Reg.

code
AIB TAB 43
COP 1840
2007-02

Maintenance instructions for

Hydraulic COP 1840HE

Rock drills COP 1840HEX
1250 0025 55

ATLAS COPCO ROCK DRILLS AB

ÖREBRO · SWEDEN
© Atlas Copco Rock Drills AB, 2007. All rights reserved.
No. 9852 1007 01d
 SAFETY REGULATIONS
· Important safety information is given at various points in these instructions.
· Special attention must be paid to the safety information contained in frames and accompanied by a war-
ning symbol (triangle) and a signal word, as shown below:

indicates hazards or hazardous procedures which COULD

WARNING result in serious or fatal injury if the warning is not observed.

indicates hazards or hazardous procedures which COULD

CAUTION result in injury or damage to equipment if the warning is not
observed.

The following safety rules must also be observed:

· Carefully read through all operating- and main-
tenance instructions for the drill rig and rock
drill before putting the rock drill to use. Always
follow the instructions given.
· Do not use or intervene in the rock drill unless
you have been trained to do so.
· The rock drill may only be used for the pre-
scribed purposes.
· Make sure that the drill rig has been maintai-
ned in accordance with the current instructions.
· Make sure that all safety labels remain in pla-
ce, and that they are kept clean and fully legib-
le. See the spare parts list for details of label
locations and part numbers.
· Always wear a safety helmet and ear protec-
tors during drilling. Any local regulations that
exist must also be observed.
· Before moving the drill rig or starting to drill,
make sure that there are no personnel in the
immediate vicinity of the drill rig.
· Use Atlas Copco genuine parts only. Any
damage or malfunction caused by the use of
unauthorized parts is not covered by Warranty
or Product Liability.
· Never attempt to carry out maintenance while
the drill rig is in operation.
· Those checks and adjustments that must be
made while the drill rig is in operation must be
carried out by at least two persons. One per-
son must man the control station and keep a
strict watch over the work.
· To prevent injury during service and mainte-
nance, all components that could possibly
move or drop must be supported safely on
blocks or trestles, or secured by means of
adequately dimensioned slings.
· Before starting work on any of the systems,
make sure that the hydraulic and air systems
are without pressure and that the electrical
system is dead.
· Check that the hoses used are of the right qua-
lity, and that all hose connections are in good
condition and properly tightened.

Contents Page

Safety regulations . . . . . . . . . . . . . . . . 2 Setting of ECL lubricating system . . . . . . . . 10

Action list . . . . . . . . . . . . . . . . . . . . . 3 Lubrication of gear . . . . . . . . . . . . . . . 11
Hose connections . . . . . . . . . . . . . . . . 4 Setting the damper pressure . . . . . . . . . . 11
Tightening torques . . . . . . . . . . . . . . . . 5 Setting the extractor-unit pressure (HEX) . . . 11
Accumulators . . . . . . . . . . . . . . . . . . 6 Removing the front head . . . . . . . . . . . . 12
– Charging the accumulators . . . . . . . . . . 6 Checking the front head . . . . . . . . . . . . 13
– Checks in the event of hose vibration . . . . . 7 Changing the flushing head and driver . . . . 14
– Changing the accumulators . . . . . . . . . . 8 Mounting the front head . . . . . . . . . . . . 16
– Changing the return accumulator . . . . . . . 9 Slinging . . . . . . . . . . . . . . . . . . . . 18
Changing the hydraulic motor . . . . . . . . . . 9 Long-term storage . . . . . . . . . . . . . . . 18
Filling with lubricating oil and bleeding the system 10 Recommended hydraulic oils and lubricants . 19

2
 WARNING
· Before starting any maintenance work,
make sure that the electrical system is
dead.
There is a risk of injury if these instructions
are not observed!
CAUTION
· Take care during rod jointing and when
handling the drill bit. Mind your fingers!
· Keep your clothing away from rotating
machine parts.
Carelessness can lead to serious injury.
· Always use ear protectors during drilling.
High noise levels damage hearing.
· Never attempt maintenance or intervene
in the rock drill, connections or hoses whi-
le the hydraulic, lubrication or flushing
systems are pressurized.
Air or oil can squirt out at high pressure
and high temperature, with the risk of
serious injury to the eyes and skin.
IMPORTANT
· Observe great cleanliness when interve-
ning in the rock drill or its hydraulic cir-
cuit.
· The following parts may be changed at the
worksite in accordance with the instruc-
tions given:
– shank adapter
– driver
– front head parts
– accumulators
– hydraulic motor
– screws
– connections.
Other repairs must be carried out in a sui-
table workshop in accordance with the
Action list
Before starting up a new- or
newly overhauled rock drill: Page
· Connect up the hoses . . . . . . . . . . . . 4
· Charge the accumulators . . . . . . . . . . . 6
· Select a suitable hydraulic oil and lubricant . 19
· Fill the lubricating system with oil . . . . . . . 10
· Adjust and set the lubricating system . . . . 10
· Set the damper pressure . . . . . . . . . . . 11
· Set the extractor-unit pressure (HEX) . . . . 11
Every shift
· Check that air and lubricating oil come out
between the shank adapter and front guide
and also out of the hole in the front head . . 13
· Check that the damper-pressure gauge on
the drill rig shows the normal value. In case
of deviation, adjust the damper pressure . . . 11
· Check that the shank-adapter threads are
not damaged . . . . . . . . . . . . . . . . . 13
· Keep an eye on the hydraulic hoses. If they
vibrate too much, check the accumulators . . 7
· Check that there is no leakage from the rock
drill. If the flushing medium leaks out of the
overflow hole in the front head, change the
seals and O-rings . . . . . . . . . . . . . . . 13
· When changing the shank adapter or remov-
ing the front head, check the internal compo-
nents, including the visible parts of the piston,
driver and rotation chuck bushing . . . . . . . 13
In the event of defect, remove to a suitable
workshop for repair or replacement.
After the first shift when using a
new- or newly overhauled rock drill
· Tighten all threaded unions . . . . . . . . . 5
After every 40th percussion-hour
· Grease the gear . . . . . . . . . . . . . . . 11
· Tighten all threaded unions . . . . . . . . . 5
· Check the safety labels on the accumulators.
Replace them if they are damaged or illegible . 6
· Check the return accumulator . . . . . . . . 7
Every 400th percussion-hour:
· Remove the rock drill from the drill rig and
send it to a suitable workshop for over-
hauling*.
* The rock drill should be overhauled at suitable intervals,
based on local conditions. The characteristics of the rock will
have a great influence on the rate of wear, and thus on the
required frequency of overhauling.
3
Hose connections
7 COP E
H
8 1840

AIR

6 COP EX
1250 0075 12

H
1840

5
4
3
2

1. Drainage 10
2. Rotation to the left 9
6
3. Rotation to the right
4. Percussion mechanism, return
5. Percussion mechanism, intake
6. Flushing
7. Lubricating air
8. Damper, intake
9. Extractor unit, return
10. Extractor unit, intake

Connecting the hoses

CAUTION · Clean the hose connections on the rock drill be-
fore removing the protective plugs (or caps).
· Never attempt maintenance or intervene
in the rock drill, connections or hoses whi- · Never remove a protective plug until the hose is
le the hydraulic, lubrication or flushing ready to be connected.
systems are pressurized. · Always store the rock drill with all hose connec-
Air or oil can squirt out at high pressure tions plugged. Use suitable protective plugs or
and high temperature, with the risk of caps, and make sure that they are clean.
serious injury to the eyes and skin.
· Pressure hoses with an internal diameter
of 19 mm (3/4") or more are rated SAE 100
R9R (i.e. high-pressure hose with four lay-
ers of spirally wound steel-wire reinforce-
ment). See spare parts list for drill rig.
For safety reasons, these hoses must not,
under any circumstances, be replaced
with hoses of a lower rating.
There is a risk of injury if these instruc-
tions are not observed!

4
Tightening torques
6 COP
1
5 1840HE
4

3A
14

9
13
1250 0075 13

COP
6 X
12 1840HE
7 11
9 10
8
15
16
13

COP 1840HE COP 1840HEX

3B

3A 2
2

N.B. Tighten item Nos. 1–3 in the prescribed order.

Ref.No. Qty. Check point Torque Instructions

Nm lbf.ft

1 2 Side bolts 300 220 Tighten the rear nuts

2 1 Front bolt 300 220 Tighten the front bolt
3A 2 Side bolts (HE) 350 260 Tighten the front nuts
3B 3 Side bolts (HEX) 300 220 Tighten the front nuts
4 3 Back head 220 160 Tighten the screws alternately to full torque
(uppermost screw last)
5 1 Regulating plug 80 60
6 4 Accumulators 220 160 Tighten the screws alternately to full torque
7 4 Hydraulic motor 65 48 Tighten the nuts alternately
8 2 Clamping attachment,
return accumulator 30 22
9 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque
10 1 Plug 45 33
11 4 Valve covers 145 105 Tighten the screws alternately to full torque
12 2 Connection plate 120 90 Tighten the screws alternately to full torque
13 1 Flushing connection 300 220
14 4 Inlet, flushing medium 90 65 Tighten the screws alternately to full torque
15 1 Intake, extractor unit 120 90
16 1 Return, extractor unit 120 90

5
Accumulators

The accumulators are fitted with safety labels as

shown in the figure below.

= Read the instruction book carefully

before servicing or changing

1250 0027 19
1250 0020 91

1. Damper accumulator
2. Intake accumulator
= Must be charged with nitrogen only 3. Return accumulator
4. Protective cap
5. Valve nut
6. Gas valve

1 5

3 6
2
0
20
0

0
15

25
0
10

R
A
B
0
0
20
0

0
15

25
0
10

R
A
B
0
0
20

1250 0175 94
0

0
15

25
0
10

R
A
B
0

Charging the accumulators

· Remove the protective cap (4).
· Open the valve nut (5) by 2–3 turns, and con-
WARNING nect the gas hose.
· Open the gas valve (6).
· The accumulators must be charged with
nitrogen (N2) only! Charge the accumulators to the correct
Other gases can cause an explosion. pressure, as follows:
– Damper accumulator (1): 20–25 bar
(290–360 psi)
– Intake accumulator (2): 30-40 bar
below the collaring pressure (435-580 psi)
CAUTION NB. It is better to undercharge rather than over-
charge the accumulators
· Do NOT charge the accumulators until · Tighten the valve nut (5) and close the gas valve
they have been fitted to the rock drill. (6).
There is a risk of injury if these instruc-
tions are not observed!
· Remove the gas hose and fit back the protective
cap (4) to the accumulator valve.
The return accumulator (3) must not be charged.

6
Checking the accumulators in the event of hose vibration
Damper accumulator (1) and
Intake accumulator (2)
1. Press in the pin on the test valve (7). If the ac-
cumulator is charged, the pin will stick out by
4.5 mm and give a firm resistance when pres-
sed in.
N.B. The damper-accumulator pin is somewhat
easier to press in.
If it is easy to press in the pin, it means that the-
re is no gas pressure (diaphragm damaged or
defektive charging valve).
2. Change the accumulator if it is not functioning
properly (see page 8).
3. After fitting a new accumulator, charge it with
nitrogen.

Return accumulator (3)

1. Put the rock drill in the horizontal position, as
shown in the figure.
2. Remove the plug with O-ring (8). If oil comes
out, the diaphragm is damaged or the accumu-
lator has been charged with too high pressure.
3. Fit a new diaphragm or charging valve as ne-
cessary, or replace the accumulator altogether,
and then charge the accumulator.
N.B. Do not check the gas pressure to often,
since the valve seat can be easily deformed by
repeated opening and closing. In fact, it is advi-
sable to change the charging valve quite frequ-
ently.
4. If the diaphragm is touching the outer pipe,
press down the diaphragm using a blunt, 1. Damper accumulator
cylindrical mandrel (ø 7–9 mm). See fig. A. 2. Intake accumulator
For the correct diaphragm position, see fig. B.1. 3. Return accumulator
Put the rock drill in the horizontal position, as 7. Test valve
shown in the figure. 8. Plug with O-ring

A
1250 0175 95

B 3 8 2 1

7
Changing the accumulators
1250 0041 44
Removal
CAUTION
· Release all gas before removing the ac-
cumulators from the rock drill.
To do this, remove the protective cap (A),
loosen the valve nut (B) and open it by
2–3 turns.
There is a risk of injury if these instruc-
tions are not observed!
Remove the accumulators (1 and 2) together with
the O-rings (3) by removing the screws (4 and 5).
Now send the accumulators to a workshop for
overhauling!
8
Mounting
CAUTION
· Mount the accumulators to the rock drill
using undamaged original screws.
The intake accumulator (2) must have two
screws (4) of length 100 mm.
The damper accumulator (1) must have
two screws (5) of length 70 mm.
Change both screws at the same time,
even if only one of them is corroded (or
damaged in some other way).
Defective screws can cause dangerous oil
leakage, or can cause the accumulator to
be blown off.
Squirting oil can seriously injure the eyes
and skin.
Parts that come loose can cause serious
injury.
Fit the sealings (3) into the grove in the intermedia-
te part (7) and then fit the accumulators (1 or 2) to
the intermediate part (7).
Fit the damper accumulator (1) to the left-hand
side of the rock drill. Fit the intake accumulator (2)
to the right-hand side of the rock drill, i.e. the hose
side. Tighten the screws (4 and 5) alternately to a
torque of 220 Nm (160 lbf.ft).
Now charge the accumulators with nitrogen (N2).
See page 6.
Changing the return accumulator Changing the hydraulic
motor

4
1250 0075 14

1
6

8 5
9

1250 0027 23
7

3
2

Removal Removal
Disconnect the hydraulic hoses (1).
CAUTION Remove the return accumulator (3).

· Before starting work on any of the sys- Remove the nuts (2) and take off the hydraulic mo-
tems, make sure that there is no pressure tor (3).
in the hydraulic and air systems.
Pull out the coupling (4).
· Pressure hoses with an internal diameter
of 19 mm (3/4") or more are rated SAE 100
R9R (i.e. high-pressure hose with four lay-
ers of spirally wound steel-wire reinforce-
ment). See spare parts list for drill rig.
For safety reasons, these hoses must not,
under any circumstances, be replaced Mounting
with hoses of a lower rating.
Make sure that the circlip (5) is fitted into the coup-
There is a risk of injury if these instructions ling (4).
are not observed!
Grease the splines inside the coupling, and slide
the coupling on to the output shaft of the hydraulic
Disconnect the hydraulic hose (8) from the return motor (3).
accumulator (3).
Fit the hydraulic motor (3) with gasket (7) to the
Remove the return accumulator (3) by removing cylinder (6). Change the gasket if it is damaged.
the nuts (2), screws (1), screw (4) and holder (6).
Tighten the nuts (2) to a torque of 65 Nm (48 lbf.ft).
Pull off the clamp (5) and unscrew the accumulator
from the nipple (7). Connect the hydraulic hoses (1). Check that the
motor rotates in the correct direction.
Now send the accumulator to a workshop for
overhauling!

Mounting
Fit the return accumulator (3) to the nipple (7) and
tighten in such a way that the plug (9) is accessible
for checking the accumulator diaphragm.
Slide the clamp (5) on to the accumulator, and fit
the holder (6) by means of the screws (1 and 4)
and nuts (2).
Connect the hydraulic hose (8) to the return
accumulator (3).

9
Filling with lubricating oil and bleeding the system
· If the lubricating system has been empty of
CAUTION oil, it must be bled after filling.
This is done as follows:
· Never intervene in the lubricating system – Loosen the cap (6) and let the lubricating oil
while it is pressurized. escape until all air has been discharged from
Lubricating oil can squirt out, with the the lubricating oil pump. Now tighten the cap.
risk of injury to the eyes and skin. – Start the lubricating system and loosen the
hose connection at pressure gauge (7), so that
all air is released from the system. Now
tighten the hose connection.
IMPORTANT – Disconnect the lubricating-air hose (12) from
the nipple (9) on the rock drill.
· Use the recommended lubricating-air pres- – Start the lubricating pump and let it pump until
sure and the recommended lubri- oil comes out of the plastic hose (11).
cating oil. When re-starting (after standstill), oil must
Certain moving parts of the rock drill are come out of the plastic hose directly when the
lubricated by means of oil-mixed compres- lubricating pump is started.
sed air. It is important that these parts re- – Check that the plastic hose (11) for lubricating
ceive good lubrication. oil is of the correct length.
– Re-connect the lubricating-air hose (12).
· Check the oil level in the lubricating-oil container
(1) once a shift. Observe a high standard of cle-
anliness and fill with oil of the right quality (see
page 19). The lubricating-oil container holds 5
litres.

6
G

13b S 10
A
3
4
B
5 2 1
B

B Setting of ECL lubricating

Min. oil le
6
vel
9 system
13a 10 12 1. Open the electrical cabinet.
11

2. Start the lubricating system (see the operator’s

8 instructions for the drill rig).
+ 3. Check the lubricating air pressure at the rock
1250 0075 15
I

24 V 7 drill (9) using a pressure gauge (A). The pressu-

re should be 2–3 bar. If the pressure is too low,
clean the restrictor (8) or increase the diameter
of the restrictor.
4. Observe the relay window (5) and adjust the
lubricating oil dosage to 35-40 pulses/min for
1. Lubricating-oil container 10. Light-emitting diode pump (13a) and 20-25 pulses/min for pump
2. Filler cap (LED) (13b), by means of the potentiometer (4).
3. Pulse relay 11. Plastic hose 5. After making the setting, check the LED (10) on
4. Potentiometer 12. Lubricating-air hose the lubricating pump to ensure that the right pul-
5. Relay window 13a. 3217 8667 50 old se frequency has been obtained. Check also
6. Cap, bleeding 13b. 3217 8667 52 new that air and lubricating oil comes out of the hole
7. Pressure gauge (B) in the front head and between the shank
8. Restrictor A. Pressure gauge adapter and front guide.
9. Lubricating-air
connection

10
 Lubrication of gear

· Remove the bleeder plug (1).

1250 0040 44

· Grease the gear through the nipple (2) until grea-

se comes out of the hole (3). Use heat-resistant
grease (see "Recommended hydraulic oils and
lubricants", page 19).
· Fit back the plug (1).

Setting the damper pressure

1. Shut completely the constant-flow valve (B) on
the drill rig.
2. Connect a pressure gauge (A) [calibrated from
0 to 60 bar] between the hose and the damper
nipple (1).
1250 0040 48

3. Pressurize the damper circuit.

4. Check that the shank adapter is unloaded, and
that it has been pushed into the forward posi-
tion.
5. Adjust the constant-flow valve until the pressu-
re gauge (A) reads 30–35 bar.
6. Read off the pressure on the damper pressure
gauge on the drill rig.
If the pressure gauge later shows a different va-
lue, make a new pressure setting.
7. Disconnect the pressure gauge (A) and re-
connect the hose to the nipple (1).

Setting the extractor-unit

pressure (HEX)
1. Close the constant-flow valve (B) on the drill rig
completely.
1250 0040 49

2. Connect a pressure gauge (A) [calibrated from

0 to 60 bar] between the hydraulic hose and the
extractor-unit intake nipple (P).
3. Connect the circuit for the extractor unit by acti-
vating feed reverse and running the cradle to
the stop at the rear end of the feed beam. Hold
the feed lever in the "feed-reverse" position.
4. Adjust the constant-flow valve (B) until the pres-
sure gauge (A) reads 20–25 bar.
5. Disconnect the pressure gauge (A) and re-
connect the hydraulic hose to the extractor-unit
intake nipple (P).

11
 Removing the front head

CAUTION
· Never attempt maintenance work while the
drill rig is in operation.
· Before starting work on any of the sys-
tems, make sure that there is no pressure
in the hydraulic and air systems.
There is a risk of injury if these instructions
are not observed!
1250 0040 50

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

re disassembly.

COP 1840HE
Remove the flushing hose (5).
Remove the connection plate (1) and nipple (2) by
removing the screws (3) and washers (6).
Remove the cup seal (4).

Remove the front side-bolt nuts (3) with their

washers (2).
Remove the front head (1) by tugging the shank
adapter (4).
1250 0040 51

Now pull out the shank adapter (4) from the front
head (1).
Check the internal components of the front head
when changing the shank adapter.

COP 1840HEX
Remove the front side-bolt nuts (3) with their
washers (2).
Remove the front head (1) by tugging the shank
1250 0040 52

adapter (4) or by tapping the front head with a cop-

per hammer.
Now pull out the shank adapter (4) from the front
head (1).
Check the internal components of the front head
when changing the shank adapter.

12
Checking the front head

5 1 3 6 3 3 A 8 9 10 5 13 1 13 13 3 3 3 3 6 8 A 10

11 11
2
2 3 C B 7
4 14 12 C B 9
COP 1840HE COP 1840HEX

3 3 6 3 3
1m
m

HE HE HEX
8 13 12 13 13
1 mm
2 mm

HEX
m 2
1m D 2
5
1250 0075 16

53 mm

· Check that air and lubricating oil come out be-
tween the shank adapter (5) and front guide
(2), and also out of the hole (B).
· Blow clean the lubricating oil ducts (A) in the
front head (1) using compressed air, and check
that the restrictors (10) are open.
· Change the guide (2) if its internal diameter is
greater than 53 mm.
· Check the O-rings and flushing seals (3) if air is
escaping from the hole (C) in the front head.
Change the O-rings and flushing seals if they
are worn or damaged.
· Change the flushing head (6) if it is seriously cor-
roded, or if it contains cracks.
· Change the stop ring (7) if it is worn by more
than 1 mm.
· Change the extractor-unit piston (12) if the surfa-
ce toward the shank adapter has worn by more
than 1 mm.
When changing the extractor-unit piston, check
the seals and O-rings (13). Change them if they
are worn or damaged.
· Look inside the gear housing and check the spli-
nes of the driver (8). If the splines are less than
2 mm in width, the driver must be changed (see
page 14).
Fit a new driver with the aid of a suitable mandrel
and a copper hammer.
· If the rotation chuck bushing (9) is worn by more
than 1 mm, or if the striking surface of the im-
pact piston (4) is damaged in any way, the rock
drill must be sent to a suitable workshop for over-
hauling. See the overhauling instructions. NB!
Fit the rotation chuck bushing so that the lubrica-
tion grooves (D) face the damper piston (14).
· Change the shank adapter (5) if the thread is
worn out or the impact surface is upset or chip-
ped, or if the front or rear end surfaces of the
splines are worn.
· Check that the drill collar (11), which must be
used in upwards-directed drilling, is not dama-
ged and that it rotates with the shank adapter.

13
 Changing the flushing head and driver

Disassembly

CAUTION
· Take care when removing the flushing
head and driver. Mind your fingers!

Remove the flushing hose (1) from the nipple (2).

Remove the nipple (3) and its O-rings.
Press the disassembly tool (A) into the gear hou-
sing (4) until it comes to a stop, i.e. until the spli-
ned part of the tool has passed the splines of the
driver (5).
Turn the disassembly tool clockwise a little.
Tap out the driver (5) and flushing head (6) by stri-
king with the impact hammer (B).
1250 0027 34

14
 Assembly
1250 0039 24

If the rotation chuck bushing (3) has been remo-

ved, fit it back and tap into place eith the aid of a
suitable copper mandrel.
NB! Fit the rotation chuck bushing so that the lubri-
cation grooves (D) face the damper piston (14).
Tap the driver (2) into the rotation chuck in the
gear housing (1) with the aid of a mandrel (A) and
a copper hammer.
1250 0040 62

Fit the O-rings (3) and seals (4) into the flushing
head (2).
IMPORTANT! The seals (4) must be turned as
shown in the figure opposite.
Place the flushing head (2) into the cover (1) and
tap it in using a copper hammer. Check carefully
that the flushing intake in the cover lines up with
the hole in the flushing head.
Fit the O-rings (5 and 6) and back-up ring (7) on to
the nipple (8).
Fit the nipples (8, 9 and 10) and the nut (11).
Tighten the nipple (8) to a torque of 300 Nm
(220 lbf.ft) and the nipple (9) to a torque of 180 Nm
(130 lbf.ft).

15
 Mounting the front head
COP 1840HE
Fit the stop ring and shank adapter (4) into the
front head (1).
Check that the pin (6) is fitted into the cover. Fit
the front head (1) on to the side bolts (5).
Fit the washers (2) and nuts (3).
N.B. Before assembly, smear the threads with gre-
ase (type NEVER-SEEZ).
1250 0040 64

Check the tightening torques of the rear side-bolt

nuts and front side bolt (see 1–2, page 5).
Now tighten the nuts (3) alternately to a torque of
350 Nm (260 lbf.ft).
1250 0040 65

Fit the cup seal (4) into the flushing head.

Fit the connection plate (1) to the front head using
the washers (6) and screws (3). Tighten the
screws (3) to a torque of 90 Nm (65 lbf.ft).
Change the seal washer (7) if it is damaged.
Fit the nipple (2) to the connection plate, and
tighten to a torque of 300 Nm (220 lbf.ft).
Connect the flushing hose (5) and tighten the coup-
ling nut.
After assembly, check that air and lubricating
oil come out of the hole in the front head and
also between the shank adapter and the front
guide.

16
 COP 1840HEX

1250 0027 39

Fit the shank adapter (4) into the front head of the
extractor unit.
Check the tightening torques of the rear side-bolt
nuts and front side bolt (see 1–2, page 5).
Fit the cylindrical pin (5).
Fit the front head (1) over the stud bolts (6).
Fit the washers (2) and nuts (3).
N.B. Before assembly, smear the threads with gre-
ase (type NEVER-SEEZ).
Tighten the nuts (3) alternately to a torque of
300 Nm (220 lbf.ft).
Connect the flushing hose to the nipple (7).
After assembly, check that air and lubricating
oil come out of the hole in the front head and
also between the shank adapter and the front
guide.

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Slinging
1250 0040 69

Make sure that the rock drill is safely slung for

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

Rock drill weights, approx.

CAUTION COP 1840HE . . . 184 kg (405 lbs)
COP 1840HEX . . 244 kg (540 lbs)
· Lifting gear and slings must be approved
for a weight of 500 kg (1100 lbs).

Faulty lifting gear can cause the rock drill

to move unpredictably or drop.
Incorrect handling can result in crush
injuries.

Long-term storage
If the rock drill is not going to be used for a long
time, the following precautions should be taken:
· Check that all connections, including the one for
the flushing medium, are properly plugged or
capped. Use clean protective plugs or caps of
the right size.
· Clean the rock drill thoroughly. Use a degre-
asing agent and hose down the rock drill with wa-
ter.
· Thoroughly clean the front head parts that are in
contact with the flushing medium, especially in
the case of high air humidity. After cleaning, oil
the parts with clean hydraulic oil.
· Release the gas from the accumulators (see in-
structions on page 8).
· Store the rock drill in a dry place.

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Recommended hydraulic oils and lubricants

Lubricant Recommendation

Hydraulic oil · Use a mineral-base or synthetic (polyalpha-olefin or diester based) hydraulic oil with good anti-wear, anti-rust,
anti-oxidation and foam inhibiting properties, and with good air and water separation characteristics. Choose an
oil with viscosity grade (VG) and viscosity index (VI), in accordance with the table below. An oil with a high
viscosity index is less sensitive to the effects of temperature.

Hydraulic oil temperature in tank oC ( oF) Viscosity Viscosity

Normal operating temp. Min. starting temp. Max. temp. grade VG index VI
(viscosity 25–50 cSt) (viscosity min. 1000 cSt) (ISO 3448)
+50 to +70 (122 to 158) +5 (41) 80 (176) ISO VG 100 Min. 100
+45 to +60 (113 to 140) –5 (23) 75 (167) ISO VG 68 Min. 100
+35 to +50 (95 to 122) –10 (14) 65 (149) ISO VG 46 Min. 100
+25 to +40 (77 to 104) –15 (5) 55 (131) ISO VG 32 Min. 100
+10 to +25 (50 to 77) –25 (–13) 35 (95) ISO VG 15 Min. 100

Air tool oil · Use a mineral based air tool oil.

Ambient temperature oC ( oF) Viscosity grade (ISO 3448)
–30 to 0 (–22 to +32) ISO VG 32–68
–10 to +20 (14 to 68) ISO VG 68–100
+10 to +50 (50 to 122) ISO VG 100–150

Grease · IMPORTANT! Because of the operating temperature in the rock drill gear housing (see "Lubrication of gear"),
always use a high-temperature grease containing an ashless thickening agent and additives that give
resistance to oxidation and rust. The grease should also have good resistance to water.
Grease properties NLGI-number 2 Base oil viscosity 110 cSt at 40 oC (104 oF)
Dropping point 250 oC (480 oF) Operating temp. –20 to +150 oC (–4 to 300 oF)

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