Atlas Copco Rock Drill

COP 1238K
Maintenance instructions

PM no. 9852 2619 01

2012-10
 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 2012, 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
 Contents
1. GENERAL .......................................................................................................... 5
1.1 Description of the serial number........................................................................................... 5
1.2 In the event of leakage problems ......................................................................................... 5
1.3 During dismantling................................................................................................................ 5
1.4 During assembly................................................................................................................... 5
1.5 Environment ......................................................................................................................... 5
1.6 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 the first 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 .................................................................................... 11

3.1 Connecting the hoses......................................................................................................... 11

4. TIGHTENING TORQUES ................................................................................. 13

4.1 Tightening the side bolts .................................................................................................... 14
4.2 Retightening the side bolts ................................................................................................. 14

5. ACCUMULATOR.............................................................................................. 15
5.1 Safety label location ........................................................................................................... 15
5.2 Safety label instructions ..................................................................................................... 15
5.3 Charging the accumulators ................................................................................................ 16
5.4 Checking the accumulators in the event of hose vibration ................................................. 16
Intake accumulator (1)....................................................................................................... 16
Return accumulator (2)...................................................................................................... 17
5.5 Replacing the intake accumulator ...................................................................................... 18
General.............................................................................................................................. 18
Dismantling........................................................................................................................ 18
Assembly........................................................................................................................... 18
5.6 Replacing the return accumulator ...................................................................................... 19
General.............................................................................................................................. 19
Dismantling........................................................................................................................ 19
Assembly........................................................................................................................... 19

6. CHANGING THE HYDRAULIC MOTOR.......................................................... 21

6.1 Dismantling......................................................................................................................... 21
6.2 Assembly............................................................................................................................ 21

7. FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM............. 23

8. SETTINGS ........................................................................................................ 25
8.1 ECL Lubricating system settings ........................................................................................ 25

3
9. REMOVING THE FRONT HEAD ...................................................................... 27
10. CHECKING THE FRONT HEAD ...................................................................... 29
11. MOUNTING THE FRONT HEAD ...................................................................... 33
12. DISMANTLING FROM THE CRADLE.............................................................. 35
12.1 Slinging .............................................................................................................................. 35
12.2 Rock drill weights ............................................................................................................... 35
12.3 Long-term storage.............................................................................................................. 35

13. LUBRICATING THE GEAR HOUSING ............................................................ 37

14. FUNCTION AND CONDITION TEST OF THE HYDRAULIC MOTOR............. 39
14.1 Function test ...................................................................................................................... 39
14.2 Belle-test ............................................................................................................................ 39
14.3 Half Belle test ..................................................................................................................... 40

15. HYDRAULIC AND LUBRICANT RECOMMENDATIONS................................ 41

15.1 Hydraulic fluid .................................................................................................................... 41
15.2 Pneumatic tool oil............................................................................................................... 42
15.3 Grease ............................................................................................................................... 42

4
1. General
This instruction is intended as a guide when performing maintenance on your rock drill.

1.1 Description of the serial number

All rock drills gets a serial number depending on the place of manufacture, year, family and version. The
serial number is stamped and the placement on the rock drill varies between the models.

1. Factory code for manufacturing unit:

AVO= Atlas Copco Rock Drills AB 2 4
2. Production year.
3. Family letter identifying number series:
D = Hydraulic rock drill
P = Pneumatic rock drill
T = Rotation units
AVO 12 D 333B

1250 0404 84
4. Serial number in the “Family group”.
1 3 5
5. Revision letter for the product. To show the
relevant spare parts list/ manual.

1.2 In the event of leakage problems

Check the source of the leak 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

Pneumatic tool oil must be applied to the internal parts during all fitting unless otherwise stated.

1.5 Environment

Environmental regulations
Care for the environment!
Changing oils, air 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 pneumatic tool oils wherever possible

1.6 Safety regulations

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

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

5
 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 prop-
erty if the warning is not heeded.

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 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 water and air systems are depressurised and that the electrical system is de-ener-
gised 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.

6
Important!
A mining machine has many components and functions that are controlled by a air 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 air 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 air 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.

7
8
2. Service interval
Order 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........................................................................................15
• Fill the lubricating system with oil .........................................................................................................7
• Adjust and set the lubricating system ...................................................................................................8

2.2 After the first 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 from the hole in the front part in between 
the shank adapter and front guide .....................................................................................................10
• 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 dismantling 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 
a suitable workshop for servicing .......................................................................................................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
10
3. Hose connections

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 tem-
perature. 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 rea-
sons 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!

6
7
5
1
1250 0400 35

3 4
2
1. Drainage 5. Inlet impact mechanism
2. Rotation left 6. Flushing air/water
3. Rotation right 7. Lubricating air
4. Percussion return

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.

11
12
4. Tightening torques

5
4
3

14
13
9
6 15
12 16
7 1 10
8 9
1250 0400 36

3 2
Lubricate the nuts’ threads and the washers’ contact surfaces with Never-Seez Regular Grade
• NB! Tighten ref. no. 1-3 in specified order.
.

Ref. Torque
Qty. Check point Instructions
No. Nm
1 2 Side bolts 300 Tighten the rear nuts alternately to full
torque
2 1 Front bolt 300 Tighten the front bolt
3 2 Side bolt 350 Tighten the front nuts alternately to full
torque
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 4 Intake, flushing medium 90 Tighten the screws alternately to full
torque
15 2 Filler nipple Accumulator 30
16 2 Control nipple 45

13
4.1 Tightening the side bolts

1. Check whether the side bolts, nuts or washers

have cracks, scratches or rust. Replace
damaged side bolts, nuts and washers.
2. Lubricate the threads and contact surfaces of
the side bolt, nuts (1,3) and washers with
Never-Seez Regular Grade.
3. Tighten the rear nuts (1) alternately to the

1250 0400 37
1
tightening torque. The front nuts (3) must be
loose when the rear nuts (1) are tighten. 3 2
4. Tighten the front nuts (3) alternately to the
tightening torque.
5. Tighten the front bolts (2) to the tightening
torque.

4.2 Retightening the side bolts

If the threads are seized, remove the nuts and

clean and lubricate them with Never-Seez
Regular Grade.
1. Undo the front nuts (3) so that the tension
releases and the nuts (3) are loose.
2. Tighten the rear nuts (1) alternately to the
tightening torque.
1250 0400 37

3. Tighten the front nuts (3) alternately to the 1

tightening torque. 3 2
4. Tighten the front bolts (2) to the tightening
torque.

14
5. Accumulator
Check the safety labels on the accumulators. Replace them if they are damaged or illegible.

5.1 Safety label location

1. Intake accumulator
2. Return accumulator

1250 0175 08
1
2

5.2 Safety label instructions

1. Read the operator’s instructions carefully

before service or replacement of the accumu-
lator
2. Must be charged with nitrogen only.

1250 0187 04 N2

1 2

15
5.3 Charging the accumulators

Caution!
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 explosion.

1. Remove the protective cap (3).

2. Open the valve nut (6) by 2-3 turns, and
connect the gas hose.
3. Open the gas valve (5).
4. Charge the accumulators with nitrogen gas 1
(N2) to the correct pressure in accordance
with the following:
NB! Charge at the bottom if possible rather
4
6
than too high. 2 3 5
Intake accumulator (1) 80-100 bar*
Return accumulator (2) Must not be loaded
N2
*Intake accumulator 30-40 bar under collaring
pressure. Normal 80-100 bar. Max. 100 bar.
5. Tighten the valve nut (6) and close the gas
1250 0175 15

valve (5).
6. Remove the gas hose and screw in the
protective cap (3) to the accumulator valve.

5.4 Checking the accumulators in the event of hose vibration

Intake accumulator (1)

1. Push in the control valve’s pin (4). If the accu-

mulator is charged, the pin protrudes 4.5 mm
and is difficult to push in. NB! The damper
accumulator’s pin is slightly easier to push in.
If the pin is easy to push in the gas pressure
has been lost (defective diaphragm or defec-
tive filling valve).
2. Replace the accumulator if it’s broken.
1
3. Charge the new accumulator after replace-
ment. 4
NB! The seat of the filler valve is easily
1250 0199 33

deformed by repeated opening/closing. The

filler valve must be replaced frequently.

16
Return accumulator (2)

1. Position the rock drill in horizontal position.

2. Remove the plug (11) with O-ring (12). If oil
escapes then the diaphragm is damaged or
the accumulator has been overcharged.
3. Replace the accumulator, diaphragm and/or
filler valve if they are not functioning properly.
12 11
4. If the diaphragm is resting against the outer
pipe, press the diaphragm with a cylindrical
(blunt) drift (7-9 mm). See Figure A. Correct 11
position for diaphragm, see Figure B. 2
5. Refit the plug (11) and O-ring (12).
A

1250 0200 82
B

17
5.5 Replacing the intake accumulator

General

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

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.

Dismantling

1. Remove the accumulators (211) with the

sealing rings (82) by undoing the bolts (10). 10
211 51
2. Send the accumulators to a workshop for 10 82
overhauling!

211
10
1250 0184 67

82
10

Assembly

1. Locate the sealing rings (82) in the grooves on

the intermediate section (51). 10
211 51
2. Make sure that the sealing rings (82) do not 10 82
get damaged during the assembly.
3. Assemble the intake accumulators (211) on
the intermediate section (51). Assemble using
undamaged original bolts (10). Replace the
bolts in pairs even if only one bolt is corroded
or damaged in some other way.
211
4. Tighten the bolts (10) alternately to tightening 10
torque 220 Nm.
5. Charge the accumulators with nitrogen gas 
1250 0184 67

(N 2). 82
10

18
5.6 Replacing the return accumulator

General

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!

Dismantling

1. Remove the hydraulic hose from the return

accumulator (231).
2. Remove the return accumulator (231) by
removing the nuts (24), the bolts (23), the bolt
(1) and the holder (22). 23
3. Pull away the clamp (21). 1
4. Unscrew the pressure screw (5).
5. Remove the return accumulator (231) and the 7
O-ring (7) from the cylinder.
6. Send the return accumulator (231) to a work- 22
shop for overhauling.
21
1250 0402 89

5
24 231

Assembly

1. Place the O-ring (7) in the groove on the

cylinder of the rock drill.
2. Make sure that the O-ring (7) do not get
damaged during the assembly.
3. Assemble the return accumulator (231) on the
23
cylinder with the pressure screw (5). 1
4. Slide the clamp (21) on the return accumu-
lator (23) and mount the holder (22) with the
screws (1 and 23) and the nuts (24). 7
5. Connect the hydraulic hose to the return accu- 22
mulator (231).
21
1250 0402 89

5
24 231

19
20
6. Changing the hydraulic motor
6.1 Dismantling

1. Disconnect the hydraulic hoses from the

hydraulic motor (241). 3
2. Undo the nuts (246) and remove the hydraulic
motor (241).
3. Pull out the coupling (248).
241

1250 0184 69
246
247 11
248 249

6.2 Assembly

1. Make sure that the circlip (249) is fitted in the

coupling (248)
3
2. Lubricate the coupling’s splines with grease
and fit the coupling (248) on the hydraulic
motor (241).
3. Fit the gasket (247) and hydraulic motor (241) 241
onto the cylinder (3). Replace the gasket
1250 0184 69

246
(247) if it is damaged. 247 11
248 249
4. Tighten the nuts (246) alternately to a torque
of 65 Nm.
5. Connect the hydraulic hoses. Check that the
correct direction of rotation is obtained.

21
22
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 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.

23
24
8. Settings
8.1 ECL Lubricating system settings
ECL=Electric Controlled Lubrication
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 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.

Pump (3217 8667 50) 35-40 pulses/minute

Pump (3217 8667 52) 20-25 pulses/minute

• After setting, check that the correct pulse frequency has been obtained and that oil is emerging from the
front head’s hole and between the shank adapter and front guide.

25
26
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.

1. Remove the flushing hose.

2. Remove the connection plate (120) and union
by removing the bolts (125) and washers
(126).
3. Remove the sealing (124).
101
124

126
1250 0184 75
125
120

4. Remove the front side-bolt nuts (251) with

their washers (252). 101
5. Remove the front head (101) by tugging the
shank adapter (300). Following which, pull out
the shank adapter from the front head.
6. Check the internal components when
replacing the shank adapter (300).
300
1250 0184 76

251
252

27
28
10. Checking the front head
Overview of the front head, cover and gear housing.

301 A 110 143 144 140 131

105 A 142 300 132 21 71-74 86

CC
111 111 B
112
1250 0400 38

Many item numbers in the instruction below

are included in the picture above.

1. Check that air and lubricating oil escape

between the shank adapter (300) and front
guide (105), and also out of the hole (B).
2. Blow clean the lubricating air ducts (A) with
compressed air and check that the restrictions A
(71-74) are open.
1250 0310 05

3. Replace the guide (105) if the inner diameter

exceeds 39 mm and 53 mm respectively. 
NB! Max. dimension.
4. Check the lubricating ducts (x 3).
1250 0309 99

105

29
5. Check the O-rings (142-144) and flushing
seals (111-112) if air/water is escaping from 144
the hole (C) in the front head. Replace the O- 143
rings (142-144) and flushing seals (111-112) if
they are worn or damaged. 112
111
6. Replace the flushing head (110) if it is seri- 110
ously corroded, or if it contains cracks.

142 111

1250 0310 00
7. Replace the stop ring (140) if:
• a point inside the wear area that's worn
1,0
more than 1 mm, compare with a new stop
ring
• cracks (fracture) is found S
• wear surface is smooth
M - Measure point
M
S - Wear area
1250 0310 01

140

8. Look inside the gear housing and check the

splines on the driver (131). If the splines are 131
less than 2 mm in width, the driver (131) must
be changed. 
Fit a new driver with the aid of a suitable
mandrel (D) and a plastic hammer.
1250 0310 02

30
9. Send the rock drill to the workshop for service
if: 1,0
• the rotation chuck bushing (132) is worn
132
more than 1 mm on the wear area
• after 400 percussion hours
• the piston (21) impact surface is damaged in
any way
10.Also replace the rotation chuck bushing (132)
if marks are visible on the surface after the M
splines (e.g. wavy).
M - Measure point
S - Wear area
11. NB! Fit the rotation chuck bushing (132) so S
that the lubricating grooves are directed

1250 0310 03
towards the damper piston (86).

12.Replace the shank adapter (300) if:

300
• the thread is worn out
• the impact surface is damaged or chipped 171
• the front or rear end surfaces of the splines
are worn 301
13.Check that the drill sleeve (301), to be used
with upwards directed drilling, is not damaged 300
and rotates with the shank adapter (300). 171

301
1250 0310 04

31
32
11. Mounting the front head
Important!
Before fitting the parts must be lubricated with clean hydraulic oil.

1. Fit the stop ring (140) and shank adapter

(300) into the front head (101). 162
2. Make sure that the pin (162) is fitted in the
101
cover. Place the front head (101) on the side
bolts.
3. Apply grease, type Never Seez, to the threads
on the washers (252) and nuts (251).
4. Fit the washers (252) and nuts (251).
5. Check the tightening torques on the rear side- 300

1250 0404 77
bolt nuts and the front side bolt.
6. Following which, tighten the nuts (251) alter- 251
nately to a torque of 350 Nm.
252

7. Fit the sealing (124) into the flushing head

(110).
8. Fit the connection plate (120) to the front head
(101) using the washers (126) and screws
(125). Tighten the screws (125) to a torque of
90 Nm. 101
9. Replace the seal washer if it is damaged. 124
10.Fit the union on the connection plate (120).
Then tighten to tightening torque 300 Nm. 126
11. Connect the flushing hose and tighten the nut.
1250 0184 75

125
12.Check that air and lubricating oil escapes out 120
of the hole in the front head and between the
shank adapter (300) and front guide (105).

33
34
12. Dismantling from the 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.

250 0184 84

12.2 Rock drill weights

COP 1238K 176 kg

12.3 Long-term storage

If the rock drill is not going to be used for a

long time, the following precautions should
be taken.
1. Check that all connections, including the one
for the flushing medium, are properly capped
1250 0184 87

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.

35
36
13. Lubricating the gear housing

1. Unscrew the bleed plug (214) with gasket

(215). 214
2. Lubricate with heat-resistant grease through
the grease nipple (212) until grease escapes
through the hole for the bleed plug (214).
3. Tighten the bleed plug (214) with gasket
(215).

1250 0027 25
212

37
38
14. 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.

14.1 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
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14.2 Belle-test
For engines with external drainage line only.
The test indicates the general state of the engine, including axial wear, condition of sealings, 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
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value. R

Motor type Pressure port A Permitted flow

in drainage line

MS 210 bar 3.5 l/min

39
14.3 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

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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 A Permitted flow

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

40
15. Hydraulic and lubricant recommendations
15.1 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 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.

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.

41
15.2 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
1 can of 20 litres 3115 3125 01
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)

-30 to 0 VG 32-68
-10 to +20 VG 68-100
+10 to +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

15.3 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 addi-
tives 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 -150 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 -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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