Atlas Copco Rock Drill

COP 1238K
Overhauling instructions

PM no. 9853 1206 01

2012-10
 SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.

Special attention must be paid

to information alongside
this symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

©Copyright 2012, Atlas Copco Rock Drills AB, Sweden

All product names in this publication are trademarks of Atlas Copco. Any unauthorised use or copying of the
contents or any part thereof is prohibited. Illustrations and photos may show equipment with optional extras.
No warranty is made regarding specifications or otherwise. Specifications and equipment are subject to
change without notice. Consult your Atlas Copco Customer Centre for specific information.

Translation of original instructions

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
 Contents

Contents
1. General............................................................................................................... 5
1.1 Layout.................................................................................................................................. 5
1.2 Requirements for the workshop .......................................................................................... 5
1.3 In the event of leakage problems ........................................................................................ 5
1.4 During dismantling............................................................................................................... 5
1.5 During assembly.................................................................................................................. 5
1.6 Environment ........................................................................................................................ 5
1.7 Safety regulations................................................................................................................ 5
Warning boxes .................................................................................................................... 5
The following general safety regulations must be observed ............................................... 6

2. Tool list............................................................................................................... 7
3. Rock drill main parts....................................................................................... 11
4. Dismantling the rock drill’s main parts ......................................................... 13
4.1 Fitting the rock drill on the pivot plate................................................................................ 13
4.2 Removing the front head ................................................................................................... 13
4.3 Dismantling the accumulators ........................................................................................... 13
4.4 Removing the back head and plunger............................................................................... 14
4.5 Removing the side bolts, cover plate and gear housing.................................................... 14
4.6 Removing the intermediate segment................................................................................. 15
4.7 Dismantling the hydraulic motor ........................................................................................ 15

5. Dismantling, inspecting and assembling the front head ............................ 17

5.1 Removing the shank adapter and guide............................................................................ 17
5.2 Inspecting and replacing parts .......................................................................................... 17
5.3 Fitting the guide, flushing head, stop ring and adapter ..................................................... 17

6. Accumulators .................................................................................................. 19
6.1 Dismantling the accumulator ............................................................................................. 19
6.2 Inspecting and replacing parts .......................................................................................... 19
6.3 Fitting the diaphragm, cover, housing and labels.............................................................. 19
6.4 Dismantling and assembling the return accumulator ........................................................ 20

7. Back head ........................................................................................................ 21

7.1 Inspection and replacement of piston seals and seal housing .......................................... 21
7.2 Fitting the seal housing and piston seal ............................................................................ 21

8. Cover and gear housing ................................................................................. 23

8.1 Removing the side bolts, cover plate, starter bushing, rotation shaft, gears, guide sleeve 23
8.2 Inspecting and replacing parts .......................................................................................... 24
8.3 Fitting the parts in the gear housing .................................................................................. 26
8.4 Shimming the bearings in the gear housing ...................................................................... 28

9. Intermediate segment ..................................................................................... 31

9.1 Dismantling the damper piston.......................................................................................... 31
9.2 Inspecting and replacing parts .......................................................................................... 31
9.3 Fitting the seal housing, seals and damper piston ............................................................ 32

10. Cylinder, piston guide and plunger ............................................................... 35

10.1 Removing the piston guide, valve piston and regulating plug ........................................... 35
10.2 Inspecting and replacing parts .......................................................................................... 35
10.3 Fitting the valve piston, valve covers and piston guide ..................................................... 36

3
Contents

11. Function and condition test of the hydraulic motor.................................... 37

12. Fitting the rock drill’s main parts .................................................................. 39
12.1 General ............................................................................................................................. 39
12.2 Fitting the cylinder on the pivot plate ................................................................................ 39
12.3 Assembling the hydraulic motor and intermediate segment on the cylinder..................... 39
12.4 Fitting the gear housing, side bolts and cover .................................................................. 40
12.5 Fitting the plunger and back head .................................................................................... 40
12.6 Mounting the front head.................................................................................................... 41
12.7 Assembling the accumulators........................................................................................... 41
12.8 Accumulator safety labels................................................................................................. 42
12.9 Assembling the return accumulator .................................................................................. 42
12.10 Charging the accumulator................................................................................................ 42

13. Function test of rotation and percussion ..................................................... 45

14. Tightening torques ......................................................................................... 47
14.1 Tightening the side bolts................................................................................................... 48
14.2 Retightening the side bolts ............................................................................................... 48

15. Lubrication ...................................................................................................... 49

15.1 Lubrication of gear ............................................................................................................ 49

16. Hydraulic and lubricant recommendations.................................................. 51

16.1 Hydraulic fluid ................................................................................................................... 51
16.2 Pneumatic tool oil ............................................................................................................. 52
16.3 Grease .............................................................................................................................. 52

4
 General 1

1. General
These instructions are intended as a guide for the 1.6 Environment
repair of your hydraulic rock drill.

1.1 Layout Environmental regulations

The instructions are preceded by safety regula- Think of the environment!
tions, followed by a tool list for the standard and Leaking hydraulic couplings and grease are
special tools required. Following which, there is a hazardous to the environment.
description of how the rock drill’s main parts are
removed. Under each main heading there are Changing oils, hydraulic hoses and various
then detailed instructions on the removal, types of filter can be hazardous to the environ-
checking and inspection of parts, as well as fitting. ment.
The instructions are concluded with sections on Always collect oil residue, oil spill, oily waste
how the main parts are fitted, as well as which and grease residue and spill. Treat according
tests and checks that should be carried out follo- to applicable local regulations.
wing repair. Use biodegradable hydraulic fluid and lubrica-
The letters within brackets in the text refer to the tion oil wherever possible.
tool list of special tools, and figures within brackets
refer the illustrations that belong to the text.
1.7 Safety regulations
The Safety chapter contains important information
1.2 Requirements for the workshop for the prevention of accidents.
- The workshop must be separate from grinding,
welding or other work that generates particles.
- The workshop must be well-cleaned, free from Warning boxes
dust and dirt.
The manual contains warnings.
- The workshop should be equipped with
Warnings are preceded by a heading (Danger,
• suitable standard and special tools Warning and Caution).
• washing installations for cleaning and
degreasing
• air for flushing clean Warning boxes
• hydraulic press
• lifting device for min. 500 kg Danger
Indicates an imminent risk of serious or fatal
1.3 In the event of leakage problems injury if the warning is not heeded.
Check the source of the leak before removing the
rock drill from the rig. Warning
Indicates hazards or hazardous procedures
which could result in serious or fatal injury if
1.4 During dismantling the warning is not heeded.
Always wash the rock drill externally using grease
solvent before starting removal.
Caution
An assembly fixture must be used when dismant-
ling the rock drill. Indicates hazards or hazardous procedures
which could result in personal injury or
damage to property if the warning is not
1.5 During assembly heeded.
During all fitting assembly grease must be applied
to the internal parts unless otherwise stated.

5
General 1

The following general safety regulations must

be observed

• Make sure that the rock drill has been main-

Important! tained in accordance with the applicable
instructions.
• Read through the overhauling instructions
carefully before starting the repair. Follow the • Before tramming the rig and rock drill or star-
instructions given and local regulations. ting to drill, make sure that there are no
personnel in the immediate vicinity of the drill
• Ensure that the hydraulic, water and air
rig.
systems are depressurised and that the elec-
trical system is de-energised prior to remo- • Never attempt to carry out maintenance while
ving the rock drill or starting work on the the rock drill is in operation.
system. • Checks and adjustments that are necessary
• The rock drill must only be repaired by when the rock drill is in operation must be
personnel trained by Atlas Copco. carried out by at least two persons. One
person must then be present at the operating
• Make sure that the safety labels are fitted,
station and have a good view of the work.
clean and fully legible.
• Make sure that the place of work is well venti-
• Use approved lifting devices when handling
lated.
the rock drill. Avoid lifting heavy weights your-
self. • Particular attention must be paid to all
warnings in the manual.
• Components that could move or fall down
must be secured in order to prevent personal
injury during the repair. Always use an
Important!
assembly fixture (A), see the tool list.
A mining machine has many components and
• Check that hoses are of the correct quality, the
functions that are controlled by a hydraulic
correct size, with correctly pressed connec-
system, directly or indirectly. Before working on
tions and that the hose connections are unda-
or inspecting any part of the machine, it is
maged and firmly tightened. Hoses that
important to know how the machine moves and
loosen could cause serious injury.
how its functions are controlled by the hydraulic
• Always plug the hydraulic hoses immediately system.
after they have been detached. Use clean
protective plugs. Prior to starting work or inspecting any part it
must be physically locked/stopped from being
• Use only Atlas Copco original parts. Any
able to move and causing bodily injury. The
damage or malfunction caused by the use of
mechanic must be careful not to place any body
non-original Atlas Copco parts is not covered
part where a movement of the machine could
by warranty or product liability.
cause injury if the hydraulic system fails or is
• Do not use or intervene in the rock drill unless disconnected.
you have been trained to do so.
There may be occasions where components
• Make sure that the rock drill has been main-
and or vehicles start moving when trapped
tained in accordance with the applicable
energy is released. Where applicable, there
instructions.
must be confirmation that all measures to safe-
• Before tramming the rig and rock drill or star- guard against involuntary movement have been
ting to drill, make sure that there are no taken by releasing the energy and/or physically
personnel in the immediate vicinity of the drill locking/stopping the machine.
rig.
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.

6
 Tool list 2

2. Tool list

A1 A7 A13

A2 A8 A14

A3 A15
A9

A4 A10 A16

A5 A11
1250 0188 95

A6 A12

Letter Tools Part no.

A1 Plastic mallet
A2 Copper hammer
A3 Honing tool 19-70 mm
A4 U-ring spanners 10-32 mm, 46 mm
A5 Hexagon wrench 4-10 mm, 3/16"
A6 Crowbar
A7 Mandrel 2-10 mm, copper mandrel 20x250 mm
A8 Feeler gauge 0.03-0.10 mm, with 0.01 mm intervals
Feeler gauge 0.05-1.00 mm, with 0.05 mm intervals
A9 Internal lock ring pliers
A10 Torque wrench 10-350 Nm 9106 1015 40
Torque wrench 75-400 Nm 9106 1015 41
A11 Socket wrench set with sockets 10-32 mm for external hexagon
Socket wrench set with sockets 4-10 mm for internal hexagon
Socket wrench set with socket 3/16" for internal hexagon
A12 Punch
A13 T-handle with 3/4" connection bracket, Power socket 32 mm
A14 Vernier calliper
A15 Micrometer 0-25 mm
A16 Bearing puller 3115 5419 02

7
Tool list 2

A G M

B H N

C I O

P
D J

E R
K

F
1250 0188 96

Letter Tools Part no.

A Assembly fixture 3115 1897 00
B Press tool consisting of: 3115 1902 80
-Guide plate 3115 1902 00
-Nut 3115 2734 00
-Bolt 3115 0317 00
C Extension 3115 0318 00
D Mandrel 3115 1019 00
E Press tool 3115 1113 00
F Press tool 3115 1903 00
G Mandrel 3115 0312 00
H Mandrel 3115 0313 00
I Mandrel 3115 0314 00
J Fitting and removal tool 3115 1877 00
K Key set (24 mm) 3115 0343 00
Key set (32 mm) 3115 0344 00
L Fitting and removal tool 3115 2859 80
Assembly tool 3115 2859 00
Pin (x 2) 3115 2860 00
Ring 3115 2861 00
Nut (x 2) 0266 2114 00
M Assembly tool (M12) 0462 7010 34
Assembly tool (M14) 3115 1627 00
Fitting tool (M16) 3115 1126 00
Assembly tool (M20) 3115 1628 00
N Puller + accessories 3091 0455 90
O Washer 3115 0284 00
P Charging equipment 3115 3425 80
R Ring spanner 3115 2263 00

8
 Tool list 2

S BB JJ

CC
T HKK

DD
U LL

EE
V MM

FF
X
NN

GG
Y
OO

HH
1250 0199 21

AA

Letter Tools Part no.

S Fixture 3115 1897 00
T Plate 3115 1896 00
U Plates 3115 1594 00
V Mandrel 3115 1899 00
X Mandrel 3115 2163 00
Y Tensioning tool 3115 2519 00
AA Circlip 100 mm 0335 2169 00
Circlip 120 mm 0335 2176 00
BB Nut (M20x2) 3115 2265 00
CC Press tool 3115 2409 00
DD Press tool 3115 2410 00
EE Press tool 3115 2412 00
FF Press tool 3115 2422 00
GG Press tool 3115 2411 00
HH Guide ring 3115 2423 00
JJ Guide ring 3115 2471 00
KK Plug 0686 4249 00
LL Spacer pipe 3115 2739 00
MM Press tool 3115 2737 00
NN Assembly tool 3115 3373 10
OO Assembly tool 3115 3374 20

9
Tool list 2

10
 Rock drill main parts 3

3. Rock drill main parts

7
6
4
3
2
1

8
5
5
1250 0402 88

1. Front head incl. 5. Accumulators

Shank adapter Intake accumulators
Connecting plate Return accumulator
Stop ring
Flushing head 6. Cylinder incl.
Guide Plunger
Piston guides
2. Cover Valve piston
Regulating plug
3. Gear housing, incl.
Starter bushing 7. Back head incl.
Drill sleeve Rear piston seals
Driver
Rotation shaft 8. Hydraulic motor
Gear

4. Intermediate part incl.

Damper piston
Front piston seals
Damper piston seals
Non-return valve

11
Rock drill main parts 3

12
 Dismantling the rock drill’s main parts 4

4. Dismantling the rock drill’s main parts

NB! Always wash the rock drill externally using
grease solvent before starting removal.
The pivot plate (A) must be used when dismant- 162
ling the rock drill. 101
In the event of leakage problems
• Check the source of the leak before removing
the rock drill from the rig.

Important!
Observe great cleanliness when intervening
300

1250 0404 77
in the rock drill or its hydraulic circuit.
Replacement of front head parts, shank 251
adapter, accumulator, hydraulic motor, bolts 252
and connections must be carried out on the
worksite. Other repairs must be carried out in
a suitable workshop. • Loosen the front side bolt nuts (251) with the
washers (252). Remove the front head (101) by
pulling the shank adapter (300).
4.1 Fitting the rock drill on the pivot • Pull out the cylindrical pin (162).
plate
4.3 Dismantling the accumulators

Caution!
All gas must be released before removal.
Do this by 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!

• Bolt the rock drill onto the pivot plate (A).

4.2 Removing the front head

101
124

126
1250 0184 75

125
120

• Remove the connecting plate (120) by undoing

the bolts (125) with the washers (126).
• Remove the cup seal (124).

13
Dismantling the rock drill’s main parts 4

34
211
53
94
82 92

1250 0079 17
82
1250 0403 18

211 • Remove the back head (92) by undoing and

removing the screws (94).
34 • If necessary, tap with a copper hammer and
carefully prize with a crowbar or similar.
• Remove the accumulators (211) with the seals
(82) by undoing the bolts (34).

29
21

23
1

7
22
21
1250 0404 78

5
24 231 • Pull out the piston (21), together with the rear
piston guide (29), and place the piston where it
cannot be scratched or damaged.
Underground rig
• Remove the return accumulator (231) by 4.5 Removing the side bolts, cover
removing the nuts (24), the bolts (23), the bolt plate and gear housing
(1) and the holder (22). Pull away the clip (21)
and unscrew the accumulator by undoing the
pressure screw (5).
251 252
4.4 Removing the back head and
plunger

Caution!
All personnel must stand to the side of the
rock drill when removing the back head.
1250 0079 18

133

• Undo the rear side bolt nuts (251) with washers

(252).
• Undo the side bolt (133).

14
 Dismantling the rock drill’s main parts 4

4.7 Dismantling the hydraulic motor

241 247 248

103 153
161

R 246

1250 0405 66
1250 0079 19

• Undo the nuts (246) using the ring spanner (R)

130 and remove the hydraulic motor (241).
• Remove the gasket (247).
• Tap loose the gear housing (103) and the cover • Pull out the coupling (248).
plate (153) using a copper hammer and pull
them out using the side bolts (161).
In normal cases the rotation shaft (130) is
removed together with the gear housing. Other-
wise, pull out the rotation shaft.

4.6 Removing the intermediate

segment

52

• Tap loose the intermediate segment (52) with a

copper hammer. If the intermediate segment is
held firmly on the lower guide, use a crowbar or
similar and remove it.

15
Dismantling the rock drill’s main parts 4

16
 Dismantling, inspecting and assembling the front head 5

5. Dismantling, inspecting and assembling the front head

5.1 Removing the shank adapter and
guide 146
39mm R38
T38 144
300 112
110
142 147
140
1250 0148 21

143

111
111
• Pull the shank adapter (300) from the front R38
105

1250 0148 23
head. T38

D • Replace the guide (105) if the inside diameter

exceeds 39 mm.
• Replace the flushing head (110) if major
damage, cracks or similar have arisen.
V • Replace the stop ring (140) if the surface is worn
by more than 1 mm. Compare with new stop
ring.
105 • Replace all O-rings and U-cup seals.
NB! The sleeves must be turned in accordance
with the figure.
110
5.3 Fitting the guide, flushing head,
stop ring and adapter
Before fitting the parts must be lubricated with
1250 0148 37

clean hydraulic oil.

• Check that the flushing connection (120) is

removed before the press work is started.
• Press out the guide (105), the flushing head
(110) and the stop ring (14). Use the mandrel (D)
for the guide 38 mm. Supplement with socket
(V) for the guide 52 mm.

5.2 Inspecting and replacing parts

Before inspection the parts must be washed clean
in grease solvent.

17
Dismantling, inspecting and assembling the front head 5

300

D
146

171
V
147
140
A

1250 0148 25
105

• Fit the stop ring (140) with the O-ring (146), O-

1250 0024 61

ring (147) as well as the adapter (300) in the

front head (171).

• Press in the guide (7) using the mandrel (D).

• Press in the guide (14) using the drift (D) and the
sleeve (V).
• Check that the lubricating duct (A) is open by
blowing with compressed air.

110
1250 0148 24

• Press in the flushing head (110) using the

mandrel (D), or using the mandrel (D) and the
sleeve (V).
NB! The flushing head must be turned so that
the lubricating grooves are upwards. See the
figure.
• Also make sure that the flushing hole in the
flushing head is aligned with the hole (A) in the
front head.

18
 Accumulators 6

6. Accumulators
6.2 Inspecting and replacing parts
Caution!
All gas must be released before removal. Do Caution!
this by removing the protective cap and Incorrect length of bolts, as well as damaged
opening the valve nut 2-3 turns. or corroded threads on bolts, housings and
There is a risk of injury if these instructions covers may lead to dangerous oil leakage
are not observed! and parts loosening.
Risk of personal injury
6.1 Dismantling the accumulator Always replace incorrect and damaged bolts
(4), housings (1) and covers (3). Always
replace the bolts in pairs.

2
4 3
1
3 10

14 12
211 11
1250 0406 13

13 5 4
1250 0404 76

• Replace the diaphragm (3) if there is any

indication of cracks or other damage.
• When replacing the diaphragm, check that there
are no pieces of rubber stuck in the valve (4) or
in the control valve (5).
• Flush clean the gas ducts in the cover plate (1)
with air.
• Always replace the O-rings (12, 13, 14) if the
valves have been removed.
• Replace the bolts (10) if the threads are
corroded or damaged.
• Replace the housing (2) and the cover plate (1)
if the threads are damaged or highly corroded.

6.3 Fitting the diaphragm, cover,

housing and labels
Before fitting it is important that all parts are dry
and free of oil.
1250 0045 46

• Tighten the tool (L) in a vice.

• Fit the accumulator on the tool (L).
• Fit the tool (J) onto the accumulator, add the ring
(3) and screw on the nuts (4) by hand. The ring
(3) holds the tool (J) in place at high torque.
• Screw apart the accumulator with the tool (J).
Use a 32 mm power socket and extended T-
handle with 3/4" connection bracket.
• Add the socket bracket to facilitate removal.

19
Accumulators 6

2 1
3
1
10

14 12
11
1250 0406 13

13 5 4

1250 0404 74
2
• Fit the diaphragm (3) in the housing (2) and
lubricate the edge of the diaphragm with a thin • Check and replace the safety labels if required
layer of silicone grease. (1 and 2).
• Lubricate the threads of the cover plate (1) and
housing (2) with grease, type NEVER-SEEZ.
• Fit the cover plate (1) on the housing (2) and Warning!
screw the accumulator together by hand.
NB! Do not turn the accumulator over before it Do not charge the accumulators before they
has been screwed together. have been fitted onto the rock drill.
• Fit the control valve (5). Tighten with torque 45
Nm.
• Fit the valve (9) together with the O-ring (12) and 6.4 Dismantling and assembling the
tighten to tightening torque 30 Nm. return accumulator

10
5
4
6

3
7
21
24
1250 0045 53

14
13
9 8
12 11
2
23

• Fit the accumulator onto the fitting tool (L).

Tighten the housing (1) to tightening torque 300
1250 0052 63

22
1
Nm. Use the fitting tool (J) and a torque wrench.

Return accumulator 3115 2615 91

Underground rig
• Dismantle the return accumulator and check the
internal components. If the diaphragm (10) has
cracks or other damage, then replace it.
• Replace all O-rings.
• During assembly. Lubricate the diaphragm’s
flanges with a thin layer of silicone grease.
• Fit the plug (11) with the O-ring (12) and tighten
to tightening torque 45 Nm.
• Fit the tube (2) so that the plug (11) is accessible
for checking the accumulator diaphragm.

20
 Back head 7

7. Back head
7.1 Inspection and replacement of
piston seals and seal housing
Before inspection the parts must be washed clean
in grease solvent.

21

92 25
26
1250 0405 77

1250 0405 79
27

• Check whether the piston seals (26) are • The seal housing (25) only needs to be removed
damaged or worn. if it is damaged or if leakage indicates that the O-
• Check the wear of the piston seals by inserting ring (27) must be replaced.
the plunger (21) in the back head (92). Then lift • When removing, use a puller with expander 37-
in the piston. The back head should then follow. 46 mm (N).

7.2 Fitting the seal housing and piston

seal
Before fitting the parts must be lubricated with a
clean hydraulic oil.

25
26
1250 0405 78

25
• If the piston seals (26) need to be replaced, first 27
1250 0405 80

remove them carefully with a pointed object to

avoid damage to the seal housing (25) grooves.

• If the seal housing (25) has been removed then

fitting takes place as follows:
• Fit a new O-ring (27). Press the seal housing
into place with the mandrel (I).

21
Back head 7

26
1250 0405 81

• Fit the piston seals (26) in accordance with the

figure. (A seal kit consists of an O-ring and a
Teflon ring).
• Check that the grooves are clean. Grease in the
O-ring and fit it in the groove.
• Bend the Teflon ring in accordance with the
figure and press the seal into the groove.
NB! The seal lips must be turned in accordance
with the figure.

22
 Cover and gear housing 8

8. Cover and gear housing

8.1 Removing the side bolts, cover
plate, starter bushing, rotation
shaft, gears, guide sleeve

132
161
130 124

1250 0405 83
1250 0079 39

• Pull out the rotation shaft (130).

• If the shaft is stuck then it can be tapped out with
a drift of about 7 cm through the hole in the front
• Remove the side bolts (161) and the starter end of the gear housing. If a thicker drift is used
bushing (132). there is a risk of damage to the needle bearing
(124).

121 117 122 137,138,139

153

123
1250 0405 84
1250 0079 40

• Remove the drill sleeve (117) together with the

shims (137-139) and bearing outer races (121
and 122) from the gear housing by tapping on
the drill sleeve with a copper hammer.
• Tap loose the cover (153) with a copper • Then remove the gear (123) from the gear
hammer. Carefully prize with two parting tools or housing.
similar.

109
1250 0405 85

124
125

• Tap loose the rotation shaft’s front needle

bearing (124) and the two washers (109 and

23
Cover and gear housing 8

125) in the gear housing using a drift of about 10

mm.
161

103

133 161
1250 0405 86

1250 0079 46
129
• Remove the guide sleeve (129) as follows:
• Screw a plug (BB) into the guide sleeve.
• Fit the gear housing (103) onto two wooden
blocks in accordance with the figure. • Replace all O-rings.
• Tap out the guide sleeve using a drift (12x200 • Replace the side bolts (133 and 161) in the
mm). event of significant rusting or cracks.
• Replace the side bolts in pairs every 400
operating hours. Never mix new and old bolts.

131
300

127
1250 0405 87

126
1250 0405 89

• Tap out the sleeve (127) with needle bearing

(126). Use a mandrel (H).
• Replace the adapter (300) if the thread is worn
out or the impact surface is warped or chipped.
8.2 Inspecting and replacing parts • Replace the driver (131) when the boom width is
Before the inspection, the parts must be washed less than 2 mm.
clean in grease solvent.

131

117
1250 0405 90

118

• Check the wear between the drill sleeve (117)

and the driver (131) using a feeler gauge. If the

24
 Cover and gear housing 8

play exceeds 0.04 mm then the driver or drill significantly worn or if the depth of the
sleeve must be replaced. lubricating grooves (A) is less than 1.0 mm.
• Check the bushing (118). If the inner diameter • Replace the roller bearings (121 and 122) in the
exceeds 64.0 mm then the bushing must be event of noise and damage.
replaced. • Replace the shims (137,138,139) if there is any
indication of damage.

121

A16
131 122
1250 0405 91

117

1250 0403 25
• If the driver (131) needs to be replaced then use
the puller and an expander 37-46 mm (N).
• If any of the roller bearings (121 and 122) on the
drill sleeve must be replaced, then the roller
cage must be pressed off with the bearing
removal tool (A16).
1250 0405 92

118
107 154

1250 0405 95
108 155
• If the bushing (118) needs to be replaced, break
it open with a screwdriver. Be careful so as not
to damage the drill sleeve.
• Check the sealing rings (107 and 154) in the
cover and gear housing respectively with regard
to wear and damage.
• If the seals need to be replaced then this takes
121 117 122 137,138,139 place by means of undoing the lock rings (108
and 155 respectively), after which the seals are
knocked out with a drift.
1250 0405 93

• Replace the drill sleeve (117) in the event of

deforming or cracks, or if the ring gear is

25
Cover and gear housing 8

m 132
1m

N
1250 0405 96

66 mm
126
129

1250 0079 55
• Replace the starter bushing (132) if it has cracks
or scoring marks or if the surface against the
adapter is worn by more than 1 mm. Compare
with a new one.
• Polish or replace the starter bushing if the
surface to the damper piston has scoring marks. • If the rear needle bearing (126) needs to be
NB! Minimum length 66 mm. replaced, remove it from the sleeve (129) using
an extractor and an expander 23-30 mm (N).

8.3 Fitting the parts in the gear

housing
Before assembly, the parts must be lubricated with
clean hydraulic oil
1250 0405 97

107
124 123 126 128 103
108
• Replace the rotation shaft needle bearings (124
and 126) in the event of noise or damage.
1250 0405 99

• Replace the gear (123) in the event of

deforming, if cracks have arisen or if the ring
gear is significantly worn.
• Replace the sleeve gasket (128).

• Fit the sealing ring (107) in the gear housing

(103) using the press tools (B and E).
• Fit the lock ring (108).

26
 Cover and gear housing 8

125 129
124
109 128

1250 0406 03
1250 0406 00

126 123
• Fit the washer (109), the needle bearing (124) • Fit the needle bearing (126) inner ring.
with its inner ring, and washer (125). Use • Fit the gear (123).
mandrel (H). • Fit the guide sleeve (129) with a new circlip
sleeve (128). Use a drift (H).

102

126
1250 0406 01

127

• Fit the needle bearing (126) without inner race in 121

1250 0403 24

the sleeve (127). Use mandrel (H).

• Fit the roller bearing (121) outer race. Use a

copper mandrel.

127
1250 0406 02

123
118
• Fit the gear (123) as spacer in the gear housing. 117
1250 0406 04

• Fit the sleeve (127) with needle bearing turned

to the gear. Use mandrel (H).
• Remove the gear (123).

• Fit the bushing (118) in the drill sleeve (117).

Use press tool and extension (B, C and T).
NB! Press carefully so that the bushing is not
deformed when it reaches the bottom.

27
Cover and gear housing 8

8.4 Shimming the bearings in the gear

housing

D
153

131
1250 0406 05

137-139
117
122
117
• Fit the driver (131) in the drill sleeve (117). Use
the mandrel (D) and a plastic mallet.

103

1250 0079 65
121
122
• During fitting, the tension of the gear housing’s
roller bearings must always be checked.
117 NB! During shimming all parts must be free from
grease and oil. No O-rings should be fitted in the
gear housing or cover plate.
1250 0406 06

• Fit the drill sleeve (117) down into the gear

housing (103).
• Fit the front roller bearing (122) outer race. Tap
it into place using a mandrel.
• Add spacers (137, 138, 139) in against the outer
ring. Select dimension and quantity so that a
• Fit the roller bearings (121 and 122) on the drill gap with a safety margin is formed between
sleeve (117). Use press tools (B and F). gear housing (103) and cover plate ().
• Fit the cover (153).

E
155

154
153
1250 0079 64

• Fit the sealing ring (154) in the cover (153). Use

press tools and extensions (B, C and E).
• Fit the lock ring (155).

28
 Cover and gear housing 8

E
153
153
K
164

163 162

103
AA
1250 0079 66

1250 0079 67
• Fit the gear housing onto the press tool (B) and
the guide (AA).
• Align the press tool (E) on the cover plate (153).
• Rotate the drill sleeve 2-3 turns. • Grease in all parts, in particular the roller
• Tighten to a tightening torque of 200 Nm. Use bearings and O-rings. See the chapter,
wrench accessory (K). Lubricant recommendations.
• Unload the tension and retighten to tightening • Fit the O-ring (164) in the cover plate (153).
torque 20 Nm. • Fit the O-ring (163) in the gear housing (103).
• Measure the clearance between the gear Use grease on the O-rings so that they remain
housing and the extension piece with a feeler in place during fitting.
gauge. • Fit the guide pin (162) in the gear housing and
• Remove the cover plate (153) and reduce the then fit the cover (153).
number of shims (137-139) until a clearance of • If necessary, tap down the cover plate with a
0.15-0.20 mm can be measured. In this way a plastic mallet.
tension for the roller bearings of 0.15-0.20 mm is
obtained when the rock drill is finally assembled
with the side bolts.
NB! It is important that the bearing tension is
correct as well as that the tightening torque is 117 103
correct. After drilling for a while the bearing 132
seats can settle, so it is therefore important that
the bearing tension does not stop, which could
involve damage to roller bearings and spacers.
1250 0079 68

130

• Fit the rotation shaft (130) in the gear housing

(103).
• Tap in the shaft with a plastic hammer.
• Fit the starter bushing (132) in the drill sleeve
(117).

29
Cover and gear housing 8

30
 Intermediate segment 9

9. Intermediate segment
9.1 Dismantling the damper piston

86

16
1250 0074 51

15
• Tap out the damper piston (86) with a hammer

1250 0074 53
and copper drift.

9.2 Inspecting and replacing parts

Before inspection the parts must be cleaned in • If the plunger’s seals (16) need to be replaced,
grease solvent. first remove them carefully with a pointed object
to avoid damage to the seal housing (15)
grooves.
16
21
1250 0074 52

85

• Check the plunger’s seals (16) with regard to

wear and damage. 84
• The wear is measured by carefully inserting the
1250 0074 54

plunger (21). If the piston moves stiffly then the

piston seals do not normally need to be
replaced. Compare with the back head.

• Check the damper piston’s seals (85 and 84)

with regard to wear and damage.
• If they need to be replaced then dismantling
takes place in the same way as with replacing
the plunger’s seals (16).

31
Intermediate segment 9

86
0.1 mm

N
1250 0074 55

15
• Replace the damper piston (86) if the seals have 17
worn by more than 0.1 mm. Polish minor
damage.

1250 0074 57
52
• The seal housing (15) must not be removed if it
is not damaged. If the seal housing is damaged
or if leakage indicates that the O-ring (17) must
be replaced then removal takes place as
illustrated. Use a puller with an expander 37-46
mm (N).

9.3 Fitting the seal housing, seals and

73 damper piston
Before fitting the parts must be lubricated with
(o 1.2 mm) clean hydraulic oil.
1250 0074 56

• Replace the intermediate segment (52) in the

event of significant scoring damage. Minor I
scoring can be polished with fine abrasive cloth,
or honed.
• Check the nozzle (73) in the rear edge of the 15
intermediate segment carefully so that the hole
is free from dirt. Check that the nozzle is fully 17
screwed in and locked with LOCTITE 242 or
254.
1250 0074 58

• Fit the O-ring (17).

• Press the seal housing (15) into place using the
mandrel (I).

32
 Intermediate segment 9

OO NN

16

1250 0230 25
• Bend the seal ring with tool (NN) as shown in the
diagram.
• Insert the sealing rings (42 and 43) in the groove
1250 0074 59

and then press in the ring with a tool (OO).

IMPORTANT! The seals must be turned in
accordance with the figure.

• Fit the plunger’s seals (16) in accordance with

the following. (A seal kit consists of 1 x O-ring
and 1 x Teflon ring).
• Check that the sealing grooves have been
thoroughly cleaned.
• Oil the O-ring and fit it into the groove.
• Insert the sealing ring in the seal housing and 86
then press the ring into the sealing groove with
a tool shank for example.
IMPORTANT! The seal lips must be turned in
accordance with the figure.
1250 0074 63

85 84

• Lubricate the damper piston (86) and press it

into the intermediate segment.
NB! This must be carried out with the greatest
caution.
• Then press out the damper piston and check
that the seals are correctly positioned and that
they are not damaged.
1250 0074 61

NB! The damper piston must be easy to fit.

• Fit the damper piston’s seals (84 and 85) in

accordance with the following:
• Check that the sealing grooves have been
thoroughly cleaned.
• Oil the O-ring and fit it into the groove.

33
Intermediate segment 9

34
 Cylinder, piston guide and plunger 10

10. Cylinder, piston guide and plunger

10.1 Removing the piston guide, valve
piston and regulating plug

19
21
29

19
1250 0032 25

1250 0074 65
• Remove the front piston guide (19) by moving in
the piston (21) and tapping carefully.
• Check the piston guide’s contact surfaces (A) in
the cylinder.
• Polish if necessary.
• Replace all O-rings.
34 32
• Replace the piston guides (19 and 29) if they
show signs of significant cavitation damage.
• If the clearance is greater than 0.06 m then the
guide must be replaced.
• Move the piston in and measure the clearance
36 with a feeler gauge.
48 37

37
35 31
1250 0404 75

47
32 34
31
• Undo the bolts (34) holding the valve covers
(32) and press out the valve piston (31).
• Remove the regulating plug (35) and washers
(37) by undoing the nut (36).
1250 0074 66

10.2 Inspecting and replacing parts

Before inspection all parts must be cleaned in
grease solvent. • If the cylinder (3) (the cylinder bore or valve
bore) and valve piston (31) show signs of
scoring or scratches, then the parts must be
replaced. Minor scoring can be polished with
fine abrasive cloth, whetstone or honing tool.
• Clean all ducts of impurities by washing them
thoroughly.

35
Cylinder, piston guide and plunger 10

21 34 32

36
48 37

R=1
37
35 31
R=1

1250 0404 75
0.5 mm 47
1250 0074 67

32 34

L • Fit the valve piston (31).

• The valve piston is symmetrical and can be
turned. Check that the valve piston is running
• Check the impact piston (21) for scoring and smoothly.
scratches as well as the impact surface with • Fit the valve covers (32) with new O-rings (47
regard to wear and chipping. and 48).
• Minor scoring and scratches on the piston can • The end plates must slide smoothly and must
be polished with fine whetstone. not be tapped in.
• Minor damage to the piston’s impact surface • Tighten the bolts (34) to tightening torque 145
can be rectified using grinding. Grind down 0.1- Nm.
0.2 mm at a time until the surface is smooth. In • Fit the regulating plug (35) and the sealing rings
total a maximum of 0.5 mm may be ground (37). Tighten the nut (36) to tightening torque 80
down. Nm.
NB! Length dimensions (L) must not be below
specification.
21 45 19
COP 1238K L= 428.5 mm

External and internal radiuses must be restored

so that an even changeover (without sharp
edges) is obtained.
• Following grinding, check that the impact
surface is free from cracks. Clean the piston
thoroughly so that all grinding residue is
1250 0059 02

removed.

10.3 Fitting the valve piston, valve

covers and piston guide
• Insert the plunger (21) into the cylinder. Fit the
Before fitting all parts must be lubricated with O-ring (45) on the front piston guide (19). Fit the
clean hydraulic oil. piston guide with the plunger as a guide.
• Tap the guide into place with the mandrel (G).
• Then remove the impact piston from the
cylinder.

36
 Function and condition test of the hydraulic motor 11

11. Function and condition test of the hydraulic motor

• Connect the motor in accordance with the figure

(P=Pressure; R=Return) and allow it to rotate for
about 30 seconds at max. 10 l/min. Check that
the motor runs smoothly, without any jarring
noise.

37
Function and condition test of the hydraulic motor 11

38
 Fitting the rock drill’s main parts 12

12. Fitting the rock drill’s main parts

12.1 General 12.3 Assembling the hydraulic motor
All parts must be thoroughly cleaned before and intermediate segment on the
assembly. During fitting the parts must be lubri- cylinder
cated with clean hydraulic oil.
The O-rings must be replaced with new intact
ones and be greased with silicone grease. 3
241 249 248
12.2 Fitting the cylinder on the pivot
plate

3 247

1250 0062 41
246

• Make sure that the groove ring (249) is fitted in

the coupling (248).
• Lubricate the coupling’s splines with grease and
fit the coupling onto the hydraulic motor (241).
A • Fit a new gasket (247) to the cylinder’s (3) end
plate.
• Fit the hydraulic motor onto the cylinder (3).
• Tighten the nuts (246) to tightening torque 65
Nm. Use the ring spanner (R).
1250 0080 16

• Align the pivot plate (A) horizontally.

• Bolt in the cylinder (66) with two M16 bolts on 52
the pivot plate with the front head inwards in
relation to the workbench.

81

83

3
1250 0085 05

• Align the pivot plate vertically.

• Fit the O-ring (83) in the groove on the
intermediate segment (52) rear guide.
• Fit the O-ring (81) in the intermediate segment’s
(52) rear face. Add grease in the groove so that
the O-ring remains in place during fitting.
• Fit the intermediate segment (52) onto the
cylinder (3). Tap lightly with a copper hammer.

39
Fitting the rock drill’s main parts 12

12.4 Fitting the gear housing, side 12.5 Fitting the plunger and back head
bolts and cover
21
52
248

131
1250 0209 48

130 135 103

1250 0080 19
• Align the pivot plate horizontally.
• Fit the O-ring (135) in place using grease.
• Fit the gear housing (103) on the intermediate • Lubricate the impact piston (21) with clean
segment (52). If the rotation shaft (130) does not hydraulic oil.
change the coupling (248), insert a adapter in • Insert the piston into the cylinder barrel. When
the driver (131) and turn. the piston reaches the front piston seals, turn
the piston in. The piston seals could be
damaged if the plunger is tapped in.
161

29 46
133
1250 0024 62

251 252
1250 0080 18

• Fit the side bolts (601). Fit the rear washers • Fit the rear piston guide (28) with new O-ring
(252) and nuts (251). Tighten the rear side bolt (46). Tap in the piston guide using a mandrel
nuts (251) alternatingly until a tightening torque (G).
of 300 Nm has been reached. Use key set (K)
for the torque wrench.
• Fit the side bolt (133). Tighten the bolt to
tightening torque 300 Nm.
NB! Before assembly, grease must be applied
to the threads, type NEVER SEEZ.

40
 Fitting the rock drill’s main parts 12

93 38
94

101
124
1250 0080 20

126

1250 0184 75
125
120
• Fit the O-ring (93) in the cylinder. Place the O-
ring (38) in the groove on the cylinder. Use
grease so that the O-ring remains in position. • Fit the cup seal gasket (124) into the flushing
• Before fitting the back head, check that the head.
piston (21) can be moved forward and back with • Fit the connecting plate (120) on the front head
a rotating motion. (washers 126 and bolts 125). Torque-tighten the
• Fit the back head carefully on the cylinder so bolts (125) to 90 Nm. Fit the nipple on the
that the plunger or piston seals are not connecting plate. Then tighten to tightening
damaged. torque 300 Nm.
• Tighten the three screws (94) for the back head
alternately to tightening torque 220 Nm. The two 12.7 Assembling the accumulators
lower bolts must be tightened before the upper
one.
• Use key set (K) for the torque wrench.
Caution!
Fit the accumulators onto the rock drill using
12.6 Mounting the front head undamaged original bolts.
Intake accumulator (1 and 2) must have two
bolts (4) with a length of 70 mm.
162
101 Replace the bolts in pairs even if only one
bolt is corroded or damaged in some other
way.
Defective bolts may lead to dangerous oil
leakage or the accumulator working loose.

Caution!
300
1250 0404 77

The accumulators must be fitted on the rock

drill before charging.
251
252 There is a risk of injury if these instructions
are not observed!
• Fit the pin (162) in the cover. Align the front head
(101) on the side bolts (161).
• Fit the washers (252) and nuts (251).
NB! Before assembly, grease should be applied
to the threads, type NEVER-SEEZ.
• Tighten the nuts (251) alternately to tightening
torque 350 Nm.

41
Fitting the rock drill’s main parts 12

12.9 Assembling the return accumu-

34 lator
211
53
82

23
1

7
82 22
1250 0403 18

211 21

1250 0404 78
5
34 24 231

• Align the seal rings (82) in the grooves on the

intermediate segment (53) and then fit the • Screw in the return accumulator (231) by fitting
accumulators (211) on the intermediate the pressure screw (5). Do not forget the O-ring
segment (53). Check carefully that the seal (82) (7).
is not damaged during fitting. • Thread on the clip (21) and fit the holder (22)
with the bolts (23) and the nuts (24).
• Fit the bolt (1).
12.8 Accumulator safety labels
12.10 Charging the accumulator

Warning!
The accumulators must only be charged with
nitrogen gas (N2)
Any other gas could cause an explosion.

Caution!
The accumulators must be fitted on the rock
drill before charging.
1250 0404 79

• Check that the accumulators have the correct

safety labels and that these are not damaged.
• Replace damaged labels.

42
 Fitting the rock drill’s main parts 12

• The intake accumulator (1) must be charged

before starting up the drill rig.
• Remove the protective cap (3) on the
accumulator valve.
• Open the valve nut (4) 2-3 turns.
• Connect the regulator at the lowest possible
pressure and open the valve (5) on the gas
bottle.
• Charge the intake accumulator (1) to 30-40 bar
under collaring pressure.
NB! Charge at the bottom if possible rather than
too high.
• Tighten the valve nut (4) and close the valve (5)
on the gas bottle.
• Undo the filler hose and screw in the protective
cap (3) on the accumulator valve.
• The return accumulator (2) must not be
charged.

43
Fitting the rock drill’s main parts 12

44
 Function test of rotation and percussion 13

13. Function test of rotation and percussion

test equipment until the pressure gauge reads
100 bar.
• Press the button for low scale on the flow gauge
and read.

• The leakage flow for a new rock drill is 2-3 l/

minute. Leakage flow of more than 5 l/minute is
unacceptable and indicates that there is a defect
in plunger and plunger bore, valve piston and
valve piston bore, piston guides or reflex
dampers.

• Connect the hydraulic hoses P (Pressure) and R

(return) to the hydraulic motor. Supply hydraulic
oil pressure to the hydraulic motor, max.
pressure 40 bar for about half a minute.
• Check that the rotation runs smoothly, without
noise and external leakage, and in the right
direction. O
1250 0402 91
32
34
NB! Do not forget to remove the washer (O)
after the test.
• Refit the valve cover (61) and check that the
piston moves forward and back by operating the
rock drill at low hydraulic pressure (5-15 bar).

• During the condition test the hydraulic hoses

must be connected as illustrated in the figure.
• Undo the valve cover (61) on the right-hand side
of the machine.

O
1250 0402 91

32
34

• Add the washer (O) fully cleaned and refit the

end plate.
• Supply hydraulic oil pressure to the percussion
function and adjust the reducing valve on the

45
Function test of rotation and percussion 13

46
 Tightening torques 14

14. Tightening torques

5
4
3

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

3 2

Lubricate the threads and contact surfaces of the

nuts and washers with 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 2 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
13 1 Flushing connector 300
14 4 Intake, flushing medium 90 Tighten the screws alternately to full
torque
15 2 Filler nipple Accumulator 30
16 2 Control nipple 45

47
Tightening torques 14

14.1 Tightening the side bolts 14.2 Retightening the side bolts
• Undo the front nuts (3) so that the tension rele-
ases.
If the threads are seized, remove the nuts and
clean and lubricate them with Never-Seez
Regular Grade.
• Tighten the front nuts (3) manually.
1250 0400 37

1
3 2 • Tighten the rear nuts (1) to the tightening torque.
• Tighten the side bolt (2) to the tightening torque.
• Check whether the side bolts, nuts or washers
have cracks, scratches or rust. Replace • Tighten the front bolts (3) to the tightening
damaged side bolts, nuts and washers. torque.

• Lubricate the threads and contact surfaces of

the side bolt (2), nuts and washers with Never-
Seez Regular Grade.

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

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

48
 Lubrication 15

15. Lubrication

214
A 215

212
1250 0080 26

15.1 Lubrication of gear

• Undo the stopper (214).
• Lubricate with heat-resistant grease through
the nipple (212) until grease escapes through
the hole (A). See the chapter on hydraulic fluid
and lubricant recommendations.
• Tighten the stopper (214) with the washer
(215).

49
Lubrication 15

50
 Hydraulic and lubricant recommendations 16

16. Hydraulic and lubricant recommendations

16.1 Hydraulic fluid
A good hydraulic fluid provides superior protection against wear, rust and oxidisation as well as good anti-
foaming and air and water separation properties.
In order to ensure a lowest level on these properties the mineral oil based and synthetic (polyalphaolefin)
hydraulic fluids must conform to the standard ISO 11158 HM/HV or DIN 51524 HLP/HVLP.

Environmentally friendly hydraulic fluids must fulfil ISO 15380

It is essential to chose a hydraulic fluid of a suitable viscosity for the operating temperature of the drill rig.
Select a viscosity grade (VG) and viscosity index (VI) as specified in the following table. A high viscosity
index reduces the effect of temperature on the hydraulic fluid.

Normal operating
Min start temp. ºC Viscosity grade VG
temp. ºC Max temp. ºC Viscosity index VI
(Viscosity min. 1000 cSt) (ISO 3448)
Viscosity 25-50 cSt
+50 to +70 +5 80 ISO VG 100 Min. 100
+45 to +60 -5 75 ISO VG 68 Min. 100
+35 to +50 -10 65 ISO VG 46 Min. 100
+25 to +40 -15 55 ISO VG 32 Min. 100
+10 to +25 -25 35 ISO VG 15 Min. 100

If the viscosity is too low:

• The hydraulic fluid may not form a lubricating layer between surfaces, thus increasing the risk of wear.
• The hydraulic fluid can leak past seals more easily in the rock drill thus increasing fluid losses and incre-
asing energy requirements.

If the viscosity is too high:

• Flow losses in the hydraulic lines will be high increasing energy consumption and pressure levels, putting
increased strain on seals.
• The risk of cavitation will increase, thus also the risk of damage to the rock drill and hydraulic pumps.

The hydraulic fluid must be filtered to a purity of 20/18/15 in accordance to ISO 4406.
The viscosity will change during the period that the hydraulic fluid is used. In general viscosity will drop with
increased operating hours. To ensure that the viscosity of the fluid does not drop to a critical level before
the recommended service interval, a hydraulic fluid of sufficient stability must be used. The viscosity in cSt
of suitable hydraulic fluids shall drop a maximum of 25% when tested for shear stability in accordance with
DIN 51350-6 at 100 ºC.

The hydraulic fluid must be changed at regular intervals.

Factors influencing the interval between changes:
• The viscous stability of the hydraulic fluid as specified above. The hydraulic fluid must be changed before
the viscosity drops to a critical level.
• Contamination with water. If the hydraulic fluid becomes cloudy and light grey, the water content has
become such that the hydraulic fluid must be changed.
• Deterioration of properties such as oxidation inhibition and anti-foaming.

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

51
Hydraulic and lubricant recommendations 16

16.2 Pneumatic tool oil

Atlas Copco recommends the use of Atlas Copco COP OIL which has been specially developed for our
hydraulic rock drills. COP OIL is an environmentally friendly, degradable oil which can be used in ambient
temperatures between -25 º C and +50 º C.
COP OIL can be ordered with the following part numbers:

Quantity Part number

1 can of 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

16.3 Grease
NB! Because of the operating temperature in the rock drill gear housing, always use a high-temperature
grease with lithium complex soap based on a synthetic base fluid (polyalphaolefin/synthetic ester) with
additives that protect against oxidation, corrosion and wear at high loads and with EP additive.

Operating
NLGI number Drop point Base oil viscosity
Temperature
2 260 ºC 220 cst at 40 ºC -15 to +150 ºC

Atlas Copco recommends the use of Atlas Copco COP Grease, gear housing grease, which has been
specially developed for our hydraulic rock drills. COP Grease withstands temperatures between -40º C to
+150º C, and temperatures of up to 220º C during shorter periods.
COP Grease can be ordered with the following part numbers:

Quantity Part number

Tube 0.4 kg 3115 3422 00
Can 18 kg 3115 3423 00

52
 Hydraulic and lubricant recommendations 16

53
Hydraulic and lubricant recommendations 16

54
www.atlascopco.com