Atlas Copco

Maintenance instruction
Hydraulic Rock drills
COP 1019 1022 1025

Atlas Copco Rock Drill AB

Örebro, Sweden
©Atlas Copco Rock Drills AB, 2008, All rights reserved

No. 9852 0454 02b

 ©Copyright 2008, Atlas Copco Rock Drills AB, Sweden
Any unauthorised use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and draw-
ings.

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
 Innehåll

INNEHÅLL
1. GENERAL .......................................................................................................... 4
1.1 Environment ........................................................................................................................ 4
1.2 Safety regulations................................................................................................................ 4
Warning boxes ................................................................................................................... 4
The following general safety rules must be observed ........................................................ 5

2. ACTION LIST ..................................................................................................... 6

2.1 Before starting a new or newly overhauled rock drill........................................................... 7
2.2 After the first shift when using a new or newly overhauled rock drill ................................... 7
2.3 For each shift....................................................................................................................... 7
2.4 After every 40th percussion-hour ........................................................................................ 7
2.5 Every 400th percussion-hour: ............................................................................................. 7

3. HOSE CONNECTIONS ...................................................................................... 8

3.1 Connecting the hoses.......................................................................................................... 8

4. TIGHTENING TORQUES ................................................................................... 9

5. ACCUMULATOR.............................................................................................. 10
5.1 Safety label instructions. ................................................................................................... 10
5.2 Charging the accumulator ................................................................................................. 10
5.3 Checking the accumulators in the event of hose vibration ................................................ 10
5.4 Replacing the accumulator................................................................................................ 10
Dismantling....................................................................................................................... 11
Assembly.......................................................................................................................... 11

6. CHANGING THE HYDRAULIC MOTOR.......................................................... 12

Dismantling....................................................................................................................... 12
Assembly.......................................................................................................................... 12

7. FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM............. 13

8. SETTINGS ........................................................................................................ 14
8.1 Setting of ECL lubricating system ..................................................................................... 14

9. CHECKING THE FRONT HEAD ...................................................................... 15

10. FRONT HEAD .................................................................................................. 16
Dismantling....................................................................................................................... 16
Assembly.......................................................................................................................... 16

11. SLINGING, WEIGHT AND WARNING ............................................................. 17

11.1 Slinging.............................................................................................................................. 17
11.2 Rock drill weights .............................................................................................................. 17
11.3 Long-term storage ............................................................................................................. 17

12. HYDRAULIC FLUID AND LUBRICANT RECOMMENDATIONS .................... 18

12.1 Hydraulic fluid.................................................................................................................... 18
12.2 Pneumatic tool oil .............................................................................................................. 19
12.3 Grease............................................................................................................................... 19

3
General 1

1. GENERAL 1.2 SAFETY REGULATIONS

The Safety chapter contains important information
This instruction is intended as a guide when for the prevention of accidents.
performing maintenance on your rock drill.

WARNING BOXES
1.1 ENVIRONMENT The manual contains warnings.
ENVIRONMENTAL REGULATIONS Warnings are preceded by a heading (Danger,
Warning and Caution).
Think of the environment!
WARNING BOXES
Leaking hydraulic couplings and grease are
hazardous to the environment.
Danger
Changing oils, hydraulic hoses and various Indicates an imminent risk of serious or fatal
types of filter can be hazardous to the environ- injury if the warning is not heeded.
ment.

Always collect oil residues, oil spillage, oily Warning

waste and residues and spilt grease. Deal with Indicates hazards or hazardous procedures
according to local provisions. which could result in serious or fatal injury if the
warning is not heeded.
Use biodegradable hydraulic fluid and lubrica-
tion oil wherever possible.
Caution
Indicates hazards or hazardous procedures
which could result in personal injury or
damage to property if the warning is not
heeded.

4
 General 1

THE FOLLOWING GENERAL SAFETY RULES

MUST BE OBSERVED
IMPORTANT!
IMPORTANT! Make sure that the rock drill has been main-
Read through the maintenance instructions tained in accordance with the applicable instruc-
carefully before starting maintenance work. tions.
Follow the instructions given and local regula- Before moving the rig and rock drill or starting to
tions. drill, make sure that there are no personnel in
Do not use or intervene in the rock drill unless the immediate vicinity of the drill rig.
you have been trained to do so. Checks and adjustments that are necessary
Never attempt to carry out maintenance while when the rock drill is in operation must be
the rock drill is in operation. carried out by at least two persons. One person
must then be present at the operating station
Ensure that the hydraulic, water and air systems and have a good view of the work.
are depressurised and the electrical system is
de-energised prior removing the rock drill or Always wear a helmet and earmuffs when
starting work on the system. drilling. Follow local regulations

Use approved lifting devices when handling the Make sure that the place of work is well venti-
rock drill. Avoid lifting heavy weights yourself. lated.

To prevent injury during service and mainte- Make sure that the safety labels are fitted, clean
nance, all components that could possibly move and fully legible.
or drop must be supported safely on blocks or Particular attention must be paid to all warnings
trestles, or secured by means of adequately in the manual.
dimensioned slings.

Check that the hoses used are of the right

quality, and that all hose connections are in
good condition and properly tightened. Hoses
that loosen could cause serious injury.

Use only Atlas Copco original parts. Any

damage or malfunction caused by the use of
non-original Atlas Copco parts is not covered by
warranty or product liability.

5
Action list 2

2. ACTION LIST
Read all safety regulations before starting to work IMPORTANT!
on the machine. Observe great cleanliness when intervening in
the rock drill or its hydraulic circuit.
WARNING
Before starting any maintenance work, make The following parts may be changed at the
sure that the electrical system is dead. work site in accordance with the instructions
given:
There is a risk of injury if these instructions are
not observed! •shank adapter
•driver
•rotation chuck bushing
CAUTION! •front head parts
Exercise caution when jointing drill rods and •accumulators
with drill bit handling. Watch your fingers! •hydraulic motor
•screws
Make sure that clothes do not come too close •connections
to rotating machine parts.
Other repairs must be carried out in a suitable
Negligence could cause serious injury. workshop in accordance with the repair instruc-
tions for the rock drill.
Always use hearing protection when drilling.
High noise levels damage the hearing.

Never attempt maintenance or intervene in the

IMPORTANT!
rock drill, connections or hoses while the
hydraulic, lubrication or flushing systems are Ensure bolted joints are tightened to the
pressurised. Air or oil can spray out at high correct tightening torques after every 40
pressure and high temperature. There is a risk percussion hours and when reconditioning the
of serious injury to the eyes and skin. rock drill.

6
 Action list 2

2.1 BEFORE STARTING A NEW OR 2.3 FOR EACH SHIFT

NEWLY OVERHAULED ROCK Any defect must be rectified in the designated
DRILL workshop.
• Connect up the hoses..................... Chapter 3
• Check that air and lubricating oil escape in
• Charge the accumulators ............... Chapter 5 between the shank adapter and front guide. ...
........................................................ Chapter 9
• Select a suitable hydraulic oil and lubricant.....
...................................................... Chapter 12 • Check that the shank adapter threads are not
damaged ......................................... Chapter 9
• Fill the lubricating system with oil ... Chapter 7
• Keep an eye on the hydraulic hoses. If they
• Adjust and set the lubricating systemChapter 8 vibrate too much, check the accumulators
........................................................ Chapter 5
2.2 AFTER THE FIRST SHIFT WHEN
• Check that the machine does not leak. If the
USING A NEW OR NEWLY OVER-
flushing medium leaks out of the overflow hole
HAULED ROCK DRILL
in the front head, replace the seals and O-rings
• Tighten all threaded unions ............ Chapter 4
........................................................ Chapter 9

• When replacing the shank adapter or removing

the front head, check the internal components,
including the piston, driver and the visible parts
of the rotation chuck bushing
........................................................ Chapter 9

2.4 AFTER EVERY 40TH PERCUS-

SION-HOUR
• Tighten all threaded unions............. Chapter 4

• Check the safety labels on the accumulators.

Replace them if they are damaged or illegible.
........................................................ Chapter 5

2.5 EVERY 400TH PERCUSSION-

HOUR:
• Dismantle the rock drill from the drill rig. Trans-
port the rock drill to an appropriate workshop for
servicing........................................ Chapter 11

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 serv-
icing.

7
Hose connections 3

3. HOSE CONNECTIONS
CAUTION!
3.1 CONNECTING THE HOSES
Never attempt maintenance or intervene in the
• Clean the rock drill’s hose connections before
rock drill, connections or hoses while the
undoing the protective caps.
hydraulic, lubrication or flushing systems are
• Never remove a protective cap until the hose is pressurised. Air or oil can spray out at high
ready to be connected. pressure and high temperature. There is a risk
of serious injury to the eyes and skin.
• Always store the rock drill with all hose connec-
tions plugged. Use suitable protective caps, and Pressure hoses with an internal diameter of 19
make sure that they are clean. 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!

2
6
1250 0197 29

1
5 3 4

1. Lubricating air 4. Rotation left

2. Flushing air/water 5. Percussion return
3. Rotation right 6. Inlet impact mechanism

8
 Tightening torques 4

4. TIGHTENING TORQUES
2
12

5
1 5

7
9

8 4 11
10
1250 0197 30

Ref. Torque
Qty. Check point Instructions
No. Nm
1 2 Side bolts 250 Tighten the rear nuts to full torque
2 4 Front piece 220 Tighten the bolts alternately to full torque
3 2 Accumulator 220 Tighten the bolts alternately to full torque
4 4 Hydraulic motor 70 Tighten the nuts alternately
5 4 Rock drill mounting 220 Tighten the bolts alternately to full torque
6 2 Valve end plates 70 Tighten the bolts alternately to full torque
7 1 Flushing connector 180
8 2 Nipples, hydraulic motor 120
9 1 Intake, percussion 180
10 1 Outlet, percussion 180
11 1 Intake, lubricating air 120
12 1 Drill holder 70

9
Accumulator 5

5. ACCUMULATOR • Remove the gas hose and screw in the protec-

tive cap (3) to the accumulator valve.
Check the safety labels on the accumulator.
Replace them if they are damaged or illegible.
WARNING
5.1 SAFETY LABEL INSTRUCTIONS.
A gas other than N 2 could cause an explosion.

5.3 CHECKING THE ACCUMULATORS

IN THE EVENT OF HOSE VIBRA-
TION
1250 0184 64

1 2

1. Read carefully before service or replacement

2. Must be charged with nitrogen only 2 1
5.2 CHARGING THE ACCUMULATOR
1250 0197 45

3
1. Accumulator
2. Valve nut
3. Protective cap

• Remove protective cap (3).

• Open valve nut (2). If oil runs out from the valve
then the accumulator/diaphragm must be
replaced.

1. Accumulator
• Charge the new accumulator after replacement.
2. Valve nut
3. Protective cap 5.4 REPLACING THE ACCUMULATOR
4. Gas Valve

4
CAUTION!
2
Charge the accumulator when it is fitted on the 1
rock drill. There is a risk of injury if these
3
instructions are not observed!

• Remove the protective cap (3).

1250 0197 50

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

the gas hose.

• Open the gas valve (4).

• Charge the accumulator with nitrogen gas (N 2), 1. Accumulator

40 bar below collaring pressure. 2. Sealing ring
NB! Charge at the bottom if possible rather than 3. Bolt
too high. 4. Rear section

• Tighten the valve nut (2) and close the gas valve
(4).

10
 Accumulator 5

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
• Remove the accumulator (1) with the sealing
ring (2) by undoing the bolts (3). Send the accu-
mulators to a workshop for overhauling!

ASSEMBLY
• Locate the sealing ring (2) in the groove on the
rear section (4).

• Make sure that the sealing ring (2) does not get
damaged during the assembly.

• Fit the accumulator with undamaged original

bolts, length 50 mm. Replace the screws in pairs
even if only one screw is corroded or damaged
in some other way.

• Tighten the bolts (3) alternately to tightening

torque 220 Nm.

• Charge the accumulator with nitrogen gas (N 2).

11
Changing the hydraulic motor 6

6. CHANGING THE
HYDRAULIC MOTOR
1250 0197 51

2 1 4 3

DISMANTLING
• Remove the hydraulic hoses from the hydraulic
motor.

• Undo the bolts (2) and remove the flange with

the hydraulic motor.

• Undo the bolts (3) and remove the hydraulic

motor (1) from the flange (4).

ASSEMBLY
• Fit the hydraulic motor (1) onto the flange (4)
with the bolts (3).

• Fit the flange with the hydraulic motor on the

rock drill with the bolts (2).

• Fit the hydraulic hoses to the hydraulic motor

(1).

12
 Filling with lubricating oil and bleeding the system 7

7. FILLING WITH LUBRI-

CATING OIL AND IMPORTANT!
BLEEDING THE SYSTEM If the lubricating system has been empty of oil,
it must be bled after filling

CAUTION! Bleed as follows:

Never work on the lubrication system when it is • Loosen the cap (6) and let the lubricating oil
pressurised. escape until all air has been discharged from the
lubricating oil pump. Now tighten the cap.
Lubricating oil could spray out.
• Start the lubricating system and loosen the hose
There is a risk of serious injury to the eyes and connection at pressure gauge (7), so that all air
skin. is released from the system. Now tighten the
hose connection.

• Undo the lubricating air hose (12) from the rock

IMPORTANT! drill’s union (9).
Use the recommended lubrication air pressure
• Start the lubrication pump and allow it to pump
and recommended lubrication oil. Some
until oil flows from the plastic hose (11). When
moving parts on the rock drill are lubricated
restarting (after being stationary) oil should flow
with oil mixed with compressed air. Is impor-
from the plastic hose immediately when the
tant that these parts receive good lubrication.
lubrication pump is started.

• Check that the plastic hose for lubricating oil (11)

is the correct length. It must not protrude into the
rock drill.

1 • Reconnect the lubricating air hose (12).

10 6

9
13b
6
13a 10 12
11
1250 0197 46

1. Lubricant container
6. Cap, bleeding
7. Pressure gauge
9. Lubricating air connection
11. Plastic hose
12. Lubricating air hose
13a. Pump 3217 8667 50 old
13b. Pump 3217 8667 52 new

Check the level in the lubricating oil tank (1) on

every shift. Exercise cleanliness and fill with the
right grade oil. The lubrication oil tank holds 5 l.

13
Settings 8

8. SETTINGS
8.1 SETTING OF ECL LUBRICATING
SYSTEM

3
4
5 2 1
10 6

9
A
13b 6
10 12
13a 11

8
1250 0202 97

1. Lubricant container
2. Filler cap
3. Pulse relay
4. Potentiometer
5. Relay window
6. Cap, bleeding
7. Pressure gauge
8. Restrictor
9. Lubrication air connector
10. LED
11. Plastic hose
12. Lubricating air hose
13a. Pump 3217 8667 50 old
13b. Pump 3217 8667 52 new
A. Pressure gauge

• Open the electric cabinet

• Start the lubricating system.

• Check the lubricating air pressure at the rock

drill (9) using a pressure gauge (A). The pres-
sure should be 2-3 bar. If the pressure is too low,
clean the restrictor (8) or increase the diameter
of the restrictor.

• Pay attention to the relay window (5) and set the

correct lubricating oil dosage with the potenti-
ometer (4).

Pump (13a) 35-40 pulses/minute

Pump (13b) 20-25 pulses/minute

• After setting, check the lubrication pump’s LED

(10) to see that the correct pulse frequency has
been obtained and that oil is emerging from the
front head’s hole (B) and between the shank
adapter and front guide.

14
 Checking the front head 9

9. CHECKING THE FRONT

HEAD

A 2
7

13,3

10 9
8 4
2

1
56,5
1250 0202 99

3 6 5

• Replace the drill holder (1) if it is worn by more • Replace the axial bearing (7) if the thickness is
than 2 mm. less than 13.3 mm.

• Check that air and lubricating oil escape in • When replacing the drill steel, check the wear on
between the shank adapter (10) and the rotation the rotation chuck bushing (2) with the testing
chuck bushing (2) and between the rotation tool (A). If the whole of the testing tool can be
chuck bushing (2) and the drill sleeve (9). inserted then the bushing is worn and must be
replaced.
• Replace the flushing pipe (5) if it is corroded, A= 3007 0125 00 for COP 1019
cracked or damaged in some other way. A= 3091 0038 00 for COP 1022
• If water is leaking out of the restrictor plug (4), A= 3006 7352 00 for COP 1025
check the flushing pipe (5) and shank gasket • Take the front head or the whole rock drill to a
(6). Replace the flushing pipe if the shank workshop when damage or wear is detected.
gasket is damaged.

• Replace the drill steel if the impact surface is

damaged. NB! Always check the impact surface
on the piston (8) when replacing the drill steel.

• Replace the drill sleeve bearing (3) if the inner

diameter is greater than 56.5 mm.

15
Front head 10

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.
1250 0197 52

5 4 1
3

DISMANTLING
• Remove the lubricating air hose.

• Dismantle the bolts (3)

• Tap with a plastic mallet to loosen the front head

(1).

• Pull out the drill sleeve (4).

ASSEMBLY
• Fit the drill sleeve (4) in the gear housing (5).

• Fit the front head (1). Use a plastic mallet to

move the front head into place.

• Lubricate the threads on the bolts with grease

(type NEVER-SEEZ).

• Fit the bolts (3) and tighten them, tightening

torque 220 Nm.

• Fit the lubricating air hose.

• Check after fitting that air and lubricating oil

come out from the front head.

16
 Slinging, weight and warning 11

11. SLINGING, WEIGHT AND 11.3 LONG-TERM STORAGE

WARNING
11.1 SLINGING

1250 0197 49
If the rock drill is not going to be used for a long
time, the following precautions should be taken.
1250 0197 48

• Check that all connections, including the one for

the flushing medium, are properly capped with
protective caps of the right size.
Make sure that the rock drill is safely slung for
lifting. Make sure that the rock drill is securely • Clean the rock drill carefully. Use degreasing
anchored for transportation. agent and rinse with water.

• Clean thoroughly and oil in the front head

CAUTION! components in contact with flushing medium
(especially in high humidity).
Lifting devices and straps must be approved
for lifting at least 250 kg. • Release gas from the accumulators.
Incorrect lifting devices could cause the rock • Store the rock drill in a dry place.
drill to start moving or fall down.

Incorrect operation could cause crushing

damage.

11.2 ROCK DRILL WEIGHTS

COP 1019 50 kg
COP 1022 50 kg
COP 1025 52 kg

17
Hydraulic fluid and lubricant recommendations 12

12. HYDRAULIC FLUID AND LUBRICANT RECOMMENDATIONS

12.1 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 (polyalpha olefine)
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 over the period the hydraulic fluid is used. In general the viscosity will decrease
with increased operation. 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.

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

18
 Hydraulic fluid and lubricant recommendations 12

12.2 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 10 litres 3115 3125 00
48 cans of 10 litres 3115 3126 00
1 barrel of 208 litres 3115 3127 00

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

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

Ambient temperature ºC Viscosity grade (ISO 3448)

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

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

ASTM D 2783 Min. 250 kg

ASTM D 4172 (40 kg) Max. 0.5 mm

12.3 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 (polyalpha olefine/synthetic ester) with
additives that protect against oxidation, corrosion and wear at high loads and with EP additive.

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

19