Atlas Copco

Maintenance instructions
Hydraulic Rock drills

COP 1638HD, 1838HD, 2238HD

Atlas Copco Rock Drills AB

Örebro, Sweden
© Atlas Copco Rock Drills AB, 2010. All rights reserved

No. 9852 2462 01

 © Copyright 2010, Atlas Copco Rock Drills AB, Sweden
All product names in this publication are trademarks of Atlas Copco.
Any unauthorised use or copying of the contents or any part thereof is prohibited.
Illustrations and photos may show equipment with optional extras.
No warrantly is made regarding specifications or otherwise.
Specifications and equipment are subject to change without notice.
Consult your Atlas Copco Customer Center for specific information

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
www.atlascopco.com
 Innehåll

Innehåll
1. General............................................................................................................... 5
1.1 In the event of leakage problems ........................................................................................ 5
1.2 During dismantling............................................................................................................... 5
1.3 During assembly.................................................................................................................. 5
1.4 Environment ........................................................................................................................ 5
1.5 Safety regulations................................................................................................................ 5
Warning boxes .................................................................................................................... 5
The following general safety rules must be observed ......................................................... 6

2. Service interval ................................................................................................. 9

2.1 Before starting a new or newly overhauled rock drill........................................................... 9
2.2 After each shift when using a new or newly overhauled rock drill ....................................... 9
2.3 Before each shift ................................................................................................................. 9
2.4 After every 40th percussion hour ........................................................................................ 9
2.5 Every 400th percussion-hour: ............................................................................................. 9

3. Hose connections ........................................................................................... 10

3.1 Connecting the hoses........................................................................................................ 10

4. Tightening torques.......................................................................................... 11
4.1 Adjusting the side bolts ..................................................................................................... 12
Tightening the side bolts ................................................................................................... 12
Retightening the side bolts ................................................................................................ 12

5. Accumulators .................................................................................................. 13
5.1 Safety labels...................................................................................................................... 13
Location and meaning ....................................................................................................... 13
5.2 Charging the accumulators ............................................................................................... 13
5.3 Checking the accumulators in the event of hose vibration ................................................ 13
Damper accumulatorand intake accumulator ................................................................... 13
5.4 Replacing intake and damper accumulator ....................................................................... 14
Dismantling........................................................................................................................ 14
Assembly........................................................................................................................... 14
5.5 Replacing the return accumulator ..................................................................................... 15
Dismantling........................................................................................................................ 15
Assembly........................................................................................................................... 15

6. Hydraulic motor .............................................................................................. 16

6.1 Replacing the hydraulic motor........................................................................................... 16
Dismantling........................................................................................................................ 16
Assembly........................................................................................................................... 16

7. Filling with lubricating oil and bleeding the system.................................... 17

8. Settings............................................................................................................ 18
8.1 Setting of ECL lubricating system ..................................................................................... 18
8.2 Setting the damper pressure ............................................................................................. 18

9. Removing the front head................................................................................ 19

10. Checking the front head ................................................................................. 20
11. Mounting the front head ................................................................................. 21
12. Slinging, weights, storage and hose length ................................................. 22
12.1 Slinging.............................................................................................................................. 22

3
Innehåll

12.2 Rock drill weights.............................................................................................................. 22

12.3 Long-term storage ............................................................................................................ 22

13. Lubrication ...................................................................................................... 23

13.1 Lubrication of gear ............................................................................................................ 23

14. Hydraulic and lubricant recommendations.................................................. 24

14.1 Hydraulic fluid ................................................................................................................... 24
14.2 Pneumatic tool oil ............................................................................................................. 25
14.3 Grease .............................................................................................................................. 25

4
 General 1

1. General Warnings are preceded by a heading (Danger,

Warning and Caution).
This instruction is intended as a guide when
performing maintenance on your rock drill. Warning boxes

1.1 In the event of leakage problems Danger

Check the source of the leak before removing the Indicates an imminent risk of serious or fatal
rock drill from the rig. injury if the warning is not heeded.

1.2 During dismantling Warning

Always wash the rock drill externally using grease
solvent before starting removal.
An assembly fixture must be used when dismant-
ling the rock drill.
Indicates hazards or hazardous procedures
which could result in serious or fatal injury if the
warning is not heeded.

1.3 During assembly Caution

During all fitting assembly grease must be applied Indicates hazards or hazardous procedures
to the internal parts unless otherwise stated. which could result in personal injury or
damage to property if the warning is not
heeded.
1.4 Environment
Environmental regulations
Care for the environment!

Leaking hydraulic couplings and grease are

hazardous to the environment.

Changing oils, hydraulic hoses and various

types of filter can be hazardous to the environ-
ment.

Always collect rest oil, oil spill, oily waste and

grease rests and spill. Treat according to local
regulations.

Use biodegradable hydraulic and lubricating

oils where possible.

1.5 Safety regulations

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

Warning boxes
The manual contains warnings.

5
General 1
The following general safety rules must be
observed
Important!
Read through the maintenance instructions
carefully before starting maintenance work.
Follow the instructions given and local regula-
tions.
Do not use or intervene in the rock drill unless
you have been trained to do so.
Never attempt to carry out maintenance while
the rock drill is in operation.
Ensure that the hydraulic, water and air systems
are depressurised and that the electrical system
is de-energised prior to removing the rock drill
or starting work on the system.
Use approved lifting devices when handling the
rock drill. Avoid lifting heavy weights yourself.
To prevent injury during service and 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.
Check that the hoses used are of the right
quality, and that all hose connections are in
good condition and properly tightened. Hoses
that loosen could cause serious injury.
Use only Atlas Copco original parts. Any
damage or malfunction caused by the use of
non-original Atlas Copco parts is not covered by
warranty or product liability.
6
Important!
Make sure that the rock drill has been main-
tained in accordance with the applicable instruc-
tions.
Before moving the rig and rock drill or starting to
drill, make sure that there are no personnel in
the immediate vicinity of the drill rig.
Checks and adjustments that are necessary
when the rock drill is in operation must be
carried out by at least two persons. One person
must then be present at the operating station
and have a good view of the work.
Always wear a helmet and earmuffs when dril-
ling. Follow local regulations
Make sure that the place of work is well venti-
lated.
Make sure that the safety labels are fitted, clean
and fully legible.
Particular attention must be paid to all warnings
in the manual.
Exercise caution when jointing drill rods and
with drill bit handling. Watch your fingers!
Make sure that clothes do not come too close to
rotating machine parts.
Negligence could cause serious injury.
 General 1

Important!
A mining machine has many components and
functions that are controlled by a hydraulic
system, directly or indirectly. Before working on
or inspecting any part of the machine, it is
important to know how the machine moves and
how its functions are controlled by the hydraulic
system.

Prior to starting work or inspecting any part it

must be physically locked/stopped from being
able to move and causing bodily injury. The
mechanic must be careful not to place any body
part where a movement of the machine could
cause injury if the hydraulic system fails or is
disconnected.

There may be occasions where components

and or vehicles start moving when trapped
energy is released. Where applicable, there
must be confirmation that all measures to safe-
guard against involuntary movement have been
taken by releasing the energy and/or physically
locking/stopping the machine.

It is also incumbent on the individuals involved

to ensure that all local, national and federal
safety regulations are followed, before and
during the work or inspection.

7
General 1

8
 Service interval 2

2. Service interval
Part numbers for the repair kits are in the rock drill’s spare parts catalogue

2.1 Before starting a new or newly overhauled rock drill

Chapter
• Connect up the hoses ..........................................................................................................................3
• Charge the accumulators .....................................................................................................................5
• Select a suitable hydraulic oil and lubricant........................................................................................14
• Fill the lubricating system with oil .........................................................................................................7
• Adjust and set the lubricating system ...................................................................................................8
• Set the damper pressure ......................................................................................................................8

2.2 After each shift when using a new or newly overhauled rock drill
• Tighten all threaded unions ..................................................................................................................4

2.3 Before each shift

• Check that air and lubricating oil escape in between the shank adapter and front guide
and out of the hole in the front head. ..................................................................................................10
• Check that the drill rig’s damper pressure gauge is showing normal values.
Check that the drill rig’s damper pressure gauge is showing normal values. In the event of deviation,
adjust the damper pressure. .................................................................................................................8
• Check that the shank adapter threads are not damaged ...................................................................10
• Keep an eye on the hydraulic hoses. If they vibrate too much,
check the accumulators ........................................................................................................................5
• Check that the machine does not leak. If the flushing medium leaks out of the flushing head,
replace seals and O-rings...................................................................................................................10
• When replacing the shank adapter or removing the front head,
check the internal components including piston, driver and the visible parts of the rotation chuck bushing
............................................................................................................................................................10
• In the event of oil leakage from the front head: close percussion and only activate the damper
in order to determine if the leakage is coming from the percussion or damper. .................................10

2.4 After every 40th percussion hour

• Grease the gear .................................................................................................................................13
• Tighten all threaded unions ..................................................................................................................4
• Check the safety labels on the accumulators. Replace them if they are damaged or illegible.............5
• Check the accumulators .......................................................................................................................5

2.5 Every 400th percussion-hour:

• Dismantle the rock drill from the drill rig. Transport the rock drill to
an appropriate workshop for servicing................................................................................................12

Important!
Always function test the rock drill after service.

9
Hose connections 3

3. Hose connections

8
7

1250 0240 34
1
5

2 3 4

1. Drainage 5. Inlet impact mechanism

2. Rotation left 6. Flushing air/water
3. Rotation right 7. Lubricating air
4. Percussion return 8. Damper, intake

3.1 Connecting the hoses

• Clean the rock drill’s hose connections before
undoing the protective caps.
• Never remove a protective cap until the hose is
ready to be connected.
• Always store the rock drill with all hose connec-
tions plugged. Use suitable protective caps, and
make sure that they are clean.
Caution!
Never attempt maintenance or intervene in the
rock drill, connections or hoses while the
hydraulic, lubrication or flushing systems are
pressurised. Air or oil can spray out at high
pressure and high temperature. There is a risk
of serious injury to the eyes and skin.

Pressure hoses with an internal diameter of 19

mm (3/4”) or greater are of the quality SAE 100
R9R (high-pressure hose with four layers of
steel reinforcement). See the rock drill’s spare
parts list. For reasons of safety, under no
circumstance may these hoses be replaced
with hoses of a lower quality. There is a risk of
injury if these instructions are not observed!

10
 Tightening torques 4

4. Tightening torques

5 1

4
3

14 13
9
6
11 12
10
7 8

1250 0240 35
9
11
3 2 9 6

Lubricate the nuts’ threads and the washers’

contact surfaces with thread grease.

Ref. Torque
Qty. Check point Instructions
No. Nm
1 2 Side bolts 300 Tighten the rear nuts
2 1 Front bolt 300 Tighten the front bolt
3 4 Side bolt 350 Tighten the front nuts
4 3 Back head 220 Tighten the screws alternately to full
torque, top bolt last
5 1 Regulating plug 80
6 4 Accumulator 220 Tighten the screws alternately to full
torque
7 4 Hydraulic motor 65 Tighten the nuts alternately
8 2 Clamping attachment, return 30
accumulator
9 4 Rock drill mounting 250 Tighten the screws alternately to full
torque
10 1 Plug 45
11 4 Valve end plates 145 Tighten the screws alternately to full
torque
12 2 Connecting plate 120 Tighten the screws alternately to full
torque
13 1 Flushing connector 300
14 2 Intake, flushing medium 220 Tighten the screws alternately to full
torque

11
Tightening torques 4

4.1 Adjusting the side bolts

1
1250 0240 36

3
2

Tightening the side bolts Retightening the side bolts

• Check whether the side bolts, nuts or washers
have cracks, scratches or rust. Replace
damaged side bolts, nuts and washers.
• Lubricate the side bolt (2), and the nuts’ and
washers’ threads and contact surfaces with
thread grease
• Tighten the rear nuts (1) to the tightening torque.
• Tighten the side bolt (2) to the tightening torque.
• Tighten the front bolts (3) to the tightening
torque.
• Undo the front nuts (3) so that the tension rele-
ases.
If the threads are seized, remove the nuts and
clean and lubricate them with thread grease.
Tighten the front nuts (3) manually.
• Tighten the rear nuts (1) to the tightening torque.
• Tighten the side bolt (2) to the tightening torque.
• Tighten the front bolts (3) to the tightening
torque.

12
 Accumulators 5

5. Accumulators • Charge the accumulators with nitrogen gas (N 2)

to the correct pressure in accordance with the
following:
5.1 Safety labels NB! Charge at the lower pressure if possible
Check the safety labels on the accumulators. rather than too high.
Replace them if they are damaged or illegible.
Damper accumulator (1) 20-25 bar
Location and meaning
Intake accumulator (2) 30-40 bar*
Return accumulator (3) Must not be
charged with N2

*Intake accumulator 30-40 bar under collaring pressure.

Normal 80-100 bar. Max. 100 bar.

• Tighten the valve nut (5) and close the gas valve
(6).
1250 0217 44

• Remove the gas hose and screw in the protec-

tive cap (4) to the accumulator valve.
1 2
5.3 Checking the accumulators in the
event of hose vibration
1. Read the operator’s instructions carefully before
service or replacement of the accumulator
2. Must be charged with nitrogen only Damper accumulatorand intake accumulator

5.2 Charging the accumulators

1
1250 0256 25

4
2 6 7
3
• Push in the control valve’s pin (7). If the accumu-
lator is charged, the pin protrudes 4.5 mm and is
1250 0256 24

hard to push in.

NB! If the pin is easy to press in then the gas
pressure has disappeared (broken diaphragm
or defective filler valve). The damper accumu-
Caution! lator’s pin is slightly easier to press in.

Charge the accumulators when assembled on
the rock drill. There is a risk of injury if these
instructions are not observed!
Warning!
A gas other than N 2 could cause an explo-
sion.
• Replace the accumulator if it is not functioning
properly.
• Charge the new accumulator after replacement.
.......... NB! The seat of the filler valve is easily
deformed by repeated opening/closing. The
filler valve must be replaced frequently.

• Remove the protective cap (4).

• Open the valve nut (5) by 2-3 turns, and connect

the gas hose.

• Open the gas valve (6).

13
Accumulators 5

Return accumulator (3)

Caution!
8 Defective bolts may lead to dangerous oil
leakage or the accumulator working loose. Oil
spray can injure the eyes and skin.

Parts that come loose can cause serious injury.

A
1250 0200 86

Dismantling
B 3 • Remove the accumulators (211 and 221) with
8
the sealing rings (82) by undoing the bolts (C
and D). Send the accumulators to a workshop
for reconditioning!

• Position the rock drill in horizontal position. Assembly

• Remove the plug with O-ring (8). If oil escapes
then the diaphragm is damaged.
Cause: possible high accumulator charge.
• Replace the accumulator, diaphragm and/or
filler valve if they are damaged.
• If the diaphragm is resting against the outer
pipe, press the diaphragm with a cylindrical
(blunt) drift (7-9 mm). See Figure A. Correct
position for diaphragm, see Figure B.
• Refit the plug and O-ring (8).
• Locate the sealing rings (82) in the grooves on
the intermediate section.
• Make sure that the sealing rings (82) do not get
damaged during the assembly.
• Fit the damper accumulator (221) on the left
hand side of the rock drill and the intake accu-
mulator (211) on the right-hand side of the rock
drill (hose side). Replace with undamaged
screws (C and D). Replace the bolts in pairs
even if only one bolt is corroded or damaged in
some other way.

• Charge by means of admitting air at • Tighten the bolts (C and D) alternately to tighte-
atmospheric pressure into the accumulator. ning torque 220 Nm.

• Charge the accumulators with nitrogen gas (N

5.4 Replacing intake and damper 2).
accumulator
C
211
82

82
1250 0244 72

B
A
221
D

Warning!
All gas must be released prior to fitting by
means of removing the protective cap (A),
undoing the valve nut (B) and opening it 2-3
turns.

There is a risk of injury if these instructions are

not observed

14

5.5 Replacing the return accumulator
4 the nuts (2), the bolts (3), the bolt (4) and the
3
5 mulator from the pressure screw (7).
6 9
1250 0240 39
1
8
2 7
Caution!
Ensure that the hydraulic, water and air
systems are depressurised before starting
work on the system.
For reasons of safety, under no circumstance
may the pressure hoses be replaced with
hoses of a lower quality. The hoses must be
high-pressure hoses with four layers of steel
reinforcement, quality SAE 100R9R.
There is a risk of injury if these instructions are
not observed!
15
Accumulators 5
Dismantling
• Remove the hydraulic hose.
• Remove the return accumulator (1) by removing
holder (5).
• Pull away the clamp (6) and unscrew the accu-
• Send the return accumulator to a workshop for
overhauling.
Assembly
• Install new O-rings (8) and (9) in the return accu-
mulator (1).
• Loosely screw the return accumulator (1) onto
the rock drill using pressure screw (7).
• Thread the clamp (6) onto the return accumu-
lator (1) and screw the clamp with the bolts (3)
and the nuts (2) into place.
• Screw the bolt (4) into the rock drill.
• Tighten the pressure screw (7).
• Connect the hydraulic hose to the return accu-
mulator (1).
Hydraulic motor 6

6. Hydraulic motor Assembly

• Make sure that the groove ring (5) is fitted in the
coupling (4).
6.1 Replacing the hydraulic motor
• Lubricate the coupling’s splines with grease and
fit the coupling (4) on the hydraulic motor (3).

• Fit the gasket (7) and hydraulic motor (3) onto

the cylinder (6). Replace the gasket if it is
damaged.

• Tighten the nuts (2) to a torque of 65 Nm.

• Connect the hydraulic hoses (1). Check that the

1250 0184 69

correct direction of rotation is obtained.

Dismantling
• Disconnect the hydraulic hoses (1).

• Undo the nuts (2) and remove the hydraulic

motor (3).

• Pull out the coupling (4).

16
 Filling with lubricating oil and bleeding the system 7

7. Filling with lubricating oil

and bleeding the system
Caution!
Never work on the lubrication system when it is
pressurised.

Lubricating oil could spray out.

There is a risk of serious injury to the eyes and

skin.

Important!
Use the recommended lubrication air pressure
and recommended lubrication oil. Some
moving parts on the rock drill are lubricated
with oil mixed with compressed air. Is
important that these parts receive good lubri-
cation.

Check the level in the lubricating oil tank for every

shift. Exercise cleanliness and fill with the right
grade oil.

NB! If the lubricating system has been empty of

oil, it must be bled after filling.

17
Settings 8

8. Settings 8.2 Setting the damper pressure

A
8.1 Setting of ECL lubricating system
ECL=Electric Controlled Lubrication 1
Rock drill lubrication must be set with regard to the
local conditions.

• Start the lubricating system.

• Check the lubricating air pressure at the rock

drill using a pressure gauge. The pressure
B

1250 0240 40
should be 2-3 bar. If the pressure is too low,
clean the restriction or increase the diameter of
the restriction.

• Set the correct lubricating oil dose. NB! The setting should take place at normal
operating temperature for the hydraulic oil.
Pump (3217 8667 50) 35-40 pulses/minute
• Fully close the constant flow valve (B) on the drill
Pump (3217 8667 52) 20-25 pulses/minute rig.

• After setting, check that the correct pulse • Connect a pressure gauge (A), calibrated for 0-
frequency has been obtained and that oil is 60 bar, between the hose and the damper union
emerging from the front head’s hole and (1).
between the shank adapter and front guide. • Pressurise the damper circuit.

• Check that the shank adapter is unloaded and in

the forward position.

• Adjust the constant-flow valve until the pressure

gauge (A) reads 30-35 bar.

• Read off the drill rig’s damper pressure gauge. If

this pressure gauge later shows another value,
make a new pressure setting.

• Disconnect the pressure gauge (A) and connect

the hose to the union (1).

18
 Removing the front head 9

9. Removing the front head

Caution!
Never attempt to carry out maintenance while
the drill rig is in operation.

Ensure that the hydraulic and air systems are

depressurised before starting any work.

There is a risk of injury if these instructions are

not observed!

NB! Always clean the outside of the rock drill

before disassembly.

4
1

3
1250 0240 37

• Remove the flushing hose.

• Remove the connecting plate (1) by removing

the bolts (2) and washers (3).

• Remove the seal ring (4).

1
4
2
1250 0240 38

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

washers (2).

• Remove the front head (1) by tugging the shank

adapter (4). Following which, pull out the shank
adapter from the front head.

• Check the internal components when replacing

the shank adapter.

19
Checking the front head 10

10. Checking the front head

8 7 3 4 3 1 6 5 9 2 14
1250040061

C B 12
4
1 1m 5
m 3
3

3
3
2mm

D
6
1mm

• Check that air and lubricating oil escape 39mm

between the shank adapter (6) and front guide
(7), and also out of the hole (B)
• Blow clean the lubricating air ducts (A) with
compressed air and check that the restrictions
(9) are open.
• Replace the guide (7) if the inside diameter
exceeds 39 mm.
• Check the seal rings and flushing seals (3) if air
is escaping from the hole (C) in the front head.
Replace the seal rings and flushing seals if they
are worn or damaged.
• Replace the flushing head (4) if it is seriously
corroded, or if it contains cracks.
• Look inside the gear housing and check the
splines on the driver (5). If the splines are less
than 2 mm in width, the driver must be changed.
Fit a new driver with the aid of a suitable
mandrel and a copper hammer.
• If the rotation chuck bushing (2) is worn by more
than 1 mm or is damaged in any other way then
it must be replaced.
NB! Fit the rotation chuck bushing so that the
lubricating grooves (D) are directed towards the
damper piston (14).
• Replace the shank adapter (6) if the thread is
worn out or the impact surface is warped or
chipped, or if the front or rear end surfaces of the
splines are worn.

• Replace the stop ring (1) if it is worn by more • Check that the drill sleeve (8), to be used with
than 1 mm. upwards directed drilling, is not damaged and
rotates with the shank adapter.

20
 Mounting the front head 11

11. Mounting the front head After assembly

Check that air and lubricating oil escapes out of
the hole in the front head and between the shank
adapter and front guide.

6 5
1
4
2
1250 0244 31

• Fit the stop ring and shank adapter (4) into the
front head (1).

• Check that the pin (6) is fitted in the cover. Place

the front head (1) on the side bolts (5).

• Lubricate the nuts’ and washers’ threads and

contact surfaces with thread grease

• Fit the washers (2) and nuts (3).

• Check the tightening torques on the rear side-

bolt nuts and the front side bolt.

• Following which, tighten the front nuts (3) alter-

nately to a tightening torque of 350 Nm.

4
1
5
3
1250 0244 35

• Fit the seal ring (4) into the connecting plate (1).

• Fit the connecting plate (1) to the front head

using washers (3) and bolts (2). Tighten the
bolts (2) to a torque of 220 Nm.

• Replace the seal washer (5) if it is damaged.

• Fit the nipple on the connecting plate. Tighten to

a tightening torque of 300 Nm.

• Connect the flushing hose and tighten the nut.

21
Slinging, weights, storage and hose length 12

12. Slinging, weights, storage 12.3 Long-term storage

and hose length
12.1 Slinging

1250 0244 33
If the rock drill is not going to be used for a
long time, the following precautions should be
1250 0244 32 taken:

• Check that all connections, including the one for

Make sure that the rock drill is safely slung for the flushing medium, are properly plugged or
lifting. Make sure that the rock drill is securely capped. Use clean protective plugs or caps of
anchored for transportation. the right size.

• Clean the rock drill carefully. Use degreasing

agent and rinse with water.

Caution! • Clean thoroughly and oil in the front head

Lifting devices and straps must be approved
for lifting 500 kg.
Incorrect lifting devices could cause the rock
drill to start moving or fall down.
components in contact with flushing medium
(especially in high air humidity).
• Release gas from the accumulators.
• Store the rock drill in a dry place.

Incorrect operation could cause crushing

damage.

12.2 Rock drill weights

COP 1638HD 185 kg

COP 1838HD
COP 2238HD

22
 Lubrication 13

13. Lubrication

1250 0244 34
3
2

13.1 Lubrication of gear

• Unscrew the bleed plug with washer (1).

• Lubricate with heat-resistant grease through the

union (2) until grease escapes through the hole
(3).

• Tighten the bleed plug with washer (1).

23
Hydraulic and lubricant recommendations 14

14. Hydraulic and lubricant recommendations

14.1 Hydraulic fluid
A good hydraulic fluid provides superior protection against wear, rust and oxidisation as well as good anti-
foaming and air and water separation properties.

In order to ensure a lowest level on these properties the mineral oil based and synthetic (polyalphaolefin)
hydraulic fluids must conform to the standard ISO 11158 HM/HV or DIN 51524 HLP/HVLP.

Environmentally friendly hydraulic fluids must fulfil ISO 15380

It is essential to choose a hydraulic fluid of a suitable viscosity for the operating temperature of the drill rig.
Select a viscosity grade (VG) and viscosity index (VI) as specified in the following table. A high viscosity
index reduces the effect of temperature on the hydraulic fluid.

Normal operating
Min. start temp. ºC Viscosity grade VG
temp. ºC Max. temp. ºC Viscosity index VI
(Viscosity min. 1000 cSt) (ISO 3448)
Viscosity 25-50 cSt
+50 to +70 +5 80 ISO VG 100 Min. 100
+45 to +60 -5 75 ISO VG 68 Min. 100
+35 to +50 -10 65 ISO VG 46 Min. 100
+25 to +40 -15 55 ISO VG 32 Min. 100
+10 to +25 -25 35 ISO VG 15 Min. 100

If the viscosity is too low:

• The hydraulic fluid may not form a lubricating layer between surfaces, thus increasing the risk of wear.
• The hydraulic fluid can leak past seals more easily in the rock drill thus increasing fluid losses and incre-
asing energy requirements.

If the viscosity is too high:

• Flow losses in the hydraulic lines will be high increasing energy consumption and pressure levels, putting
increased strain on seals.
• The risk of cavitation will increase, thus also the risk of damage to the rock drill and hydraulic pumps.

The hydraulic fluid must be filtered to a purity of 20/18/15 in accordance to ISO 4406.

The viscosity will change during the period that the hydraulic fluid is used. In general, viscosity will drop with
increased operating hours. To ensure that the viscosity of the fluid does not drop to a critical level before
the recommended service interval, a hydraulic fluid of sufficient stability must be used. The viscosity in cSt
of suitable hydraulic fluids shall drop a maximum of 25% when tested for shear stability in accordance with
DIN 51350-6 at 100 ºC.

The hydraulic fluid must be changed at regular intervals. The following are factors influencing the
interval between changes:
• The viscous stability of the hydraulic fluid as specified above. The hydraulic fluid must be changed before
the viscosity drops to a critical level.
• Contamination with water. If the hydraulic fluid becomes cloudy and light grey, the water content has
become such that the hydraulic fluid must be changed.
• Deterioration of properties such as oxidation inhibition and anti-foaming.

Environment!
Excess and/or waste hydraulic fluid must be disposed of in an environmentally suitable manner and in
accordance with regulatory requirements.

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 Hydraulic and lubricant recommendations 14

14.2 Pneumatic tool oil

Atlas Copco recommends the use of Atlas Copco COP OIL which has been specially developed for our
hydraulic rock drills. COP OIL is an environmentally friendly, degradable oil which can be used in ambient
temperatures between -25 º C and +50 º C.
COP OIL can be ordered with the following part numbers:

Quantity Part number

1 can of 10 litres 3115 3125 00
48 cans of 10 litres 3115 3126 00
1 barrel of 208 litres 3115 3127 00

If COP OIL is not available then the oil should have the following properties:

• Use an oil with good lubricating properties intended for compressed air tools.
• The oil must have good adhesion capacity.
• The oil must have additives that prevent foam formation.
• Depending on ambient temperature, the oil should have the following viscosity grades if the viscosity
index (VI) is about 100:

Ambient temperature ºC Viscosity grade (ISO 3448)

-25 to 0 VG 15-32
-10 to +20 VG 32-46
+10 to +50 VG 46-68

• The oil must have an EP additive which covers the following load-bearing properties:

ASTM D 2783 Min. 250 kg

ASTM D 4172 (40 kg) Max. 0.5 mm

14.3 Grease
NB! Because of the operating temperature in the rock drill gear housing, always use a high-temperature
grease with lithium complex soap based on a synthetic base fluid (polyalphaolefin/synthetic ester) with
additives that protect against oxidation, corrosion and wear at high loads and with EP additive.

Operating
NLGI number Drop point Base oil viscosity
Temperature
1.5 250 ºC 400-600 mm2/s -40 to +150 ºC
at 40 ºC

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

Quantity Part number

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

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