Atlas Copco

Hydraulic Rock drill

COP 1638HD, 1838HD, 2238HD
Maintenance instructions

PM no. 9852 2462 01b

2012-12
 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 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 .......................................................................................................... 3
1.1 Description of the serial 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. SERVICE INTERVAL ......................................................................................... 7

2.1 Before starting up a new or newly overhauled rock drill............................................... 7
2.2 After the first shift with a new or newly overhauled rock drill........................................ 7
2.3 Before Each Shift ......................................................................................................... 7
2.4 After every 40th percussion-hour ................................................................................. 7
2.5 Every 400th percussion-hour: ...................................................................................... 7

3. HOSE CONNECTIONS ...................................................................................... 9

3.1 Connecting the hoses................................................................................................... 9

4. TIGHTENING TORQUES ................................................................................. 11

4.1 Adjusting the side bolts .............................................................................................. 12
4.1.1 Tightening the side bolts ...................................................................................12
4.1.2 Retightening the side bolts ................................................................................12

5. ACCUMULATORS ........................................................................................... 13
5.1 Safety label location ................................................................................................... 13
5.2 Safety label instructions ............................................................................................. 13
5.3 Charging the accumulators ........................................................................................ 14
5.4 Checking the accumulators in the event of impact vibration ...................................... 15
5.4.1 Damper accumulator (221) and intake accumulator (211) ................................15
5.4.2 Return accumulator (231) .................................................................................15
5.5 Replacing the damper and intake accumulators ........................................................ 16
5.5.1 General .............................................................................................................16
5.5.2 Dismantling .......................................................................................................16
5.5.3 Assembly ...........................................................................................................17
5.6 Replacing the return accumulator .............................................................................. 18
5.6.1 General .............................................................................................................18
5.6.2 Dismantling .......................................................................................................18
5.6.3 Assembly ...........................................................................................................18

6. CHANGING THE HYDRAULIC MOTOR.......................................................... 19

6.1 Dismantling................................................................................................................. 19
6.2 Assembly.................................................................................................................... 19

7. FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM............. 21

8. SETTINGS ........................................................................................................ 23
8.1 ECL Lubricating system settings ................................................................................ 23
8.2 Setting damper pressure ............................................................................................ 23

9. FRONT HEAD .................................................................................................. 25

9.1 Dismantling................................................................................................................. 25
9.2 Check ......................................................................................................................... 26
9.3 Assembly.................................................................................................................... 29

1
10. DISMANTLING FROM THE CRADLE.............................................................. 31
10.1 Slinging .................................................................................................................... 31
10.2 Rock drill weights ..................................................................................................... 31
10.3 Long-term storage.................................................................................................... 31

11. LUBRICATION.................................................................................................. 33
11.1 Lubricating the gear housing.................................................................................... 33

12. FUNCTION AND CONDITION TEST OF THE HYDRAULIC MOTOR............. 35

12.1 Function test ............................................................................................................ 35
12.2 Belle-test .................................................................................................................. 35
12.3 Half Belle test........................................................................................................... 36

13. HYDRAULIC AND LUBRICANT RECOMMENDATIONS................................ 37

13.1 Hydraulic fluid .......................................................................................................... 37
13.2 Pneumatic tool oil..................................................................................................... 38
13.3 Grease ..................................................................................................................... 38

2
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

3
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 prop-
erty if the warning is not heeded.

1.6.2 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.

4
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.

5
6
2. Service interval
Order numbers for the repair kits are in the rock drill’s spare parts catalogue

2.1 Before starting up a new or newly overhauled rock drill

Chapter
• Connect up the hoses ..........................................................................................................................3
• Charge the accumulators .....................................................................................................................5
• Select a suitable hydraulic oil and lubricant........................................................................................13
• Fill the lubricating system with oil .........................................................................................................7
• Adjust and set the lubricating system ...................................................................................................8
• Set the damper pressure ......................................................................................................................8

2.2 After the first shift with a new or newly overhauled rock drill
• Tighten all threaded unions ..................................................................................................................4

2.3 Before Each Shift

• Check that air and lubricating oil escapes between the shank adapter and front guide,
and also out of the hole in the front head. ...........................................................................................9
• Check that the drill rig’s damper pressure gauge is showing normal values.
In the event of deviation, adjust the damper pressure .........................................................................8
• Check that the shank adapter’s threads are not damaged...................................................................9
• 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 from the flushing head,
replace the seals and O-rings...............................................................................................................9
• When replacing the shank adapter or removing the front head, check the internal
components including piston, driver and the visible parts of the starter bushing..................................9
• 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. ...................................9

2.4 After every 40th percussion-hour

• Grease the gear .................................................................................................................................11
• 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:

• Remove the rock drill from the drill rig.
Transport the rock drill to a suitable workshop for inspection .............................................................10

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.

7
8
3. Hose connections
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!

1
5
1250 0240 34

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

3.1 Connecting the hoses

• Clean the rock drill’s hose connections before undoing the protective caps.
• Never remove a protective cap until the hose is ready to be connected.
• Always store the rock drill with all hose connections plugged. Use suitable protective caps, and make
sure that they are clean.

9
10
4. Tightening torques

5 1

4
3

14
13
9
11 16
12
17 15
10
7 8

9
11
1250 0240 35

3 9
2 6

Lubricate the nuts’ threads and the washers’ contact surfaces with thread grease, e.g. Never-Seez Regular
Grade

Ref. Torque
Qty. Check point Instructions
No. Nm
1 2 Side bolts 300 Tighten the rear nuts
2 1 Front bolt 300 Tighten the front bolt
3 4 Side bolt 350 Tighten the front nuts
4 3 Back head 220 Tighten the bolts 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 bracket, return accu- 30
mulator
9 4 Rock drill mounting 250 Tighten the screws alternately to full
torque
10 1 Plug 45
11 4 Valve covers 145 Tighten the screws alternately to full
torque
12 2 Connecting plate 120 Tighten the screws alternately to full
torque

11
 Ref. Torque
Qty. Check point Instructions
No. Nm
13 1 Flushing connector 300
14 2 Intake, flushing medium 220 Tighten the screws alternately to full
torque
15 2 Control valve, Accumulator 45
16 2 Filler valve Accumulator 30
17 1 Pressure screw 170

4.1 Adjusting the side bolts

4.1.1 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 side bolt (2), the nuts and the
washers’ threads and contact surfaces with
thread grease. 1
1250 0310 07

3. Tighten the rear nuts (1) to the tightening

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

4.1.2 Retightening the side bolts

1. Undo the front nuts (3) so that the tension

releases. If the threads are seized, remove
the nuts and clean and lubricate them with
thread grease. Tighten the front nuts (3)
manually.
2. Tighten the rear nuts (1) to the tightening 1
1250 0310 07

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

12
5. Accumulators
Check the safety labels on the accumulators. Replace them if they are damaged or illegible.

5.1 Safety label location

1. Damper accumulator (221)

221
2. Intake accumulator (211)
3. Return accumulator (231)

1250 0310 06
211

231

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.
N2
1250 0187 04

1 2

13
5.3 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 (4).

221
2. Open the valve nut (5) by 2-3 turns, and
connect the gas hose.
3. Open the gas valve (6).
4. NB! Charge at the bottom if possible rather
than too high.
5. Charge the accumulators with nitrogen gas
(N2) to the correct pressure in accordance 211 5
with the following: 231 4 6
Damper accumulator (221) 20-25 bar
Intake accumulator (211) 30-40 bar*
N2
Return accumulator (231) must not be
charged with N2
1250 0256 24

*Intake accumulator 40 bar under collaring pres-

sure. Normal 70-100 bar. Max. 100 bar.
6. Tighten the valve nut (5) and close the gas
valve (6).
7. Remove the gas hose and screw in the
protective cap (4) to the accumulator valve.

14
5.4 Checking the accumulators in the event of impact vibration

5.4.1 Damper accumulator (221) and intake accumulator (211)

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

221
mulator is charged, the pin protrudes 4.5 mm
and is hard to push in.
NB! If the pin is easy to press in then the gas
pressure has disappeared (broken diaphragm
or defective filler valve). The damper accumu-
lator’s (221) pin is slightly easier to press in.
2. Replace the accumulator if it is not functioning 211
properly.
3. Charge the new accumulator after replace- 4
ment.

1250 0310 08
NB! The seat of the filler valve is easily
deformed by repeated opening/closing. The
filler valve must be replaced frequently

5.4.2 Return accumulator (231)

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.
4. If the diaphragm is resting against the outer 12 11
pipe, press the diaphragm with a cylindrical
(blunt) mandrel (7-9 mm).See Figure A. 231 11
Correct position for diaphragm, see Figure B.
5. Refit the plug (11) and O-ring (12).
A
1250 0200 86

15
5.5 Replacing the damper and intake accumulators

5.5.1 General

Warning!
All gas must be released prior to assembly 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.

Important!
Use 65 mm long screws when using the HD accumulator.

5.5.2 Dismantling

1. Release the gas by removing the protective

cap (A) and loosening the valve nut (B) by 2-3 C
211
turns.
2. Remove the accumulators (211 and 221) with 82
the seal rings (82) by undoing the bolts (C and
D).
3. Send the accumulators to a workshop for
overhauling!

B 82
A
1250 0244 72

221
D

16
5.5.3 Assembly

1. Position the seal rings (82) in the grooves on

the rock drill’s intermediate segment. C
211
2. Make sure that the sealing rings (82) do not
get damaged during the assembly.
82
3. Fit the damper accumulator (221) (marked
with "D") on the left-hand side of the rock drill,
and the intake accumulator (211) on the right-
hand side (hose side). Replace the screws in
pairs, even if only one screw is corroded or
damaged in some other way.
4. Tighten the bolts (C and D) alternately to a
B 82
A

1250 0244 72
tightening torque of 220 Nm. 221
5. Charge the accumulators with nitrogen gas D
(N2).

17
5.6 Replacing the return accumulator

5.6.1 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!

5.6.2 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).
3. Pull away the clip (21).
4. Unscrew the pressure screw (5) with O-ring
(6).
5. Detach the return accumulator (231) with O-
ring (7) from the cylinder.
6. Send the return accumulator (231) to a work-
shop for reconditioning.
1250 0240 39

5.6.3 Assembly

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

rock drill’s cylinder.
2. Make sure that the O-ring (7) does not get
damaged during the assembly.
3. Fit the return accumulator (231) on the
cylinder with the pressure screw (5) and the
O-ring (6). Screw in the pressure screw (5)
loosely.
4. Thread the clamp (21) on the return accumu-
lator (231) and fit the holder (22) with the bolts
(1 and 23) and the nuts (24).
5. Tighten the pressure screw (5) to a tightening
torque of 170 Nm.
1250 0240 39

6. Connect the hydraulic hose to the return accu-

mulator (231).

18
6. Changing the hydraulic motor
6.1 Dismantling

1. Remove the hydraulic hoses.

2. Undo the nuts (246) and remove the hydraulic 246 241
motor (241). 249 247
248

1250 0255 34
6.2 Assembly

1. Make sure that the groove ring (249) is fitted

in the coupling (248). 247 246 241
2. Lubricate the coupling’s splines with grease 249
248
and fit the coupling (248) on the hydraulic
motor (241).
3. Fit the gasket (247) and the hydraulic motor
(241) on the cylinder. Replace the gasket
(247) if it is damaged.
1250 0255 34

4. Tighten the nuts (246) alternately until a tight-

ening torque of 65 Nm is obtained.
5. Connect the hydraulic hoses. Check that the
correct direction of rotation is obtained.

19
20
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.

21
22
8. Settings
8.1 ECL Lubricating system settings
ECL= Electrical Controlled Lubrication
Rock drill lubrication must be set with regard to local conditions.

1. Start the lubricating system.

2. Adjust the lubricating air pressure to 2-3 bar
using a pressure gauge at the rock drill. If the
pressure is too low, clean the restriction or
increase the diameter of the restriction.

1250 0244 33
3. Set the correct lubricating oil dose
Pump (3217 8667 50) - 35-40 pulses/min
Pump (3217 8667 52) - 20-25 pulses/min
4. After setting, check that the correct pulse
frequency has been obtained and that oil
emerges from the front head’s hole and
between the shank adapter and front guide.

8.2 Setting damper pressure

NB! The setting should take place at normal operating temperature for the hydraulic oil.

1. Fully close the constant flow valve (B) on the

drill rig.
A
2. Connect a pressure gauge (A), calibrated for 1
0-60 bar, between the hose and the damper
nipple (1).
3. Pressurise the damper circuit.
4. Check that the shank adapter is unloaded and
in the forward position.
5. Adjust the constant flow valve (B) until the
pressure gauge (A) shows 30-35 bar.
6. Read off the drill rig’s damper pressure gauge. B
1250 0240 40

If this pressure gauge later shows another

value, make a new pressure setting.
7. Disconnect the pressure gauge (A) and
connect the hose to the nipple (1).

23
24
9. 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!

Caution!
The percussion mechanism must not be enabled, when the shank adapter is dismantled. Piston and
front piston guide can be damaged.

NB! Always clean the outside of the rock drill before dismantling.

9.1 Dismantling

1. Remove the flushing hose.

2. Remove the connecting plate (186) by
undoing the bolts (188) with the washers
(189).
3. Remove the seal (190).
190
186

189
1250 0240 37

188

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

their washers (252).
5. Remove the front head (172) by pulling the
shank adapter (300).

162
172
1250 0240 38

300
252
251

25
9.2 Check
Overview illustration of the front head

301 177 A 178 174 175 176 185 300 131 132 A 71 86 21
1250 0400 61

192 192 C192 B 195 193

Many of the position numbers in the instruc-

tions below are included in the figure above.

1. Check that air and lubricating oil escape

between the shank adapter (300) and front
guide (177), and also out of the hole (B)
301
2. Blow clean the lubricating air ducts (A) with
compressed air and check that the restrictions
(71) are open.
1250 0311 94

300
B

3. Replace the guide (177) if the inside diameter

exceeds 39 mm. NB! Max. dimension. 177
4. Check the lubricating ducts.
m
39m
1250 0311 87

26
5. Check the O-rings (193, 195), seal rings (192)
and the U-sleeves (175, 176, 178) if air is 185
escaping from the hole (C) in the front head. 192195 193
176
Replace the O-rings (193, 195), seal rings 175
174
(192) and U-sleeves (175, 176, 178) if they 175
are worn or damaged. NB! The U-sleeves
192
must be turned in accordance with the figure. 177 178
6. Replace the flushing head (174) if it is seri-
ously corroded, or if it contains cracks.
7. Check that the wiper (178) is not worn or

1250 0311 88
damaged. NB! The wiper (178) must be
turned in accordance with the figure.

8. Replace the stop ring (185) if:

• any point within the wear surface (S) is worn
1,0
more than 1 mm, compare with a new stop
ring
• any cracks (signs of breakage) are found S
• the wear surface (S) is uneven
M - Measuring point
M
S - Wear surface
1250 0311 89

185

9. Look inside the gear housing and check the

splines on the driver (131). If the splines are
less than 2 mm in width, the driver (131) must
be replaced. Fit a new driver with the aid of a
suitable mandrel and a plastic mallet.

131
2mm
1250 0311 90

27
10.Send the rock drill to a workshop for inspec-
tion if: 1,0
• the starter bushing (132) is worn more than
132
1 mm on the wear surface (S)
• after 400 percussion hours
• if the impact piston’s (21) impact surface is
damaged in any way
11. Also replace the starter bushing (132) if marks
(wave type) from splines are visible on the M
wear surface (S).
12.NB! Fit the starter bushing so that the lubri-
cating grooves are directed towards the
damper piston (86).
M - Measuring point S

1250 0311 91
S - Wear surface

13.Replace the shank adapter (300) if:

300
• the thread is worn out
• the impact surface is crushed or chipped
• the front or rear end surfaces of the splines
are worn
1250 0311 92

14.Check that the drill collar (301), to be used

with upwards directed drilling, is not damaged
and rotates with the shank adapter (300).
301
1250 0311 93

300

28
9.3 Assembly

1. Fit the stop ring (185) and the shank adapter

(300) in the front head (172).
2. Make sure that the pin (162) is fitted in the
cover plate. Place the front head (172) on the
side bolts.
3. Lubricate the threads and contact surfaces for
162
the washers (252) and nuts (251) with thread
grease. 172

1250 0240 38
300
4. Fit the washers (252) and nuts (251). 252
5. Check the tightening torques on the rear side- 251
bolt nuts and the front side bolt.
6. Following which, tighten the front nuts (251)
alternately to a tightening torque of 350 Nm.

7. Fit the seal ring (190) into the connecting plate

(186).
8. Fit the connecting plate (186) on the front
head using washers (189) and screws (188).
NB! Also make sure that the flushing hole in
the flushing head (174) aligns with the hole in
the front head (172). 190
9. Tighten the bolts (188) to a tightening torque 186
of 220 Nm.
10.Replace the seal washer if it is damaged.
11. Fit the nipple on the connecting plate. Tighten 189
1250 0240 37

to a tightening torque of 300 Nm. 188

12.Connect the flushing hose and tighten the nut.
After assembly
Check that air and lubricating oil escape from the
holes (B and C) in the front head and between the
shank adapter (300) and front guide.

29
30
10. Dismantling from the cradle
10.1 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 0244 32

10.2 Rock drill weights

COP 1638HD 185 kg

COP 1838HD
COP 2238HD

10.3 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 0244 33

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. Fill grease in the nipples in the front.
5. Release gas from the accumulators.
6. Store the rock drill in a dry place.

31
32
11. Lubrication
11.1 Lubricating the gear housing

1. Unscrew the bleed plug (104) with gasket

(105).
2. Lubricate with heat-resistant grease through
the grease nipple (106) until grease escapes
through the hole for the bleed plug (104).
3. Tighten the bleed plug (104) with gasket 105
(105).
104

1250 0244 34
106

33
34
12. 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.

12.1 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

12.2 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
1250 0403 67

value. R

Motor type Pressure port A Permitted flow

in drainage line

MS 210 bar 3.5 l/min

35
12.3 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 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

36
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 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
increasing 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.

37
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 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

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 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 -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 -40 ºC to
+150 ºC, and temperatures of up to 220 ºC 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

38
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