Hydraulic Rock Drill

COP 1435 Ver. A

Maintenance

Original instructions
2017-02-03 | No: 9852 3260 01d 3025862667.1.3025905291 en-US
Hydraulic Rock Drill COP 1435 Ver.A Table of Contents

Table of Contents
1 Introduction ...........................................................................................................  5
1.1 Safety first................................................................................................................................... 5
1.2 The Purpose of This Publication .............................................................................................. 5
1.3 Target Group .............................................................................................................................. 6
1.4 Feedback and Contact Information .......................................................................................... 6

2 General Information ..............................................................................................  7

2.1 Component Replacement.......................................................................................................... 7
2.2 Manufacturing Number.............................................................................................................. 7
2.3 Cleaning ...................................................................................................................................... 8
2.3.1 Safety Precautions Before Cleaning.........................................................................................  8
2.3.2 Cleaning ...................................................................................................................................  8
2.3.3 Hydraulic Hoses .......................................................................................................................  8
2.4 Hydraulic Components.............................................................................................................. 9
2.4.1 General.....................................................................................................................................  9
2.4.2 Hydraulic Workshops................................................................................................................  9
2.4.3 Hydraulic Hose Replacement .................................................................................................  10
2.5 Welding ..................................................................................................................................... 10
2.6 Long Period of Storage ........................................................................................................... 10
2.7 After Long Period of Storage .................................................................................................. 10

3 Maintenance Tables ............................................................................................  11

3.1 New or Overhauld Rock Drill................................................................................................... 11
3.2 Work Shift ................................................................................................................................. 11
3.3 Percussion Hours .................................................................................................................... 11

4 Lifting Rock Drill .................................................................................................  13

5 Hose Connections...............................................................................................  15

5.1 Connect Hoses ......................................................................................................................... 15
5.2 Check Hydraulic Hoses ........................................................................................................... 16

6 Tools.....................................................................................................................  17
6.1 Standard Tools ......................................................................................................................... 17
6.2 Special Tools ............................................................................................................................ 19

7 Tightening Torques.............................................................................................  21

7.1 Tighten All Threaded Unions .................................................................................................. 21

8 Accumulators ......................................................................................................  23

8.1 Check Accumulator Warning Signs ....................................................................................... 23
8.2 Check Accumulator Pressure ................................................................................................. 23
8.3 Discharge Accumulators......................................................................................................... 24
8.4 Removing Intake and Damper Accumulators........................................................................ 25
8.5 Installing Intake and Damper Accumulators ......................................................................... 25
8.6 Charge Accumulators.............................................................................................................. 26
8.6.1 Connecting Accumulator Charger to Gas Cylinder.................................................................  26
8.6.2 Connecting Accumulator Charger to Accumulator .................................................................  28
8.6.3 Filling Accumulator with Accumulator Charger.......................................................................  28

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Hydraulic Rock Drill COP 1435 Ver.A Table of Contents

8.6.4 Disconnecting Accumulator Charger ......................................................................................  29

9 Hydraulic Motor...................................................................................................  31

9.1 Removing Hydraulic Motor ..................................................................................................... 31
9.2 Installing Hydraulic Motor ....................................................................................................... 31
9.3 Function and Condition Test Hydraulic Motor ...................................................................... 32
9.3.1 Testing Hydraulic Motor..........................................................................................................  32
9.3.2 Half Belle Test ........................................................................................................................  33

10 Front Head ...........................................................................................................  35

10.1 Dissassembling Male Front Head........................................................................................... 35
10.2 Inspecting and Replacing Male Front Head Parts................................................................. 36
10.3 Assembling Male Front Head.................................................................................................. 40
10.4 Inspect Shank Adapter Threads ............................................................................................. 41
10.5 Check for Leaks During Drilling ............................................................................................. 42

11 Lubrication...........................................................................................................  43
11.1 Select Lubricant ....................................................................................................................... 43
11.2 Fill Air Lubricant Oil................................................................................................................. 44
11.3 Lubricate Front Head ............................................................................................................... 45
11.4 Lubricate Gears........................................................................................................................ 45
11.5 Check ECL Lubricant Oil Return ............................................................................................ 46

12 Settings ................................................................................................................  47

12.1 Set ECL Lubrication System ................................................................................................... 47
12.2 Set Damper Pressure............................................................................................................... 48
12.3 Check Damper Pressure During Drilling................................................................................ 48

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Hydraulic Rock Drill COP 1435 Ver.A 1 Introduction

1 Introduction

1.1 Safety first

WARNING
Serious injury
Risk of personal injury!
u Never operate the Rock Drill in any explosive environment.
u Always read the machine Safety Manual before start maintenance work on the Rock
Drill.
u Always observe local regulations.
u Always carry out a documented risk analysis and take the necessary precautions be-
fore maintenance work.
u Only use clean, calibrated tools in good condition.
u Only use approved handling and working equipment in good condition.
u Always use personal protective equipment.
u During maintenance work, the equipment should be shut down, in service mode, and
the main switch turned off and locked.
u Attach WORK IN PROGRESS signs according to local regulations, or at least at the
main switch and operator's station.

WARNING
Serious injury or death
Serious danger when working on the hydraulic system!
u Ensure that the air, water and hydraulic system is depressurised before starting work.
u Adjacent moving units should always be anchored before working on a system part.
u Always stop work if there is an unforeseen or suspected risk.

1.2 The Purpose of This Publication

The objective of these instructions is to detect and rectify faults at an early stage so that
breakdowns, costly secondary damage and accidents can be prevented. Regular mainte-
nance is a precondition for planning necessary interruptions in operation such as recondi-
tioning and repairs. This allows work to be carried out when it's most suitable with regard to
production instead of causing complete breakdown.

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Hydraulic Rock Drill COP 1435 Ver.A 1 Introduction

1.3 Target Group

! NOTE: This instruction is an example of workflow during maintenance.

The maintenance instructions are intended for use by maintenance and service personnel.
Persons working to these instructions must have completed relevant Atlas Copco training
for the Rock Drill.

1.4 Feedback and Contact Information

Atlas Copco works actively with the development and continuous improvement of its prod-
ucts and associated documentation. Provide your feedback on products and documenta-
tion and access your local supplier under "Contact Us" at www.atlascopco.com.

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Hydraulic Rock Drill COP 1435 Ver.A 2 General Information

2 General Information

2.1 Component Replacement

Use original Atlas Copco Spare Parts to guarantee the safety and reliability of the Rock
Drills function and design.

2.2 Manufacturing Number

All Rock Drills are given a manufacturing number depending on place of Manufacture,
Year, Family, and Version. The manufacturing number is stamped on and the location on
the Rock Drill varies, depending on the model.

1. Factory code for manufactured unit:

AVO = Atlas Copco Rock Drills AB
2. Year that the product was produced.
3. Family letter that identifies the number series:
D = Hydraulic Rock Drills
P = Pneumatic Rock Drills
T = Rotation Units
4. Serial number in the family group.
5. Version letter for the product, shows which Manual and Spare part list that is relevant.

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Hydraulic Rock Drill COP 1435 Ver.A 2 General Information

2.3 Cleaning

2.3.1 Safety Precautions Before Cleaning

WARNING
Serious Injury
Risk of personal injury
u Always read general safety regulations before starting maintenance work. Refer to
Safety manual.
u Always turn off the equipment and the main switch before cleaning and maintenance
work is carried out. Set up WORK IN PROGRESS warning signs at the main switch
and control positions.
u Be aware of the units kinetic energy due to accumulated hydraulic pressure. Relieve
pressure in hydraulic, water, and compressed air systems and always secure moving
units.

2.3.2 Cleaning
First read: Safety Precautions Before Cleaning [} 8]

1. Clean the Rock Drill frequently from rock fragments, drill cuttings and accumulations
of dust.

2. Clear away fragments of rock and other objects from air, water and hydraulic hoses
and cables frequently to avoid the risk of chafing on sharp edges.

3. Rinse the Rock Drill with water after every work shift. Use only rinsing pressure and
avoid spraying directly at seals. Wipe away any accumulations of water.

2.3.3 Hydraulic Hoses

First read: Safety Precautions Before Cleaning [} 8]

WARNING
Serious Injury
Risk of abrasions and crushing injuries.
u Always change damaged hoses and couplings.

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Hydraulic Rock Drill COP 1435 Ver.A 2 General Information

n Wet areas around hoses and connections is a sign for leaks that can cause spurting oil
or burst hoses if the leak worsens.
n The hose casing must be intact without any swelling (sign of inner hose or cord break-
age).
n Couplings must not have indentations or cracks and must make a secure connection.
Retighten or feel the coupling connection manually if a leak is suspected.
n Check that all hose attachments and clamps are intact. Loose attachments means that
hoses are damaged or get jammed during angle adjustment or when lowering the ma-
chine.
n Replace or rectify in the event of any faults.

2.4 Hydraulic Components

2.4.1 General
The hydraulic system is sensitive to contamination. The environment where the machine is
normally used is generally an unsuitable place for repairing hydraulic components. Inter-
vention in hydraulic systems in workplaces must be limited. Components must be repaired
in an adapted environment, refer to Hydraulic Workshops.
Observe the following points to avoid breakdowns and interruptions in operation due to
fouled hydraulic oil:
n Keep the machine clean. Hose it down at regular intervals using a degreasing additive.
n Before opening any connection, clean the area around it.
n Use clean tools and work with clean hands.
n Always plug hydraulic connections immediately after they have been detached. Use
clean protective plugs.
n Hydraulic components like hoses, valves, engines must always be stored with suitable
protective plugs fitted in place.

2.4.2 Hydraulic Workshops

Workshops that are used for the repair of hydraulic components must:
n Be separate from activities which generate dust and particles, such as welding, grind-
ing, the transportation of vehicles.
n Have own suitable washing equipment required for repairing the components.
n Use only tools from a hydraulic workshop consisting of standard and special tools.
n Have a ventilation system that does not admit dust into the premises.
n Use trained mechanics.

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Hydraulic Rock Drill COP 1435 Ver.A 2 General Information

2.4.3 Hydraulic Hose Replacement

Load, vibration, and other mechanical stresses place high demands on hydraulic hoses.
When replacing hydraulic hoses, check that they are replaced with hydraulic hoses:
n With the correct crimped couplings
n Of the correct quality class
n Of the correct dimensions
All pressurized hoses have pressed couplings and can therefore be purchased ready made
from Atlas Copco. Grades and dimensions of hoses are specified in the spare part catalog
for the machine in question. Also make sure that hose couplings are clean, not damaged
and properly tightened.

2.5 Welding
n All welding on the Rock Drill is forbidden.

2.6 Long Period of Storage

Action must be taken to protect the equipment from corrosion and storage damage if stor-
age expected to last longer than three months.
n Wash the equipment and thoroughly wipe it dry. Use compressed air to blow any col-
lections of water out of cavities and pockets.
n Store equipment on site with regulated temperature and ventilation. Recommended
storage environments maintain a temperature of 10-20 ºC and max 20–50% humidity.
n Apply corrosive protection compound to machined surfaces.
n Apply touch up paint to any scratches and damage on painted areas.
n Cover with plastic.
n Clean old grease away from lubrication points to prevent coke formation. Pump new
grease into the lubrication nipples. Ensure that you use the correct grease for each
point.
n Hoses and rubber parts can be packed in airtight plastic to reduce desiccation, but en-
sure that the components are dry before packing.

2.7 After Long Period of Storage

n Change lubricant and hydraulic oil where appropriate.

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Hydraulic Rock Drill COP 1435 Ver.A 3 Maintenance Tables

3 Maintenance Tables

3.1 New or Overhauld Rock Drill

Maintenance Task Work Shift First Service

8.6 Charge Accumulators Before

11.1 Select Lubricant Before

11.2 Fill Air Lubricant Oil Before

12.1 Set ECL Lubrication System Before

12.2 Set Damper Pressure Before

11.5 Check ECL Lubricant Oil Return During

7.1 Tighten All Threaded Unions After

3.2 Work Shift

Maintenance Task Work Shift

10.4 Inspect Shank Adapter Threads Before

12.3 Check Damper Pressure During Drilling Before

5.2 Check Hydraulic Hoses During

10.5 Check for Leaks During Drilling During

11.5 Check ECL Lubricant Oil Return During

11.3 Lubricate Front Head After

3.3 Percussion Hours

Maintenance Task Percussion Hours

7.1 Tighten All Threaded Unions 40

8.1 Check Accumulator Warning Signs 40

8.2 Check Accumulator Pressure 40

11.4 Lubricate Gears 40

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Hydraulic Rock Drill COP 1435 Ver.A 3 Maintenance Tables

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Hydraulic Rock Drill COP 1435 Ver.A 4 Lifting Rock Drill

4 Lifting Rock Drill

WARNING
Risk of Lifting the Rock Drill
Incorrect handling can cause serious crushing injury or death.
u Use extreme caution when strapping and lifting heavy objects.
u Lifting must be done through the center of gravity.
u Only use straps that are intact and designed for the load they will carry.
u Do not approach a suspended load.

1. Attach the straps to the intended lifting points.

2. Lift the Rock Drill carefully through the center of gravity. Make sure the Rock Drill is
balanced and the straps do not slip.

Rock Drill Weight

COP 1435 Ver. A 87 kg

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Hydraulic Rock Drill COP 1435 Ver.A 4 Lifting Rock Drill

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Hydraulic Rock Drill COP 1435 Ver.A 5 Hose Connections

5 Hose Connections

5.1 Connect Hoses

WARNING
Pressurized Systems
Can cause serious injury to eyes and skin.
u Always de-pressurize hydraulic, lubrication, and flushing system before any mainte-
nance work.
u Never replace new hoses with hoses of lower grade and quality.
u Always use gloves and eye protection.

1 Flushing, air/water

2 Lubrication air, out

3 Lubrication air, in

4 Rotation right (out)

5 Rotation left (in)

6 Damper, in

7 Impact, in

8 Percussion, return

n Always clean the rock drills hose connections before removing the protective caps.

n Pressure hoses with an internal diameter of 19 mm (3/4") or greater, must be of grade

SAE 100 R 9R.

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Hydraulic Rock Drill COP 1435 Ver.A 5 Hose Connections

5.2 Check Hydraulic Hoses

n If the hydraulic hoses vibrates hard, check the accumulator pressure. See chapter Ac-
cumulators.

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Hydraulic Rock Drill COP 1435 Ver.A 6 Tools

6 Tools

6.1 Standard Tools

Ref. No. Tools

A Plastic mallet

B Sledge hammer

C Honing tool 19–70 mm

D Open-end wrenches 10–32 mm, 46 mm

E Allen keys 4–10 mm

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Hydraulic Rock Drill COP 1435 Ver.A 6 Tools

Ref. No. Tools

F Screwdriver

G Mandrel 2–10 mm, brass mandrel 20x250 mm

H Feeler gauge 0.03-0.10 mm with 0.01-mm inter-

vals
Feeler gauge 0.05-1.00 mm with 0.05-mm inter-
vals

I Internal lock ring pliers

J Socket wrench set 10–32 mm for external

hexagon
Socket wrench set 4–10 mm for internal hexagon

K Awl

L T-handle with 3/4" connection bracket, power

socket 32 mm

M Vernier caliper

N Micrometer 0-25 mm

O Puller with accessories

P Assembly tool thread insert (M12)

Assembly tool thread insert (M14)
Assembly tool thread insert (M16)
Assembly tool thread insert (M20)

R Bearing puller

S Magnet

T Puller

Table 1: Standard tools

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Hydraulic Rock Drill COP 1435 Ver.A 6 Tools

6.2 Special Tools

Ref. No. Tools Part Number

A1 Fixture 3115 0329 80

A2 Retaining plate 3115 3457 00

A3 Rotary actuator 9495 5916 80

A4 Mandrel for gear housing 9495 5917 00

A5 Mandrel for cylinder and front 9495 5918 00

A6 Mandrel for piston guide 9495 5919 00

A7 Mandrel for plug on cylinder 9495 5920 00

A8 Mandrel for front, d=45 mm 9495 5921 00

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Hydraulic Rock Drill COP 1435 Ver.A 6 Tools

Ref. No. Tools Part Number

A9 Fitting and removal tool 3115 5251 80

A10 Key set, 24 mm 3115 0343 00

Key set, 30 mm 3115 3521 00
Key set, 32 mm 3115 0344 00

A11 Spanner 3115 2236 00

A12 Plates 9495 5922 00

A13 Torque wrench 10-100 Nm 9106 1015 40

Torque wrench 75-400 Nm 9106 1015 41

A14 Charging equipment for accumu- 3115 6001 92

lators

A15a Adapter, discharging accumula- 3115 5748 00

tors

A15b Pressure gauge inclusive 3115 3799 80

adapter

A16 Assembly tool (M8x2) 3115 1127 00

Fitting tool (M16) 3115 1126 00
Assembly tool (M14) 3115 1627 00
Assembly tool (M20x2) 3115 1628 00

A17 Puller 3091 0455 00

A18 Motor fixture 3115 6000 87

Table 2: Special tools

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Hydraulic Rock Drill COP 1435 Ver.A 7 Tightening Torques

7 Tightening Torques

7.1 Tighten All Threaded Unions

n Check all tightening torques on the rock drill according to the torque table below.
Always use a calibrated torque wrench.

Ref. No. Quantity Torque Lubricant Instructions

A 4 220 Nm (162 lbf-ft) oil Tighten alternately to

full torque

8 2 250 Nm (184 lbf-ft) Anti-seize Tighten alternately to

paste full torque

9 4 220 Nm (162 lbf-ft) oil Tighten alternately to

full torque

10, 11 2 80 Nm (59 lbf-ft) oil Tighten alternately to

full torque

222 2 45 Nm (33 lbf-ft) oil Tighten alternately to

full torque

366 4 220 Nm (162 lbf-ft) oil Tighten alternately to

full torque

604 2 30 Nm (22 lbf-ft) oil Tighten alternately to

full torque

608 4 220 Nm (162 lbf-ft) oil Tighten alternately to

full torque

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Hydraulic Rock Drill COP 1435 Ver.A 7 Tightening Torques

Recommended Oil

Hydraulic oil or Motor oil

Recommended Anti-Seize Paste

Loctite LB 8009 or corresponding thread lubricant

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Hydraulic Rock Drill COP 1435 Ver.A 8 Accumulators

8 Accumulators

8.1 Check Accumulator Warning Signs

1. Check that signs are in the correct location, clean, and fully legible on the machine,
replace damage signs.

Symbol Description

Warning sign
n Read the instruction manual thor-
oughly before performing service or
replacement

Warning sign
n Charge only with nitrogen gas

Table 3: Warning signs

8.2 Check Accumulator Pressure

WARNING
Explosion Risk
There is a risk of personal injury or death when using wrong gas.
u Only use dry nitrogen (N2).

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Hydraulic Rock Drill COP 1435 Ver.A 8 Accumulators

1. Remove the accumulators charging valve protective cap (A).

2. Install the pressure gauge (A15) with nipple (B) to the charging valve (604) hand tight.

3. Read the pressure gauge and check the values for correct accumulator pressure.

a. Intake accumulator (D) Recommended base settings: 70 bar. Max setting 100
bar.

b. Damper accumulator (C): 10 bar.

4. Remove the pressure gauge (A15) and the nipple (B).

5. Charge the accumulators with nitrogen gas (N2) if necessary. See Chapter Charging
Accumulators.

6. Reinstall the charging valve protective cap (A) hand tight.

8.3 Discharge Accumulators

1. Remove the charging valves (604) protective cap (A).

2. Install connection adapter (B) to valve (604).

! NOTE: Aim the connection adapter (B) so there is no risk for per-
sonal injury when the gas is released.

3. Release the nitrogen gas (N2) from the accumulators.

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Hydraulic Rock Drill COP 1435 Ver.A 8 Accumulators

4. Remove the connection adapter (B) and install the charging valve protective cap (A).

8.4 Removing Intake and Damper Accumulators

Precondition p Accumulators must be discharged.

1. Undo and remove screws (608) together with damper accumulator (600) and seal ring
(233) from the damper side (A).

2. Undo and remove screws (608) together with intake accumulator (600) and seal ring
(320) from the intake side (B).

! NOTE: Always replace the accumulator screws if the accumulator

diaphragm has broken and the gas has leaked out.

8.5 Installing Intake and Damper Accumulators

All parts must be clean, dry, and free of oil before installing.

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Hydraulic Rock Drill COP 1435 Ver.A 8 Accumulators

1. Position the seal ring (233) in the grooves on the rock drill damper side (A).

2. Apply oil on two undamaged original accumulator screws (608).

! NOTE: Always replace bolts all bolts, even if only one bolt is cor-
roded or otherwise damaged.

3. Install the damper accumulator (600) with two accumulator screws (608) on the rock
drill damper side (A).

4. Tighten the screws alternately to 220 Nm (162 lbf-ft).

5. Apply oil on two undamaged original accumulator screws (608).

6. Install the intake accumulator (600) with two accumulator screws (608) on the rock
drill intake side (B).

7. Tighten the screws alternately to 220 Nm (162 lbf-ft).

Recommended Oil

Hydraulic oil or Motor oil

8.6 Charge Accumulators

WARNING
Explosion Risk
There is a risk of personal injury or death when using wrong gas.
u Only use dry nitrogen (N2).

8.6.1 Connecting Accumulator Charger to Gas Cylinder

WARNING
Explosion Risk
There is a risk of personal injury or death when using wrong gas.
u Only use dry nitrogen (N2).

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Hydraulic Rock Drill COP 1435 Ver.A 8 Accumulators

1. Check that the gas cylinder (20) contains Nitrogen (N2) gas.

2. Secure the gas cylinder (20) so that it cannot fall over and cause damage.

3. Check that the gas cylinder valve (19) is closed.

4. Remove protective nut (18) from the gas cylinder valve and check that the gas cylin-
der valve threads are undamaged and clean.

5. Check that the bottle connection (110) and the o-ring (1) are undamaged and clean.

6. Connect the hose connection (110) to the gas cylinder valve (19) hand tight. Check
that the hose (60) is not twisted or stretched.

7. Check that the pressure regulator (140) is closed.

8. Check that the needle valve (40) is closed.

9. Open the gas cylinder valve (19) slowly by turning it counterclockwise and check that
the high-pressure gauge (50) shows full pressure reading.

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Hydraulic Rock Drill COP 1435 Ver.A 8 Accumulators

8.6.2 Connecting Accumulator Charger to Accumulator

1. Remove the protective nut (17) from the accumulator valve (16).

2. Check that the threads of the accumulator valve (16) are undamaged and clean.

3. Close the hose valve (3) by turning it clockwise.

4. Connect the hose connection (130) to the accumulator valve (16) hand tight. Check
that the hose (70) is not twisted or stretched. Connection (90) is used instead of con-
nection (130) with the earlier version of accumulator valve.

8.6.3 Filling Accumulator with Accumulator Charger

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Hydraulic Rock Drill COP 1435 Ver.A 8 Accumulators

1. Turn on the manometer (100).

2. Open hose valve (3) by turning it counterclockwise.

3. Charge the accumulators to the correct pressure as follows:

a. Intake Accumulator (600) Recommended Base setting: 70 bar. Max setting

100 bar.

b. Damper Accumulator Setting (600): 10 bar.

4. Open the pressure regulator (140) slowly by turning the knob clockwise while monitor-
ing the manometer (100) until correct filling pressure is achieved.

5. Close the pressure regulator (140).

6. If the pressure in accumulator gets too high:

a. Slowly open the needle valve (40) by turning the knob counterclockwise until cor-
rect pressure is achieved.

7. Close the hose valve (3) by turning it clockwise. When using connection (90) with the
earlier version of accumulator valve, the accumulator valve (16) must be closed.

8.6.4 Disconnecting Accumulator Charger

1. Check that hose valve (3) is closed.

2. Close the gas cylinder valve (19).

3. Open needle valve (40) to evacuate the gas, check that the manometers (50) and
(100) drops to 0.

4. Disconnect hose connection (90) from the accumulator valve (16).

5. Install protection cap (17) on the accumulator valve (16).

6. Disconnect hose connection (110) from the gas cylinder valve (19).

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Hydraulic Rock Drill COP 1435 Ver.A 8 Accumulators

7. Install protection cap (18) in the gas cylinder valve (19).

8. Transport the gas cylinder (20) to the designated location and secure it.

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Hydraulic Rock Drill COP 1435 Ver.A 9 Hydraulic Motor

9 Hydraulic Motor

9.1 Removing Hydraulic Motor

1. Undo and remove lock nuts (11) and screws (10).

2. Remove hydraulic motor (500) from gear housing (200).

9.2 Installing Hydraulic Motor

1. Lubricate the gear housing (200) and the hydraulic motor splines (500) with grease.

2. Install hydraulic motor (500) to gear housing (200).

3. Apply oil to screws (10) and lock nuts (11).

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Hydraulic Rock Drill COP 1435 Ver.A 9 Hydraulic Motor

4. Install screws (10) and lock nuts (11).

5. Tighten screws (10) and lock nuts (11) to 80 Nm (59 lbf-ft).

Recommended Oil

Hydraulic oil or Motor oil

9.3 Function and Condition Test Hydraulic Motor

The following test gives an approximation of the present state of the motor. The following
are required to conduct the test:
n Apparatus for hydraulic flow and pressure.
n Pressure gauge.
n Flow meter 0-15 l/min.
n Couplings and hoses to assemble the components.
n Motor fixture for the hydraulic motor.
n Oil grade HLP46 at 50 °C and viscosity approximate 35 CST.

9.3.1 Testing Hydraulic Motor

1. Connect the hydraulic pressure hose (P) to port (A) and the return hose (R) to port (B)
on the hydraulic motor.

2. Allow the motor to rotate or approximately 30 seconds with a maximum flow of 10 l/

min.

3. Make sure that rotation is constant and without any abnormal noise.

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Hydraulic Rock Drill COP 1435 Ver.A 9 Hydraulic Motor

9.3.2 Half Belle Test

The following test indicates the condition of the gear wheel in the motor. The test can be
used for all motors.

1. Connect return hose (R) to port (B) with a T-coupling If the motor has a drain line.

2. Connect the flow meter to port (B) on the motor.

3. Secure the motor shaft with suitable equipment, it must not rotate. This lock (A18) unit
can be ordered for MS type motors.

4. Pressurize port (A) in accordance with the following table, make sure that you use the
correct pressure for the current motor type.

5. Measure the flow from port (B) (if necessary, with the drain line).

6. Replace the motor if it exceeds the specified value.

Motor Type Pressure Port A Permitted Flow Port B

MP 80-160 120 bar 10 l/min

MP 200 100 bar 10 l/min

MP 315-400 60 bar 10 l/min

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Hydraulic Rock Drill COP 1435 Ver.A 9 Hydraulic Motor

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Hydraulic Rock Drill COP 1435 Ver.A 10 Front Head

10 Front Head

10.1 Dissassembling Male Front Head

1. Remove the flushing hose (A).

2. Remove the nipple (15), flushing adapter (107), and o-ring (108).

3. Remove the four screws (9).

4. Remove the front part (101) together with o-rings (113) by pulling the shank adapter
and hitting the front part (101) with a plastic mallet.

5. Remove lock ring (118).

6. Remove the shank adapter (16), stop ring (130), washer (105), and drill collar (19)
from front part (101).

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Hydraulic Rock Drill COP 1435 Ver.A 10 Front Head

7. Press out inner components from the front head (101) using tool (A5).

10.2 Inspecting and Replacing Male Front Head Parts

1. Inspect guide (102) and the lubrication ducts (A). Replace the guide (102) if the inside
diameter exceeds 36 mm.

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Hydraulic Rock Drill COP 1435 Ver.A 10 Front Head

2. If air and water penetrates through the front head tell tail holes or around the shank
adapter (16):

a. Inspect o-rings (112) on flushing head (104).

b. Inspect cup seals (115) and seals (117) in flushing head (104).

c. Inspect wiper (114) in guide (102).

d. Inspect o-ring (132) on stop ring (131).

e. Replace parts if worn or damaged.

3. Inspect flushing head (104). Replace if seriously damaged or cracked.

4. Replace stop ring (131) if:

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Hydraulic Rock Drill COP 1435 Ver.A 10 Front Head

a. The wear surface is worn more than 1 mm.

b. The wear surface is uneven.

c. Any cracks found.

5. Lock inside the gear housing and inspect the splines on the driver (212), rotation
chuck bushing (206), and impact piston (305). If parts look damage or worn, remove
them with a puller for further inspection.

a. Measure the width of the driver (212) splines. If less than 2 mm the driver (212)
must be replaced.

b. Measure the wear of the rotation chuck bushing (206). If worn more than 1 mm
the Rock Drill must be sent for overhaul. See chapter Rock Drill Overhaul.

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Hydraulic Rock Drill COP 1435 Ver.A 10 Front Head

c. Inspect the impact pistons (305) impact surface. If damages in any way, the
Rock Drill must be sent for overhaul. See chapter Rock Drill Overhaul.

6. Replace the shank adapter (16) if:

a. The threads is worn out.

b. The impact surface is crushed or chipped.

c. The front or rear end surface of the splines are worn.

7. Clean lubrication channels with compressed air.

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Hydraulic Rock Drill COP 1435 Ver.A 10 Front Head

10.3 Assembling Male Front Head

1. Install wiper (114) in guide (102).

2. Press guide (102) into front part (101).

3. Install cup seals (115) and seals (117) into flushing head (104).

4. Install the four o-rings (112) in the grooves on flushing head (104).

5. Press flushing head (104) into the front part (101). Make sure the flushing holes in the
flushing head (104) and the front part (101) aligns.

6. Install o-ring (108), flushing adapter (107) and nipple (15) in the front part (101).

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Hydraulic Rock Drill COP 1435 Ver.A 10 Front Head

7. Install the washer (105) and lock ring (118) in the front part (101).

8. Install stop ring (133) and o-ring (132) on the shank adapter (16).

9. Install the shank adapter (16) together with the stop ring (133) in the front part (101).

10. Install the drill collar (19) on the shank adapter (16).

11. Install o-rings (113) to the front part (101).

12. Inspect that spring pin (116) and pin (236) is installed in correct position.

13. Install the front head (101) onto gear housing (201).

14. Apply oil to the four screws (9).

15. Install and tighten screws (9) alternately to 220 Nm (162 lbf-ft).

10.4 Inspect Shank Adapter Threads

1. Replace the shank adapter (16) if the thread is worn out. See chapter Front Head

2. When replacing the shank adapter, inspect internal components. See Instruction In-
specting and Replacing Front Head Parts.

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Hydraulic Rock Drill COP 1435 Ver.A 10 Front Head

10.5 Check for Leaks During Drilling

n If the flushing media leaks from the flushing head replace the cup seals and O-rings.
See chapter Front Head.

n If oil leaks from the front head, shut of the percussion and activate the damper only to
determine if it is percussion or damper leakage. See chapter Rock Drill Overhaul.

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Hydraulic Rock Drill COP 1435 Ver.A 11 Lubrication

11 Lubrication

11.1 Select Lubricant

Introduction
Atlas Copco lubricating oils and greases are made for Atlas Copco equipment. Using these
products creates optimal machine condition and minimizes breakdowns. Correct grade se-
lection of lubricating oils improves and extends the efficiency and service life of the Rock
Drill components.
In addition to these product recommendations, the following apply:
n Never mix lubricating oils or lubricating greases of a different type or grade.
n Lubricants containing solid particles such as Molybdenum Disulfide (MoS2) or graphite
should be avoided.
n Dispose of surplus oil in an environmentally-friendly manner, as recommended by
proper environmental authorities.
n If in doubt, contact your local Atlas Copco representative.
Temperature

Temperature Zone Temperature [C°] Temperature [F°]

Artic -30 to 0 -22 to 32

Normal -10 to 30 14 to 86

Tropical 20 to 60 68 to 140

Hydraulic oil

Temperature Zone Viscosity Minimum Requirements

Normal ISO VG 46 Min Vl 140, DIN 51524 Parts 3

HVLP

Normal ISO VG 46 ISO 15380 HEES

Artic ISO VG 32 Min Vl 140, DIN 51524 Parts 3

HVLP

Tropical ISO VG 68 Min Vl 140, DIN 51524 Parts 3

HVLP

Lubrication oil

Pneumatic oil Temperature Biodegradable Viscosity Minimum Re-

Zone quirements

COP OIL All Yes - Contact Atlas

Copco

Rock Drill 100 Normal No - Contact Atlas

Copco

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Hydraulic Rock Drill COP 1435 Ver.A 11 Lubrication

Grease Temperature Biodegradable Viscosity Minimum Re-

Zone quirements

COP Grease All No - Contact Atlas

Copco

Specification

Pneumatic oil 1 Can of 4 litres 1 Can of 20 1 Barrel of 209 1000 litres

litres litres

COP OIL 3115 3125 02 3115 3125 01 3115 3127 00 3115 3129 00

Rock Drill 100 9106 2303 37 9106 2303 38

Grease Tube 0.4 kg Can 18 kg

COP Grease 3115 3422 00 3115 3423 00

11.2 Fill Air Lubricant Oil

WARNING
Serious injury
Risk of serious injury to the eyes and skin.
u Never work on the lubrication system when it is pressurised. Lubrication air and oil may
spray out.

NOTE: Certain moving parts on the Rock Drill are lubricated with compressed air con-
! taining oil. Is important that these parts receive good lubrication. Use the recom-
mended lubrication air pressure and lubricant.

1. Check the level in the lubrication tank on every shift. Exercise cleanliness and fill with
the right grade oil. See chapter: Lubricating.

2. If the lubrication system is drained of oil, bleeding must take place after filling. See the
appropriate Rig manuals for instructions.

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Hydraulic Rock Drill COP 1435 Ver.A 11 Lubrication

11.3 Lubricate Front Head

1. Lubricate both grease nipples (119) until grease exits through the tell tales holes for
flushing water.

2. Move the shank adapter (16) to distribute the grease inside the front.

11.4 Lubricate Gears

1. Loosen and remove the bleed plug (239) that is in the highest position.
The plug (239) to remove can vary depending on how the Rock Drill is positioned.

2. If the Rock Drill is positioned vertically (A), the grease nipple (237) and one of the
bleeding plugs (239) must change places.

3. Lubricate with recommended grease through the grease nipple until grease emerges
out through the upper bleeding hole.

4. Install and tighten the bleed plug (239).

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Hydraulic Rock Drill COP 1435 Ver.A 11 Lubrication

11.5 Check ECL Lubricant Oil Return

n After a few minutes of drilling and regularly during the shift, check that air and lubri-
cant oil come out of the ECL return outlet.

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Hydraulic Rock Drill COP 1435 Ver.A 12 Settings

12 Settings

12.1 Set ECL Lubrication System

! NOTE: Configure Rock Drill lubrication to local conditions.

1. Start the lubrication system.

2. Recommended lubricating air pressure is 2–3 bar at the Rock Drill, use a pressure
gauge to check the pressure.

3. If the pressure is too low, clean the restriction or increase the diameter of the restric-
tion.

4. Set the correct lubricating oil dose:

a. Pump (3217 8667 50): 35–40 pulses/min

b. Pump (3217 8667 52): 20–25 pulses/min

5. Check that the correct pulse frequency has been obtained.

6. Check that air and lubricating oil is emerging from the ECL return outlet.

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Hydraulic Rock Drill COP 1435 Ver.A 12 Settings

12.2 Set Damper Pressure

! NOTE: Configure Rock Drill settings at normal operating temperature for the hydraulic
oil.

1. Close the constant flow valve on the rig.

2. Connect a pressure gauge (A), calibrated for 0-60 bar, between the hose and the
damper nipple (1).

3. Pressurize the damper circuit.

4. Check that the shank adapter is unloaded and in the forward position.

5. Adjust the constant flow valve (B) until the pressure gauge (A) shows 25 bar (Opera-
tor panel shows 30 bar).

6. Disconnect the pressure gauge (A) and connect the hose to the damper nipple (1).

12.3 Check Damper Pressure During Drilling

n Check that the drill rig damper pressure gauge shows normal values during drilling. In
the event of deviation adjust the damper pressure. See chapter Settings.

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 12 Settings

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Hydraulic Rock Drill COP 1435 Ver.A 12 Settings

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 12 Settings

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