M2. coce Sitlas Copco STK #3 CoP 1019" 022/1025 1595-05 Maintenance instructions for Hydraulic COP 1019 Rock drills COP 1022 iS COP 1025 ATLAS COPCO ROCK DRILLS AB STOCKHOLM e SWEDEN Onis Cope Rack OAD 15 AE mse No. 9852 0454 01a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 @ wwatning symbol (triangle) and a signal word, as shown below: ZX WARNING A\ CAUTION ‘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- sctibed purposes. Make sure that the dill rig has been main- tained in accordance with the current instruc- tions. Make sure that all safety labels remain in place, and that they are kept clean and fully legible, See the spare parts list for details of label locations and part numbers. Always wear a safety helmet and ear protec- tors during driling. Any local regulations that exist must also be observed. Before moving the dill rig or starting to drill, make sure that there are no personnel in the immediate vicinity of the dri rig Contents Page Safety regulations : : Action listo... Societe Hose connections Tightening torques . . . Accumulator Rese ~ Charging the accumulator. = Checks in the event of hose vibration = Changing the acournulator Filing with lubricating ol and bleeding the system. indicates hazards or hazardous procedures which COULD result in serious or fatal injury if the warning is not observed. indicates hazards or hazardous procedures which COULD result in injury or damage to equipment if the warning is not observed. ‘¢ Use Atlas Copco genuine parts only. Any dam: age ot malfunction caused by the use of un- authorized parts is not covered by Warranty or Product Liability. # Never attempt to carry out maintenance while the drill rig isin operation. ‘© Those checks and adjustments that must be made while the drill rig is in operation must be cartied 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 mainten- ance, all components that could possibly move cr 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 hydrauli, air and water sys- tems are without pressure, and that the elect cal system is dead. Check that the hoses used are of the right quality, and that all hose connections are in ‘g00d condition and properly tightened. Setting of ECL lubricating system... 9 Changing the hydraulic motor... 2... 9 Removing the fronthead.... . . . ; 10 Checking the fronthead ... 2... aecaieet tt Mounting the front head a 12 Slinging ... 2... 2 Long-term storage . . . 13 Recommended hydraulic ois and lubricants. 1ZX CAUTION « Take care when changing the drill steel. The drill-steel retainer must be closed during drilling. Mind your fingers! * Keep your clothing away from rotating 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 while the hydraulic, lubrication or flushing systems are pressurized. Air or off 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 interven- ing in the rock drill or its hydraulic circuit. ‘© The following parts may be changed at the worksite in accordance with the instruo- tions giver = front head parts accumulator hydraulic motor = screws ~ connections, Other repairs must be carried out in a suit- able workshop in accordance with the overhauling instructions for the rock dri Action list Before starting up a new- or newly overhauled rock drill Page © Connectupthehoses ©... 2.2.2.0 4 ¢ Charge the accumulator . . 6 © Select a suitable hydraulic oll and lubricant. 13 + Fill the lubricating systern with oil 8 « Asjust and set the lubricating system... 9 Every shift '® Check that air and lubricating oil come out between the drilstee! shank and chuck bushing, and between the chuck pee and rotation chuck... . mn + Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulator. . 6 ‘© Check that there is no leakage from the rock dil. Ifthe flushing medium leaks out of the throttle plug in the back of the gear housing, change the shank packing... . . ‘* When changing the dil stee! or removing the. front head, check the internal components, including the visible parts of the piston and rotation chuck bushing... .. . ott Inthe event of defect, remove to a suitable’ ‘workshop for repair or replacement. 1" After the first shift when using a hnew- or newly overhauled rock drill © Tighten all threaded unions... . 22... 5 After every 40th percussion-hour « Tighten all threaded unions + Check the safety labels on the accumblator. Replace them i they are damaged or legible . 6 Every 400th percussion-hour # Remove the rock drill from the dril rig and send itto a suitable workshop for over- hhauling*. * The rock dil should be overhauled at culable interval, ‘based on local conattans The characteristics of fo rock wit ‘have a great influence on to rate of wear, and thus on the required roquency of overhautingHose connections 1, Lubrigating ait 2. Flushing aitvwater ( 3. Rotation to the sight 4. Rotation to the left 5. Percussion mechanism, return 8. Percussion mechanism, intake ———— Connecting the hoses A\ CAUTION « Clean the hose connections on the rock dil be- fore removing the protective plugs or caps. ‘¢ Never attempt maintenance or intervene # Never remove a protective plug until the hose is in the rock drill, connections or hoses ready to be connected. while the hydraulic, lubrication or flushing ¢ Always store the rock dill with ali hose connec- systems are pressurized. tions plugged. Use suitable protective plugs or Air of oil can squirt out at high pressure caps, and make sure that they are clean, ‘ and high temperature, with the risk of ‘serious injury to the eyes and skin, Pressure hoses with an internal diameter ‘of 19 mm (9/4") or more are rated SAE 100 ROR (ie. high-pressure hose with four ( layers of spirally wound steol-wite 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 injun tions are not observed!Tightening torques 12 Ref.No. | Qty. | Check point Torque _ | Instructions Nm Ibftt 1 2 | Side bolts 250. 185 | Tighten the rear nuts alternately to full torque 2 4 | Fronthead 220 160 | Tighten the screws altemately to full torque 3 2 | Accumulator 220 160_| Tighten the screws alternately to full torque 4 4 | Hydraulic motor 70 50 | Tighten the screws altemately 5 4 | Rock drill mounting 220 160 | Tighten the screws altemately to full torque 6 2 | Valve cover 70 50 | Tighten the screws altematoly to full torque T 1 | Flushing connection 180 130 8 2 | Nipples, hydraulic motor 120 90 9 1 | Intake, percussion mechanism | 180 130 10 1 | Return, percussion mechanism | 180 130 1 1 | Infet, lubrication 120 90 12 1 | Drill-steel retainer 70 50Accumulator ‘The intake accumulator (1) is fitted with safety labels as shown in the figure below. Charging the accumulator ZX WARNING © The accumulator must be charged with nitrogen (N2) only! Other gases can cause an explosion. ZX CAUTION @ Do NOT charge the accumulator untit it hhas been fitted to the rock aril. ‘There is a risk of injury if these instruc tions are not observed! ¢ Remove the protective cap (3). # Open the valve nut (2) by 2-8 turns, and con rect the gas hose. '* Open the gas valve (4), ‘© Charge the intake accumulator (1) to the collaring pressure minus 30 bar/435 psi; (max. 110 bar/1595 psi) ‘* Tighten the vaive nut (2) and close the gas valve 4), # Remove the gas hose and fit back the protective cap (8) to the accumulator valve. = Must be charged with nitrogen only /= Read the instruction book carefully before servicing or changing e) B) Checking the accumulator in the event of hose vibration If the hydraulic hoses start to vibrate excessively, do the following: ‘¢ Remove the protective cap (3). ‘¢ Open the valve nut (2). IF oll comes out of the valve, change the accumulator. ‘© Charge the accumulator.Changing the accumulator @ ° ) Removal Mounting ZX cauTION ZX cauTION «Release all gas before removing the accu- mulator 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 accumulator (1) together with the (O-ring (2) by removing the screws (3). Now send the accumulator to a workshop for overhauling! ‘* Mount the accumulator to the rock dil using undamaged original screws. ‘The accumulator (1) must have two screws (3) of length 50 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 Teakage, 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 O-ring (2) to accumulator (1), and then fit the accumulator to the back head (4). Tighten the screws (3) alternately to a torque of 220 Nm (160 Ibt.f). ‘Now charge the accumulator with nitrogen (Ne). See page 6.Filling with lubricating oil and bleeding the system ZX CAUTION itervene in the lubricating system itis pressurized. Lubricating oil can squirt out, with the risk of injury to the eyes and skin. IMPORTANT Use the recommended lubricating-air pressure and the recommended lubri- cating oll. Certain moving parts of the rock drill are lubricated by means of oil-mixed com- pressed air. itis important that these parts receive good lubrication. 1. Lubricating-oll container 2 Filler cap 8 Pulse relay 4 Pulse relay 5 Relay window 6 Potentiometer 7. Nipple, bleeding & Pressure gauge, lubricating-oll pressure 9 Restrictor 10. Plastic hose 11. Pressure gauge, lubricating air pressure A. Lubricating-air connection F Light-emiting diode (LED) G. Green LED A Yollow LED Ti. Adjustment screw, light-emitting time 72 Adustment screw, pulse frequency © Check the oil level in the lubricating-oll container (1) once a shift, Observe a high standard of Gleanliness and fill wth oil of the right quality (ee page 13). The lubricating-oil container holds 5 litres. « If the lubricating system has been empty of oil, it must be bled after filling. ‘This is done as follows: — Loosen the nipple (7) and let the lubricating oi! escape unti all air has been discharged from the lubricating oil pump. eee = Start the lubricating system and loosen the nipple at pressure gauge (8), so that all air is released from the system, Now tighten the nipple. = Disconnect the lubricating-air hose from the rock dri. ~ Start the lubricating pump and let it pump until oll comes out of the plastic hose (10). ‘When re-starting (after standstl), oil must ‘come out of the plastic hose directly when the lubricating pump is started. = Check that the plastic hose (10) for lubricating oils of the correct length so that it reaches the rock dri. ~Re-connect the lubricating-air hose.Setting of ECL lubricating system 1, Open the electrical cabinet. 2. Start the lubricating system (see the operator's instructions for the dil rig) ‘8. Check the lubricating air pressure at the rock drill (A) using a pressure gauge (11). The press- ure should be 2-3 bar. I the pressure is too low, clean the restrictor (9) or increase the diameter of the restrictor. Underground drill rigs 4. Check that the green light emitting diode (G) indicates power on. 5. Adjust the screw (T1) so that the light emitting time of the yellow diode (R) is 0.5 seconds. 6. Observe the yellow diode (R) and adjust the lubricating oil dosage to 35-40 pulses/min, by ‘means of the screw (T2). Surface drill rigs 4. Observe the relay window (5) and acjust the lubricating oil dosage to 40-0 pulses/min, by means of the potentiometer (6). Atter making the respective setting, check the LED () on the lubricating pump to ensure that the right pulse frequency has been obtained. Check also that oil comes out between the drill-stee! shank ‘and chuck bushing, and between the chuck bush: ing and rotation chuck. Changing the hydraulic motor ZX CAUTION © Before starting work on any of the sys- tems, make sure that there Is no pressure in the hydraulic, water and air systems, and that the electrical system is dead. * Pressure hoses with an internal diameter ‘of 19 mm (3/4") or more are rated SAE 100 ROR (ie. high-pressure hose with four layers of spirally wound steel-wire rein- forcement). 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 instructions. are not observed! Removal Disconnect the hydraulic hoses (1). Remove the hydraulic motor (5). To do this, remove the two screws (2) and washers (3). (The other two screws [4] only hold the motor together.) Mounting Fit back the hydraulic motor (6). To ai the motor lightly with a plastic hammer. ting, tap Fit the washers (3) and the screws (2). Tighten the screws (2) to a torque of 70 Nm (60 lb-ft). At the same time, check that the motor sorews (4) are torqued to 70 Nm (60 Ibf. ft). Connect the hydraulic hoses (1). Check that the motor rotates in the correct direction.10 Removing the front head ZX WARNING ‘ 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, water and air systems, and that the electrical system is dead. N.B. Always clean the outside of the rock drill be- fore disassembly. Disconnect the lubricating-air hose (2) from the front head (1) Remove the screws (3). Remove the front head (1). Loosen it by tapping with a copper hammer, Remove the rotation chuck (4) from the gear housing (6).Checking the front head ‘* Change the dril-stee! retainer (1) if tis worn by © When changing the drill steel, check the wear on more than 2 mm. the chuck bushing (2) with the aid of a gauge: * Check that air and lubricating oil come out be- ~ 3007 0125 00 for COP 1019 (H19) seen the dril-steel shank (10) and chuck bush- = 8091 0038 00 for COP 1022 (H22) ing (2), and between the chuck bushing (2) and = 3006 7352 00 for COP 1025 (H25) rotation chuck (9). If the gauge can be pushed in all the way into ‘© Change the flushing tube (6) if itis rusted, Hs cae ene, ta sting fe Worn Ou cracked or damaged in some other way. ‘* Change the rotation chuck bearing (3) if its in- « ifwater has leaked out of the throttle plug (4), side diameter is greater than 56.5 mm. ‘check the flushing tube (5) and shank packing ‘® Change the axial bearing (7) ifits thickness is (6). (This is especially important in the case of less than 13.3 mm. water flushing.) In the event of wear or damage, «In the event of damage, or if the stated wear change the flushing tube and shank packing. limits have been reached, send the front head or ‘© Change the drill see! if the impact surface or whole rock dill to a workshop for overhauling. shank is upset or chipped. See the overhauling instructions. N.B. Check the striking surface of the impact pis- ton (8) whenever you change the dil steel.12 Mounting the front head | Fit the rotation chuck (4) into the gear housing (5). Fit the front head (1). Use @ copper hammer to tap itinto place. N.B. Before assembly, smear the threads with grease (type NEVER-SEEZ) Fit the screws (3) and tighten them alternately to torque of 220 Nm (160 Ibt-ft). Check the torque of the rear side-bolt nuts (see age 5). Smear the side bolts with an anti-rust ‘compound such as "Dinitrol Car Fit the lubricating-air hose (2). After assembly, check that air and lubricating oil come out at the front head. AX CauTION |. Liting gear and stings must be approved for a weight of 250 kg (550 Ibs). Faulty lifting gear can cause the rock drill to move unpredictably or drop. Incorrect handling can result in crush injuries. Make sure that the rock dril is safely slung for liting. Make sure that the rock drill is securely anchored for transportation. Rock drill weights, approx. COP 1019... . S0kg (110 tbs) COP 1022... . . 50kg (110 tbs) COP 1025... .... 52kg (115 lbs)Long-term storage Ikthe rock dri is not going to be used for a long time, the following precautions should be taken: ‘* Check that all connections, inctuding 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 degreas- ing agent and hose down the rock drill wth water. ‘* Thoroughly clean the front head parts that are in contact with the flushing medium, especially in the case of high air humidity. After cleaning, oll the parts with clean hydraulic ol. ‘* Release the gas from the accumulator (see in- structions on page 7). © Store the rock dri in a dry place. Recommended hydraulic oils and lubricants Lubricant Recommendation Hyeraulle ot ‘* Use.@ mineral based hycraute of with good ant-wear, ati-rust, anf-cxédation and foam inking propertioa, vif Good a ar watt separation eherectestes. Choose ao wn vasoaly rade (Vo) and vane Index (ij in accordance withthe lable below. An ol witha high viscoslly index fess seneiive tothe etects of temperature ‘Tiydkaulo oll taraperature In tank (°F) Viscosity | Viscosity ‘Normal operating temp Min. staring ton. ‘Max temp VG | index VP (wiscosty 25-50 cS!) _(iscasly min. 1000 et) (50.2446) igloo tanto 14H 20 (476) 1S0¥e 100 | Min. 100 445 to +60 (113 0 140) 78 (29) 75 (187) 'sovass’ | Hin. 100 435 to 450 (95 to 122) 10 (14) 5 (149) Wove4s | Min: 400 425 to +40 (77 to 108) 5) 55 (131 Woves2 | Min. 100 Hote #25 601077) 5 (13) 35(85) 'sove15 | Min’ 100 Air toot ofl” Use a mineral based air ool ol Ambient temperature °C (°F) Viscosity grade (ISO.9448) elo of a8 10299 'g0 Ve 92-68 “F010 +20 (14 to 62) 180 VG 68-100. Oo 450 (500 122) 180 VG 100-150 ‘Recommended when the elecicelly controlled ECL hibisaling systems wsed. 13‘Rios Copco Noa 1805,