Atlas Copco

Hydraulic Rock Drill

COP 3060MEX Version B
Maintenance instructions

PM no. 9852 3402 01

2013-12
 SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.

Special attention must be paid

to information alongside
this symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

© Copyright 2013, 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 warranty is made regarding specifications or otherwise. Specifications and equipment are subject to
change without notice. Consult your Atlas Copco Customer Centre for specific information.

Translation of original instructions

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
 Table of Contents

Table of Contents
1. GENERAL .......................................................................................................... 3
1.1 Description of manufacturing number .......................................................................... 3
1.2 In the event of leakage problems ................................................................................. 3
1.3 During dismantling........................................................................................................ 3
1.4 During assembly........................................................................................................... 3
1.5 Environment ................................................................................................................. 3
1.6 Safety regulations......................................................................................................... 4
1.6.1 Warning boxes ....................................................................................................4
1.6.2 The following general safety rules must be observed .........................................4

2. TOOL LIST.......................................................................................................... 7
3. SERVICE INTERVAL ......................................................................................... 9
3.1 Before starting up a new or newly overhauled rock drill............................................... 9
3.2 After the first shift with a new or newly overhauled rock drill........................................ 9
3.3 Before Each Shift ......................................................................................................... 9
3.4 After every 40th percussion-hour ................................................................................. 9
3.5 Every 600 percussion hours......................................................................................... 9

4. HOSE CONNECTIONS .................................................................................... 11

4.1 General....................................................................................................................... 11
4.2 Connecting the hoses................................................................................................. 12

5. TIGHTENING TORQUES ................................................................................. 13

5.1 Threaded unions ........................................................................................................ 13
5.2 Nipples ....................................................................................................................... 14

6. ACCUMULATORS ........................................................................................... 15
6.1 Safety label location ................................................................................................... 15
6.2 Safety label instructions ............................................................................................. 15
6.3 Charging the accumulators ........................................................................................ 16
6.4 Pressure checking the accumulators ......................................................................... 18
6.4.1 Intake (440a) and return accumulator (440b) ....................................................18
6.5 Replacing the accumulators ....................................................................................... 19
6.5.1 General .............................................................................................................19
6.5.2 Dismantling .......................................................................................................19
6.5.3 Assembly ...........................................................................................................20

7. REPLACING THE HYDRAULIC MOTOR ........................................................ 21

7.1 Dismantling................................................................................................................. 21
7.2 Assembly.................................................................................................................... 22
7.3 Function and condition test of the hydraulic motor..................................................... 22
7.3.1 Function Test ....................................................................................................22
7.3.2 Belle-test ...........................................................................................................23
7.3.3 Half Belle test ....................................................................................................23

8. FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM............. 25

9. SETTINGS ........................................................................................................ 27
9.1 Setting of ECL lubricating system .............................................................................. 27
9.2 Setting damper pressure ............................................................................................ 27

10. FRONT HEAD .................................................................................................. 29

10.1 Dismantling............................................................................................................... 29
10.2 Check ....................................................................................................................... 31

1
Table of Contents

10.3 Assembly ................................................................................................................. 35

11. LUBRICATION.................................................................................................. 39
11.1 Lubrication of gear ................................................................................................... 39

12. DISMANTLING FROM CRADLE...................................................................... 41

12.1 Slinging .................................................................................................................... 41
12.2 Rock drill weights ..................................................................................................... 41
12.3 Action before service and long-term storage ........................................................... 41

13. HYDRAULIC AND LUBRICANT RECOMMENDATIONS................................ 43

13.1 Hydraulic fluid .......................................................................................................... 43
13.1.1 If the viscosity is too low: ................................................................................43
13.1.2 If the viscosity is too high: ...............................................................................43
13.1.3 The hydraulic fluid must be changed at regular intervals. ...............................43
13.2 Pneumatic tool oil..................................................................................................... 44
13.3 Grease ..................................................................................................................... 44

2
 1. General

1. General
This instruction is intended as a guide when performing maintenance on your rock drill.

1.1 Description of manufacturing number

All rock drills are given a manufacturing number depending on place of manufacture, year, family and
version.
The manufacturing number is stamped on and the location on the rock drill varies depending on the model.

1. Factory code for manufactured unit:

AVO = Atlas Copco Rock Drills AB 2 4
2. Year the product was produced.
3. Family letter that identifies the number series:
D = Hydraulic rock drills
P = Pneumatic rock drills
T = Rotation units
AVO 12 D 333B

1250 0404 84
4. Serial number in the "Family Group". 1 3 5
5. Version letter for the product. To show which
manual/spare parts list that is relevant.

1.2 In the event of leakage problems

Check the source of the leakage before removing the rock drill from the rig.

1.3 During dismantling

Always wash the rock drill externally using grease solvent before starting removal.
An assembly fixture must be used when dismantling the rock drill.

1.4 During assembly

During all fitting assembly grease must be applied to the internal parts unless otherwise stated.

1.5 Environment

Environmental regulations
Think of 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 environment.
Always collect oil residue, oil spill, oily waste and grease residue and spill. Treat according to appli-
cable local regulations.
Use biodegradable hydraulic fluid and lubrication oil wherever possible.

3
1. General

1.6 Safety regulations

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

1.6.1 Warning boxes

The manual contains warnings.
Warnings are preceded by a heading (Danger, Warning and Caution).

Warning boxes
Danger
Indicates an imminent risk of serious or fatal injury if the warning is not heeded.
Warning
Indicates hazards or hazardous procedures which could result in serious or fatal injury if the warning
is not heeded.
Caution
Indicates hazards or hazardous procedures which could result in personal injury or damage to
property if the warning is not heeded.

1.6.2 The following general safety rules must be observed

r

Important!
Read through the maintenance instructions thoroughly before starting maintenance work. Follow
the instructions given and local regulations.
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 maintenance, 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 condi-
tion 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.

Important!
Make sure that the rock drill has been maintained in accordance with the applicable instructions.
Before tramming 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 drilling. Follow local regulations
Make sure that the place of work is well ventilated.
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.

4
 1. General

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 safeguard 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.

5
1. General

6
 2. Tool list

2. Tool list
Letter Tools Part no.
A1 Plastic mallet

A4 U-ring spanners 10-32 mm

A5 Allen keys 4-10 mm

A10 Torque wrenches 10-350 Nm

A11 Socket wrench set with sockets 10-32 mm for external

hexagon
Socket wrench set with sockets 4-10 mm for internal
hexagon
A14 Vernier calliper

C2 Tool for mounting bushing in extraction unit 3115 5001 16

D Mandrel 3115 5001 13

J Bushing removal tool for extraction unit 3115 5074 00

L Sleeve for front guide 3115 5768 00

Q Charging equipment for accumulators 3115 3425 80

7
2. Tool list

Letter Tools Part no.

Puller

8
 3. Service interval

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

3.1 Before starting up a new or newly overhauled rock drill

Chapter
• Connect up the hoses ..........................................................................................................................4
• Charge the accumulators .....................................................................................................................6
• Fill the lubricating system with oil .........................................................................................................8
• Adjust and set the lubricating system ...................................................................................................9
• Set the damper pressure ......................................................................................................................9
• Select a suitable hydraulic oil and lubricant........................................................................................13

3.2 After the first shift with a new or newly overhauled rock drill
• Tighten all threaded unions ..................................................................................................................5

3.3 Before Each Shift

• Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulators .....................6
• Check that the drill rig’s damper pressure gauge is showing normal values. In the event of deviation,
adjust the damper pressure. ................................................................................................................9
• Check that the shank adapter threads are not damaged ...................................................................10
• Check that air and lubricating oil comes out at the outlet for the ECL oil ...........................................10
• Check that the machine does not leak. If the flushing medium leaks out from the overflow holes,
replace the seals and O-rings ............................................................................................................10
• When replacing the shank adapter or removing the front head,
check the internal components including piston nose, driver and the visible parts of the
starter bushing ...................................................................................................................................10

3.4 After every 40th percussion-hour

• Tighten all threaded unions ..................................................................................................................5
• Check the safety labels on the accumulators. Replace them if they are damaged or illegible.............6
• Check the accumulators .......................................................................................................................6
• Grease the gear .................................................................................................................................11

3.5 Every 600 percussion hours

• Remove the rock drill from the drill rig.
Transport the rock drill to a suitable workshop for inspection ............................................................12

Important!
Servicing should be carried out at appropriate time intervals based on local conditions. The condition
of the rock has a major affect on the amount wear and with that the need of servicing.

Important!
Always function test the rock drill after service.

9
3. Service interval

10
 4. Hose connections

4. Hose connections
4.1 General

Caution!
Never attempt any maintenance or work on the rock drill, connections or hoses while the hydraulic,
lubrication or flushing pressure 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!

11 10
8

2
4
3 6
5
7

4
3
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9
1. Flushing air (F) 8. Damper intake (HDP)
2. ECL oil outlet* (ALR) 9. Stroke length regulation (HS)
3. Rotation, intake (RRL) 10. Extraction unit, intake (BHP)
4. Rotation, return (RRR) 11. Extraction unit, return (BHT)
5. Percussion pressure intake (HP) *Always open or connected to ECL return
6. Percussion return (HT)
7. Lubricating air intake (AL)

11
4. Hose connections

4.2 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 connections plugged. Use suitable protective caps, and make sure
that they are clean.

12
 5. Tightening torques

5. Tightening torques
5.1 Threaded unions

6
8
7

4
3

11 1
6 9
7
8

3
5
1
9
2
1250 0346 20

4 10
Lubricate the nuts’ threads and the washers’ contact surfaces with Never-Seez Regular Grade.
Ref. Qty. Check point Torque Torque Instructions
No. Nm Ibf*ft
1 2 Cradle 500 370 M24x80
2 3 Cradle 300 221 M20, grade 8.8
3 4 Side bolts 500 370 M24x1.5
4 8 Valve covers 220 162 M16, grade 10.9
5 6 Back head 220 162 M16, grade 10.9
6 8 Intake and return accumulators 220 162 M16
7 22 Intake and return accumulators 220 162 M16
8 2 Filling valve 30 23
9 8 Hydraulic motor 90 66 M12
10 4 Percussion mode 40 31 M10
11 4 Intake, flushing medium 40 31 M10

13
5. Tightening torques

5.2 Nipples

11
10 8

2
4
3
6
5
7

4
3
1250 0346 22

Ref. Def. Check point Torque Torque Instructions

No. Nm Ibf*ft
1 F Flushing air/water 430 318 G 1 1/4
2 ALR ECL oil outlet 85 63 G 1/2
3 RRL Rotation, intake 85 63 G 1/2
4 RRR Rotation, return 85 63 G 1/2
5 HP Percussion, pressure intake 430 318 G 1 1/4
6 HT Percussion, return 430 318 G 1 1/4
7 AL Lubricating air, intake 85 63 G 1/2
8 HDP Damper, intake 85 63 G 1/2
9 HS Stroke length reduction 70 52 G 3/8
10 BHP Extraction unit, intake 70 52 G 3/8
11 BHT Extraction unit, return 70 52 G 3/8

14
 6. Accumulators

6. Accumulators
Check the safety labels on the accumulators. Replace them if they are damaged or illegible.

6.1 Safety label location

440a. Intake accumulator

440b. Return accumulator
440b

440a

1250 0346 23

6.2 Safety label instructions

1. Read the operator’s instructions carefully

before service or replacement of the accumu-
lator.
2. Must only be charged with nitrogen gas (N2).
N2
1250 0187 04

1 2

15
6. Accumulators

6.3 Charging the accumulators

Caution!
Charge the accumulators when they are assembled on the rock drill.
There is a risk of injury if these instructions are not observed!

Warning!
A gas other than N2 could cause an explosion.

1. Remove the protective cap (2) from the filler

valve.

1250 0333 07

2. Fit the gas hose with connection adapter (3)

on the new filler nipple (1).
Tighten the connection adapter (3) using
manual force.

1
3

N2
1250 0333 08

16
 6. Accumulators

3. Close the bleed valve (8) by turning the

control knob clockwise. 440b
4. Close the pressure regulator (7) by turning the 440a
control knob anticlockwise (-).
5. Open the bottle valve (9) slowly and check
that the high pressure gauge (4) gives
readings to full bottle pressure.
NB! Charge at the bottom if possible rather than
too high.
6. Slowly turn the pressure regulator knob (7)
clockwise (+) and set the desired filling pres-
sure on the low pressure gauge (6) or high
pressure gauge (5).
Return accumulator (440b) - 2-3 bar.
Intake accumulator (440a) - 80-100 bar*
*Intake accumulator 30-40 bar under collaring 9
5 3
pressure. Normal 80-100 bar. Max. 100 bar. 1
6
7. In the event of the pressure being too high,
adjust the pressure regulator control knob (7)
anticlockwise (-). Evacuate the overpressure 8 N2
carefully by turning the control knob for the
bleed valve (8) anticlockwise and then close 4 7
1250 0346 25

the bleed valve. Adjust the pressure regulator

(7) slowly to the correct accumulator pres-
sure.
8. Close the pressure regulator (7) by turning the
control knob anticlockwise (-).
9. Close the bottle valve (9).

10.Loosen the connection adapter (3) from the

filler nipple (1).
NB! The gas in the hose will hiss out. The
accumulator is switched off and will not
release gas when the adapter is removed.
11. Fit the protective cap on the filler nipple (1).

1
3

N2
1250 0333 08

17
6. Accumulators

6.4 Pressure checking the accumulators

Warning!
The hydraulic system must be depressurised before checking the accumulators.

6.4.1 Intake (440a) and return accumulator (440b)

1. Remove the protective cap from the filler

nipple (1). 1
2. Fit the pressure gauge (10) on the filler nipple
(1). Tighten using manual force.

10

1250 0333 11

3. Read the pressure gauge (10) and check that

the correct accumulator pressure is obtained.
Return accumulator (440b) - 2-3 bar. 1
Intake accumulator (440a) - 80-100 bar*
*Intake accumulator 30-40 bar under collaring
pressure. Normal 80-100 bar. Max. 100 bar.
10
1250 0333 12

18
 6. Accumulators

4. Remove the pressure gauge (10).

5. Charge the accumulator as required or fit the 1
protective cap on the filler nipple (1).

10

1250 0333 11
6.5 Replacing the accumulators

6.5.1 General

Warning!
All gas must be released before removal, by means of removing the protective cap and fitting the
connection adapter (3).
There is a risk of injury if these instructions are not observed!

Caution!
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.

6.5.2 Dismantling

1. Remove the protective cap (2) from the filler

nipple.
2. Fit the connection adapter (3) and the
nitrogen gas (N2) in the accumulator is rele-
ased.
NB! Align the connection adapter so that
there is no risk of personal injury.

2 3
1250 0346 45

19
6. Accumulators

3. Remove the accumulators (440a and 440b)

by undoing the screws (6). 6
4. Remove the seal ring (7) and O-ring (8).
5. Send the accumulators to a workshop for 5
overhauling!
440b
440a 7
8

1250 0333 10

6.5.3 Assembly

1. Position the greased seal ring (7) and the

greased O-ring in their respective grooves on 6
the accumulator and then fit the accumula-
tors. 5
2. Make sure that the seal ring (7) and O-ring (8)
do not become damaged during assembly. 440b
3. Tighten the bolts (6) alternately to the tighte- 7
ning torque. 440a
4. Charge the accumulators with nitrogen gas 8
(N2).
1250 0333 10

20
 7. Replacing the hydraulic motor

7. Replacing the hydraulic motor

Caution!
Ensure that the hydraulic, water and air systems are depressurised before starting any work on the
systems.
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!

7.1 Dismantling
Depending on the size of the hydraulic motor, the rock drill needs to be detached from the cradle.

1. Remove the hydraulic hoses.

2. Undo the nuts (309) and remove the hydraulic 309 2 307
motor (2).
3. Remove the O-ring (307) from the hydraulic
motor (2).

308

307
1250 0333 15

2
309

21
7. Replacing the hydraulic motor

7.2 Assembly

1. Fit the O-ring (307) on the hydraulic motor (2).

2. Lubricate the coupling’s splines with grease. 309 2 307
Use the same grease as for the gear.
3. Fit the hydraulic motor (2) to the gear housing.
4. Tighten the nuts (309) to the correct tightening
torque.
5. Connect the hydraulic hoses.
6. Check that the correct rotation direction is
obtained for both motors.

308

307
1250 0333 15

2
309

7.3 Function and condition test of the hydraulic motor

The following tests give an approximation of the present state of the engine.
The following items are required to conduct the tests:
• Apparatus for hydraulic flow and pressure.
• A pressure gauge.
• A flow meter in the range 0-15 l/min, preferably with an accuracy of at least 0.5 l/min
• Couplings and hoses to assemble the components.
• A fixture to lock the rotation of the rear axle.
Oil grade HLP46 at 50 degrees and viscosity approx. 35 CST

7.3.1 Function Test

1. Connect the hydraulic hoses P (Pressure) and

R (return) to the hydraulic motor.
2. Allow the engine to rotate for about 30
seconds with a maximum flow of 10 l/min.
3. Make sure rotation is smooth and without
noise.
P

R
1250 0403 66

22
 7. Replacing the hydraulic motor

7.3.2 Belle-test
For engines with external drainage line only.
The test indicates the general state of the engine, including axial wear, condition of seals, valves, etc.
Replace the engine if the size of the leak exceeds table value.

Test procedure:
1. Plug port "B" with a suitable plug. B A
2. Connect a flow meter to the engine’s drainage
line. T (drain)
3. Make sure the rear axle can rotate freely.
4. Pressurise port "A" in accordance with the
following table. Make sure to use the correct
pressure for the current engine type! P
5. Measure the flow from the drainage line.
Replace the engine if it exceeds the specified

1250 0403 67
value. R

Motor type Pressure port Permitted flow

A in drainage line

MS 210 bar 3,5 l/min

7.3.3 Half Belle test

The following test indicates the condition of the gear wheel in the engine. It can be used for all engines.

Test procedure:
B
1. If the engine has a drainage line, couple it to A
port "B" with a T-coupling.
T (drain)
2. Couple the flow meter to port "B" on the
engine.
3. Secure the rear axle with suitable equipment.
It must not rotate. S
4. This unit can be ordered for type MS engines. P
5. Pressurise port "A" in accordance with the
1250 0403 68

following table. Make sure to use the correct R

pressure for the current engine type!
6. Measure the flow from port "B" (if necessary in
combination with the drainage line). Replace
the engine if it exceeds the specified value.

Motor type Pressure port Permitted flow

A in drainage line

MS 80-160cc 140 bar 10 l/min

MS 200-315 110 bar 10 l/min

MS 400-475 70 bar 10 l/min

23
7. Replacing the hydraulic motor

24
 8. Filling with lubricating oil and bleeding the system

8. 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 lubrication.

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.

25
8. Filling with lubricating oil and bleeding the system

26
 9. Settings

9. Settings
9.1 Setting of ECL lubricating system
ECL=Electric Controlled Lubrication
Rock drill lubrication must be set with regard to local conditions.

1. Start the lubricating system.

2. Check the lubricating air pressure at the rock
drill using a pressure gauge. The pressure
should be 3-4 bar. If the pressure is too low,
clean the restriction or increase the diameter
of the restriction.
3. Set the correct lubricating oil dose.
Pump (3217 8667 52) - 20-25 pulses/min
4. After setting, check that the correct pulse
frequency has been obtained and that air and
lubricating oil emerge from the ECL return
(ALR nipple).
1250 0346 24

9.2 Setting damper pressure

NB! The setting should take place at normal

operating temperature for the hydraulic oil.
1. Make sure that the machine has the correct
operating temperature.
2. Fully close the constant flow valve (B) on the
drill rig.
3. Connect a pressure gauge (A), calibrated for
0-60 bar, between the hose and the damper
union (508).
4. Pressurise the damper circuit. 508
5. Check that the shank adapter is unloaded and
B
1250 0346 26

in the forward position.

6. Adjust the constant flow valve until the pres- A
sure gauge (A) shows 20 bar (8 l/min) at the
rock drill (operator panel shows 25 bar).
7. Disconnect the pressure gauge (A) and
connect the hose to the union (508).

27
9. Settings

28
 10. Front head

10. 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!

Important!
Always clean the outside of the rock drill before disassembly.

10.1 Dismantling

1. Remove the flushing hose.

2. Remove the nipple (507).
3. Remove the connecting plate (132) with the
screws (134) from the front head (110).
4. Remove the O-ring (133).

110 507
133
1250 0346 28

132
134

5. Remove the front side-bolt nuts (10) with their

washers (11).
235 12 320
6. Remove the front head (110) and extractor
unit (235) by pulling the shank adapter (1) or
10 11 110
by tapping with a plastic mallet.
1250 0346 29

7. Pull out the shank adapter (1) backwards from

the front head (110) and extractor unit (235). 235 1
110
8. Check the internal components when repla-
cing the shank adapter (1).
1250 0346 30

29
10. Front head

9. Remove the wiper (135) from the front head

(110). 110

135

1250 0339 07
10.Use sleeve (L) to press out the flushing head
(150) and the guide (131) from the front head
(110).

131

150
1250 0339 08

110

30
 10. Front head

10.2 Check
Overview illustration of the front head

135 110 235 320 325 330

1 131 150 211 233 221 234 362 429 438

151 151 239 213 222 332

1250 0346 31

152 152 237 212 223 224 238

Many of the position numbers in the instruc-
tions below are included in the figure above.

1. Check that air and lubricating oil comes out

from the connection for the ECL oil’s outlet (2).
See also chapter Hose connections.
2. Blow clean the lubricating air duct and the
connection for the ECL oil’s outlet using
compressed air.

2
1250 0346 35

3. Check and replace the wiper (135) if it is worn

or damaged. 135
1250 0339 13

31
10. Front head

4. Replace the front guide (131) if the inner

diameter D exceeds 61 mm. OBS! Max.
dimension.
5. Check the lubricating ducts on the front guide
(131).

ØD
1250 0339 11
6. Check the O-rings (152) and the U-sleeves
(151) if there is leakage in front of or behind 239
the flushing head (150). Replace the O-rings
(152) and U-sleeves (151) if they are worn or 237
damaged.
NB! The U-sleeves must be turned in accor- 152
dance with the figure.
7. Replace the flushing head (150) if it is serio- 151
usly corroded, or if it contains cracks. 150
8. Check and replace the O-ring (237) if it is worn
or damaged. 151
9. Check and replace the seal (239) if it is worn 152
or damaged.
1250 0346 36

10.Replace the extractor unit piston if:

• dimension L exceeds 47 mm L
• any surfaces or edges are worn
• any cracks (signs of breakage) are found 107
M - Measuring point
S - Wear surface
M
S
1250 0343 06

32
 10. Front head

11. Check and replace the O-ring (238) if it is worn

or damaged.
12.Check and replace the seal (332) if it is worn 332
or damaged.
238

1250 0346 38
13.Look inside the gear housing and check the
splines on the driver (325). If the thickness of 325
the splines is less than 2 mm then the driver
must be replaced.
1250 0342 52

14.Send the rock drill to a workshop for inspec-

tion if: 1,0
• the starter bushing (330) is worn more than 330
1 mm on the wear surface (S)
• after 600 percussion hours
• if the impact piston’s (438) impact surface is
damaged in any way
15.Also replace the starter bushing (330) if marks
(wave type) from splines are visible on the M
wear surface (S).
M - Measuring point
S - Wear surface

S
1250 0339 15

33
10. Front head

16.Replace the shank adapter (1) if:

• the thread is worn out
• the impact surface is crushed or chipped
• the front or rear end surfaces of the splines 1
are worn .
17.Check for rust on the surface of the flushing
seal, if there is any rust then polish it away.

1250 0346 37

34
 10. Front head

10.3 Assembly

Important!
Before fitting the parts must be lubricated with clean hydraulic oil.

1. Press the front guide (131) into the front head

(110) with tools L and D.

110

1250 0339 19
131

2. Lubricate O-rings and parts with grease/oil in

order for them to press in easily. 332
3. Fit the U-sleeves (151) in the flushing head
(150). NB! The U-sleeves must be turned in
accordance with the figure. 152
4. Replace the O-rings (152) on the flushing
head (150). 151
150

151
152
250 0339 12

35
10. Front head

5. Press down the flushing head (150) with press

tool (C2). Check that the flushing hole in the
flushing head (150) coincides with the flushing
hole in the front head (110).

C2

110

150

131
1250 0339 20

6. Fit the wiper (135) in the front head (110). NB!

The wiper must be turned in accordance with 110
the figure.

135
1250 0339 07

7. Check that pin (232) is mounted in the

extractor unit (235). 235
232 1
8. Check that O-ring (237) and seal (239) are 110
mounted in the groove on the extractor unit.
9. Slide the shank adaptor (1) through the
extractor unit (235) and the front head (110).

237
1250 0346 39

239

36
 10. Front head

10.ount the seal (332) in the groove on the cover

plate (320).
235 12 331
11. Fit the O-ring (238) in the groove on the 10 11 110
extractor unit (235).
12.Make sure that the pin (331) is fitted in the
cover plate (320).

1250 0346 40
13.Apply the intended grease to the threads, type 238 320
1 332
Never Seez, before assembly.
14.Mount the front part (110) and extractor unit
(235) on the side bolts (12).
15.Fit the washers (11) and nuts (10).
16.Tighten the nuts (10) alternately to the correct
tightening torque.

17.Fit the O-ring (133) on the connection plate

(132).
18.Assemble the connecting plate (132) on the
front head (110) with the bolts (134).
19.Fit the nipple (507).
20.Connect the flushing hose.
110 507
133
1250 0346 28

132
134

37
10. Front head

38
 11. Lubrication

11. Lubrication
11.1 Lubrication of gear

1. Lubricate with heat-resistant grease through

the nipple (319) until new grease escapes
through the check valve (314) on the under- 319
side. Nipple (319) and plug (317) can change
sides to facilitate lubrication. The plug (317)
does not need to be removed for filling. (The
hydraulic motor is removed in order to visua-
lise the position of the check valve).

317
314
1250 0333 18

39
11. Lubrication

40
 12. Dismantling from cradle

12. Dismantling from cradle

12.1 Slinging

Caution!
Lifting devices and straps must be approved for lifting at least 500 kg.
Incorrect lifting devices could cause the rock drill to start moving or fall down.
Incorrect operation could cause crushing damage.

Make sure that the rock drill is safely slung for

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

1250 0346 27

12.2 Rock drill weights

COP 3060MEX 404 kg

12.3 Action before service and long-term storage

1. Check that all connections, including the one

for the flushing medium, are properly capped
with protective caps of the right size
2. Clean the rock drill carefully. Use degreasing
agent and rinse with water.
3. Clean thoroughly and oil in the front head
components in contact with flushing medium
(especially in high humidity).
4. Release gas from the accumulators.
5. Store the rock drill in a dry place.
1250 0346 24

41
12. Dismantling from cradle

42
 13. Hydraulic and lubricant recommendations

13. Hydraulic and lubricant recommendations

13.1 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 chose a hydraulic fluid of the correct viscosity for the oil operating temperature of the rock
drill. Select a viscosity grade (VG) and viscosity index (VI) as specified in the following table. A high visco-
sity 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

13.1.1 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.

13.1.2 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 100ºC.

13.1.3 The hydraulic fluid must be changed at regular intervals.

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.

43
13. Hydraulic and lubricant recommendations

13.2 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 ºC and +50 ºC.
COP OIL can be ordered with the following part numbers:

Quantity Part Number

1 can of 4 litres 3115 3125 02
1 can of 20 litres 3115 3125 01
24 cans of 20 litres 3115 3126 01
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)

-30 to 0 VG 32-68
-10 till +20 VG 68-100
+10 till +50 VG 100-150

• 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

13.3 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
2 260 ºC 220 cst at 40 ºC -15 to +150 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 -40ºC to
+150ºC, and temperatures of up to 220ºC 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

44
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