTACT US'.
Epiroc values customer feedback and we do our best to promptly answer questions.
Postal Address:
Epiroc Rock Drills AB

SE-701 91 Örebro
Sweden
8 No: 9853 1345 01i. en-US

COP MD20 Ver.A 2 General Information
2 General Information
2.1 Component Replacement

Use original Epiroc Spare Parts to guarantee the safety and reliability of the Rock Drill
function and design.
2.2 Manufacturing Number

All Rock Drills are given a manufacturing number depending on place of Manufacture,
Year, Family, and Version. The stamped manufacturing number location varies on the
Rock Drill depending on the model.
1. Factory code for manufactured unit:

AVO = Epiroc Rock Drills AB
2. Year that the product was produced.
3. Family letter that identifies the number series:
D = Hydraulic Rock Drills
P = Pneumatic Rock Drills
T = Rotation Units
4. Serial number in the family group.
5. Version letter for the product, shows which Manual and Spare part list that is relevant.
9 No: 9853 1345 01i. en-US

2.3 Cleaning
2.3.1 Safety Precautions Before Cleaning
WARNING
Serious Injury
Risk of personal injury
u Always read general safety regulations before starting maintenance work. Refer to
Safety manual.
u Always turn off the equipment and the main switch before cleaning and maintenance
work is carried out. Set up WORK IN PROGRESS warning signs at the main switch
and control positions.
u Be aware of the units kinetic energy due to accumulated hydraulic pressure. Relieve
pressure in hydraulic, water, and compressed air systems and always secure moving
units.
2.3.2 Cleaning
1. Clean the Rock Drill frequently from rock fragments, drill cuttings and accumula-
tions of dust.
2. Clear away fragments of rock and other objects from air, water and hydraulic hoses
and cables frequently to avoid the risk of chafing on sharp edges.
3. Rinse the Rock Drill with water after every work shift. Use only rinsing pressure and
avoid spraying directly at seals. Wipe away any accumulations of water.
2.3.3 Hydraulic Hoses
WARNING
Serious injury
Risk of serious injury to the eyes, hands and skin.
u Never work on the lubrication system when it is pressurized. Lubrication air and oil may
spray out.
u Never use hands or fingers to locate a leakage.
u Always use gloves and eye protection.
10 No: 9853 1345 01i. en-US

WARNING
Serious Injury
Risk of abrasions and crushing injuries.
u Always change damaged hoses and couplings.
• Wet areas around hoses and connections is a sign for leaks that can cause spurting oil
or burst hoses if the leak worsens.
• The hose casing must be intact without any swelling (sign of inner hose or cord break-
age).
• Couplings must not have indentations or cracks and must make a secure connection.
Retighten or feel the coupling connection manually if a leak is suspected.
• Check that all hose attachments and clamps are intact. Loose attachments means that
hoses are damaged or get jammed during angle adjustment or when lowering the ma-
chine.
• Replace or rectify in the event of any faults.
2.4 Hydraulic Components
2.4.1 General
The hydraulic system is sensitive to contamination. The environment where the machine is
normally used is generally an unsuitable place for repairing hydraulic components. Inter-
vention in hydraulic systems in workplaces must be limited. Components must be repaired
in an adapted environment, refer to Hydraulic Workshops.
Observe the following points to avoid breakdowns and interruptions in operation due to
fouled hydraulic oil:
• Keep the machine clean. Hose it down at regular intervals using a degreasing additive.
• Before opening any connection, clean the area around it.
• Use clean tools and work with clean hands.
• Always plug hydraulic connections immediately after they have been detached. Use
clean protective plugs.
• Hydraulic components like hoses, valves, engines must always be stored with suitable
protective plugs fitted in place.
2.4.2 Hydraulic Workshops

Workshops that are used for the repair of hydraulic components must:
11 No: 9853 1345 01i. en-US

• Be separate from activities which generate dust and particles, such as welding, grind-
ing, and transportation of machines.
• Have their own suitable washing equipment necessary for repairing the components.
• Use only tools from a hydraulic workshop consisting of standard and special tools.
• Have a ventilation system that does not allow dust into the premises.
• Use trained mechanics.
2.4.3 Hydraulic Hose Replacement

Hose requirements are according to ISO 4413:2010.
High pressure system with alternating pressure levels and high peaks.
Load, vibration, and other mechanical stresses place high demands on hydraulic hoses.
When replacing hydraulic hoses, check that they are replaced with hydraulic hoses:
• With the correct pressure rating according to rig manual
• With the correct crimped couplings
• Of the correct quality class
• Of the correct dimensions
Always make sure that hose couplings are clean, not damaged and properly tightened.
All pressurized hoses have pressed couplings and can therefore be purchased ready made
from Epiroc. Grades and dimensions of hoses are specified in the spare part catalog for
the machine in question.
2.5 Welding
• All welding on the Rock Drill is forbidden.
2.6 Prepare for Long Period of Storage or Marine

Transportation
Action must be taken to protect the equipment from corrosion and storage damage if stor-
age expected to last longer than three months or it will be exposed to marine environment.
• Wash the equipment and thoroughly wipe it dry. Use compressed air to blow any accu-
mulated water out of cavities and pockets.
• Store the equipment in a temperature-, and humidity-controlled environment. Recom-
mended storage environments maintain a temperature of 10-20 °C and max 20–50%
humidity.
• Purge the flushing system with dry air. Add lubrication oil (COP Oil) to the air to protect
against corrosion.
• Purge the lubrication system (ECL) with dry air. Add extra lubrication oil (COP Oil) and
increase the number of lubrication pulses for (minimum) five minutes.
• Apply corrosive prevention compound to the shank adapter. Make sure that the area
for flushing air and flushing water is also protected.
• Apply corrosive prevention compound to untreated machine surfaces.
• Clean old grease away from lubrication points to prevent residue buildup. Pump fresh
grease into each lubrication nipple. Make sure that you use the correct quantity and
type of grease for each point.
• Hoses and rubber parts can be packed in airtight plastic to reduce desiccation. Make
sure that the components are dry before packing.
12 No: 9853 1345 01i. en-US

2.7 After Long Period of Storage

• Change lubricant and hydraulic oil where appropriate.
13 No: 9853 1345 01i. en-US

14 No: 9853 1345 01i. en-US

COP MD20 Ver.A 3 Lift Rock Drill
3 Lift Rock Drill
WARNING
Risk of Lifting the Rock Drill
Incorrect handling can cause serious crushing injury or death.
u Use extreme caution when strapping and lifting heavy objects.
u Lifting must be done through the center of gravity.
u Only use straps that are intact and designed for the load they will carry.
u Do not approach a suspended load.
1. Attach the two straps to the intended lifting points according to the figure.
2. Lift the rock drill carefully through the center of gravity. Make sure the rock drill is
balanced and the two straps do not slip.
Rock Drill Weight
COP MD20 Ver. A 186 kg (410 lbs)
15 No: 9853 1345 01i. en-US

COP MD20 Ver.A 3 Lift Rock Drill
16 No: 9853 1345 01i. en-US

COP MD20 Ver.A 4 Tools
4 Tools
4.1 Standard Tools
Standard tools
Ref. No. Tools
A1 Plastic mallet
A2 Sledge hammer
A3 Honing tool 19–70 mm
A4 Open-end wrenches 10–32 mm, 46 mm
17 No: 9853 1345 01i. en-US

Ref. No. Tools
A5 Allen keys 4–10 mm
A6 Screwdriver
A7 Mandrel 2–10 mm, brass mandrel 20x250 mm
A8 Feeler gauge 0.03-0.10 mm with 0.01-mm intervals

Feeler gauge 0.05-1.00 mm with 0.05-mm intervals
A9 Internal lock ring pliers
A10 Socket wrench set 10–32 mm for external hexagon

Socket wrench set 4–10 mm for internal hexagon
A11 Small pointed tool
A12 T-handle with 3/4" connection bracket, power socket 32 mm
A13 Vernier caliper
A14 Micrometer 0-25 mm
A15 Magnet
A16 Pry bar
A17 Slide hammer
4.2 Special Tools
Special tools
Ref. No. Tools Part Numbers
B1 Fixture 3115 5844 30
B3 Charging equipment 3115 6001 92
B5 ½" Torque wrench, torque range 20–100 Nm 9106 1015 40

½" Torque wrench, torque range 80–420 Nm 9106 1015 41
18 No: 9853 1345 01i. en-US

B20 Extractor tool 3091 0455 90
B22a Adapter, discharging accumulators 3115 5748 00

B22b Pressure gauge inclusive adapter 3115 3799 80
B46 Bearing puller 3115 6001 23
Special tools
D1 Adapter plate with screws 3115 5875 00
D2a Disassembly tool, Adapter 3115 6008 37

D2b Disassembly tool, Slide Hammer 3115 6008 38
19 No: 9853 1345 01i. en-US

D3 Tools, Accumulator complete 3115 5641 80
D4 Tool, Bearing Gear Housing 3115 6000 69
D5 Assembly tool, Damper Liner 9495 8096 00
D6 Assembly tool, Guide and Flushing head 9495 8097 00
D7 Assembly tool, Cylinder Liner 9495 8110 00
D8 Assembly tool, Guide and Flushing head 3115 6000 50
D9 Motor fixture 3115 6000 87
D10 Pressing tool 3115 6001 72
D12 Extractor tool 3115 3804 01
D16 Mandrel 3115 5652 00
D21 Damper seal tool 3115 6001 09
20 No: 9853 1345 01i. en-US

COP MD20 Ver.A 5 Tightening Torques
5 Tightening Torques
5.1 Tighten All Threaded Unions

Always use a calibrated torque wrench.
Lubricate threads and contact surfaces on the washers with the recommended lubri-
cant according to the table.
Ref. Quantity Torque Lubricant Instructions

No.
A 4 200 Nm (162 lbf-ft) (steel cra- oil Tighten alternately to full torque
dle)
3 8 350 Nm (258 lbf-ft) anti-seize Tighten alternately to full torque

paste Re-tightening, see chapter Re-tighten
Side Bolts
14 4 80 Nm (59 lbf-ft) oil Tighten alternately to full torque
115 6 45 Nm (33 lbf-ft) oil

Re-tightening, see chapter Re-tighten
Side Bolts
21 No: 9853 1345 01i. en-US

Ref. Quantity Torque Lubricant Instructions

No.
344 2 45 Nm (33 lbf-ft) oil
345 2 30 Nm (22 lbf-ft) oil
Recommended Oil
Hydraulic oil or Motor oil
Recommended Anti-Seize Paste
Loctite LB 8009 or corresponding thread lubricant
5.2 Tighten Nipples

A calibrated torque wrench must be used for tightening.
A. Standard hose attachment, B. Optional hose attachment
22 No: 9853 1345 01i. en-US

Tightening Torque
Ref. No. Definition Check Point Torque Nm
1 RRL Rotation, intake 170 Nm (125 lbf-ft)
2 RRR Rotation, return 170 Nm (125 lbf-ft)
3 HT Percussion, return 330 Nm (243 lbf-ft)
4 HP Percussion, intake 330 Nm (243 lbf-ft)
5 F Flushing 300 Nm (221 lbf-ft)
6 AL Lubricating air and oil 70 Nm (52 lbf-ft)
7 HDP Damper, intake 70 Nm (52 lbf-ft)
8 ALR ALR Collection (Optional - always 170 Nm (125 lbf-ft)

one out of three outlets open on
front)
23 No: 9853 1345 01i. en-US

24 No: 9853 1345 01i. en-US

COP MD20 Ver.A 6 Main Parts
6 Main Parts
Pos. Main part Contains
2 Hydraulic Motor
101 Front Head Shank Adapter, Guide, Stop Ring
201 Gear Housing Rotation Chuck, Rotation Chuck Bushing, Driver, Damping
Piston, Wear Ring
301 Cylinder Impact Piston, Piston Guides, Valve Piston, Front Seal
Housing, Intake Accumulator, Return Accumulator
302, 307 Accumulators Intake accumulator (not shown), Return accumulator
303 Back Head Rear Seal Housing
25 No: 9853 1345 01i. en-US

COP MD20 Ver.A 6 Main Parts
26 No: 9853 1345 01i. en-US

COP MD20 Ver.A 7 Disassemble Rock Drill
7 Disassemble Rock Drill
7.1 Secure Rock Drill to Work Surface
WARNING
Risk of Crushing Injuries
Can cause serious personal injury or damage to property.
u Use extreme caution when strapping and lifting heavy objects.
u Secure Rock Drill, adapter plate, and fixture with proper fasteners.
u Work surface must be strong enough to hold the Rock Drill weight, even in tilted posi-
tion.
1. If a fixture (B1) is used, attach the fixture to a suitable work surface.
NOTE: The work surface must be strong enough to support the

! rock drill weight, even in tilted position.
2. Attach the adapter plate with the screws (D1) to a suitable work surface or on the
fixture (B1).
3. Attach the rock drill to the adapter plate (D1) with screws (A).
27 No: 9853 1345 01i. en-US

7.2 Discharge Accumulators

1. Remove the charging valves protective cap (B).
2. Aim the connection adapter (B22a) so there is no risk for personal injury when the
gas is released.
3. Tighten the connection adapter to the charging valve to release the nitrogen gas
(N2) from the accumulator.
4. Remove the connection adapter (B22a) and install the charging valve protective
cap (B).
7.3 Front Head
7.3.1 Disassemble Front Head

1. Undo and remove the six screws (115) with the lock washers (116).
28 No: 9853 1345 01i. en-US

a. Install tools (D12) to the connecting plate (107) and remove the connecting
plate.
b. Install the tools (D12) to the plug (106) and remove the plug.
c. Remove the o-rings (120).
2. Remove the four front side dome nuts (3).
a. Remove the front head (101) by pulling the shank adapter (1).
b. Only remove the pin (229) from gear housing if it is loose.
29 No: 9853 1345 01i. en-US

3. Remove the shank adapter (1) and the drill collar (12) from the front head (101).
4. Use tool (D6) to press out the front guide (150), the flushing head (130), the rear
guide (154), and the stop ring (105).
NOTE: The connecting plate (107) and the plug (106) locks the
! flushing head and must be removed from the front head before
this step is executed.
30 No: 9853 1345 01i. en-US

7.3.2 Disassemble Front Head Parts Seals and O-Rings

1. Use a pointed tool to remove the cup seal (152), the wiper (151), and the o-ring
(153) carefully on the front guide (150).
2. Use a pointed tool to remove the cup seals (131) and the o-rings (132) carefully
from the flushing head (130).
31 No: 9853 1345 01i. en-US

3. Use a pointed tool to remove the cup seal (155) and the o-ring (156) carefully from
the rear guide (154).
4. Use a pointed tool to remove the o-ring (109) carefully from the rear stop ring (105).
32 No: 9853 1345 01i. en-US

5. Use a pointed tool to remove the seal rings (114, 123) carefully from the connect
plate (107) and the plug (106).
7.4 Gear Housing
7.4.1 Disassemble Gear Housing

1. Remove the lock screw (238) and the washer (202).
33 No: 9853 1345 01i. en-US

2. Loosen the pre-load and remove the nut (203) with tool (D4).
a. Loosen the (E) on the tool (D4) so the tool runs freely.
b. Install the tool (D4) with the four screws in the nuts threaded holes (203).
c. Lock the tool (D4) by holding the key grip (D) and tighten the nut (E).
d. Loosen the pre-load and remove the nut (203) by turning the tool main nut (C)
counterclockwise.
3. Remove the dome nuts (3) from the studs (228) and pull the gear housing (201)
and the cylinder (301) apart.
a. Use tool (B20) to remove the front seal housing (333) if it is left in the gear
housing.
34 No: 9853 1345 01i. en-US

4. Tap on the ring (226) with a plastic mallet and tool (D17) to loosen and remove the
ring (207), the rotation chuck (210), the rings (212, 213), the liner (222), and the
ring (226).
a. Only remove the roller bearings (208, 211) from the rotation chuck (210) if the
bearing is worn or at the specified service interval. Use tool (B46) to remove the
roller bearing.
5. Remove the hydraulic motor (2), the o-ring (11), and the seals (15).
a. Only remove the spring pin (16) if it is loose.
35 No: 9853 1345 01i. en-US

6. Remove the slide washer (255) using a M8 screw or a magnet.
7. Install slide hammer (D2) with M12 treads to the washer (230).
a. Remove the washer (230) and the gear wheel (252) together with the inner ring
(232), and the needle bearings (231, 237).
8. Remove the studs (228).
36 No: 9853 1345 01i. en-US

7.4.2 Disassemble Gear Housing Parts, Seals, and O-Rings

1. Remove the seal (204), the spacer (205), and the o-ring (206) from the support ring
(207).
2. Remove the spacer (214), the seal (215), and the seal ring (221) from the ring
(213).
3. Use a pointed tool to remove the seals (219, 224) carefully, do not damage the
sealing grooves in the liner (222).
37 No: 9853 1345 01i. en-US

a. Use a pointed tool to remove the o-ring (218), and the seal rings (220, 221)
carefully, do not damage the sealing grooves on the liner (222).
4. Use a pointed tool to remove the seal (240) carefully, do not damage the sealing
groove.
5. Wash the gear housing and all disassembled parts with grease solvent before in-
spection.
7.5 Cylinder, Liner, and Impact Piston
7.5.1 Disassemble Cylinder, Liner, and Impact Piston
WARNING
Release Nitrogen gas
Risk of personal injury.
u All Nitrogen gas (N2) must be released before accumulators are removed or disassem-
bled!
38 No: 9853 1345 01i. en-US

1. Write down the positions and remove the nipples (4, 5) and the plugs (6, 7).
2. Undo the four screws (314) with washers (329) and remove the back head (303).
3. Undo the four screws (343) on each side of the cylinder (301) to remove the accu-
mulators. Remove the seal rings (330).
NOTE: Nitrogen gas (N2) must be released before removing the

! accumulators! See instruction "Discharge Accumulators"
39 No: 9853 1345 01i. en-US

4. Tap carefully the piston (304) forward with manual force to remove front seal hous-
ing (333), wave spring (352), and front piston guide (332).
5. Use tool (D15) and a plastic mallet to remove the rear seal housing (370), rear pis-
ton guide (306), and wave spring (353).
40 No: 9853 1345 01i. en-US

6. Use tool (D17) and a plastic mallet to remove the liner (308).
7. Install the slide hammer (D2) with M12 threads and remove the valve cover (313).
8. Use a magnet to remove the plunger (311) backwards.
41 No: 9853 1345 01i. en-US

9. Use a magnet to remove the valve piston (310) backwards.
10. Install the slide hammer (D2) with M12 threads and remove the valve cover (312)
and the piston liner (305).
11. Remove the two screws (A). Wash the cylinder (301) and clean the channels with
compressed air.
42 No: 9853 1345 01i. en-US

7.5.2 Disassemble Cylinder Parts, Seals, and O-Rings

1. Remove the seal kits (371, 373) and the seal (372) carefully with a pointed tool
from the rear seal housing (370).
2. Remove the seal kits (327, 335) and the seal ring (339) carefully with a pointed tool
from the front seal housing (333).
3. Remove the seal rings (318) and the seals (338) carefully with a pointed tool from
the liner (308).
43 No: 9853 1345 01i. en-US

4. Remove the seal rings (317) carefully with a pointed tool from the valve liner (305).
5. Remove the seal rings (315, 317) carefully with a pointed tool from the valve covers
(312, 313).
6. Remove the surface seal (356) and the o-ring (331) carefully with a pointed tool
from the cylinder (301).
7. Remove the surface seals (348) carefully with a pointed tool from the accumulators
(302, 307).
44 No: 9853 1345 01i. en-US

8. Remove the surface seal (348) carefully with a pointed tool from the back head
(303).
9. Remove the seals (317, 320, 321, 322) carefully with a pointed tool from the back
head (303).
10. Wash all disassembled parts with grease solvent before inspection.
7.6 Accumulators
7.6.1 Disassemble Intake and Return Accumulator
WARNING
Release Nitrogen gas
u All Nitrogen gas (N2) must be released before accumulators are removed or disassem-
bled!
Precondition p Accumulators must be discharged.
45 No: 9853 1345 01i. en-US

1. Use tool (D3) to disassemble the accumulators. Tighten plate (A) in a vice and in-
stall the accumulator on studs (E) and distance (B).
a. Install disassembly tool (F) pins in the accumulator house holes (340) according
to the figure.
2. Install the ring (C) on the studs (E), attach the nuts (D) on the studs by hand. Cover
(C) holds tool (F) in place at high torque.
a. Use a 32-mm 3/4 socket and an extended T-handle on disassembly tool (F) to
loosen the accumulator house (340) from the accumulator cover.
46 No: 9853 1345 01i. en-US

3. Remove the nuts (D) and the ring (C) from the studs.
4. Remove the disassembly tool (F) and the accumulator house (340) from the accu-
mulator cover.
a. Remove the diaphragm (342) from the accumulator cover. Remove the accu-
mulator cover (341).
5. Wash all disassembled parts with grease solvent.
47 No: 9853 1345 01i. en-US

48 No: 9853 1345 01i. en-US

COP MD20 Ver.A 8 Inspection Rock Drill Parts
8 Inspection Rock Drill Parts
8.1 Front Head
8.1.1 Inspect Channels, Restrictions, and Plugs
NOTE: Do not remove plugs and nozzles unnecessarily, only replace missing or
! faulty plug or nozzle.
1. Clean / blow all channels with compressed air.
2. Inspect that the plugs (3) and the nozzles (4) are free from dirt.
a. Use a gauge and inspect that the nozzles have the correct dimension and are
not cavitated.
Nozzle (4) Ø1.7 mm
3. If a nozzle is worn or damaged, replace the nozzle.
NOTE: Use a controlled flame when removing the nozzles.

! Do not heat the material around the nozzle.
49 No: 9853 1345 01i. en-US

a. Use grease solvent to clean the threads on the nozzle and the front head.
b. Use Loctite 243 or similar and tighten the nozzle (4) with 18 Nm (14.6 lbf-ft).
4. If a plug is leaking or missing, replace the plug.
NOTE: Use a controlled flame when removing the plugs. Do

! not heat the material around the plug.
a. Use grease solvent to clean the threads on the plug and the front head.
b. Use Loctite 243 or similar and tighten the plug (3) with 18 Nm (14.6 lbf-ft).
! NOTE: Loctite needs cure time up to 24 hours before exposed for hydraulic oil.
8.1.2 Inspect and Replace Front Head Parts

Precondition p The parts must be washed with grease solvent before the inspection.
1. Replace the guides (150, 154) if the inside diameter exceeds 39 mm (max. dimen-
sion).
2. Inspect the flushing head (130). Replace if seriously damaged or cracked.
50 No: 9853 1345 01i. en-US

3. Replace the stop ring (105) if:
M Measurement surface
S Wear surface
a. any point within the wear surface (S) is worn more than 1 mm, compare with a
new stop ring.
b. any cracks or signs of breakage are found.
c. the wear surface (S) is uneven.
4. Replace the shank adapter (1) if:
a. the thread (A) is worn out.
b. the front or rear end surfaces of the splines (B) are worn.
c. the impact surface (C) is crushed or chipped.
8.2 Gear Housing
51 No: 9853 1345 01i. en-US

2. Inspect that the plugs (2, 7) and the nozzle (5, 6, 8) are free from dirt.
not cavitated.
Nozzle (5) Ø 2.4 mm
Nozzle (6) Ø1.7 mm
Nozzle (8) Ø1.5 mm
3. If a nozzles is worn or damaged, replace the nozzle.

a. Use grease solvent to clean the threads on the nozzles and the gear housing.
b. Use Loctite 243 or similar and tighten the nozzle (5) with 18 Nm (14.6 lbf-ft).
c. Use Loctite 270 or similar and tighten the nozzles (6, 8) with 18 Nm (14.6 lbf-ft).
4. If a plug is leaking or missing, replace the plug.

52 No: 9853 1345 01i. en-US

a. Use grease solvent to clean the threads on the plugs and the gear housing.
b. Use Loctite 243 or similar and tighten the plug (2) with 18 Nm (14.6 lbf-ft).
c. Use Loctite 270 or similar and tighten the plugs (7) with 205 Nm (166 lbf-ft).
8.2.2 Inspect and Replace Parts in Gear Housing

1. Replace the studs (228) at scheduled percussion hours, or in the event of cracks,
damage threads. Never mix new and old studs.
2. Replace the rotation chuck (210) if it is deformed or have cracks or the ring gear is
worn.
53 No: 9853 1345 01i. en-US

3. Replace the driver (209) at scheduled percussion hours, or if the boom width is less
than 2 mm.
4. Replace the rotation chuck bushing (217) at scheduled percussion hours, or if:
a. it is scored or cracked.
b. the surface against the adapter is worn by more than 0.5 mm (min total length
46.1 mm).
c. marks (wave type) or splines are visible on the wear surface.
5. Some cavitation can be visible and is accepted.

Change the damper liner (222) at scheduled percussion hours.
54 No: 9853 1345 01i. en-US

6. Replace the damping piston (223) at scheduled percussion hours, or if the seal sur-
face is worn more than 0.1 mm.
55 No: 9853 1345 01i. en-US

2. Inspect that the plugs (3, 6) are not leaking, and that the nozzles (2, 8) are free
from dirt and not damaged.
not cavitated.
Nozzle (8) Ø1.2 mm

a. Use grease solvent to clean the threads on the nozzle and the cylinder.
b. Use Loctite 270 or similar and tighten the nozzle (2) to 40 Nm (32.4 lbf-ft).
c. Use Loctite 270 or similar and tighten the nozzle (8) to 8 Nm (6.5 lbf-ft).
4. If a plug (3) is leaking or missing, replace the plug.

a. Use grease solvent to clean the threads on the plug and the cylinder.
b. Use Loctite 270 or similar and tighten the plug (3) to 135 Nm (109 lbf-ft).
56 No: 9853 1345 01i. en-US

5. If a plug (6) is leaking:
a. Use a weld with a 300l/min nozzle and a controlled flame. Heat one plug at a
time in a circular motion to remove the Loctite.
NOTE: Use a controlled flame when removing the plug.

Do not heat the material around the plug!
! NOTE: Heat for max. 30 seconds!
NOTE: Heating material may result in material cracking.
b. Use a drive tool with a connected 3/8" allen key socket to remove the plug.
c. Let the material cool down before starting to heat the next plug.
d. Use grease solvent to clean the threads on the cylinder.
e. Use Loctite 542 or similar and tighten a new plug (6) to 205 Nm (166 lbf-ft).
6. Inspect that the nozzles (358, 360) are free from dirt.
57 No: 9853 1345 01i. en-US

not cavitated.
Nozzle (360) Ø1.7 mm

a. Use grease solvent to clean the threads on the nozzle and the back head.
b. Use Loctite 270 or similar and tighten the nozzle (358) to 18 Nm (14.6 lbf-ft).
c. Use Loctite 270 or similar and tighten the nozzle (360) to 40 Nm (32.4 lbf-ft).
8.3.2 Inspect and Replace Cylinder, Liner, and Impact Piston Parts
1. Clean and inspect the piston guides (332, 306).
58 No: 9853 1345 01i. en-US

a. Replace the piston guides (A, C) if they show signs of wear, cavitation, or other
damage.
(Schematic figure)
b. When replacing the impact piston (B), both the piston guides must be replaced.
2. Inspect the impact piston (304) for scoring and scratches as well as the impact sur-
face (A) regarding wear and chipping. Minor scoring and scratches on the piston
can be polished with fine abrasive cloth.
a. Damage to the piston impact surface and piston nose can be reconditioned us-
ing a turning lathe. See document: Recondition Impact Piston.
3. If the cylinder liner (308) show signs of cutting damage or scratches, then the parts
must be replaced. Minor cutting damage can be polished with a fine abrasive cloth
or honing tool.
59 No: 9853 1345 01i. en-US

4. If the valve piston liner (305) or the valve piston (310) show signs of cutting dam-
age or scratches, then the parts must be replaced. Minor cutting damage can be
polished with a fine abrasive cloth.
a. Inspect the valve covers (312, 313), and the plunger (311).
8.4 Accumulators
8.4.1 Inspect and Replace Parts Intake and Return Accumulator
WARNING
Damaged Screws, Threads, and Covers
Incorrect quality or length of screws, and damaged or corroded threads on screws,
housings, and covers can lead to dangerous oil leakage or cause the accumulator to
work loose.
u Parts that work loose can cause serious personal injury.
u Always replace incorrect and damaged screws, housings, and covers.
u Always replace all screws, even if only one screw is damaged.
Parts must be washed with grease solvent before the inspection.
60 No: 9853 1345 01i. en-US

1. Replace the diaphragm (342) if there is any indication of cracks or other damage.
a. When replacing the diaphragm, check the charging valve (344) for rubber
pieces from the broken diaphragm.
2. Replace the charging valve if it is damaged. Lubricate the threads with oil and
tighten to 45 Nm (33 lbf-ft).
3. Clean the gas channels with compressed air.
4. Always replace the o-ring (349) if the plug (345) has been removed. Lubricate the
plug threads with oil and tighten to 30 Nm (22 lbf-ft).
5. Replace with new accumulators (302, 307) if the accumulator house threads (340)
or the accumulator cover threads (341) are corroded or damaged.
6. Replace the screws (343) if the threads are corroded or damage. Always replace all
screws, not just the corroded or damaged ones.
NOTE: Use Epiroc Original Spare Parts when the accumulator

! screws are replaced. Always replace all screws, even if only one
screw is corroded or otherwise damaged.
61 No: 9853 1345 01i. en-US

62 No: 9853 1345 01i. en-US

COP MD20 Ver.A 9 Assemble Rock Drill
9 Assemble Rock Drill
9.1 Accumulators
9.1.1 Assemble Intake and Return Accumulator

1. Use tool (D3) to assemble the accumulators. Tighten plate (A) in a vice and install
the accumulator cover (341) on the four studs (E) and distance (B).
2. Lubricate the accumulator house (340) threads with anti-seize paste (Loctite LB
8009).
a. Install the diaphragm (342) and the accumulator house (340) in the accumulator
cover (341).
b. Thread down the accumulator house (340) by hand.
63 No: 9853 1345 01i. en-US

3. Install assembly tool (F) pins in the accumulator house holes (340) according to the
figure.
4. Install ring (C) and Install the nuts (D) by hand to the studs (E).
a. Tighten the nut on assembly tool (F) then tighten the nuts (D) by hand.
64 No: 9853 1345 01i. en-US

5. Cover (C) holds tool (F) in place at high torque.
a. Use a 32-mm 3/4 socket and a torque wrench on assembly tool (F) to tighten
the accumulator house (340) to 300 Nm (221 lbf-ft).
6. Remove the nuts (D) and the ring (C) from the studs. Remove the assembly tool
(F.)
7. Remove the accumulator from the four studs (E).
65 No: 9853 1345 01i. en-US

9.2 Front Head
9.2.1 Assemble Seals and O-Rings

1. Lubricate and install the cup seal (152) accordance to the figure in the forward
guide (150) sealing groove.
a. Lubricate and install the wiper (151) accordance to the figure in the forward
guide sealing groove.
b. Lubricate and install the o-ring (153) on the forward guide sealing groove.
2. Lubricate and install the two cup seals (131) accordance to the figure in the flushing
head (130) sealing grooves.
a. Lubricate and install the two o-rings (132) on the flushing head sealing grooves.
66 No: 9853 1345 01i. en-US

3. Lubricate and install the cup seal (155) accordance to the figure in the rear guide
(154) sealing groove.
a. Lubricate and install the o-ring (156) on the rear guide sealing groove.
4. Lubricate and install the o-ring (109) to the stop ring (105).
5. Lubricate and install the seal rings(114, 123) on the connecting plate (107) and the
plug (106).
67 No: 9853 1345 01i. en-US

9.2.2 Assemble Front Head

1. Use tool (D8) to press in the guide (150).
2. Install the flushing head (130) with the diameter 67 mm side first into the front head
(101).
a. Use the groves (see the red arrow) in the rear end of the flushing head as an
orientation mark when installing the flushing head.
68 No: 9853 1345 01i. en-US

b. Use tool (D8) to press in the flushing head (130).
c. Make sure that the flushing holes in the flushing head (130) align with the flush-
ing holes in the front head.
3. Use tool (D8) to press in the rear guide (154).
69 No: 9853 1345 01i. en-US

4. Install the shank adapter (1), the drill collar (12) and the stop ring (105) with o-ring
(109) into the front head.
Recommended Oil
9.3 Gear Housing
9.3.1 Assemble Gear Housing Seals and O-Rings

1. Lubricate and install the seal (204) and the o-ring (206) accordance to the figure (A)
in the support ring (207) sealing grooves together with the spacer (205). Use tools
(D18, D19) to install the sealing (204).
70 No: 9853 1345 01i. en-US

a. If there is a wear grove in the rotating chuck, the seal (204) and the spacer
(205) can be assembled in an alternative way (B). In this way, the seal (204) is
moved to a new location on the rotating chuck.
2. Lubricate and install the seal (215) and the seal ring (221) in accordance to the fig-
ure (A) in the support ring (213) sealing grooves together with the spacer (214).
Use tools (D18, D19) to install the sealing (215).
a. If there is a wear grove in the rotating chuck, the seal (215) and the spacer
(214) can be assembled in an alternative way (B). In this way, the seal (215) is
moved to a new location on the rotating chuck.
3. Lubricate and install the seals (219, 224) in the liner (222) sealing groove.
a. Bend the o-ring and install in accordance with the figure.
71 No: 9853 1345 01i. en-US

b. Bend the seal ring and install in accordance with the figure.
4. Press down the tool (D21) into the liner (222) to seat the seals properly.
5. Lubricate and install the seals (218, 220, 221) in the liner (222) sealing grooves.
72 No: 9853 1345 01i. en-US

6. Lubricate and install the seal (240) to the gear housing (201).
9.3.2 Assemble Gear Housing

1. Secure the gear housing (201) to the fixture.
2. Use tool (D14) to install the wear ring (226) from the front side, accordance to the
figure.
NOTE: If the wear ring (226) is installed incorrect, there will be a

! gap when assembling the front head to the gear housing.
73 No: 9853 1345 01i. en-US

3. Install the two studs (B) from tool (D5) on the gear housing.
a. Insert the damping piston liner (222) carefully in the gear housing.
b. Install the tool (D5) and nuts (C) on the studs (B).
c. Press the damping piston liner (222) with tool (D5) and a key wrench carefully
into the gear housing.
d. Remove tool (D5).
4. Install the studs (228) to the gear housing.
74 No: 9853 1345 01i. en-US

5. Install the damping piston (223) in the damping piston liner.
a. Install the wave spring (216).
b. Install the pre-assembled support ring (213).
c. Install the rotation chuck bushing (217) in the damping piston.
6. Use the two tools (D14, D19) to install the ring (212).
75 No: 9853 1345 01i. en-US

7. Install the outer ring of the roller bearing (211).
8. Use tool (D10) to press the rear roller bearing (211) onto the rotation chuck (210).
9. Use tool (D11) to press the front roller bearing (208) onto the rotation chuck (210).
76 No: 9853 1345 01i. en-US

10. Install the driver (209), the rotation chuck (210), and the roller bearings (208, 211).
11. Install the ring (207) by tapping carefully with a mandrel and a plastic mallet.
12. Lubricate the external threads on the nut (203) with oil and install the nut hand tight.
77 No: 9853 1345 01i. en-US

13. Use tool (D4) to pre-load the bearings (2082, 211).
a. Release the nut (E) on the tool (D4) so the tool runs freely.
b. Install the tool with the four (minimum three) screws in the nut's (203) threaded
holes.
c. Rotate the bearings 5 laps by rotating the key grip (D).
d. Lock the tool (D4) by holding the key grip (D) and tighten the nut (E).
e. Pre-load the bearings (208, 211) by turning the tool main nut (C) until 250 Nm
(184 lbf-ft) is reached.
f. Release the tool by holding the key grip (D) and release the nut (E).
g. Rotate the bearings 5 laps by rotating the key grip (D).
h. Hold the key grip (D) and tighten the nut (E).
i. Pre-load the bearings by turning the tool main nut (C) until 500 Nm (368 lbf-ft) is
reached.
j. Hold the key grip (D) and release the nut (E).
k. Rotate the bearings 5 laps by rotating the key grip (D).
l. Hold the key grip (D) and tighten the nut (E).
m. Tighten the tool main nut (C) until 500 Nm (368 lbf-ft) is reached.
n. Remove the tool by removing the screws.
78 No: 9853 1345 01i. en-US

14. Install the ring (202) and the screw (238). Tighten the screw (238) to 20 Nm (16 lbf-
ft).
15. Use tool (D13) to install the washer (230) and the needle bearing (231).
16. Pre-assemble the gear wheel (252).
a. Install the inner ring (232) on the gear wheel.
b. Install the inner ring of the needle bearing (237) on the gear wheel.
c. Install the spacer (254) together with the slide washer (255) inside the gear
wheel.
79 No: 9853 1345 01i. en-US

17. Install the gear wheel complete (235) and use tool (D13) to install the needle bear-
ing (237).
18. Apply Loctite SI 5970 or Loctite SI 5980 along the contour of the hydraulic motor
(2).
19. Lubricate and install the o-ring (11), the seals (15), and the hydraulic motor (2) with
the pin (16).
a. Lubricate the screws (14) with oil and tighten the screws alternately to 80 Nm
(59 lbf-ft).
80 No: 9853 1345 01i. en-US

Recommended Oil
9.4.1 Assemble Seals and O-Rings

1. Lubricate and install the seal kits (371, 373) in the seal housing (370) sealing
groove. Install the o-ring and bend the seal ring in accordance with the figure.
! NOTE: The relieve channel must be in the non-sharp bend area.
a. Lubricate and install the seal (372) in the seal housing sealing groove.
2. Lubricate and install the seal kits (327, 335) in the sealing house (333) sealing
groove. Install the o-ring and bend the seal ring in accordance with the figure.
! NOTE: The relieve channel must be in the non-sharp bend area.
a. Lubricate and install the seal ring (339) in the seal housing sealing groove.
81 No: 9853 1345 01i. en-US

3. Lubricate and install the seal rings (315, 317) in the valve covers (312, 313).
a. Install the plunger (311) into the valve piston (310).
b. Lubricate and install the valve piston into the valve liner (305).
c. Install the valve covers (312, 313) into the valve liner.
4. Lubricate and install the seal rings (318) and the seals (338) in the liner (308) seal-
ing grooves.
5. Lubricate and install the seal (357) to the back head (303).
82 No: 9853 1345 01i. en-US

6. Lubricate and install the seal rings (317, 320, 321, 322) to the back head (303).
9.4.2 Assemble Cylinder, Valve Piston, Cover, and Impact Piston

Guide
1. Secure the cylinder (301) to the fixture with screws (A).
2. Install a M12 screw (A) in the rear valve cover (313) and insert it in the cylinder.
83 No: 9853 1345 01i. en-US

a. Tap on the M12 screw using a plastic mallet to install the valve covers (312,
313), the valve liner (305), the valve piston (310), and the plunger (311).
3. Lubricate and insert the liner (308) in the cylinder.
a. Install tool (D7) with the dome nuts to the cylinder.
b. Press the liner (308) with tool (D7) and a wrench carefully into the cylinder.
c. Remove tool (D7).
4. Use tool (D14) and a plastic mallet to install the wave spring (353) and the rear pis-
ton guide (306) into the cylinder.
84 No: 9853 1345 01i. en-US

5. Insert the impact piston (304) carefully into the cylinder liner (308) and the rear pis-
ton guide (306).
6. Use tool (D16) and a plastic mallet to install the forward piston guide (332), the
wave spring (352), and the seal housing (333).
7. Use tool (D16) and a plastic mallet to install the rear seal housing (370).
8. Lubricate and install the seal ring (330) carefully in the cylinder sealing groove.
NOTE: Make sure that the seal rings (330) do not get damaged
! during the assembly.
85 No: 9853 1345 01i. en-US

a. Lubricate and install the seals (348) carefully in the accumulators (302, 307)
sealing groove.
b. Apply oil on the threads and heads of eight undamaged original accumulator
screws (343).
c. Install the intake accumulator (302) with four screws (343) on the right side of
the rock drill.
d. Install the return accumulator (307) with four screws (343) on the left side of the
rock drill.
e. Tighten the screws alternately to 200 Nm (162 lbf-ft).
86 No: 9853 1345 01i. en-US

9. Install the back head (303) to the cylinder.
a. Apply oil on the four back heads screws (314) and washers (329).
b. Install and tighten the screws alternately to full torque 180 Nm (133 lbf-ft).
10. Look at your notes and install the nipples (4, 5) and the plugs (6, 7) with washers
(8, 9).
87 No: 9853 1345 01i. en-US

11. Lubricate and install the seal (356) and the o-ring (331) to the cylinder.
12. Lubricate and install the seal rings (323, 354) to the cylinder.
13. Install the pin (355) into the cylinder.
88 No: 9853 1345 01i. en-US

Recommended Oil
9.5 Rock Drill
9.5.1 Assemble Rock Drill

Precondition p The seal (356), the pin (355), and the seal rings (323, 354) must be installed to the
cylinder.
1. Secure the cylinder to the fixture.
2. Install the gear housing (201) to the cylinder (301) on the four front studs (228).
a. Apply anti-seize paste on four dome nuts (3) and the rear studs (228) threads.
b. Install the dome nuts (3) to the rear studs (228).
c. Tighten the dome nuts (3) alternately to 350 Nm (258 lbf-ft).
3. Make sure the pin (229), the seal (240), and the seal ring (239) are installed to the
gear housing (201).
a. Install the front head (101) to the gear housing on the four front studs (228).
b. Apply anti-seize paste on four dome nuts (3) and the front studs (228) threads.
89 No: 9853 1345 01i. en-US

c. Install the dome nuts (3) to the front studs (228).
d. Tighten the dome nuts (3) alternately to 350 Nm (258 lbf-ft).
NOTE: If there is a gap between the front head and the gear
! housing when reaching the tightening torque, see wear ring (226)
in chapter Assemble Gear Housing.
4. Lubricate and install the o-rings (120) to the connecting plate (107) and the plug
(106).
a. Apply oil to the threads on the six screws (115).
b. Install the connecting plate (107) with screws (115) and lock washers (116).
c. Install the plug (106) with screws (115) and lock washers (116).
d. Tighten the screws (115) alternately to 45 Nm (33 lbf-ft).
90 No: 9853 1345 01i. en-US

COP MD20 Ver.A 10 Warning Signs
10 Warning Signs
10.1 General
It is important that all the signs are in the correct location, clean, and fully legible on the
machine. Check and replace damage signs.
10.2 Warning Signs Accumulators

Warning signs
Symbol Description
Warning sign
• Read the instruction manual thoroughly before performing service
or replacement
Warning sign
• Charge only with nitrogen gas
10.3 Warning Sign Location Accumulators
Pos 302 Intake Accumulator
Pos 307 Return Accumulator
91 No: 9853 1345 01i. en-US

COP MD20 Ver.A 10 Warning Signs
92 No: 9853 1345 01i. en-US

COP MD20 Ver.A 11 Charge Accumulators
11 Charge Accumulators
WARNING
Explosion Risk
Usage of wrong gas causes risk of personal injury or death.
u Only use dry nitrogen (N2).
11.1 Connect Accumulator Charger to Gas Cylinder
WARNING
Explosion Risk
Usage of wrong gas causes risk of personal injury or death.
u Only use dry nitrogen (N2).
1. Check that the gas cylinder (20) contains Nitrogen (N2) gas.
2. Secure the gas cylinder (20) so that it cannot fall over and cause damage.
3. Check that the gas cylinder valve (19) is closed.
4. Remove protective nut (18) from the gas cylinder valve and check that the gas
cylinder valve threads are undamaged and clean.
5. Check that the bottle connection (110) and the o-ring (1) are undamaged and
clean.
93 No: 9853 1345 01i. en-US

6. Connect the hose connection (110) to the gas cylinder valve (19) hand tight. Check
that the hose (60) is not twisted or stretched.
7. Check that the pressure regulator (140) is closed.
8. Check that the needle valve (40) is closed.
9. Open the gas cylinder valve (19) slowly by turning it counterclockwise and check
that the high-pressure gauge (50) shows full pressure reading.
11.2 Connect Accumulator Charger to Accumulator
1. Remove the protective cap (B) from the accumulator valve (A).
2. Check that the threads of the accumulator valve (A) are undamaged and clean.
3. Close the ball valve (3) by turning it clockwise.
4. Connect the hose connection (130) to the accumulator valve (A) hand tight. Check
that the hose (70) is not twisted or stretched.
94 No: 9853 1345 01i. en-US

11.3 Charge Accumulator
NOTE: Charge the accumulator in normal room temperature.
! NOTE: If the gas cylinder or rock drill are at a considerable lower temperature (approx.
-5°C) the charging should be checked and re-done after reaching working temperature.
1. Turn on the manometer (100).
2. Open hose valve (3) by turning it counterclockwise.
3. Charge the accumulators to the correct pressure.
a. Intake accumulator (302) Recommended Base setting: 80 bar. Max setting

100 bar.
NOTE: Intake accumulator (302): 30-40 bar under collaring

! pressure, max.100 bar.
b. Return accumulator (307) Recommended Base setting: 2 bar. Max setting

2 bar.
95 No: 9853 1345 01i. en-US

4. Open the pressure regulator (140) slowly by turning the knob clockwise while moni-
toring the manometer (100) until correct filling pressure is achieved.
5. Close the pressure regulator (140).
6. If the pressure in accumulator gets too high:
a. Slowly open the needle valve (40) by turning the knob counterclockwise until
correct pressure is achieved.
7. Close the hose valve (3) by turning it clockwise. When using connection (90) with
the earlier version of accumulator valve, the accumulator valve (16) must be
closed.
11.4 Disconnect Accumulator Charger
1. Check that ball valve (3) is closed.
2. Close the gas cylinder valve (19).
3. Open needle valve (40) to evacuate the gas, check that the manometers (50) and
(100) drops to 0.
4. Disconnect hose connection (130) from the accumulator valve (A).
5. Install protection cap (B) on the accumulator valve (A).
6. Disconnect hose connection (110) from the gas cylinder valve (19).
7. Install protection cap (18) in the gas cylinder valve (19).
8. Transport the gas cylinder (20) to the designated location and secure it.
96 No: 9853 1345 01i. en-US

COP MD20 Ver.A 12 Function Tests
12 Function Tests
12.1 Hydraulic Motor
12.1.1 Function and Condition Test Hydraulic Motor

The following tests give an approximation of the present state of the hydraulic motor.
The following are required to complete the tests:
• Apparatus for hydraulic flow and pressure.
• Pressure gauge.
• Flow meter 0-15 l/min.
• Couplings and hoses to assemble the components.
• Oil grade HLP46 at 50 °C and viscosity approximate 35 CST.
• Motor fixture for the hydraulic motor.
1. Apply oil on the hydraulic motor screws (14).
2. Install the cover (E) with the o-ring (11), the seals (15), and the four screws (14) to
the hydraulic motor (2).
3. Tighten the screws (14) alternately to 80 Nm (59 lbf-ft).
4. Install the nipples (D, F) to the cover (E).
5. Performing Half Belle Test: Install the o-ring (H), the axle lock (C), the o-ring (G),
the end plate (C), and the two screws (A).
6. Performing Hydraulic Motor Test: Install the o-ring (G), the end plate (C), and the
two screws (A).
97 No: 9853 1345 01i. en-US

12.1.2 Perform Hydraulic Motor Test
WARNING
Pressurized Systems
Can cause serious injury.
u Never stand behind the hydraulic motor during the test.
u Only the operator is to be around the hydraulic motor during the test.
u Never use a body part when checking for leakage.
1. Install the motor fixture (D9) for the hydraulic motor.

Do not install the shaft lock.
2. Connect the return hose (R) and the drain line (D) to the return port (B) with a T-
coupling.
3. Connect the pressure hose (P) to the inlet port (A).
4. Slowly increase the hydraulic flow until the flow meter reaches 10 l/min maximum.
a. Allow the motor to rotate approximately 30 seconds.
b. Make sure that rotation is constant and without any abnormal noise.
5. Stop the test and depressurize the hydraulic pressure in the hydraulic motor until
the pressure manometer reaches 0 bar.
6. Carefully loosen and remove the hoses, a small pressure can remain in the system.
Plug all connections to secure them from dirt.
98 No: 9853 1345 01i. en-US

12.1.3 Perform Half Belle Test
WARNING
Pressurized Systems
u Never stand behind the hydraulic motor during the test.
u Only the operator is to be around the hydraulic motor during the test.
1. Install the motor fixture (D9) for the hydraulic motor with shaft lock (C).
2. Connect the return hose (R) and the drain line (D) to the return port (B) with a T-
coupling.
3. Connect the pressure hose (P) to the inlet port (A).
4. Slowly increase the hydraulic pressure until pressure manometer reaches 140 bar.
a. Measure the flow from port (B).
b. Replace the motor if it exceeds Permitted Flow Drainage Line 10 l/min.
5. Stop the test and depressurize the hydraulic pressure in the hydraulic motor until
99 No: 9853 1345 01i. en-US

12.2 Leakage Test
12.2.1 Prepare for Leakage Test

• Install the rock drill in an isolated room.
• ECL channels must be cleaned before performing the leakage test.
• Recommended oil temperature is between 25–40 C° while performing the leakage
test.
• The front part, including the shank adapter, must be assembled on the rock drill before
the leakage test.
• While assembling the rock drill before the test, push the piston all the way forward.
This is the position that piston reaches when pressurized.
• Accumulators must be charged with the correct pressure to keep the diaphragm safe.
• Check all plugs and threads to make sure that the threads are in a good condition and
that the plugs are tight.
12.2.2 Perform Leakage Test
WARNING
Pressurized Systems
u Install the rock drill in an isolated room, and connected with long hoses to the test unit.
u Never stand around the rock drill during the test.
u Only the operator can enter the test room to inspect the rock drill.
Precondition p Accumulators are charged with nitrogen gas according to maintenance instructions.
100 No: 9853 1345 01i. en-US

p Front head including shank adapter must be assembled during this test.
1. Connect the pressure hose (P) to the percussion inlet port (HP).
2. Plug all the remaining ports except one of the lubrication inlet ports (AL).
3. Slowly pressurize the rock drill until the 20 bar is reached on the connected
manometer. The pressure increase must be done gradually up to 20 bar to prevent
the impact of the piston and reduce any potential risk.
a. Make a quick visual inspection for leakage on the rock drill.
b. Check ECL outlet port (A) for visible leakage.
c. If a considerable leakage is seen, stop the test by gradually depressurizing the

rock drill until the pressure manometer reaches 0 bar and continue with step 7.
4. Slowly pressurize the rock drill until the 40 bar is reached on the connected
manometer and keep the pressure for 30 minutes.
5. Connect workshop pneumatic air, max 6 bar, to lubrication inlet (AL).
6. Check for leakage by putting a white paper at the outlet port (A). No oil is to be visi-
ble from the ECL outlet port (A).
7. Stop the test by gradually depressurize the hydraulic pressure in the rock drill until
12.3 Percussion Test
12.3.1 Prepare for Percussion Test

• It is recommended that the oil is warm while performing the percussion test.
the percussion test.
• During assembly, make sure the piston moves smoothly.
• Accumulators must be charged with the correct pressure to keep the diaphragm safe.
• Check all plugs and threads to ensure that the threads are in a good condition and that
the plugs are tight.
12.3.2 Perform Percussion Test
WARNING
Pressurized Systems
101 No: 9853 1345 01i. en-US

Precondition p Accumulators are charged with nitrogen gas according to maintenance instructions.
p Front head including shank adapter must be assembled during this test.
1. Connect the return hose (R) to percussion return port (HT).
2. Connect the pressure hose (P) to percussion inlet port (HP).
3. Plug all remaining ports on rock drill.
4. Slowly pressurizing the rock drill until the hydraulic pressure manometer reaches
40 bar and the piston starts to move.
a. If percussion does not start, gradually increase the pressure up to max 75 bar.
b. When percussion starts, reduce the pressure to 40 bar.
5. Keep the percussion running for 30 seconds with 40 bar.
6. Stop the test by gradually depressurizing the hydraulic pressure in the rock drill un-
til the pressure manometer reaches 0 bar.
12.4 Rotation Test
12.4.1 Prepare for Rotation Test

• It is recommended that the oil is warm while performing the rotation test.
the rotation test.
• Check all plugs and threads to ensure that the threads are in a good condition and that
the plugs are tight.
102 No: 9853 1345 01i. en-US

12.4.2 Perform Rotation Test
WARNING
Pressurized Systems
1. Connect the return hose (R) to rotation return port (RRR).
2. Connect the pressure hose (P) to rotation inlet port (RRL).
3. Connect the percussion return hose (HT) to rotation tank (T).
4. Plug all remaining ports on rock drill.
5. Slowly pressurize the motor until the hydraulic pressure manometer reaches 40 bar
or the rotation starts.
6. Check that the rotation runs smoothly, without noise and external leakage and in
the correct direction. Keep the rotation running for 30 seconds with 40 bar.
7. Stop the test an depressurize the hydraulic pressure in the rock drill until the pres-
sure manometer reaches 0 bar.
103 No: 9853 1345 01i. en-US

104 No: 9853 1345 01i. en-US

COP MD20 Ver.A 13 Lubrication
13 Lubrication
13.1 Hydraulic and Lubricant Recommendations
13.1.1 Hydraulic Fluid

The hydraulic fluid of rock drill, in addition to containing decent lubrication properties,
should provide superior protection against wear, rust and oxidation, as well as good an-
tifoaming, water resistance, and air separation properties. For a hydraulic fluid, it is essen-
tial to have high shear stability, to ensure that viscosity and viscosity index remain con-
stant, even at high-pressure drops over sealing gaps and valves. The use of an appropri-
ate hydraulic fluid with proper viscosity, guarantee minimum energy losses in hydraulic
systems.
There are various hydraulic fluids to fulfil all limit values of viscosity as required for different
operating conditions and ambient temperatures. Various types of oils across these ranges,
may differ from mineral to synthetic based. Epiroc recommends the use of hydraulic fluids,
which conform to standards ISO 11158 HM, DIN 51524 HLP/HVLP and ISO 15380 (for en-
vironmentally friendly hydraulic fluids and biodegradable options).
Hydraulic fluids shall be chosen in relation to operational requirements and varying temper-
ature ranges. It is important to select a hydraulic fluid of the correct viscosity (VG), suited to
your operating temperature and environment. Viscosity is highly affected by temperature. A
high viscosity index (VI), reduces the effect of temperature on the hydraulic fluid. The fol-
lowing table can be used to choose an appropriate viscosity grade (VG) and viscosity index
(VI), based on your needs:
Normal Operat- Min. Start Temp Max. Operating Viscosity Grade Viscosity Index
ing Temp °C °C Temp °C VG VI
Viscosity 25-50 ISO 3448
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
NOTE: In compliance with ISO 4406, the hydraulic fluid must be filtered to the purity
! class of 20/18/15.
If 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 fluid losses
and increasing energy requirements.
If viscosity is too high:
105 No: 9853 1345 01i. en-US

• Flow losses in the hydraulic lines are increased. The high flow losses amplify energy
consumption and pressure levels, and put increased strain on seals.
• The risk of cavitation increases, which leads to the risk of damage to the rock drill and
hydraulic pumps.
The hydraulic fluid must be changed at regular intervals
Oil viscosity changes 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 suffi-
cient stability must be used. In compliance with DIN 51350-6, viscosity of suitable hydraulic
fluids shall drop a maximum of 25% when tested at 100 ºC for shear stability.
Factors influencing the interval between changes are:
• 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 wa-
ter content has become such that the hydraulic fluid must be changed.
• Deterioration of properties such as oxidation inhibition and anti-foaming.
13.1.2 Pneumatic Tool Oil

Pneumatic tool oil is used for cooling and lubricating your rock drill. Depending on ambient
temperature, the oil should have the following viscosity grades if the viscosity index (VI) is
about 100:
Ambient Temperature C° Viscosity
-30 to ±0 VG 32-68
-10 to +20 VG 68-100
+10 to +50 VG 100-150
The tool oil must have an EP additive which covers the following load-bearing properties:
Referenced Standard Load-Bearing Property
ASTM D 2783 Min. 250 kg
ASTM D 4172 (40 kg) Max. 0.5 mm
The tool oil should also have the following properties:

• The oil must have good lubricating properties, intended for compressed air tools.
• The oil must have good adhesion capacity.
• The oil must have additives that prevent foam formation.
Epiroc recommends the use of Epiroc COP OIL which has been specially developed for
our hydraulic rock drills. COP OIL is an environmentally friendly, biodegradable oil, which
can be used in ambient temperatures between -25 ºC and +50 ºC. COP OIL can be or-
dered with the following part numbers:
1 Can of 4 litres 1 Can of 20 litres 24 Can of 20 litres 1 Barrel of 208 litres
3115 3125 02 3115 3125 01 3115 3126 01 3115 3127 00
106 No: 9853 1345 01i. en-US

13.1.3 Grease
Considering the high operating temperature in the rock drill gear housing, always use a
high-temperature grease with lithium complex soap based on a synthetic base fluid (polyal-
phaolefin/synthetic ester) with EP additive, and additives that protect against oxidation, cor-
rosion and wear at high loads. The grease should meet the specifications, specified in the
table below:
NLGI Number Drop Point Base Oil Viscosity Operating Temp
2 260 °C 220 cSt at 40 °C -15 to +150 °C
NOTE: Molybdenum (Molybdenum disulfide) grease is harmful for seals and shall be
! avoided.
Epiroc recommends the use of Epiroc COP GREASE, which has been specially developed
for our hydraulic rock drills, and is suitable to be used in both gear housing and flushing
seals. COP Grease withstands temperatures between -40ºC to +150ºC, and temperatures
of up to 220ºC during shorter periods. COP Grease is developed to be implemented in
both arctic and tropical conditions, and can be ordered with the following part numbers:
Grease Tube 0.4 kg Can 18 kg
COP Grease 3115 3422 00 3115 3423 00
107 No: 9853 1345 01i. en-US

2021-04-08 | No: 9853 1345 01i. en-US
epiroc.com

9853 1345 01 Manual Mantenimiento Cop MD20

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

9853 1345 01 Manual Mantenimiento Cop MD20

Uploaded by

Copyright:

Available Formats

Overhaul

COP MD20 Ver.A

3 Lift Rock Drill ....................................................................................................... 15

5 Tightening Torques ............................................................................................. 21

7 Disassemble Rock Drill ....................................................................................... 27

8 Inspection Rock Drill Parts ................................................................................. 49

iii No: 9853 1345 01i. en-US

8.1.1 Inspect Channels, Restrictions, and Plugs ........................................................................... 49

9 Assemble Rock Drill ............................................................................................ 63

11 Charge Accumulators ......................................................................................... 93

12 Function Tests ..................................................................................................... 97

iv No: 9853 1345 01i. en-US

13.1.1 Hydraulic Fluid.................................................................................................................... 105

v No: 9853 1345 01i. en-US

vi No: 9853 1345 01i. en-US

1.1 Safety first

1.2 The Purpose of This Publication

7 No: 9853 1345 01i. en-US

1.3 Target Group

! NOTE: This instruction is an example of workflow during maintenance.

1.4 Feedback and Contact Information

Epiroc Rock Drills AB

8 No: 9853 1345 01i. en-US

2.1 Component Replacement

2.2 Manufacturing Number

1. Factory code for manufactured unit:

9 No: 9853 1345 01i. en-US

2.3.1 Safety Precautions Before Cleaning

2.3.3 Hydraulic Hoses

10 No: 9853 1345 01i. en-US

2.4 Hydraulic Components

2.4.2 Hydraulic Workshops

11 No: 9853 1345 01i. en-US

2.4.3 Hydraulic Hose Replacement

2.6 Prepare for Long Period of Storage or Marine

12 No: 9853 1345 01i. en-US

2.7 After Long Period of Storage

13 No: 9853 1345 01i. en-US

14 No: 9853 1345 01i. en-US

3 Lift Rock Drill

Rock Drill Weight

COP MD20 Ver. A 186 kg (410 lbs)

15 No: 9853 1345 01i. en-US

16 No: 9853 1345 01i. en-US

4.1 Standard Tools

Ref. No. Tools

A3 Honing tool 19–70 mm

A4 Open-end wrenches 10–32 mm, 46 mm

17 No: 9853 1345 01i. en-US

Ref. No. Tools

A5 Allen keys 4–10 mm

A7 Mandrel 2–10 mm, brass mandrel 20x250 mm

A8 Feeler gauge 0.03-0.10 mm with 0.01-mm intervals

A9 Internal lock ring pliers

A10 Socket wrench set 10–32 mm for external hexagon

A11 Small pointed tool

A12 T-handle with 3/4" connection bracket, power socket 32 mm

A13 Vernier caliper

A14 Micrometer 0-25 mm

A16 Pry bar

A17 Slide hammer

4.2 Special Tools

Ref. No. Tools Part Numbers