Atlas Copco

Maintenance instructions
Hydraulic Rock drills
COP 1840, 1840EX

Atlas Copco Rock Drills AB

rebro, Sweden
Atlas Copco Rock Drills AB, 2009, All rights reserved

No. 9852 1007 01k

Copyright 2009, 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 drawings.
Atlas Copco Rock Drills AB
SE-70191 rebro, Sweden

CONTENTS

CONTENTS
1.

GENERAL .......................................................................................................... 5
1.1
1.2

2.

SERVICE INTERVAL.......................................................................................... 7
2.1
2.2
2.3
2.4
2.5

3.

TIGHTENING THE SIDE BOLTS...................................................................................... 12

RETIGHTENING THE SIDE BOLTS................................................................................. 12

ACCUMULATORS............................................................................................ 13
5.1
5.2
5.3
5.4
5.5

5.6

6.

CONNECTING THE HOSES ............................................................................................ 10

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

4.1
4.2

5.

BEFORE STARTING A NEW OR NEWLY OVERHAULED ROCK DRILL ......................... 8

AFTER EACH SHIFT WHEN USING A NEW OR NEWLY OVERHAULED ROCK DRILL 8
FOR EACH SHIFT .............................................................................................................. 8
AFTER EVERY 40TH PERCUSSION-HOUR ..................................................................... 9
EVERY 400TH PERCUSSION-HOUR:............................................................................... 9

HOSE CONNECTIONS .................................................................................... 10

3.1

4.

ENVIRONMENT.................................................................................................................. 5
SAFETY REGULATIONS.................................................................................................... 5
WARNING BOXES.............................................................................................................. 5
THE FOLLOWING GENERAL SAFETY RULES MUST BE OBSERVED .......................... 6

SAFETY LABEL LOCATION............................................................................................. 13

SAFETY LABEL INSTRUCTIONS .................................................................................... 13
CHARGING THE ACCUMULATORS................................................................................ 13
CHECKING THE ACCUMULATORS IN THE EVENT OF HOSE VIBRATION................. 14
INTAKE AND DAMPER ACCUMULATORS ..................................................................... 14
REPLACING INTAKE AND DAMPER ACCUMULATOR.................................................. 14
DISMANTLING.................................................................................................................. 15
ASSEMBLY ....................................................................................................................... 15
REPLACING THE RETURN ACCUMULATOR................................................................. 15
DISMANTLING.................................................................................................................. 15
ASSEMBLY ....................................................................................................................... 15

CHANGING THE HYDRAULIC MOTOR.......................................................... 16

DISMANTLING.................................................................................................................. 16
ASSEMBLY ....................................................................................................................... 16

7.

FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM ............. 17

8.

SETTINGS ........................................................................................................ 18
8.1
8.2
8.3

9.

SETTING OF ECL LUBRICATING SYSTEM.................................................................... 18

SETTING DAMPER PRESSURE...................................................................................... 18
SETTING EXTRACTOR PRESSURE............................................................................... 19

REMOVING THE FRONT HEAD...................................................................... 20

9.1

EXTRACTOR FRONT HEAD............................................................................................ 20

10. CHECKING THE FRONT HEAD ...................................................................... 21

10.1 EXTRACTOR FRONT HEAD............................................................................................ 22

11. REPLACING THE FLUSHING HEAD AND DRIVER....................................... 23

DISMANTLING.................................................................................................................. 23
ASSEMBLY ....................................................................................................................... 23
11.1 EXTRACTOR FRONT HEAD............................................................................................ 24
DISMANTLING.................................................................................................................. 24
ASSEMBLY ....................................................................................................................... 24

CONTENTS

12. MOUNTING THE FRONT HEAD ..................................................................... 25

12.1 EXTRACTOR FRONT HEAD ........................................................................................... 25

13. SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING ............ 26

13.1
13.2
13.3
13.4

SLINGING ........................................................................................................................
ROCK DRILL WEIGHTS ..................................................................................................
LONG-TERM STORAGE .................................................................................................
STROKE LENGTH SETTING...........................................................................................
BASIC SETTING ..............................................................................................................

26
26
26
26
26

14. LUBRICATION ................................................................................................. 29

14.1 LUBRICATION OF GEAR ................................................................................................ 29

15. HYDRAULIC AND LUBRICANT RECOMMENDATIONS................................ 31

15.1 HYDRAULIC FLUID ......................................................................................................... 31
15.2 PNEUMATIC TOOL OIL ................................................................................................... 32
15.3 GREASE........................................................................................................................... 32

GENERAL 1

1. GENERAL

1.2 SAFETY REGULATIONS

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

This instruction is intended as a guide when

performing maintenance on your rock drill.

WARNING BOXES
The instructions include warnings.

1.1 ENVIRONMENT

Warnings are preceded by a heading (Danger,

Warning and Caution).

ENVIRONMENTAL REGULATIONS
Care for the environment!

WARNING BOXES

Leaking hydraulic couplings and grease are

hazardous to the environment.

Danger
Indicates an imminent risk of serious or fatal
injury if the warning is not heeded.

Changing oils, hydraulic hoses and various

types of filter can be hazardous to the environment.
Always collect oil residues, oil spillage, oily
waste and residues and spilt grease. Deal with
according to local provisions.

Warning
Indicates hazards or hazardous procedures
which could result in serious or fatal injury if the
warning is not heeded.

Use biodegradable hydraulic and lubricating

oils where possible.

Caution
Indicates hazards or hazardous procedures
which could result in personal injury or
damage to property if the warning is not
heeded.

GENERAL 1

THE FOLLOWING GENERAL SAFETY RULES

MUST BE OBSERVED

IMPORTANT!

IMPORTANT!

Make sure that the rock drill has been maintained in accordance with the applicable instructions.

Read through the maintenance instructions

carefully before starting maintenance work.
Follow the instructions given and local regulations.

Before moving the rig and rock drill or starting to

drill, make sure that there are no personnel in
the immediate vicinity of the drill rig.

Do not use or intervene in the rock drill unless

you have been trained to do so.

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.

Never attempt to carry out maintenance while

the rock drill is in operation.
Ensure that the hydraulic, water and air systems
are depressurised and that the electrical system
is de-energised prior to removing the rock drill
or starting work on the system.

Always wear a helmet and earmuffs when drilling. Follow local regulations

Use approved lifting devices when handling the

rock drill. Avoid lifting heavy weights yourself.

Make sure that the place of work is well ventilated.

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.

Make sure that the safety labels are fitted, clean

and fully legible.
Particular attention must be paid to all warnings
in the instructions.

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.

SERVICE INTERVAL 2

2. SERVICE INTERVAL
IMPORTANT!

Read all safety regulations before starting to work

on the machine.

Observe great cleanliness when intervening in

the rock drill or its hydraulic circuit.

Order numbers for the repair kits are in the

rock drills spare parts catalogue.

The following parts may be changed at the

work site in accordance with the instructions
given:

WARNING!

shank adapter
driver
front head parts
accumulators
hydraulic motor
screws
connections

Before starting any maintenance work, make

sure that the electrical system is dead.
There is a risk of injury if these instructions are
not observed!

CAUTION!

Other repairs must be carried out in a suitable

workshop in accordance with the repair
instructions for the rock drill.

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.

IMPORTANT!

Negligence could cause serious injury.

Ensure bolted joints are tightened to the

correct tightening torques after every 40
percussion hours and when reconditioning the
rock drill.

Always use hearing protection when drilling.

High noise levels damage the hearing.
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 temperature. There is a risk
of serious injury to the eyes and skin.

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.

SERVICE INTERVAL 2

IMPORTANT!
Any defect must be rectified in the designated workshop

2.1 BEFORE STARTING A NEW OR

NEWLY OVERHAULED ROCK
DRILL
Action

Chapter

Connect up the hoses

Charge the accumulators
Select a suitable hydraulic oil and lubricant
Fill the lubricating system with oil
Adjust and set the lubricating system
Set the damper pressure
Set the extractor unit pressure

3
5
15
7
8
8
8

2.2 AFTER EACH SHIFT WHEN USING

A NEW OR NEWLY OVERHAULED
ROCK DRILL
Action

Chapter

Tighten all threaded unions

2.3 FOR EACH SHIFT

Action

Chapter

Check that air and lubricating oil escape from the hole in the front head
Check that the drill rigs damper pressure gauge is showing normal values. Check
that the drill rigs damper pressure gauge is showing normal values. In the event of
deviation, adjust the damper pressure.
Check that the shank adapter threads are not damaged
Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulators
Check that the machine does not leak. If the flushing medium leaks from the flushing
head, replace the seals and O-rings
When replacing the shank adapter or removing the front head, check the internal
components including piston, driver and the visible parts of the rotation chuck bushing
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
8

10
5
10
10

10

SERVICE INTERVAL 2

2.4 AFTER EVERY 40TH PERCUSSION-HOUR

Action

Chapter

Grease the gear

Tighten all threaded unions
Check the safety labels on the accumulators. Replace them if they are damaged or
illegible
Check the accumulators

14
4
5
5

2.5 EVERY 400TH PERCUSSIONHOUR:

Action

Chapter

Dismantle the rock drill from the drill rig. Transport the rock drill to an appropriate
workshop for servicing

13

IMPORTANT!
Always function test the rock drill after service.

HOSE CONNECTIONS 3

3. HOSE CONNECTIONS
CAUTION!

3.1 CONNECTING THE HOSES

Never attempt maintenance or any work 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 temperature. There is a risk
of serious injury to the eyes and skin.

Clean the rock drills 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.

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). 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!

1250 0210 53

5
2

6
1.
2.
3.
4.
5.

Drainage
Rotation left
Rotation right
Percussion return
Inlet impact mechanism

6. Flushing air/water
7. Lubricating air
8. Damper, intake
9. Extractor unit, return
10.Extractor unit, intake

10

10

TIGHTENING TORQUES 4

4. TIGHTENING TORQUES

5 1

3A
14

3A 2

9
13
12
11
8 9 10

3B
15
16

1250 0210 54

13

Lubricate the nuts threads and the washers

contact surfaces with Never-Seez Regular Grade.
Ref.
No.

Qty.

Check point

Torque
Nm

1
2
3A
3B
4

2
1
2
3
3

Side bolts
Front bolt
Side bolt
Side bolts EX
Back head

300
300
350
300
220

5
6

1
4

Regulating plug
Accumulator

80
220

7
8

4
2

65
30

Hydraulic motor
Clamping attachment, return
accumulator
Rock drill mounting

250

10
11

1
4

Plug
Valve end plates

45
145

12

Connecting plate

120

13
14

1
4

Flushing connector
Intake, flushing medium

300
90

15
16

1
1

Intake, extractor unit

Return, extractor unit

120
120

11

Instructions

Tighten the rear nuts

Tighten the front bolt
Tighten the front nuts
Tighten the front nuts
Tighten the screws alternately to full
torque, top bolt last
Tighten the screws alternately to full
torque
Tighten the nuts alternately

Tighten the screws alternately to full

torque
Tighten the screws alternately to full
torque
Tighten the screws alternately to full
torque
Tighten the screws alternately to full
torque

TIGHTENING TORQUES 4

4.1 TIGHTENING THE SIDE BOLTS

4.2 RETIGHTENING THE SIDE BOLTS

Not extractor unit version

Undo the front nuts (3A) so that the tension releases.

1250 0219 79

If the threads are seized, remove the nuts and

clean and lubricate them with Never-Seez
Regular Grade.

3B

Tighten the front nuts (3A) manually.

Both versions

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

Tighten the side bolt (2) to the tightening torque.

Tighten the front bolts (3A or 3B) to the tightening torque.

3A

Check whether the side bolts, nuts or washers

have cracks, scratches or rust. Replace
damaged side bolts, nuts and washers.
Lubricate the threads and contact surfaces of
the side bolt (2), nuts and washers with NeverSeez Regular Grade.
Tighten the rear nuts (1) to the tightening torque.
Tighten the side bolt (2) to the tightening torque.
Tighten the front bolts (3A or 3B) to the tightening torque.

12

ACCUMULATORS 5

5. ACCUMULATORS

5.3 CHARGING THE ACCUMULATORS

Check the safety labels on the accumulators.

Replace them if they are damaged or illegible.

1250 0210 55

5.1 SAFETY LABEL LOCATION

221

CAUTION!

231

211

Charge the accumulators when assembled on

the rock drill. There is a risk of injury if these
instructions are not observed!

221.Damper accumulator
211.Intake accumulator
231.Return accumulator

WARNING!
A gas other than N 2 could cause an explosion.

5.2 SAFETY LABEL INSTRUCTIONS

Remove the protective cap (A).

1250 0210 56

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

the gas hose.
Open the gas valve (C).

Charge the accumulators with nitrogen gas (N 2)

to the correct pressure in accordance with the
following:
NB! Charge at the bottom if possible rather than
too high.

1. Read the operators instructions carefully before

service or replacement of the accumulator.
2. Must be charged with nitrogen only

Damper
accumulator (221)

20-25 bar

Intake
accumulator (211)

30-40 bar
(80-100 bar)*

Return
accumulator (231)

Must not be
charged with N2

*Intake accumulator 30-40 bar under collaring pressure.

Normal 80-100 bar. Max. 100 bar.

Tighten the valve nut (B) and close the gas valve
(C).
Remove the gas hose and screw in the protective cap (A) to the accumulator valve.

13

ACCUMULATORS 5

5.4 CHECKING THE ACCUMULATORS

IN THE EVENT OF HOSE VIBRATION

RETURN ACCUMULATOR

INTAKE AND DAMPER ACCUMULATORS

1250 0210 58

1250 0210 59

A
B

231 C

Position the rock drill in horizontal position.

211 221

Remove the stopper with O-ring (C). If oil

escapes then the diaphragm is damaged.

Push in the control valves pin (A). If the accumulator is charged, the pin protrudes 4.5 mm
and is hard to push in.
If the pin is easy to press in then the gas pressure has disappeared (broken diaphragm or
defective filler valve). NB! The damper accumulators pin is slightly easier to press in.
Replace the accumulator, diaphragm and/or
filler valve if they are damaged.

Replace the accumulator and/or diaphragm if

they are damaged.
If the diaphragm is in contact against the outer
tube, press diaphragm with a cylindrical (blunt)
mandrel (7-9 mm). See Figure A. The correct
position for the diaphragm is, see Figure B.
Refit the stopper and O-ring (C).
Charge by means of admitting air at atmospheric pressure into the accumulator.

Charge the new accumulator after replacement.

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

5.5 REPLACING INTAKE AND

DAMPER ACCUMULATOR

221
82

BA

1250 0210 60

53

211
C

82
BA

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

14

ACCUMULATORS 5

5.6 REPLACING THE RETURN ACCUMULATOR

CAUTION!
Defective bolts may lead to dangerous oil
leakage or the accumulator working loose. Oil
spray can injure the eyes and skin.

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

Parts that come loose can cause serious injury.

DISMANTLING
Remove the accumulators (221, and 211) with
the sealing rings (82) by undoing the bolts (C
and D). Send the accumulators to a workshop
for reconditioning!

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!

ASSEMBLY
Locate the sealing rings (82) in the grooves on
the intermediate section (53).

1250 0210 61

Make sure that the sealing rings (82) do not get

damaged during the assembly.
Fit the damper accumulator (221) on the rock
drills left-hand side and the intake accumulator
(211) on the rock drills right-hand side (hose
side). Fit with undamaged original bolts (D)
length of 70 mm and (C) length 100 mm.
Replace the bolts in pairs even if only one bolt is
corroded or damaged in some other way.

23
A

21

11
B

24

25
231

Tighten the bolts (C and D) alternately to tightening torque 220 Nm.

DISMANTLING
Remove the hydraulic hose (A) from the return
accumulator (231).

Charge the accumulators with nitrogen gas (N

2).

Remove the return accumulator (231) by removing the nuts (24) and the bolts (23).
Pull away the clamp (21) and unscrew the accumulator from the nipple (B).
Send the return accumulator to a workshop for
overhauling.
ASSEMBLY
Screw in the return accumulator (231) onto the
nipple (B) in such a way that the stopper (11) is
accessible for checking the accumulators
diaphragm.
Fit the clamp (21) onto the return accumulator.
Fit the rock drills with the bolts (23) and the nuts
(24).
Connect the hydraulic hose (A) to the return
accumulator (231).

15

CHANGING THE HYDRAULIC MOTOR 6

6. CHANGING THE

ASSEMBLY
Make sure that the groove ring (130) is fitted in
the coupling (249).

HYDRAULIC MOTOR

Lubricate the couplings splines with grease and

fit the coupling (249) on the hydraulic motor
(241).

1250 0210 62

241

248

Replace the gasket (248) if it is damaged.

Fit the gasket (248) and the hydraulic motor
(241) on the cylinder (3). Tighten the nuts (246)
to tightening torque 65 Nm.

246

Connect the hydraulic hoses (A). Check that the

correct direction of rotation is obtained.

249 130

DISMANTLING
Detach the hydraulic hoses (A).
Undo the nuts (246) and remove the hydraulic
motor (241).
Pull out the coupling (249).

16

FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM 7

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.

17

SETTINGS 8

8. SETTINGS

8.2 SETTING DAMPER PRESSURE

8.1 SETTING OF ECL LUBRICATING

SYSTEM

ECL=Electric Controlled Lubrication

Rock drill lubrication must be set with regard to the
local conditions.
Start the lubricating system.
1250 0210 72

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.

NB! The setting should take place at normal

operating temperature for the hydraulic oil.

Set the correct lubricating oil dose.

Pump (3217 8667 50)

35-40 pulses/minute

Pump (3217 8667 52)

20-25 pulses/minute

Fully close the constant flow valve (B) on the drill

rig.
Connect a pressure gauge (A), calibrated for 060 bar, between the hose and the damper union
(1).

After setting, check that the correct pulse

frequency has been obtained and that oil is
emerging from the front heads hole and
between the shank adapter and front guide.

Pressurise the damper circuit.

Check that the shank adapter is unloaded and in
the forward position.
Adjust the constant flow valve until the pressure
gauge (A) shows 30-35 bar at the rock drill
(operator panel shows 10-15 bar higher value).
Read off the drill rigs damper pressure gauge. If
this pressure gauge later shows another value,
make a new pressure setting.
Disconnect the pressure gauge (A) and connect
the hose to the union (1).

18

SETTINGS 8

8.3 SETTING EXTRACTOR PRESSURE

1250 0210 73

P
B

Fully close the constant flow valve (B) on the drill

rig.
Connect a pressure gauge (A), calibrated for 060 bar, between the hose and the extractor
units intake union (P).
Connect the extractor unit circuit by activating
the return feed and running the cradle against
the stop. Let the lever remain in this position.
Adjust the constant flow valve (B) until the pressure gauge (A) shows 20-25 bar.
Disconnect the pressure gauge (A) and connect
the hose to the union (P).

19

REMOVING THE FRONT HEAD 9

9. REMOVING THE FRONT

HEAD
172

CAUTION!
Never attempt to carry out maintenance while
the drill rig is in operation.

1250 0210 76

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!

300
252 251

NB! Always clean the outside of the rock drill

before disassembly.
Remove the front side-bolt nuts (251) with their
washers (252).
Remove the front head (172) by pulling the
shank adapter (300).
Then pull the shank adapter from the front head.

1250 0210 75

180

Always check the internal components, also

when replacing the shank adapter.

179
178

9.1 EXTRACTOR FRONT HEAD

173 177

Remove the flushing hose (A).

162

Remove the connecting plate (177) and nipple

(173) by removing the bolts (178) and washers
(179).
1250 0210 77

Remove the cup seal (180).

300
252 251

Remove the front side-bolt nuts (251) with their

washers (252).
Remove the front head (162) by pulling the
shank adapter (300) or by tapping with a copper
hammer.
Then pull the shank adapter from the front head.
Always check the internal components, also
when replacing the shank adapter.

20

CHECKING THE FRONT HEAD 10

10. CHECKING THE FRONT

HEAD
192
300 172 190 174 191 176

A 131 132

1250 0210 74

F
173

175
131

185

185

1m
m

2 mm

173

21

m 132
1m

86

175 190 174

192
191

176
175

300

53 mm

D
Check that air and lubricating oil escape
between the shank adapter (300) and front
guide (173), and also out of the hole (B)

If the rotation chuck bushing (132) is worn more

than 1 mm or the piston (21) impact surface is
damaged in any way then the rock drill must be
sent to a workshop for inspection. NB! Fit the
rotation chuck bushing so that the lubricating
grooves (D) are aligned towards the damper
piston (86).

Blow clean the lubricating air ducts (A) in the

front head (172) with compressed air and check
that the restrictions (E) are open.
Replace the guide (173) if the inside diameter
exceeds 53 mm.

Replace the shank adapter (300) if the thread is

worn out or the impact surface is warped or
chipped, or if the front or rear end surfaces of the
splines are worn.

Check the O-rings (190-192) and flushing seals

(175,176) if air is escaping from the hole (C) in
the front head. Replace the O-rings and flushing
seals if they are worn or damaged.
Replace the flushing head (174) if it is seriously
corroded, or if it contains cracks.
Replace the stop ring (185) if it is worn by more
than 1 mm.
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 must be changed.
Fit a new driver with the aid of a suitable
mandrel and a copper hammer.

21

CHECKING THE FRONT HEAD 10

131

162
170
172 168
171 193
185
194
185
195
185
196
185
182

167
169

300

10.1 EXTRACTOR FRONT HEAD

21

F
1250 0210 88

163
181
131
2 mm

132
194
193 185

m 132
1m

182

196
185 195

D
169 167

163
53 mm

300

181

170 168 171,172

1 mm

grooves (D) are aligned towards the damper

piston (86).

Check that air and lubricating oil escape

between the shank adapter (300) and front
guide (163), and also out of the hole (B)

Replace the shank adapter (300) if the thread is

worn out or the impact surface is warped or
chipped, or if the front or rear end surfaces of the
splines are worn.

Blow clean the lubricating air ducts (A) in the

front head (162) with compressed air and check
that the restrictions (E) are open.
Replace the guide (163) if the inside diameter
exceeds 53 mm.

Check that the drill sleeve (F), to be used with

upwards directed drilling, is not damaged and
rotates with the shank adapter.

Check the O-rings (193-195) and flushing seals

(185) if air is escaping from the hole (C) in the
front head. Replace the O-rings and flushing
seals if they are worn or damaged.

Replace the extractor units piston (181) if the

surface against the shank adapter has worn
more than 1 mm. When replacing the extractor
units piston check the seals (167,168) and Orings (169-172). Replace the seals and O-rings
if they are worn or damaged.

Replace the flushing head (182) if it is seriously

corroded, or if it contains cracks.
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 must be changed.
Fit a new driver with the aid of a suitable
mandrel and a copper hammer.

If the rotation chuck bushing (132) is worn more

than 1 mm or the piston (21) impact surface is
damaged in any way then the rock drill must be
sent to a workshop for inspection. NB! Fit the
rotation chuck bushing so that the lubricating

22

REPLACING THE FLUSHING HEAD AND DRIVER 11

11. REPLACING THE

ASSEMBLY

FLUSHING HEAD AND

DRIVER

D
V

CAUTION!
Exercise care when dismantling flushing head
and the driver. Watch your fingers!

174

Press the flushing head (174) into the front head

using a mandrel and sleeve.
NB! The flushing head must be reversed so that
the lubricating grooves are turned upwards.

V
173
174
1250 0210 89

1250 0210 50

DISMANTLING

Make sure that the flushing hole in the flushing

head (174) aligns with the hole in the front head.

185

Use a mandrel and suitable sleeve to push out

the guide (185), the flushing head (174) and the
stop ring (173) from the front head.

131

1250 0210 49

1250 0210 51

131
B

117

Use a mandrel and plastic hammer to fit the

driver (131) in the drill sleeve (117).

The driver (131) is pulled out manually or with an

extractor (C) and an expander 37-46 mm, alternatively with dismantling tool (A)(3115 2724 80).

23

REPLACING THE FLUSHING HEAD AND DRIVER 11

11.1 EXTRACTOR FRONT HEAD

Tap in the rotation chuck bushing (132) with a

suitable copper mandrel.

131
A 182

198
197
184
183
263

183
103
263

AB
Fit the O-rings (193-196) and the seals (185) in
the flushing head (182).
Important! The seals (185) must be turned in
accordance with the illustration.

Remove the flushing hose (C) from the nipple

(263).
Remove the nipple (183) and its O-rings and
support ring.

Fit the flushing head (182) in the cover plate

(153) and tap it in with a copper hammer. Check
carefully that the flushing intake in the cover is
aligned with the hole in the flushing head.

Press the removal tool (A) (3115 2724 80) into

the gear housing (103) until the tool moves to
the stop, i.e. the tools splines-equipped section
has then passed the drivers (131) splines.

Fit the O-rings (197,198) and the support ring

(184) on the nipple (183).

Turn the removal tool clockwise slightly.

Fit the nipples (183,263 and B) and the nut (A).

Tap out the driver (131) and flushing head (182)

using the sliding hammer (B).

Torque tighten the nipple (183) to 300 Nm and

the nipple (263) to 180 Nm.

Normally the rotation chuck bushing (132)

follows as well when removing the driver. If this
is not the case, then remove the rotation chuck
bushing using a puller and an expander.

1250 0210 8

ASSEMBLY

103

185
195
196

132
1250 0210 83

1250 0210 81

153

DISMANTLING

182

Exercise care when dismantling flushing head

and the driver. Watch your fingers!

193
194
185

Tap the driver (131) into the drill sleeve in the

gear housing (103) using a mandrel (A) and a
copper hammer.

CAUTION!

131 A

132

Fit the rotation chuck bushing (132) so that the

lubricating grooves are aligned towards the
damper piston.

24

MOUNTING THE FRONT HEAD 12

12. MOUNTING THE FRONT

After assembly
Check that air and lubricating oil escapes out of
the hole in the front head and between the shank
adapter and front guide.

HEAD

12.1 EXTRACTOR FRONT HEAD

172

1250 0210 78

1250 0210 8

162

300 162

263 188

300
161

186

252 251

Fit the shank adapter (300) in the extractor units

front head (162).

252 251

Fit the stop ring and shank adapter (300) in the

front head (172).

Fit the cylindrical pin (188).

Fit the front head (162) on the side bolts (186).

Make sure that the pin (162) is fitted in the cover

plate. Position the front head (172) on the side
bolts (161).

Apply grease, type Never Seez, onto the

threads of the side bolts (186).

Apply grease, type Never Seez, onto the

threads of the side bolts (161).

Fit the washers (252) and nuts (251).

Fit the washers (252) and nuts (251).

Check the tightening torques on the rear sidebolt nuts and the front side bolt.

Check the tightening torques on the rear sidebolt nuts and the front side bolt.

Following which, tighten the nuts (251) alternately to a torque of 300 Nm.

Following which, tighten the nuts (251) alternately to a torque of 350 Nm.

Connect the flushing hose to the nipple (263).

After assembly
Check that air and lubricating oil escapes out of
the hole in the front head and between the shank
adapter and front guide.

1250 0210 79

180

173 177

179
178

Fit the cup seal (180) into the flushing head.

Fit the connecting plate (177) to the front head
using the washers (179) and bolts (178). Tighten
the bolts to a torque of 90 Nm.
Fit the nipple (173) on the connecting plate.
Tighten the nipple to tightening torque 300 Nm.
Fit the flushing hose (A) and tighten the nut.

25

SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING 13

13. SLINGING, WEIGHT,

13.2 ROCK DRILL WEIGHTS

STORAGE AND STROKE

LENGTH SETTING
13.1 SLINGING

COP 1840

184 kg

COP 1840EX

247 kg

1250 0184 84

1250 0184 87

13.3 LONG-TERM STORAGE

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

long time, the following precautions should be
taken.

Make sure that the rock drill is safely slung for

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

Check that all connections, including the one for

the flushing medium, are properly capped with
protective caps of the right size.

caution!

Clean the rock drill carefully. Use degreasing

agent and rinse with water.

Lifting devices and straps must be approved

for lifting 500 kg.
Incorrect lifting devices could cause the rock
drill to start moving or fall down.

Clean thoroughly and oil in the front head

components in contact with flushing medium
(especially in high air humidity).

Incorrect operation could cause crushing

damage.

Release gas from the accumulators.

Store the rock drill in a dry place.

13.4 STROKE LENGTH SETTING

63

1250 0210 52

66

BASIC SETTING
On cylinder (66) there is a plug (63). Turning the
plug changes the stroke length of the piston.
There are two different positions. They are
shown on the plug (63) by punched dots. For

26

SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING 13

example, when two dots are shown upward the

setting is 2

27

SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING 13

28

LUBRICATION 14

14. LUBRICATION
1

1250 0210 87

14.1 LUBRICATION OF GEAR

Unscrew the bleed plug (1).
Lubricate with heat-resistant grease through the
nipple (2) until new grease escapes through the
hole (3).
Tighten the plug (1).

29

LUBRICATION 14

30

HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15

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 antifoaming 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
temp. C
Viscosity 25-50 cSt

Min start temp. C

(Viscosity min. 1000 cSt)

Max temp. C

Viscosity grade VG
(ISO 3448)

Viscosity index VI

+50 to +70
+45 to +60
+35 to +50
+25 to +40
+10 to +25

+5
-5
-10
-15
-25

80
75
65
55
35

ISO VG 100
ISO VG 68
ISO VG 46
ISO VG 32
ISO VG 15

Min. 100
Min. 100
Min. 100
Min. 100
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 C.
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.

31

HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15

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 C and +50 C.
COP OIL can be ordered with the following part numbers:
Quantity

Part number

1 can of 10 litres
48 cans of 10 litres
1 barrel of 208 litres

3115 3125 00
3115 3126 00
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 C

Viscosity grade (ISO 3448)

-25 to 0
-10 to +20
+10 to +50

VG 15-32
VG 32-46
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

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 additives that protect against oxidation, corrosion and wear at high loads and with EP additive.
NLGI number

Drop point

Base oil viscosity

1.5

250 C

400-600 mm2/s
at 40 C

32

Operating
Temperature

-40 to +150 C

HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15

33