Meo cone Sltlas Copco 38 A843 hi ‘COP 00 1222-07 Overhauling instructions for Hydraulic COP 1019 Rockdrills COP 1022 COP 1025 COP 1028 Special attention must be paid to informa- tion carrying this symbol, ATLAS COPCO TUNNELING AND MINING AB STOCKHOLM » SWEDEN No. 9853 0927 01General ‘These instructions are intended as a guide to the re- pair and overhaul of the COP 1019/1022/1025/1026 hydraulic rock drilis. N.B. Never Intervene in a rock dill or undo connections while hydrauille pressure Is engage Observe the strictest cleanliness when intervening In a hydraulic rock drill. Replacement of the shank adapt- er, front-head components, accumula- tor, rotation motor, bolts and connec: tlons may be carried out at the work- site, Other repairs must be cartied out Ina suitable workshop. Order of sequence ‘The instructions begin with a list of the standard ‘and special tools needed to repair or overhaul the rock crills. This is followed by instructions on how to disassemble the rock cfill into its main compo- nents, Then, under the respective main headings, detailed instructions are given on further disas- sembly, checking and inspection of parts, and re- assembly. Finally, instructions are given on how to re-assemble the main components of the rock dil, followed by details of the tests and checks which must be car- ried out after repatr. ‘The numbers in brackets in the text refer to the ex ploded views on pages 36, 45 and 47 Demands on the workshop Any workshop used for the repair of hydraulic rack drills must meet the following standards: « Itmust be completely separate from any dust- ‘generating activities, such as welding, grinding ete; ‘+ Itmust be very clean (free of dust, dirt eta); ‘+ It must be equipped with a washer unit, as well ‘as compressed ait for blow-cleaning hydraulic ‘components; ‘+ It must be equipped with suitable standard and special tools (see List of tools). Demands on personnel * All personne involved in tha repair and overhaul of hydraulic rock drills must first receive training from Atlas Copco, List of contents Page General ee List of toois 3 Main parts of the rock grils ‘COP 1019/1022/1025 . ? Main parts of rock dril COP 1028... 2... 8 Disassembly of rock drill into main parts... .-- 9 Disassembly, inspection, replacement of parts and re-assembly ~ Front head ang rotation chuck, COP 101971022025 .....' 12 ~Front head, COP 1028 . “47 ~Gear housing . 123 = Cylinder, impact Piston and vaive Bit ton. 26 = Back head te 2.30 Accumulator 33 = Hydraulic motors... fete BB = Exploded view, hydraulic motor 236 Function- and condition testing of hydraulic motor... 37 Assembly of main rock dil components... 38 Function test of impact mechanism and rotation 42 Tightening torques .... : Recommended oils. Exploded view COP 1019/1022/1025 | Exploded view COP 1028List of tools / Standard tools 1.Plastic matiot 2. Copper hammer 3, Sledge hammer 4. Combination spanners. Spanner width: 18, 24, 27 mm Spanner width: 7/8", 1 1/8" 5. Allen key Wiel 6. Screwdrivers 7. Punches, 210 mm, 8. Internat circtip pliers 9. Torque wrenches, 30-250 Nm (20-185 Ibt. ft) 10. Sockets for torque wrench Socket width: 24, 27 mm. ‘14, Hexagon bit adaptor for torque wrench Width: 8 mm 12, Ratchet shaft 13. Depth micrometer, 0-25 mm 14. Vernier caliperList of tools / Special tools and test equipment Part number Description use 3115 1092.80 Plate + 2 bolts (M16 x 75) ‘Mounting fixture for use during disassembly, re-assembly and testing. 3115 1102.00 Mandrel Removal and fitting of front, bearing (24* or 25). Fitting of chuck bushing (16) In ‘COP 1022. 3115 1094.00 Mandrel Fitting of front piston guide (@2* or 29% and front seal housing. 3115 1095 00 Mandrot Fitting of rear piston guide (42* or 43%) and rear seal housing (41* or 42%), 3145 1098 00 Mandel Fitting of rotation chuck bearing (2) and rear bearing 26" or 27), Removal and fitting of axial bearing (19). Used togeth with plates 9115 1097 00 and 3115 2343 00. ‘3115 1177 00 Mandrel Removal of front seal housing (20* or 21", ‘3116 1603.60, Mandrel Removal of chuck bushing (16% ‘gi16 1246.00 Mandrel Used as a guide when fiting the chuck bushing (16) In Cop 1025, * In COP so1g/oza/025 * In COP 1028List of tools / Special tools and test equipment Too! Partnumber | Deseription Use 4 3115159500 | Mendrel Removal of rotation chuck K 315 159300 | Plate Removal of rotation chuck L 2115299200 | Mandret Disassembly of rotation chuck (16% and rotation chuck bearing (24). Removal and fiting of bushing (2). ™ aits 15400 | Plates Removal of rotation chuck = bearing (2). SSS N 3145 109700 | Plate Fitting of rotation chuck bearing (29). = ° 3115234300 | Plate Fitting of rotation chuck <>) bearing (2). Sy P ‘311s 230900 | mandrel Fitting of ehuek bushing (16) In COP 1019 and river (18) C hb In CoP 1028. a 3116 110000 | Assembly and | Disassembly and assembly disassembly tool, | of accumulator. Width across flats = 82 mm R 3118 1101 00 ‘Assembly and disassembly toot Disassembly and assembly of accumulator. * In COP ro19/o2a/1025 In COP 1028List of tools / Special tools and test equipment Tool Partnumber [Description Use s 3115182180 | charging hose, | Hose for charging of comalete accumulator. 3115064200 [Nipple 3115064400 |—Nippie 3115207500 |= Adapter T 3115084600 | Regulator Pressure reducing valve for ‘accumulator charging. 3115087800 | Pressure gauge | Forchecking accumulator prossure, u 3091 045590 | Extractors access-| Removal of rear seal ories housing (31" or 42"), front and rear plston guides (22 or 23% and 42" of 43"), a8 wellas driver (16°). v 3115 034400 | Wrench adapter, | Adapter for use with torque 32mm ‘wrench during tightening, w _ 3115113100 [Test plate For locking of rotation motor chat. o Kae x 3115112600 [Assembly tool | For fitting of thread insert Mi6 into gear housing (18) and back head (46* or 47"), 3115112700 [Assembly tool |For fitting of thread insert M182 Into gear housing (3). Y 3115132600 [auide Removal of chuck bushing i) z 3007 012800 | Gauge COP 1019- Measurement of wear in chuck bushing (16). 3091 003800 | Gauge COP 1022 - Measurement of ‘weer In chuck bushing (16). 3008735200 | Gauge COP 1025 - Measurement of wear in chuck bushing (16). * In COP so19/022/1025 ™ in COP 1028Main parts of the rock drills COP 1019 / COP 1022 / COP 1025 Fig. 1. Hydraullc rock dlls COP 1019/1022/1025, main parts 1. Back head, Including 4, Hydraulic motor ‘+ Flushing tube * Rear seal housing Rear piston guide 5. Gear housing, including ‘+ Rear piston seals et eoal bearing accumulate 6. Front head, including * Dril-stee! retainer * Rotation chuck bearing 3. Cylinder, including * Chuck bushing « Impact piston * Rotation chuck * Valve piston ‘+ Front seal housing ‘+ Front piston guide ‘+ Front piston sealsMain parts of the rock drill COP 1028 Fig. 2 Hydraulic rock anit COP 1028, main parts 1. Back head, including ‘* Rear seal housing «Rear piston guide * Rear piston seals 2. Accumulator 3, Cylinder, Including © Impact piston © Valve piston «© Front seal housing * Front piston guide «Front piston seals 4. Hydraulic motor 5, Geer housing, including * Axial bearing 6. Front head, including * Bushing * Stop ring * Flushing head = Adapter * Pressure ring * Driver * Rotation chuck bearing * Rotation chuckDisassembly of rock drill into main parts Use plate (Incl. two bolts) 3115 1092 80 (see fig. A, page 4) when disassembling the rock drill, Disassembly sequence: * Front head * Hydraulic motor ‘+ Back head, Impact piston and valve piston + Accumulator and flushing tube Gear housing and cylinder * Side botts Fig. 3 Attaching the rock dri to the plate (A) Fig 5 Removing the hyaraute moter Front head N.B, Before disassembling the rock drill, al- Ways wash down the outside of the machine using a degreasing agent. Fix plate 3115 1092 60 (see fig. A, page 4) securely ina vice. Bolt the rock drill securely to the plate. Loosen the bolts (8* or 12%) Remove the front head (1). Tap it loose using a copper hammer. Hydraulic motor Loosen the two bolts (18). (The other two screws 14 serve only to hold together the motor itself) Remove the hydraulic motor (27* or 26) + cop rors/ro2e/1025 "COP 1028Accumulator and flushing tube N.B. Before the accumulator ts temoved, all gas must be released. To do this, remove the protective cap on valve nut (A) and loosen the vaive ut. Remove the bolts (61) Take off the accumulator (58). Fig. 6. Removing the accumulator ( Unscrew the hexagonal nipple (62"). Withdraw the flushing tube (60*) and its gasket (48%). 82 50 «« Fig. 7. Removing the ftushing tube Side bolts ( Remove the nuts (65* or 62) and washers (47* or 48"), Withdraw the side bolts (48 or 49%) 65 47 62 AB - i Fig 8 Remeving he side bolts 1, 008 torancaarioas 10Fig. 9. Removal of back head and impact piston Fig. 10. Removal of valve cover and vaive piston Fig 11. Removal of gear housing Back head, impact piston and valve piston Remove the back head (46" or 47%) carefully, in order to avoid damaging the impact piston (30* or 31"), With¢raw the impact piston and place it some- where where it will not be scratched or damaged in any way. Remove the valve cover (88* or 39%) and with- draw the valve piston (40° or 41%). Also place these parts somewhere where they will not be scratched or damaged in any way. Gear housing and cylinder Tap loose the gear housing (18) using @ copper hammer. Now unbolt the cylinder (83* or 34") from the plate (A). + COP torg/tozerio2s * COP 1028 nFront head and rotation chuck COP 1019/1022/1025 Fig 14. Removing ihe rotation chuck bearing 12 Disassembi) Inspection, replacement of parts Assembly Disassembly Disassemble the dil-steel retainer (8) by remov- ing the nut (14) and pulling out the arm (12). Remove the circlip (6). Pull out the spring (7) and dril-steal retainer (8). Remove the rotation chuck (15) by hand, or with the aid of mandrel 3115 2392 00 (see fig. L, page 5). Press out the rotation chuck bearing (2) from the front head (1). Use the mandrel 3115 2392 00 and Plate 3115 1593 00 (see figs. Land K, page 5).Fig. 15 Checking the chuck bushing Fig. 16. Removing the chuck bushing a8 565e0m . Fig. 17. Checking the rolation chuck bearing Inspection, replacement of parts Before inspection, all parts must be washed thoroughly in a degreasing agent. Check the wear in the chuck bushing (16), using the appropriate gauge (see fig. Z, page 6): ~ 8007 0125 00 for COP 1019 ~ 3081 0038 00 for COP 1022 ~ 3006 7352 00 for COP 1025 Ifthe gauge can be inserted all the way into the ‘chuck bushing, the partis worn out and must be re- placed. Press out the chuck bushing (16) from the rotation chuck (16). Use the mandrel 3115 1603 00 and guide 3118 1926 0 (200 figs. G and Y, pages 4 and 6) Replace the rotation chuck bearing (2) ifthe inside diamoter exceeds 66.5 mm. 13Fig. 19. Fitting the rotation chuck bearing Fig 20 Fiting the chuck bushing, COP 1019/1022 4 Assembly Before assembly, all parts must be oiled with clean air-tool oll. Replace the drill-stee! retainer (8) if wear exceeds 2 mm (see figure). Press the rotation chuck bearing (2) into the front head (1) with the aid of mandrel 3115 1086 00 and plate 3115 1097 00 (see figs. E and N, pages 4 and 5) Note the groove in the rotation chuck bearing, Assembly of chuck bushing tor COP 1019/1022 Press the chuck bushing (16) into the rotation chuck (15) with the aid of mandrel 3115 2383 00 (COP 1019) ot 3115 1102 00 (COP 1022}. See fig. P, page 6 and fig. B, page 4)Assembly of chuck bushing for COP 1025 Place the mandrel 3115 1246 00 (see fig. H, page 4) in the rotation chuck (15) Press in the chuck bushing (16). The mandrel will guide the lugs on the chuck bushing into the {grooves in the rotation chuck. Fig, 21. Fiting of chuck bushing (COP 1025) Tap in the locking wire (17) using a hammer and punch, Fig. 22, Fitting of locking wire (COP 1025) 16Fig 23. Blow-cleaning the lubrication duct 12 Fig, 24. Assembly of dril-stee! retainer and tront head 16 Check that the lubricating duct is not blocked. To do this, blow compressed air through the duct. Replace the O-rings (9 and 10) in the front head (1). Tap in the drill-stee! retainer (8), and then turn itto one of its end positions, Insert the spring (7) and fit the circiip (6) into the hole in the front head (1). Use a hammer and punch to tap the circlip down into its groove. Fit the ‘arm (12) and secure it by means of the nut (11) Fit the rotation chuck (18).Fig 28. Removing the stop ring and flushing head 4 Fig 27. Removing the bushing Front head, COP 1028 Disassembly Inspection, replacement of parts Assembly Disassembly ‘Tap out the adapter (8) and pressure ring (9) using a copper mandrel Remove the flushing head (7) and stop ring (4) by striking the underside of the front head against two blocks of wood. A Mind your fingers! Risk of pinching! Ifthe flushing head does not come out, it can be pressed out fogether with the bushing (see fig. 27). Press out the bushing (8) with the aid of mandrel 8116 2992 00 (see fig. L, page 5). W7Ifthe driver (16) needs to be replaced, this should be done as shown in the figure, using the extractor 3091 0455 80 (see fig. U, page 6) anda 37-46 mm expander. Fig. 28, Removing the driver When changing the rotation chuck bearing (2), the plates 3115 1594 00 (seo fig. M, page 5) must be placed against the front side of the rotation chuck bearing, in the internal clearance of the front head. ‘Then press out the rotation chuck bearing using the mandrel 3115 1595 00 (see fig. J, page 6). Fig, 29. Removing the rotation chuck bearing Inspection, replacement of parts Wash the front head, its components and ducts thoroughly in a degreasing agent. Check the adapter (8) and replace iti = the thread is worn ~ the impact surface is deformed or chipped | =the splines are deformed or worn down, | Fig. 30. Checking the adepter | 18Fig. 31. Checking the pressure ring Fig. 82. Checking the fushing head Fig. 39. Checking the stop ring Fig. 84. Checking the bushing Check the pressure ring (@) and replace ttf the stopping edge is worn by more than 0.7 mm. Check the flushing head (7) and replace it if itis, corroded, or if cracking has occurred. ‘Check the stop ring (4) and replace it ifthe stop- ping edge is worn by more than 0.7 mn, Check the bushing (8) and replace it ifits internal diameter exceeds 40.5 mm. 19Inspect the driver (16). Change the driver if the spline width is less than half the width of the splines in a new driver, Check the rotation chuck bearing (2). Replace it if the internal diameter exceeds 71.5 mm. Check that the lubricating duct is open. To do this, blow compressed air into the duct. Fig. 36. Blow-cleaning the lubricating duct 1 eB) 3 S- ress in the bushing (8) withthe aid of the mandrel 8115 2392 00 (see fig. L, page 5) Fig. 37 Fitting the bushing 20Press in the rotation chuck bearing (2) with the ald of plate 3115 2843 00 and mandrel 3115 1096 00 (eee figs. O and E, pages 4 and 5). Take care to Centralize the rotation chuck bearing! Fig. 98. Fitting the rotation chuck beating Pp [+ Press the driver (16) into the rotation chuck (17) with the aid of mandrel 3115 2893 00 (see fig. P, page 5). e Fig 39. Fiting the driverReplace the three seals (6) in the flushing head (7). To remove the seals, break them up using a Scratch awi or @ small screwdriver. Fitthe new seals as shown in the figure opposite, Replace the three O-rings (6) on the flushing head, Fig. 40. Changing the seals and O-rings Fitthe adapter (8) and tap down the pressure ring (©) with the aid of a copper mandrel. B- : 4 8 ‘Tap down the flushing head (7) and stop ring (4) ae using a plastic mallet Fig. 41. Fitting the fushing head, stop ring, adapter and pressure ring 22Gear housing Disassembly Inspection, replacement of parts. Assembly Disassembly Remove the axial bearing (19) from the gear hous- ing (18) with the eid of mandrel 3118 1096 00 (see fig. E, page 4), Fig. 42. Removing the axial bearing Remove the gear-wheel (25% or 26") and rear bearing (26* or 27) by tapping on the gear-wheel with the aid of a hammer and punch. Fig. 43. Removing the gear-wheel and rear bearing cop torg/rozernoes * CoP 1028 23.‘Tap out the front bushing (24* or 25%) using the mandrel 3115 1102 00 (See fig. B, page 4). Fig. 44, Removing the front bearing | rmini33 men Inspection, replacement of parts Before inspection, all parts must be washed ‘thoroughly in a degreasing agent | The axial beating (19) must be replaced if its thick- ness dimension is less than 18.3 mm. or Fig, 45. Checking the axial bearing 26 ’ ar r0x2530m| ‘The rear bearing (26* or 27") must be replaced if its internal diameter exceeds 25.3 mm. The front bearing (24* or 25%) must be replaced if \, Fa. 48. Cheching the font and rear bearings 1, Soe iagrenaocs 24Fig. 47, Fitting the axial bearing Fig. 48, Fitting the front bearing 4 Fig. 49. Fiting the rear bearing Assembly Before assembly, all parts must be oiled with clean air toot oi Fit the axial bearing (19) into the gear housing (18). Use the mandrel 3115 1096 00 (see fig. E, page 4). Fit the front bearing (24* or 25") into the gear housing (18) with the aid of mandrel 3115 1102 00 (see tig. B, page 4) Fit the gear-wheel (25* or 26). ‘Tap down the rear bearing (26* or 27%) into the gear housing (18). Use the mandrel 3115 1096 00 (see fig. E, page 4) + COP torg/roz2/1025 + CoP 1028 25Cylinder, impact piston and valve piston Disassembly Inspection, replacement of parts Assembly Disassembly Remove the vaive cover (37* or 38) by removing the screws (36* or 37) and pulling out the valve cover. ‘The front seal housing (20* or 21*) must not be removed if the piston guide (22* or 23") or seal housing do not need to be replaced. Ifthe parts have to be replaced, remove the seal housing with the aid of mandrel 3115 1177 00 (see fig. F, page 4), as shown in the figure opposite. To remove the seals, work a small screwdriver or scratch awl underneath the seals, and carefully break them up. Fig, 51. Removing the front seal housing Remove the front piston guide (22* or 23%) from the front seal housing (20* or 21%) with the aid of extractor 3091 0455 90 (see fig. U, page 6). Fi ving the frent piston guide * COP rorgnozenozs ig. $2 Removing the front piston gu tee fora) 26Ret 0.5 mm Fig. 53. Inspecting the impact piston Garni (Oh Fig. 54 Inspecting the vaive piston and valve covers Fig 55. Adjusting the cylinder Fig 56 Checking the front piston seals, Inspection, replacement of parts Bofore Inspection, the parts must be washed thoroughiy in a degreasing agent. Inspect the piston (80* or 31%). Replace it if the surfaces thet are in contact with the seals or piston guides show signs of scoring, or ifthe piston lands, have serious score damage. Check also that the striking surface of the piston is not damaged. ‘The striking surface of the piston may be ground by a maximum of 0.5 mm (R=1). See figure oppo- site, Inspect the valve piston (40* or 41™) and valve ‘covers (37* or 36% and 38* or 39%), and replace the pars ifthey show signs of scoring, Minor scoring on the valve piston (40* or 41%) can e polished using a whetstone. Inspect the cylinder (83° or 34%) and replace It if the cylinder- or valve barrals show signs of score damage. In the event of minor scoring or scratching, the cy- linder- and valve barrels can be polished very lightly, using a fine abrasive cloth or whetstone. Check the front piston seals (21* or 22") for wear or damage. Weer can be checked by sliding the im- pact piston (80* or $1) through the front piston ‘seals, and observing the tolerance. Ifthe tolerance is tight, the seals do not need to be replaced. * cop roreyrozeyto2s COP 1028 ar40 Fig $7. Fitting the valve cover to the cylinder 4 Tr i 2 23 ied 21 { Lo Fig. 68. Fitting the front piston guide 28 Assembly Before assembly, all parts must be oiled with clean air-too! oil Fit the valve cover (37* or 38) with its O-ring (39* or 40%), ‘The screws (36* or 37%) must be tightened to a torque of 70 Nm (50 tof.) Press the front piston guide (22* or 23) into the front seal housing (20* or 21%). Use mandrel 3115 1084 00 (see fig. C, page 4). + COP tors/tozerso2s "COP 1028Fig. 59. iting the front piston seals Fig. 60 Fitting the front seal housing Fit the front piston seals (21* or 22*) as shown in the figure opposite (a seal ring consists of an O- ring and a teflon ring). Fit the O-ring into the groove. Bend the teflon ring inward as shown in the figure, and press the seal into the groove. IMPORTANTI The seal lips must face the direction shown in the figure. Fit the O-ring (@* or 20%) to the front seal housing (20* or 21%). Press the front seal housing into the oylinder (33* or 34*4) with the aid of mandrel 3115 1084 00 (see fig. C, page 4. * cop 1o19/1022/1005 ** COP 1028 29Back head Disassembly Inspection, replacement of parts Assembly Disassembly ‘The rear seal housing (41* or 42") must not be removed ifthe piston guide (42* or 43") or seal housing are not damaged. Ifthe parts must be re- placed, remove the rear seal housing with the eld of extractor 3091 0455 90 (see fig. U, page 6). Make sure that the expanders in the extractor are located underneath the seal housing. Remove the rear piston guide (42* or 43%) from the seal housing (41* or 42%) with the aid of ex- tractor 3091 0455 90 (se9 fig. U, page 6). Fig. 62. Removing the rear piston guide Inspection, replacement of parts Before inspection, all parts must be washed thoroughly in @ degreasing agent. Chock the rear piston seals (43* or 44%) for wear ‘or darnage. To check the wear on the reat piston seals, slide the Impact piston (80* or 314) through ( the seals and observe the tolerance. Ifthe toler ance is tight, the piston seals do not need to be re- placed ‘To remove the piston seals, insert a small screw- driver or scratch awl under the seals, and break them up carefully. 20 a Fig 62 Checking the rear piston seais 2. SOP sorgnozesroas 3048 a9 i —— Fig. 64. Inspecting the side bolts 49 50 Bt ey Fig. 65. Inspecting the flushing tube and O-ting 62 i) 33 ~ C =» Ov NO) Fig 66. Fiting the hose adapter D 42 Gr a i) 42 Fig 67. Fiting the rear piston guide Inspect the side bolts (48* or 49%) and replace them if they are damaged or corroded. N.B, When replacing the side bolts, BOTH bolts must always be replaced at the same time, COP 1019/1022/1025 Inspect the flushing tube (50). Replace it if itis cracked, deformed or corroded. Inspect the O-ring (61). Replace it fit is damaged. Also inspect the gasket (49) in the back head, and replace if necessary. Assembly Before assembly, all parts must be oiled with clean air-tool oil Fit the hose adapter (62* or 53%), and tighten to a torque of 120 Nm (80 Ibf.ft). Press the rear piston guide (42* or 43%) into the seal housing (44* or 42") with the aid of mandrat 8115 1095 00 (see fig. D, page 4). + CoP torgitoze/025 ~ COP 1028 atFit the rear piston seals (49* or 44%) as shown in the figure opposite (a seal ring consists of an O- ring and a teflon ring). Fit the O-ring into the groove. Bend the teflon ring inward (as shown in the figure) and press it into the groove. IMPORTANT! The seal lips must face the direc- tion shown In the figure. ig. 68, Fitting the rear piston seals Press the rear seal housing (41* or 42") into the back head (46* or 47"). Use mandrel 3116 1095, 00 (see fig. D, page 4) Fig. 69. Fiting the rear seal housing + COP rors/te22005 "= COP 1028 32Fig. 70. Disassembly of the accurnutator Fig 71. Inspecting the diaphragm, valve housing and cover Accumulator Disassembly Inspection, replacement of parts Assembly Disassembly N.B. Before disassembly, all gas must bbe released from the accumulator, To do this, simply remove the protective ‘cap from valve nut (A) and loosen the nut. ‘Secure the disassembly tool 3115 1101 00 ina Vice (see fig. R, page 8). Place the accumulator (58) on the disassembly ‘ool and unscrew the cover from the housing, Using the disassembly tool 9115 1100 00 (see fg. Q, page §). Inspection, replacement of parts ‘Always change the diaphragm (67) and valve (59) if the diaphragm shows signs of cracking, or if either of these parts is damaged. Always change the O-ring (65). Check that the duct for gas-charging is not blocked. Change the housing (66) and cover (58) ifthe threads are damaged or severely corroded. Damaged or severely corroded threads ‘on the accumulator housing or cover could result in 2 serlous accident. 33Fig. 73 Assembly of the accumulator Fig. 74 Checking and charging of the accumulator 34 Assembly Before assembly, make absolutely sure that all paris of the accumulator are dry and free of oil, ‘Smear a thin layer of silicon grease around the ‘edge (perimeter) of the diaphragm (57), and place the diaphragm into the housing (56) N.B, Grease the threads of the accumulator cover (68) and housing (56) with molybdenum grease. Screw the cover (68) to the housing (66) by hand, keeping the parts facing inthe directions shown in the illustration opposite, Fit the valve (69) together with the O-ring and tighten to a torque of 30 Nm (20 tof. f). Do not turn the accumulator upside-down until it hhas been properly screwad together. Now place the accumulator on to the assembly tool 3115 1101 00 (see fig. R, page 5). Tighten the cover to the housing, to a torque of ‘800 Nm (220 Ibf. ft Use the assembly tool 3115 1100 00 and wrench adapter 3116 0344 00 with the torque wrench (see figs. Q end V, pages § and 6) Checking — Charging the accumulator N.B. Do not charge the accumulator until it has been properly fitted to the rock drill. IMPORTANT The accumulator may be charged with nitrogen gas only! Use of another gas could cause an explosiont 1. Remove the protective cap (D) from the accu- mulator valve 2, Ifithas not already been done, release all gas from the accumulator by loosening the valve nut (E) and turning it outward by 2-3 turns, ( 3, foil comes out of the nipple, the accumulator or its diaphragm must be replaced. 4, Use the gas regulator (T) 3115 0646 00 and charging hose (S) 3115 1821 80 (see figs. T and 8, page 6) 5. Connect the charging hose and open the gas valve (F). Then charge the high-pressure accu- tmulator (B) to half the percussion mechanism pressure (max. 90 bai/1300psi). 6. Tighten the vaive nut (&) and close the gas valve (F 7. Remove the charging hose and fit back the pro- tective cap (D) to the accumulator valve, After the check has been carried out, the gas must be released from the accumulator. The diaphragm can be damaged if the rock drill is stored with the accumulator in the charged conditionoad Fig. 75. Disassembly of hydraulte motor Fig. 78. Removing the seal ring 1 Fig. 77. Checking the axial play Hydraulic motor Disassembly Inspection, replacement of parts ssernbly Function and condition test Disassembly Remove the two screws (14), Separate the motor (27* or 28%) by tapping on the shaft with a plastic mallet. 2 28 > Remove the seal ring (15) from the cover (1). Now remove the rotors (6, 9), axial bearings (7, 10), sleeves (17), O-rings (2, 4), balls (5) and springs (6. See fig. 79. Inspection, replacement of parts Clean all parts thoroughly before inspection. ‘When overhauling the hydraulic motor, the packing set 3115 1058 92 must be used Place the housing (11) with axial bearing (10) ona work bench or similar surface. N.B. The teflon sido of the axial bearing must face upward. Check the axial play. Measure the play with the aid ofa depth micrometer. The axial play should be 0.025-0.050 mm. If the play is greater than this, the axial bearing must be replaced. Ifthe play is too smal, the teflon side of the axial bearing must be polished until the prescribed play is obtained. + COP rorg/t0ze/1025 * Cop 1028 35Fig, 78. Fiting the O-rings (4) Fig 79. Assembly of the hydraulic motor 36 Assembly Al parts must be cleaned thoroughly before as- sembly. Before assembly, the parts must be olled with clean hydraulic oil ‘All O-rings must be replaced with new ones. Be- fore fiting the O-rings, smear them with silicone grease. Acomplete packing set for the hydraulic motor can be ordered on part No. 3115 1058 82 ‘Smear the seal ring (15) with a thin layer of slicon grease, and fititinto the cover (1) —see fg. 79. ‘Smear the O-rings (4) with a thin layer of silicon ‘ease (so that they stick in place), and fit them into their respective grooves in the cover (1). Fit the axial bearing (10) with its tefion side facing upward in the housing (11). Oil the rotors (8 and 8) and fit them into the housing. ‘Check the O-ring (2) and replace it if itis dam- ‘aged. Fit it into the groove in the cover (1). Insert the balls (5) with their springs (6) into their respective positions in the cover, Place the axial bearing (7) on the cover, with the teflon side facing away from the cover. Fitthe sleeves (17) into the housing (11) Check the other O-ring (2) and replace itt itis damaged. Fit the O-ring into the housing (11)Fig. 80. Assembling the main parts of the hycraulic. ‘motor Fig. 81. Testing the function of the hydraulle motor w Fig. 82. Testing the condttion ofthe hydraulic motor Use a plastic mallet to tap the main parts of the motor together, Fit the screws (14) and tighten them to a torque of 70 Nm (60 Ibf. f). Tighten the nipples (28* or 29%) to a torque of 420 Nm (80 ib. ft). Function and condition testing of hydraulic motor Connect the pressure and return ines (P and R) to the hydraulic motor. Switch on the pump and let the motor rotate for approx. 1 minute. Do not iet the motor operate with a flow that exceeds 10 Yimin (2.6 US gal/min). Check that the housing (11) does not become hot and that the motor rotates evenly, without dissonance Connect the test plate 3115 1131 00 (see fig. W, page 6) to the hydraulic motor, using the screws (19). This will jock the output shaft of the motor {(.e. prevent it from rotating). ‘The motor must be connected as shown in the figure. Adjust the pressure to 100 bar (1450 psi) and take a flow reading. The maximum flow should not exceed 2.5 l/min (0.66 US gal/min). If the maxi- mum flow exceeds this value, this is an indication that there is excessive internal leakage in the motor. + cop 1o1s/1022/1025 * COP 1028 37Assembly of main rock drill components General Assembly sequence: | All parts must be cleaned thoroughly before * Cylinder | assembly. « Gear housing Before assembly, all parts must be olled with «* Impact piston and valve piston lean alr-tool oll. ‘+ Back head and side bolts Always fit new O-rings, and smear them with ‘+ Accumulator and hydraulic motor silicon grease before fitting. The part No. for a * Front head complete O-ring set for the rock drill is 3115 1047 90, The plate 3115 1082 80 (see fig. A, page 4) should be used to facilitate assembly of the rock drill. Cylinder Bolt the cylinder (83* or 34%) to the plate 3115 41082 80 (see fig. A, page 4). Check that the Heli-Coil inserts in the gear housing (18) are in good condition, 18 )= Gear housing Fit the O-ring (82* or 33%), Insert the pin (31% or 32%) into the gear housing (18). Tap the gear housing on to the cylinder (33* or 34”), using a copper hammer. COP rorgyo2a025 COP 1028 Fig 85. Fitting the gear housing 38Impact piston and valve piston Insert the impact piston (80* or 31%) into the cylin- der barrel, When the piston reaches the front pis- ton seals (21* or 22%), tum the piston as you slide it through the seals. N.B. if the impact piston is knocked into position, the piston seals can be damaged. ll and fit the valve piston (40* or 41*). Fit the O-ring (88* or 40%) to the valve cover (37* or 38), and then fit the valve cover. Fig. 86. Fitting the impact piston and valve piston Back head and side bolts Fit the O-ring (44* or 45%). Fit the O-rings (82* or 33% and 45* or 46") into the back head. First smear the O-rings with grease so that they do not fall off during assembly of the rock dil Fitthe back head (46* or 47%) to the cylinder. Take care not to damage the impact piston and seals as, you fitthe back head. Fit the side bolts (48" or 49%) with thoir washers S 8 aioe tae tas (47* or 48%) and tighten the nuts (65* or 62*) to a torque of 250 Nm (186 lo.) Fig 87. Fitting the back head and side bolts Flushing tube, COP 1019/1022/1025 Fitthe flushing tube (60), gasket (49) and hexag- onal nipple (62) with its O-ring (51). Tighten the nipple to a torque of 200 Nm (150 iff). 52 81 50 Fig, 88 Fitting the fushing tube COP 1028 On the COP 1028, the plug 3115 1475 00 must be fitted instead of the flushing tube + COP rorg/rozertoes COP 1028 39Accumulator and hydraulic motor Fit the accumulator (68) with its O-ring (65). Tighten the screws (61) alternately to a torque of 220 Ne (160 IbF.f), Fig. 69. Fiting the accumulator Fig. £0. Fitting the hydrautc motor Fit the hycraulic motor (27* or 28%). Tap the motor lighty into place using @ plastic mallet. Fit the screws (19) and tighten them to a torque of 70 Nm (60 Ibf. tl). At the same time, check the ter sion of the sorews (14), which should also be tight- ened to a torque of 70 Nm (60 Ibf. ft) Fit the rotation chuck (15* or 17) into the gear housing, as shown in the figure opposite. Fig 91, Fitting the rotation chuck = COP ro19/102H/1005 COP 1028 40Front head, COP 1019/1022/1025 Fit the front head (1), tapping it into place with a copper hammer. Tighten the bolts (8) alternately to a torque of 220 Nm (160 Ibff). Fig. 92. Fitting the front head, COP 1019/1022/1025 Front head, COP 1028 Fit the front head (1), tapping it into place with a copper hammer. Fit the bolts (12) and tighten them alternately to a torque of 220 Nm (160 Ibf. ft Fig 93. Fitting the front head, COP 1028 4aFunction test of impact mechanism and rotation | Impact mechanism Using adapter (62* or 83), connect the pressure line (P) to the rock drt, Using the return nipple (34* 1 35%), connect the return fine (R) to the rock dri. Charge the accumulator with nitrogen to half the impact mechanism pressure (max. 90 bar/1800 psi). ‘Switch on the pump and let the impact mechanism | hammer for approx. half a minute, at a max. press- | ure of 30 bar (435 psi). Check that the piston works normally, and that there is no leakage. Switch off the pump. | Fig. 94. Testing the function of the impact mechanism Rotation Connect the pressure- and return lines (P and A) to the nipples (26* or 29) on the hydraulic motor. ‘Switch on the pump and let the rotation motor work for approx. half a minute, at a max. flow of 5 Yin (1.3 US gal/min) Check that rotation is even and that no leakage occurs. Switch off the pump Fig. 95 Testing the function of the rotation motor + COP torsyrazeyso2s =» COP 1028 42 |Tightening torques COP to19/1022/1025 Description Quantity | Tightening torque, Nm (lo. Sido bott 2 250 (185) Sore, accumulator 2 220 (160) Bolt, front head 4 220 (160) Serew, hydraulic motor 4 70 (60) Screw, valve cover 2 70 (50) Nipple, Impact mechanism, infet 1 480 (130) ‘Nipple, Impact mechanism, return 1 480 (130) Nipple, hydraulic motor im 120 (90) Nipple; lubricating alr 1 120 (90) Nipple, flushing i +20 (130) COP 1028 43Recommended oils labia Teonmendaton Gerauical’ | » Uaea pra progres gn ve atu nonce a eon note popes, Se ee sey, wipes oaae septal Ceaie sig aes tae em es shat cae (CHydeeulle off temperature in tank °C (°F) Viscosity Viscosity arrigen tkccaihe mace — rege | ey [eee Mant coy Fess | gis Zo tzzto tsa) 80,176) isove oo | Min 100 emma sei wim legvewe | ewe seeig pee i Sis lage | une ageees Si Be | uae ieaeiet + Vena ial onda all ‘Ambient temperature °C (°F) Viscosity grado (ISO 9448) 720 10 0-22 to +92) Isoves2-68 A010 +20 (14 10 68) 180 VG 68-100 310 fe $50 {500 122) 150.VG 100-150 44Rock drill COP 1028 53 64 30Rock drills COP 1019 /1022 / 1025