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Atlas Copco

Maintenance instruction
Hydraulic Rock drills
COP 1840HE, 1840HEX

AIR

Atlas Copco Rock Drill AB


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

No. 9852 1007 01f


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

Atlas Copco Rock Drills AB


SE-70191 Örebro, Sweden
Innehåll

INNEHÅLL
1. SAFETY REGULATIONS................................................................................... 5
1.1 Warning boxes .................................................................................................................... 5
1.2 The following general safety rules must be observed ......................................................... 5

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


2.1 Before starting a new or newly overhauled rock drill........................................................... 6
2.2 After the first shift when using a new or newly overhauled rock drill ................................... 7
2.3 For each shift....................................................................................................................... 7
2.4 After every 40th percussion-hour ........................................................................................ 7
2.5 Every 400th percussion-hour: ............................................................................................. 7

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


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

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


5. ACCUMULATORS ........................................................................................... 10
5.1 Safety label location .......................................................................................................... 10
5.2 Safety label instructions. ................................................................................................... 10
5.3 Charging the accumulators ............................................................................................... 11
5.4 Checking the accumulators in the event of hose vibration ................................................ 12
Damper accumulator (1) and intake accumulator (2) ....................................................... 12
Return accumulator (3)..................................................................................................... 12
5.5 Replacing intake and damper accumulators .................................................................... 13
Dismantling....................................................................................................................... 13
Assembly.......................................................................................................................... 14
5.6 Replacing the return accumulator ..................................................................................... 14
Dismantling....................................................................................................................... 14
Assembly.......................................................................................................................... 15

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


Dismantling....................................................................................................................... 16
Assembly.......................................................................................................................... 16

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


8. SETTINGS ........................................................................................................ 19
8.1 Setting of ECL lubricating system ..................................................................................... 19
8.2 Setting damper pressure ................................................................................................... 20
8.3 Setting the extractor unit pressure (HEX).......................................................................... 20

9. CHECKING THE FRONT HEAD ...................................................................... 21


10. REMOVING THE FRONT HEAD...................................................................... 22
10.1 COP 1840HE..................................................................................................................... 22
10.2 COP 1840 HEX ................................................................................................................. 23

11. MOUNTING THE FRONT HEAD...................................................................... 24


11.1 COP 1840HE..................................................................................................................... 24
11.2 COP 1840HEX .................................................................................................................. 25

12. REPLACING THE FLUSHING HEAD AND DRIVER....................................... 26


Dismantling....................................................................................................................... 26
Assembly.......................................................................................................................... 26

3
Innehåll

13. SLINGING ........................................................................................................ 28


13.1 Rock drill weights.............................................................................................................. 28

14. LONG-TERM STORAGE ................................................................................. 29


15. LUBRICATION ................................................................................................. 30
15.1 Lubrication of gear ............................................................................................................ 30
15.2 Hydraulic fluid and lubricant recommendations ................................................................ 30
Hydraulic oil ..................................................................................................................... 30
Pneumatic tool oil ............................................................................................................ 30
Grease............................................................................................................................. 31

16. STROKE LENGTH SETTING .......................................................................... 32


16.1 Basic setting ..................................................................................................................... 32

4
Safety regulations 1

1. SAFETY REGULATIONS 1.2 THE FOLLOWING GENERAL


SAFETY RULES MUST BE
The Safety chapter contains important information OBSERVED
for the prevention of accidents.
IMPORTANT!
1.1 WARNING BOXES • Read through the maintenance instructions
The manual contains warnings. carefully before starting a repair. Follow the
Warnings are preceded by a heading (Danger, instructions given and local regulations.
Warning and Caution).
• Ensure that the hydraulic, water and air
WARNING BOXES systems are depressurised and the electrical
system is de-energised prior removing the
rock drill or starting work on the system.
Danger
Indicates an imminent risk of serious or fatal • The rock drill must only be repaired by
injury if the warning is not heeded. personnel trained by Atlas Copco.
• Make sure that the safety labels are fitted,
Warning clean and fully legible.
Indicates hazards or hazardous procedures
which could result in serious or fatal injury if • Use approved lifting devices when handling
the warning is not heeded. the rock drill. Avoid lifting heavy weights on
your own.
Caution • Components that could move or fall down
Indicates hazards or hazardous procedures must be secured in order to prevent personal
which could result in personal injury or injury during repair. Always use a pivot plate
damage to property if the warning is not
(A), see the tool list.
heeded.
• Check that the hoses used are of the correct
quality, and that all hose connections are in
good condition and properly tightened. Hoses
that work loose could cause serious injury.
• Use only Atlas Copco original parts. Any
damage or operational interruption caused by
using parts other than Atlas Copco original
parts will not be covered by warranty or
product liability.
• Do not use or intervene in the rock drill unless
you have been trained to do so.
• Make sure that the rock drill has been main-
tained in accordance with the applicable
instructions.
• 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.
• Never attempt to carry out maintenance while
the rock drill is in operation.
• 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.
• Make sure that the place of work is well venti-
lated.
• Particular attention must be paid to all
warnings in the manual.

5
Action list 2

2. ACTION LIST
Read all safety regulations before starting to work on the machine.

WARNING!
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!

2.1 BEFORE STARTING A NEW OR NEWLY OVERHAULED ROCK DRILL


Chapter
• Connect up the hoses ........................................................................................................................ 3
• Charge the accumulators................................................................................................................... 5
• Select a suitable hydraulic oil and lubricant ..................................................................................... 15
• Fill the lubricating system with oil....................................................................................................... 7
• Adjust and set the lubricating system ................................................................................................ 8
• Set the extractor unit pressure (HEX) ................................................................................................ 8

CAUTION!
Exercise caution when jointing drill rods and with drill bit handling. Watch your fingers!

Make sure that clothes do not come too close to rotating machine parts.

Negligence could cause serious injury.

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 pres-
sure and high temperature, with the risk of serious injury to the eyes and skin.

6
Action list 2

IMPORTANT!
Observe great cleanliness when intervening in the rock drill or its hydraulic circuit.

The following parts may be changed at the work site in accordance with the instructions given:

•shank adapter
•driver
•front head parts
•accumulators
•hydraulic motor
•screws
•connections
Other repairs must be carried out in a suitable workshop in accordance with the repair instruc-
tions for the rock drill.

2.2 AFTER THE FIRST SHIFT WHEN USING A NEW OR NEWLY OVERHAULED
ROCK DRILL
Chapter
• Tighten all threaded unions ................................................................................................................4

2.3 FOR EACH SHIFT


Any defect must be rectified in the designated workshop.

• Check that air and lubricating oil escapes between the shank adapter and front guide, and also out of
the hole in the front head....................................................................................................................9
• Check that the shank adapter threads are not damaged ...................................................................9
• Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulators ...................5
• Check that there is no leakage from the rock drill. If the flushing medium leaks out of the overflow hole
in the front head, replace the seals and O-rings.................................................................................9
• When replacing the shank adapter or removing the front head, check the internal components, including
the visible parts of the piston, driver and rotation chuck bushing .......................................................9

2.4 AFTER EVERY 40TH PERCUSSION-HOUR


• Grease the gear................................................................................................................................15
• Tighten all threaded unions ................................................................................................................4
• Check the safety labels on the accumulators. Replace them if they are damaged or illegible ...........5
• Check the return accumulator ............................................................................................................5

2.5 EVERY 400TH PERCUSSION-HOUR:


• Remove the rock drill from the drill rig and send it to a suitable workshop for overhauling. .............13

The rock drill should be overhauled at suitable intervals, based on local conditions. The character-
istics of the rock will have a great influence on the rate of wear, and thus on the required frequency
of overhauling.

7
Hose connections 3

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

CAUTION!
Never attempt maintenance or intervene in the rock drill,
connections or hoses while the hydraulic, lubrication or
flushing systems are pressurised. Air or oil can spray out
at high pressure and high temperature, with the risk of
serious injury to the eyes and skin.

Delivery hoses with internal diameter 19 mm (3/4") or


larger are the SAE 100 R9R grade (high-pressure hose
with four layers of steel reinforcement). See the rock drill
spare parts list. For safety reasons these hoses must not
be replaced with lower grade hoses under any circum-
stances. There is a risk of injury if these instructions are
not observed.

7 CO P E
H
8 1840

AIR

6 COP EX
1250 0075 12

H
1840

5
4
3
2

9 10
6

1. Draining 6. Flushing air/water


2. Rotation left 7. Lubricating air
3. Rotation right 8. Damper, intake
4. Percussion return 9. Extractor unit, return
5. Inlet impact mechanism 10.Extractor unit, intake

8
Tightening torques 4

4. TIGHTENING TORQUES
6 COP
1
5 1840HE
4

3A
14
9
13
1250 0075 13

COP
6
12 1840HEX
7 11
9 10
8
15
16
13

COP 1840HE COP 1840HEX

3B

3A 2
2

Lubricate the bolted joints lightly with Never Seez or similar when tightening.
NB! Tighten ref. no. 1-3 in specified order.

Ref. Torque
Qty. Check point Instructions
No. Nm
1 2 Side bolts 300 Tighten the rear nuts
2 1 Front bolt 300 Tighten the front bolt
3A 2 Side bolt (HE) 350 Tighten the front nuts
3B 3 Side bolts (HEX) 300 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 bolts 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 bolts alternately to full torque
10 1 Plug 45
11 4 Valve end plates 145 Tighten the bolts alternately to full torque
12 2 Connecting plate 120 Tighten the bolts alternately to full torque
13 1 Flushing connector 300
14 4 Intake, flushing medium 90 Tighten the bolts alternately to full torque
15 1 Intake, extractor unit 120
16 1 Return, extractor unit 120

9
Accumulators 5

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

5.1 SAFETY LABEL LOCATION

3 2
1250 0184 63

1. Damper accumulator
2. Intake accumulator
3. Return accumulator

5.2 SAFETY LABEL INSTRUCTIONS.


1250 0184 64

1 2
1. Read carefully before service or replacement
2. Must be charged with nitrogen only

10
Accumulators 5

5.3 CHARGING THE ACCUMULATORS

1. Damper accumulator
2. Intake accumulator
3. Return accumulator
4. Protective cap
5. Valve nut
6. Gas Valve

CAUTION!
Charge the accumulators when they are fit-
ted on the rock drill. There is a risk of injury
if these instructions are not observed.

• Remove the protective cap (4).


• Open the valve nut (5) by 2-3 turns, and connect the gas hose.
• Open the gas valve (6).
• Charge the accumulators with nitrogen gas (N2) to the correct pressure in accordance with the follo-
wing:
NB! Charge at the bottom if possible rather than too high.

Damper accumulator (1) 20-25 bar


Intake accumulator (2) 30-40 bar (under collaring pres-
sure. Normally 80-100 bar, max.
100 bar)
Return accumulator (3) Must not be charged

• Tighten the valve nut (5) and close the gas valve (6).
• Remove the gas hose and screw in the protective cap (4) to the accumulator valve.

WARNING!
A gas other than N 2 could cause an explo-
sion.

11
Accumulators 5

5.4 CHECKING THE ACCUMULATORS IN THE EVENT OF HOSE VIBRATION

8 7

A
1250 0184 66

B 3 8 2 1
1. Damper accumulator
2. Intake accumulator
3. Return accumulator
7. Test valve
8. Plug with O-ring

DAMPER ACCUMULATOR (1) AND INTAKE ACCUMULATOR (2)


• Press in the pin for the control valve (7). If the accumulator is charged then the pin protrudes 4.5 mm
and is difficult to push in. NB! The damper accumulator’s pin is slightly easier to push in. If the pin is easy
to push in then the gas pressure has disappeared (broken diaphragm or defective filler valve).
• Replace the accumulator if it is not functioning properly.
• 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.

RETURN ACCUMULATOR (3)


• Position the rock drill in horizontal position.
• Remove the plug with O-ring (8). If oil escapes then the diaphragm is damaged or the accumulator has
been overcharged.
• Replace the accumulator, diaphragm and/or filler valve if they are not functioning properly.
• If the diaphragm is resting against the outer pipe, press the diaphragm with a cylindrical (blunt) drift (7-
9 mm). See Figure A. Correct position for diaphragm, see Figure B.
• Refit the plug and O-ring (8).
• Charge the accumulator.
NB! The seat of the filler valve is easily deformed by repeated opening/closing.
The filler valve must be replaced frequently.

12
Accumulators 5

5.5 REPLACING INTAKE AND DAMPER ACCUMULATORS


5 BA
1
3

2 3
BA
4
1250 0197 55

1. Damper accumulator
2. Intake accumulator
3. Sealing ring
4. Bolt
5. Bolt
7. Intermediate section

WARNING!
All gas must be released prior to fitting by
means of removing the protective cap (A),
undoing the valve nut (B) and opening it 2-3
turns.

There is a risk of injury if these instructions


are not observed

CAUTION!
Defective screws can cause dangerous oil
leakage, or can cause the accumulator to
be blown off. Oil spray could seriously
injure the eyes and skin.

Parts that come loose can cause serious


injury.

DISMANTLING
• Remove the accumulators (1, and 2) with the sealing rings (3) by undoing the bolts (4 and 5). Send the
accumulators to a workshop for overhauling!

13
Accumulators 5

ASSEMBLY
• Locate the sealing rings (3) in the grooves on the intermediate section (7).
• Make sure that the sealing rings (3) do not get damaged during the assembly.
• Fit the damper accumulator (1) on the left-hand side of the rock drill and the intake accumulator (2) on
its right-hand side (hose side). Fit using undamaged original bolts with a length of 70 mm for the damper
accumulator and a length of 100 mm for the intake accumulator. Replace the bolts in pairs, even if only
one of the bolts is corroded or damaged in some other way.
• Tighten the bolts (4 and 5) alternately to tightening torque 220 Nm.
• Charge the accumulators with nitrogen gas (N 2).

5.6 REPLACING THE RETURN ACCUMULATOR

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

For safety reasons the delivery hoses must


not be replaced with lower grade hoses
under any circumstances. The hoses must
be high-pressure hoses with four layers of
steel reinforcement, grade SAE 100R9R.

There is a risk of injury if these instructions


are not observed!

4
1
6

8 5
9
7
1250 0184 68

2 3

1. Bolt
2. Nut
3. Return accumulator
4. Bolt
5. Clip
6. Holder
7. Union
8. Hydraulic hose

DISMANTLING
• Remove the hydraulic hose (8) from the return accumulator (3).
• Remove the return accumulator (3) by removing the nuts (2), the bolts (1), the bolt (4) and the holder (6).

14
Accumulators 5

• Pull away the clip (5) and unscrew the accumulator from the union (7).
• Send the return accumulator to a workshop for overhauling.

ASSEMBLY
• Screw in the return accumulator (3) onto the union (7) in such a way that the plug (10) is accessible for
checking the accumulator’s diaphragm.
• Thread on the clip (5) and fit the holder (6) with the bolts (1, 4) and the nuts (2).
• Connect the hydraulic hose (8) to the return accumulator (3).

15
Changing the hydraulic motor 6

6. CHANGING THE HYDRAULIC MOTOR


1250 0184 69

1. Hydraulic hoses
2. Nuts
3. Hydraulic motor
4. Coupling
5. Groove ring
6. Cylinder
7. Gasket

DISMANTLING
• Disconnect the hydraulic hoses (1).
• Undo the nuts (2) and remove the hydraulic motor (3).
• Pull out the coupling (4).

ASSEMBLY
• Make sure that the groove ring (5) is fitted in the coupling (4).
• Lubricate the coupling’s splines with grease and fit the coupling (4) on the hydraulic motor (3).
• Fit the gasket (7) and hydraulic motor (3) onto the cylinder (6). Replace the gasket if it is damaged.
• Tighten the nuts (2) to a torque of 65 Nm.
• Connect the hydraulic hoses (1). Check that the correct direction of rotation is obtained.

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 lubricating air pres-
sure and the recommended lubricating oil.
Certain moving parts of the rock drill are
lubricated by means of oil-mixed com-
pressed air. It is important that these parts
receive good lubrication.

1
10 6

13b
6 9
13a 10 12
11
1250 0184 70

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

Check the level in the lubricating oil container (1) every shift. Observe cleanliness and fill with oil of the
correct grade. The lubricating oil container holds 5 litres.

NB! If the lubricating system has been empty of oil, it must be bled after filling.

17
Filling with lubricating oil and bleeding the system 7

Bleed as follows:
• Undo the cap (6) and allow the lubricating oil to flow out until the lubrication pump is free of air. Then
tighten the cap.
• Start the lubricating system and undo the hose connection at the pressure gauge (7) so that all air is
released from the system. Then tighten the hose connection.
• Undo the lubricating air hose (12) from the rock drill’s union (9).
• Start the lubrication pump and allow it to pump until oil flows from the plastic hose (11). When restarting
(after being stationary) oil should flow from the plastic hose immediately when the lubrication pump is
started.
• Check that the plastic hose for lubricating oil (11) is the correct length. It must not extend into the rock
drill.
• Reconnect the lubricating air hose (12).

18
Settings 8

8. SETTINGS
8.1 SETTING OF ECL LUBRICATING SYSTEM
A
3
4
B
5 2 1
10 6 B
B
9
13b 6
10 12
13a 11

8
1250 0184 71

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

• Open the electric cabinet


• Start the lubricating system.
• Check the lubricating air pressure at the rock drill (9) using a pressure gauge (A). The pressure should
be 2-3 bar. If the pressure is too low, clean the restrictor (8) or increase the diameter of the restrictor.
• Pay attention to the relay window (5) and set the correct lubricating oil dosage with the potentiometer (4).

Pump (13a) 35-40 pulses/minute


Pump (13b) 20-25 pulses/minute

• After setting, check the lubrication pump’s LED (10) to see that the correct pulse frequency has been
obtained and that oil is emerging from the front head’s hole (B) and between the shank adapter and front
guide.

19
Settings 8

8.2 SETTING DAMPER PRESSURE


1250 0184 72

• Fully close the constant flow valve (B) on the drill rig.
• Connect a pressure gauge (A), calibrated for 0-60 bar, between the hose and the damper union (1).
• 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.
• Read the drill rig’s 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).

8.3 SETTING THE EXTRACTOR UNIT PRESSURE (HEX)


1250 0184 73

• Fully close the constant flow valve (B) on the drill rig.
• Connect a pressure gauge (A), calibrated for 0-60 bar, between the hose and the extractor unit’s intake
union (P).
• Connect the extractor unit by activating return feed and operating the cradle to stop. Allow the lever to
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).

20
Checking the front head 9

9. CHECKING THE FRONT HEAD

5 1 3 6 3 3 A 8 9 10 5 13 1 13 13 3 3 3 3 6 8 A 10

11 11
2
2 3 C B 7
4 14 12 C B 9
COP 1840HE COP 1840HEX

3 3 6 3 3
1m
m

HE HE HEX
8 13 12 13 13
1 mm
2 mm

HEX
m 9
1m D 2
5
1250 0075 16

53 mm

• Check that air and lubricating oil escape between the shank adapter (5) and front guide (2), and also
out of the hole (B)
• Blow clean the lubricating air ducts (A) in the front head (1) with compressed air and check that the
restrictors (10) are open.
• Replace the guide (2) if the inside diameter exceeds 53 mm.
• Check the O-rings and flushing seals (3) 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 (6) if it is seriously corroded, or if it contains cracks.
• Replace the stop ring (7) if it is worn by more than 1 mm.
• Replace the extractor unit piston (12) if the surface against the shank adapter is worn by more than 1
mm. When replacing the extractor unit piston check the seals and O-rings (13). Replace the seals and
O-rings if they are worn or damaged.
• Look inside the gear housing and check the splines of the driver (8). If the splines are less than 2 mm
in width, the driver must be replaced. Fit a new driver with the aid of a suitable drift and a copper
hammer.
• If the rotation chuck bushing (9) is worn by more than 1 mm, or if the striking surface of the piston (12)
is damaged in any way, the rock drill must be sent to a suitable workshop for overhauling. NB! Fit the
rotation chuck bushing so that the lubricating grooves (D) are directed towards the damper piston (14).
• Replace the shank adapter (5) 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 that the drill sleeve (11), to be used with upwards directed drilling, is not damaged and rotates
with the shank adapter.

21
Removing the front head 10

10. REMOVING THE FRONT HEAD

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

Ensure that the hydraulic and air systems


are depressurised before starting any work.

There is a risk of injury if these instructions


are not observed!

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

10.1 COP 1840HE


1250 0184 75

• Remove the flushing hose (5).


• Remove the connection plate (1) and union (2) by removing the bolts (3) and washers (6).
• Remove the cup seal (4).
1250 0184 76

• Remove the front side-bolt nuts (3) with their washers (2).
• Remove the front head (1) by tugging the shank adapter (4). Following which, pull out the shank adapter
from the front head.
• Check the internal components when replacing the shank adapter.

22
Removing the front head 10

10.2 COP 1840 HEX

1250 0184 77

• Remove the front side-bolt nuts (3) with their washers (2).
• Remove the front head (1) by tugging the shank adapter (4) or by tapping with a copper hammer. Follo-
wing which, pull out the shank adapter from the front head.
• Check the internal components when replacing the shank adapter.

23
Mounting the front head 11

11. MOUNTING THE FRONT HEAD


11.1 COP 1840HE
6
1

4
1250 0184 81

5 2 3
• Fit the stop ring and shank adapter (4) into the front head (1).
• Check that the pin (6) is fitted into the cover. Fit the front head (1) on to the side-bolts (5).
• Fit the washers (2) and nuts (3).
NB! Before assembly, grease must be applied to the threads, type NEVER SEEZ.
• Check the tightening torques on the rear side-bolt nuts and the front side bolt.
• Following which, tighten the nuts (3) alternately to a torque of 350 Nm.

6
3
1250 0184 82

5 2 7 1

• Fit the cup seal (4) into the flushing head.


• Fit the connection plate (1) to the front head using the washers (6) and screws (3). Tighten the screws
(3) to a torque of 90 Nm.
• Replace the seal washer (7) if it is damaged.
• Fit the union (2) to the connection plate. Following which, tighten to a torque of 300 Nm.
• Connect the flushing hose (5) and tighten the nut.

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.

24
Mounting the front head 11

11.2 COP 1840HEX

1250 0184 83 6 4 1

7 5 2 3
• Fit the shank adapter (4) in the extractor unit’s front head.
• Check the tightening torques on the rear side-bolt nuts and the front side bolt.
• Fit the cylindrical pin (5).
• Fit the front head (1) onto the screw studs (6).
• Fit the washers (2) and nuts (3).
NB! Before assembly, grease must be applied to the threads, type NEVER SEEZ.
• Connect the flushing hose to the union (7).

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.

25
Replacing the flushing head and driver 12

12. REPLACING THE FLUSHING HEAD AND DRIVER


5

4
A 6
B

3
1250 0184 78

2 1

CAUTION!
Exercise caution when removing the flush-
ing head and driver. Watch your fingers!

DISMANTLING
• Remove the flushing hose (1) from the union (2).
• Remove the union (3) and its O-rings.
• Press the removal tool (A) into the gear housing (4) until the tool moves to the stop, i.e. the tool’s splines-
equipped section has then passed the driver’s (5) splines.
• Turn the removal tool clockwise slightly.
• Tap out the driver (5) and flushing head (6) using the sliding hammer (B).

ASSEMBLY

1 2 A

3
1250 0184 79

• If the rotation chuck bushing (3) has been removed, tap it in with a suitable copper drift.
NB! Fit the rotation chuck bushing so that the lubricating grooves are directed towards the damper
piston.
• Tap the driver (2) into the drill sleeve in the gear housing (1) using a drift (A) and a copper hammer.

26
Replacing the flushing head and driver 12

1 3 4 2 4 3

5
6
7
8

9
1250 0184 80

11 10

• Fit the O-rings (3) and the seals (4) in the flushing head (2).
Important! The seals (4) must be turned in accordance with the illustration.
• Position the flushing head (2) in the cover (1) and tap it in with a copper hammer. Check carefully that
the flushing intake in the cover coincides with the hole in the flushing head.
• Fit the O-rings (5, 6) and the support ring (7) on the union (8).
• Fit the unions (8,9 and 10) and the nut (11).
• Torque tighten the union (8) to 300 Nm and the union (9) to 180 Nm.

27
Slinging 13

13. SLINGING
1250 0184 84

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

CAUTION!
Lifting devices and straps must be
approved for lifting at least 500 kg.

Incorrect lifting devices could cause the


rock drill to start moving or fall down.

Incorrect operation could cause crushing


damage.

13.1 ROCK DRILL WEIGHTS

COP 1840HE 184 kg


COP 1840HEX 244 kg

28
Long-term storage 14

14. LONG-TERM STORAGE


1250 0184 87

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

• Check that all connections, including the one for the flushing medium, are properly capped with protec-
tive caps of the right size.
• Clean the rock drill thoroughly. Use a degreasing agent and hose down the rock drill with water.
• Clean thoroughly and oil in the front head components in contact with flushing medium (especially in
high humidity).
• Release gas from the accumulators.
• Store the rock drill in a dry place.

29
Lubrication 15

15. LUBRICATION

1
3
1250 0184 85

15.1 LUBRICATION OF GEAR


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

15.2 HYDRAULIC FLUID AND LUBRICANT RECOMMENDATIONS

HYDRAULIC OIL
Use mineral based or synthetic (polyalpha olefine or diester) hydraulic oil with good rust, wear, oxidising
and foam inhibitive properties as well as good air and water separation ability. Select an oil with viscosity
grade (VG) and viscosity index (VI) as specified in the table. Oil with high viscosity index is less temperature
dependent.
Hydraulic oil temperature in tank ºC.

Normal operating Min. start temp


Viscosity grade VG
temp. Viscosity min. 1000 Max. temp. Viscosity index VI
(ISO 3448)
Viscosity 25-50 cSt 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

PNEUMATIC TOOL OIL


The pneumatic tool oil must have a high grade of lubricating properties, additives for good adhesion and
additives for preventing foaming.

30
Lubrication 15

Ambient temperature ºC (ºF) Viscosity grade (ISO 3448)


-30 to 0 (-22 to +32) ISO VG 15-32
-10 to +20 (14 to 68) ISO VG 32-46
+10 to +20 (50 to 122) ISO VG 46-68

Additives in oil for extreme pressures


(EP additives (extreme pressure)

Four-ball apparatus test, welding load ASTM 2783 Min. 250 kg


(Four ball WL (Welding load))
Four-ball apparatus test, mean scar diameter at 40 kg load ASTM 4172 Max. 0.5 mm
Four ball MSD (40 kg) (mean scar diameter)

GREASE
NB! Because of the operating temperature in the rock drill gear housing, always use a high-temperature
grease containing an ashless thickening agent and with additives that give resistance against oxidation and
rust. The grease should also have good resistance to water.

NLGI number Drop point Base oil viscosity Operating Temperature


2 250 ºC 110 cSt at 40 ºC -20 to +150 ºC

31
Stroke length setting 16

16. STROKE LENGTH SETTING

63

66
1250 0184 95

16.1 BASIC SETTING


• Plug (63) is fitted on cylinder (66). Adjust piston stroke length by turning the plug. There are three diffe-
rent positions. They are indicated on the plug (63) by punched dots. E.g. when two dots appear upwards
the setting is 2.

32
Stroke length setting 16

33