9853 1090 01b Overhauling Instructions COP 1532

Reg.
code
ASB TAB 43
COP 1532
2007–05
Overhauling instructions for
Hydraulic COP 1532

Rock drill
1250 0027 80
List of contents Page

Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main parts of the rock drill . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembling the rock drill into its main parts . . . . . . . . . . 9
Disassembly, inspection, replacement of parts
and assembly of:
– Front head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– Back head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– Cover and gear housing. . . . . . . . . . . . . . . . . . . . . . . . . 19
– Intermediate part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
– Cylinder, piston guides and impact piston . . . . . . . . . . . 35
– Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembling the main parts of the rock drill . . . . . . . . . . . . 45
Charging the accumulators . . . . . . . . . . . . . . . . . . . . . . . . 49
Greasing the gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Recommended hydraulic oils and lubricants. . . . . . . . . . . 50
Testing the rotation and percussion functions. . . . . . . . . . 51
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ATLAS COPCO ROCK DRILLS AB

ÖREBRO · SWEDEN
© Atlas Copco Rock Drills AB, 2007. All rights reserved.
No. 9853 1090 01b
SAFETY INSTRUCTIONS
· Important safety information is given at various points in these instructions.
· Special attention must be paid to the safety information contained in frames and accompanied by a war-
ning symbol (triangle) and a signal word, as shown below:
indicates hazards or hazardous procedures which COULD

WARNING result in serious or fatal injury if the warning is not observed.
indicates hazards or hazardous procedures which COULD

CAUTION result in injury or damage to equipment if the warning is not
observed.
The following safety rules must also be observed:

· Carefully read through the overhauling instruc- · When lifting the rock drill, use approved lifting
tions before disassembling the rock drill. Fol- equipment only. Avoid lifting heavy weights
low the instructions given and also observe manually.
any local regulations. · To avoid injury when repairing or overhauling
· Before loosening or disconnecting hoses and the rock drill, any components that could pos-
removing the rock drill from the drill rig, always sibly move or drop when disconnected, expo-
make sure that there is no pressure in the hyd- sed or removed must be secured safely.
raulic, water and air systems. Also check that Always use the pivoted fixture A (see List of
the electrical system is dead. Tools, page 4).
· Repair or overhauling of the rock drill is restric- · Check that the hoses used are of the right qua-
ted to personnel who have received the neces- lity, and that all hose connections are in good
sary training from Atlas Copco. condition and properly tightened.
· Make sure that all safety labels remain in pla- · Use Atlas Copco genuine parts only. Any
ce, and that they are kept clean and fully legib- damage or malfunction caused by the use of
le. See the spare parts list for details of label unauthorized parts is not covered by Warranty
locations and part numbers. or Product Liability.
General
The following instructions are intended as a guide Workshop standards
for service personnel involved in the overhauling of
the COP 1532 hydraulic rock drill. Workshops for the overhauling of hydraulic
machines must be:
Layout of these instructions · Isolated from all dust- and particle-generating
activities such as grinding, welding etc.
These instructions begin with the safety instructions,
followed by a list of the standard and special tools · Very clean, i.e. free of dust and dirt.
needed to overhaul the rock drill. This is followed · Equipped with
by instructions on how to disassemble the rock drill – all necessary standard and special tools
into its main parts. Then, under respective headings – washing facilities for cleaning and degreasing
for the main parts, detailed instructions are given on components
the further disassembly, checking, inspection of – compressed air for blow cleaning components
parts and re-assembly. – a hydraulic press
The instructions end with a section describing how – hoisting facilities with a minimum capacity of
the main parts of the rock drill are put back toget- 250 kg.
her, followed by the tests and checks that must be
carried out after the machine has been overhauled.
CAUTION
The letters enclosed in brackets in the instructions
refer to the list of special tools on pages 4–7. The · Never intervene in the rock drill, connec-
numbers enclosed in brackets in the instructions re- tions or hoses when the hydraulic system
fer to the exploded views of the machine on pages is pressurized.
43 (hydraulic motor) and 53 (rock drill). Hydraulic oil at high pressure and high
temperature can squirt out with great force.
Risk of injury to eyes and skin.
2
List of tools / Standard tools
Plastic hammer
Copper hammer
Honing tool ø 20–50 mm
Combination spanners
Spanner widths: 10–32 mm, 46 mm
Allen keys
Width across flats: 4–10 mm
Screwdrivers
Punches, 2–10 mm
Copper punch, 20 x 250 mm
Feeler gauge, 0.03–0.10 mm, with 0.01 mm

increment
Feeler gauge, 0.05–1.00 mm, with 0.05 mm
increment
Internal circlip pliers
Torque wrenches, torque range 10–350 Nm

(7–260 lbf. ft)
Socket set with:

– sockets for external hexagon, 10–32 mm
– sockets for internal hexagon, 4–10 mm
– socket for internal hexagon, 3/16"
Awl
T-handle with 3/4" square drive

Impact socket 32 mm
1250 0022 43
Vernier calliper
Micrometer, 0–25 mm
3
List of tools / Special tools and test equipment
Tool Part number Name Use
A 3115 0329 80 Pivoted mounting Disassembly, assembly and

fixture testing of rock drill (figs. 2, 90).
1250 0024 27
B 3115 1902 80 Press Basic tool for use with other

press tools (figs. 39, 45,
– 3115 1902 00 – Guide plate 46, 48).
– 3115 2734 00 – Nut
– 3115 0317 00 – Screw
1250 0024 28
C 3115 0318 00 Extension sleeve For use with press B (fig. 46).
1250 0024 29
D 3115 1019 00 Mandrel Removal and fitting of guide,

flushing head, guide sleeve
1250 0024 30
and driver (figs. 13, 15, 16,

41, 44).
E 3115 2750 00 Press tool Fitting of seal rings and

damper piston liner (figs. 39,
1250 0028 33
46, 60).
Shimming of roller bearings
(fig. 48).
F 3115 2751 00 Press tool Fitting of tapered roller

1250 0028 34
bearings (fig. 45).
G 3115 2753 00 Mandrel Removal of front seal hou-

1250 0028 37
sing with piston guide (fig.

66).
4
H 3115 0313 00 Mandrel Assembly of gear housing

(fig. 40).
1250 0024 34
I 3115 0314 00 Mandrel Fitting of bushing for damper

1250 0024 35
piston (fig. 59).
J 3115 1877 00 Assembly and Assembly and disassembly of

1250 0024 36
disassembly tool accumulators (figs. 19, 22).
K 3115 0344 00 Wrench adapter Adapter for use with torque

1250 0028 38
(32 mm) wrench when tightening up

the machine (figs. 48, 94).
L 3115 2859 80 Assembly and Assembly and disassembly of

tool,
disassembly tool accumulators (figs. 19, 22).
consisting of:
3115 2859 00 Ass. tool
3115 2860 00 Stud ( 2pcs )
3115 2861 00 Ring
0266 2114 00 Nut ( 2pcs )L
1250 0045 44
M 3115 1627 00 Assembly tool Fitting of thread inserts into

(M14) intermediate part and cylinder.
1250 0024 39
3115 1126 00 Assembly tool

(M16)
N 3091 0455 90 Extractor + See figs. 34, 55, 65, 69.

adapters
1250 0024 40
O 3115 2754 00 Mandrel Fitting of needle bearing,

spacer ring and seal ring
1250 0028 39
(fig. 42).
5
P 3115 3425 80 Charging Equipment for charging of ac-

R
equipment cumulators.
TO
LA
MU ER
CU RG
AC HA
C
200
150
250
100
RE
BAR
SSU
0
RE
200
G P
GIN
150
250
1250 0177 32
AR
CH
100
BAR
RE
SSU
0
RE
G P
GIN
AR
CH
200
150
250
100
BAR
RE
SSU
0
RE
R P
DE
LIN
CY
R
TO
LA
MU
CU ER
ACARG
CH
R 3115 2747 00 Adapter plate Used in conjunction with

pivoted mounting fixture A
1250 0028 40
for disassembly, assembly

and testing of rock drill
(figs. 2, 90).
S 3115 2756 00 Mandrel Removal of washers, needle

1250 0028 41
bearing, guide sleeve and

spacer ring in gear housing
(figs. 29, 30).
T 3115 2163 00 Sleeve Fitting of bushing into inter-

mediate part (fig. 59).
1250 0024 51
U 3115 1594 00 Plates Removal of damper piston

1250 0024 49
liner (fig. 53).
V 3115 2755 00 Spacer ring Removal of needle bearing,

1250 0028 42
(fig. 30).
X 3115 1899 00 Sleeve Removal and fitting of

bushing into front head
(figs. 13, 15, 16).
1250 0024 50
6
AA 0335 2141 00 Circlip ø 46 mm Removal of slide bearing

1250 0028 43
(fig. 54).
BB 3115 2749 00 Press tool Removal of guide sleeve

(fig. 30).
1250 0028 44
Fitting of damper piston

(fig. 62).
CC 3115 2846 00 Mandrel Removal of needle bearing,

1250 0028 45

(fig. 30).
DD 3115 2752 00 Press tool Fitting of slide bearing into

intermediate part (fig. 63).
1250 0028 46
Fitting of piston guide (fig.

73) and seal housing (fig. 74)
into cylinder.
EE 3115 2844 00 Extension sleeve Fitting of seal ring (fig. 39).

1250 0028 47
FF 3115 2757 00 Press tool Removal of slide bearing

from intermediate part
1250 0028 48
(fig. 54).
GG 3115 2918 80 Bottle regulator Reducing valve with 16-bar

- 3115 0643 00 Nipple pressure gauge for charging
- 3115 2640 00 Tee nipple of return accumulator (92)
located on right-hand side of
rock drill seen from behind
(fig. 100).
7
Main parts of the rock drill
7 6
5
5
5
8
4
1250 0005 13
3
2
1
Fig. 1. Hydraulic rock drill COP 1532, main parts
1. Front head, incl. 5. Accumulators

· Shank adapter · Intake accumulator
· Flushing connection · Damper accumulator
· Stop ring · Return accumulator
· Flushing head
· Guide
6. Cylinder, incl.
· Impact piston
2. Cover · Piston guides
· Valve piston
3. Gear housing, incl.
· Rotation chuck 7. Back head
· Driver
· Rotation shaft
8. Hydraulic motor
4. Intermediate part, incl.

· Damper piston
· Damper-piston liner
· Damper-piston seals
8
Disassembling the rock drill into its main parts
The pivoted mounting fixture (A) must be used when disassembling the rock drill.
Disassembly sequence:
IMPORTANT
· Front head
· Always observe a high standard of cleanli- · Accumulators
ness when opening up the rock drill or its · Back head and impact piston
connections.
· Cover and gear housing
· Only the front-head parts, shank adapter, · Intermediate part
accumulators, hydraulic motor, bolts and · Hydraulic motor
connections may be changed at the work-
site. All other repairs must be carried out
in a suitable workshop.
N.B. Always wash down the outsides of the

rock drill using a degreasing agent before di-
sassembly begins.
Bolt the rock drill securely to the pivoted mounting
R fixture (A) and adapter plate (R) using two M16
screws.
1250 005 54
A
Fig. 2. Fitting the rock drill to the pivoted mounting fixture
1250 0027 86
2 3 4 8
Front head
Remove the flushing connection (5), nipple (6) and
plug (8).
2
Remove the O-rings (2, 3) and back-up rings (4).
3
4
5
6
Fig. 3. Removing the flushing connection
10
1250 0027 88
2
Remove the front side-bolt nuts (2) with washers
1 (3). Remove the front head (1) by tapping it with a
copper hammer.
Take out the cylindrical pin (10).
3
2
Fig. 4. Removing the front head
9
Accumulators
CAUTION
· All gas must be released from the ac-
cumulators before they are removed from
the rock drill.
To release the gas, remove the protective
cap (A) and loosen the valve nut (B) by
2–3 turns.
Failure to follow this procedure can result
in injury.
Take off the accumulators (63, 91, 92) together

with the seal rings (64) by removing the screws
(4).
71 95
64 63
95
37 64 91
92
95
1250 0005 55
64
Fig. 5. Removing the accumulators
Back head and impact piston

90 89 Loosen and remove the screws (90).
Remove the back head (89) by tapping it with a
copper hammer and carefully prizing it free with
the aid of two screwdrivers.
1250 0005 56
Fig. 6. Removing the back head
10
87
Tap out the impact piston (87), removing it through
the rear of the rock drill. Put it in a safe place whe-
re it will not be scratched or damaged.
1250 005 57
Fig. 7. Removing the impact piston
3 Cover and gear housing

Remove the rear side-bolt nuts (2) with washers
(3), as well as the two front screws (5).
1250 0005 58
5
Fig. 8. Removing the side bolts
Tap free the gear housing (18) and cover (6) using
a copper hammer, and pull them off with the aid of
18 the side bolts (4).
6 The rotation shaft (27) usually comes out with the
gear housing.
1250 005 59
4
27
Fig. 9. Removing the cover and gear housing
11
71
1250 005 60
37
Intermediate part
Tap free the intermediate part (37) using a copper
hammer. If the intermediate part sticks on the cylin-
der (71), use a screwdriver or similar implement, to
prize it free.
Fig. 10. Removing the intermediate part
25 Hydraulic motor
51 Remove the screws (25) using a 16 mm combina-
48 tion spanner, and remove the hydraulic motor (51).
Pull out the coupling (48).
1250 0005 61
Fig. 11. Removing the hydraulic motor
12
Front head
Disassembly
Inspection, replacement of parts
Assembly
25, 27
15, 20
Disassembly
Pull out the shank adapter (25 or 27) together with
the sleeve (21) and split stop-ring (20) or solid stop-
1250 0028 11
ring (15).
Fig. 12. Removing the shank adapter
Press out the guide (9 or 22) and flushing head

9
(12 or 24).
22
Use the mandrel (D) to remove the guides (9).
Also use the sleeve (X) when removing the guide
(22).
12
1250 0028 12
24
Fig. 13. Removing the guide
13
Before inspection, all parts must be washed
clean in a degreasing agent.
Change the guide (22 or 9) if its inside diameter ex-
ceeds 56 or 39 mm.
Change the flushing head (24 or 12) and the ring
(28) if it is severely damaged or shows signs of
cracking or fatigue.
1 mm
Change the stop ring (20 or 15) if the surface is
1 mm worn down by more than 1 mm. Use a new stop
ring as a gauge for comparison.
15 Change all O-rings and cup seals.

IMPORTANT! The cup seals must face the direc-
12 tions shown in the figure opposite.
20
39 mm
1250 0055 90
28
24
56 mm
22
Fig. 14. Checking the guide, O-rings, seal rings, flushing

head and stop ring
;;
D
Assembly
Before assembly, the parts must be oiled with
X clean hydraulic oil.
9, 22 Press in the guide (9) with the aid of mandrel (D).
;;;;
Also use the sleeve (X) when fitting the guide (22).
1250 0028 14
Check that the lubricating duct (A) is not blocked.

To do this, blow through it with compressed air.
A
Fig. 15. Fitting the guide
14
D
Press in the flushing head (12 or 24) with the aid of
;;
;;;;
mandrel (D) and sleeve (X).
X
N.B. Make sure that the flushing holes in the flus-
12, 24 hing head line up with the corresponding holes in
the front head.
1250 0028 15
Fig. 16. Fitting the flushing head
Fit the split stop-ring (20) or one-piece stop-ring

(15) as appropriate.
Fit the O-ring (13) and shank adapter (25 or 27)
1250 0055 91
25
into the front head (1).
15
13
1
13
27
20
28
Fig. 17. Fitting the stop ring and shank adapter
15
Accumulators
Disassembly
Assembly
67 = Read the instruction book carefully

92
before servicing or changing
91
1250 0020 91
= Must be charged with nitrogen only
D
1250 0028 17
The rock drill is equipped with three accumulators:

– the intake accumulator (67)
– the damper accumulator (91)
Fig. 18. The accumulators on the rock drill – the return accumulator (92)
4
Disassembly
3
CAUTION
· All gas must be released from the ac-
J cumulators before they are removed from
50 the rock drill.
52 To release the gas, remove the protective
67 / 92 cap (A) and loosen the valve nut (B) by
2–3 turns.
91 Failure to follow this procedure can result
A B
92 in injury.
L
Clamp the tool (L) in a vice.
1250 0047 45
Place the accumulator (67, 91, 92) on tool (L).

Place tool (J) on the accumulator. Fit ring (3) and
tighten the nuts (4) by hand. Ring (3) serves to
keep tool (J) in place when high torque is applied.
Unscrew the housing from the cover with the aid of
tool (J). Use a 32 mm impact socket and extended
T-handle with a 3/4" square drive.
If necessary, strike the top of the drive with a
copper hammer to help loosen the thread.
125 0045 46
Fig. 19. Disassembling an accumulator
16
CAUTION
· Screws of incorrect length, as well as rus-
ted or damaged threads on the screws,
housing or cover can lead to dangerous
oil leakage and can cause the compon-
ents to loosen.
Risk of injury to personnel.
· Always change the screws (4 or 95), hou-
sing (1) or cover (3) if they are corroded,
worn, defective or damaged. Always
change BOTH screws at the same time.
Change the diaphragm (2) if it shows signs of

cracking or other damage.
1 2 3
When changing the diaphragm, make sure that no
bits of rubber have lodged in the valve (9) or in the
10 test valve (5).
9
11 Blow clean the gas ducts in the cover (3) with
compressed air.
4 Change the valves if they are damaged.
1250 0029 98
Always change the O-rings (6, 7, 11) if the valves

8 have been disassembled.
7
6 Change the screws (4) if they are rusted or
5 damaged.
Fig. 20. Checking the diaphragm, valve housing and cover Change the housing (1) and cover (3) if the thre-
(Figure shows intake accumulator) ads are damaged or badly rusted.
Assembly
Before assembly, it is important that all parts
are clean, dry and free of oil.
Place the diaphragm (2) in the housing (1) and gre-
1 ase the edges of the diaphragm with a thin layer of
2 silicone grease.
3
Smear the threads of the accumulator cover (3)
and housing (1) with grease of type NEVER-SEEZ.
7
8 Fit the cover (3) on to the housing (1) and thread
9
10 the accumulator together by hand.
D
Do not turn the accumulator upside down until it

has been screwed together.
1250 0029 97
6
Fit the valve plunger (10) together with O-rings
4 (8 and 9), and fit the valve body (7). Tighten to a
torque of 45 Nm (32 lbf. ft).
5
Fit the valve (4) and cap (5) together with the
Fig. 21. Fitting back the diaphragm and cover into the O-ring (6), and tighten to a torque of 45 Nm
housing (32 lbf. ft).
(Figure shows damper accumulator)
17
J
Now place the accumulator on the assembly tool

1 (L).
Tighten the housing (1) to a torque of 300 Nm
(220 lbf. ft) using the assembly tool (J) and a
L torque wrench.
1250 0045 53
Fig. 22. Tightening the housing
10
Inspect the safety labels (10, 11), and change

them if necessary.
N.B. Do not charge the accumulators until they
have been fitted securely to the rock drill.
D
11
10 11
1250 0028 22
Fig. 23. The accumulator safety labels
89
Back head
88
1250 0028 23
Before inspection, the back head must be was-

hed in a degreasing agent.
Change the O-rings (88).
Fig. 24. Fitting the O-rings on to the back head
18
Cover and gear housing
Disassembly
Assembly
Disassembly
1250 0028 24
Remove the side bolts (4).

4
Fig. 25. Removing the side bolts

1250 0028 25
6
Tap free the cover (6) using a copper hammer. Ca-
refully prize the cover off the gear housing with the
aid of two screwdrivers.
Fig. 26. Removing the cover
27
1250 0028 26
Tap out the rotation shaft (27) using a punch

28 (ø approx. 7 mm) inserted through the hole in the
front end of the gear housing.
If a thicker punch is used, there is a risk of dama-
ging the needle bearing (28).
Fig. 27. Removing the rotation shaft
19
15
14
13
11 Remove the rotation chuck (14) together with the
shims (11) and outer rings (13 and 15) of the bea-
rings from the gear housing by tapping the rotation
chuck with a copper hammer.
1250 0028 27
Fig. 28. Removing the rotation chuck with shims and be-
aring rings
Take out the gear-wheel (36) and washer (30)

from the gear housing.
Using the mandrel (S), tap out the rotation shaft’s
24 front needle bearing (28) and two washers (24 and
S 29) from the gear housing.
28
36
29
30
1250 0028 28
Fig. 29. Removing the gear-wheel and the rotation

shaft’s front needle bearing with washers
20
Locate the spacer ring (V) as shown in the figure
S S opposite. Then, with the aid of mandrels (S and
CC), tap out the needle bearing (33), spacer ring
(34), seal ring (35) and O-ring (32).
The guide sleeve (31) should not normally be re-
moved. If, for some reason, it does need to be re-
BB
moved, it can be tapped out with the aid of mand-
rel (S) and the press tool (BB), which should be po-
CC sitioned as shown in the figure opposite.
31
33
34
V
1250 0028 29
35
32
Fig. 30. Removing the spacer ring and needle bearing

Before inspection, all parts must be washed in
1250 0028 30
a degreasing agent.
Change all O-rings.
5
4 Change the side bolts (4) and screws (5) if they
3 are badly rusted or if they show signs of crack for-
mation.
Fig. 31. Checking the side bolts, screws and washers. Change all side bolts after every 400 hours of
operation. Never mix new and old side bolts.
27
25 Change the shank adapter (27or 25) if the thread

1250 0028 31
is worn out, or if the impact surface is upset or chip-

ped.
12 Change the driver (12) when the spline width is

less than 2 mm.
m
2m
Fig. 32. Checking the shank adapter and driver
21
14 Check the wear between the rotation chuck (14)
and the driver (12) using a feeler gauge. If the clea-
rance exceeds 0.2 mm, the driver or rotation chuck
should be changed.
1250 0028 49
12
Fig. 33. Checking the wear
If the driver (12) needs to be changed, it can be re-

moved with the aid of the extractor (N) and a
37–46 mm expander. See figure.
12
1250 0028 50
Fig. 34. Removing the driver
15
14
13
11
1250 0028 51
Change the rotation chuck (14) if it shows signs of

deformation or cracking, or if the gear ring is badly
worn. Change the roller bearings (13 and 15) in
the event of dissonance or damage.
Change the shims (11) if they show signs of damage.
Fig. 35. Checking the rotation chuck, roller bearings,

seals and shims
22
If either of the roller bearings (13 or 15) on the rota-
tion chuck needs to be changed, the roller cage
1250 0028 52
must be broken up with a screwdriver. The inner
rings of the roller bearing must then be removed
by an extractor.
13
15
Alternatively, cut through the inner rings of the bea-

ring using a grinder.
Fig. 36. Removing the inner rings of the bearings
96 8
22
7
Check the seal rings (7 and 22) in the cover and
gear housing for wear and damage.
If the seals need to be changed, remove the circlip
1250 0028 53
(8) and knock out the seals using a punch.

Change the O-ring (96).
Fig. 37. Removing the seal rings from the gear housing
and cover
Change the needle bearings (28 and 33) of the ro-

35 tation shaft in the event of dissonance or damage.
Change the gear-wheel (36) if it shows signs of de-
33 formation or cracking, or if the gear ring is badly
worn.
36
Change the cup seal (35).
28
1250 0028 54
Fig. 38. Checking the rotation-shaft needle bearings,

gear-wheel and cup seal
23
EE
Assembly
E Before assembly, all parts must be oiled with
clean hydraulic oil.
18
22
Fit the seal ring (22) into the gear housing (18)
with the aid of the press (B), press tool (E) and
extension sleeve (EE).
B
1250 0028 55
Fig. 39. Fitting the seal ring in the gear housing
Fit the washer (24) and needle bearing (28) with its
inner ring and washer (29). Use mandrel (H).
1250 0028 56
29
28
24
Fig. 40. Fitting the washers and needle bearing
If the guide sleeve (31) has been removed, press it

;;
;; ; 31
18
back into the gear housing (18) with the aid of
mandrel (D).
; ;
;;
;;
1250 0028 57
Fig. 41. Fitting the guide sleeve
24
Y
35
34
;;;;;;
;;;
33 With the aid of mandrel (Y), fit the needle bearing
(33), spacer ring (34) and seal ring (35) into the
18 gear housing (18).
;;;;
1250 0028 58
Fig. 42. Fitting the needle bearing, spacer ring and seal
ring
27
;;;; Insert the washer (30) and gear-wheel (36) into the
gear housing.
;; ;;
;; ;;;
15 Fit the outer ring of the roller bearing (15). Use a
copper mandrel.
18
1250 0028 59
Fit the shaft (27) into the gear housing (18). Make
;;;; 30
sure that the shaft splines mesh with the splines in
the gear wheel (36). If necessary, tap the shaft to
the bottom using a plastic hammer.
36
Fig. 43. Fitting the gear-wheel and rotation shaft
;;
;
D
Fit the driver (12) into the rotation chuck (14). Use
the mandrel (D) and a plastic or copper hammer.
;;;
12
1250 0028 60
14
Fig. 44. Fitting the driver
25
B
13 Fit the roller bearings (13 and 15) on to the rotation

chuck (14).
Use the press (B) and press tool (F).
14
1250 0028 61
15
Fig. 45. Fitting the roller bearing
7 C
E
Fit the seal ring (7) into the cover (6). Use the
6
press (B) with extension sleeve (C) and press tool
(E).
Fit the circlip (8).
1250 0028 62
Fig. 46. Fitting the seal ring into the cover
26
Preloading the bearings in the
gear housing by means of shims
N.B. During the preloading exercise, all parts
must be free of grease and oil.
Do not fit any O-rings into the gear housing or
6 cover for the preloading exercise.
Fit the rotation chuck (14) into the gear housing

(18).
11 Fit the outer ring of the front roller bearing (13).
;;; ;;
Tap it into place with the aid of a punch.
Place the shims (11) on the outer ring of the bea-
;;;
; ;;
14 ring. Choose the thickness and quantity of shims
so that a definite "gap" is created between the
13
gear housing (18) and the cover (6) when the latter
is assembled later.
;;;;
1250 0028 63
18 Fit the cover (6).
Fig. 47. Fitting the rotation chuck, outer ring and shims
into the gear housing for the preloading exercise
Place the gear housing on the press (B).

Place the press tool (E) on the cover (6).
Rotate the rotation chuck 2 - 3 turns.
Tighten to a torque of 200 Nm (150 lbf. ft) using
the adapter wrench (K).
Release the tension and tighten again, this time to
a torque of 20 Nm (15 lbf. ft).
K Use a feeler gauge to measure the clearance be-
E tween the gear housing and the cover.
6 Remove the cover (6) and reduce the number
of shims (11) until a measured clearance of
0.15–0.20 mm is obtained. This will give the
roller bearings a preloading of 0.15–0.20 mm when
the rock drill is finally pulled together by the side
1250 0028 64
bolts.
N.B. It is important that the bearings are preloa-
ded correctly, and also that the tightening
torque is correct. After a period of drilling, the
seats of the bearings can become bedded in.
B
When this happens, it is important that preloa-
ding of the bearings does not cease, which
could result in damage to the roller bearings
and shims.
Fig. 48. Checking the preloading of the bearings
27
23
18 Grease all parts, especially the roller bearings.
See grease recommendations on page 50.
10 Fit the O-ring (9) into the cover (6). Place the O-
9 rings (16, 17) in the gear housing (18). First smear
the O-rings with grease, so that they stick in place
6 during assembly.
Fit the guide pin (10) and washer (23) into the gear
housing.
1250 0028 65
Now fit the cover (6). If necessary, tap down the

cover using a plastic hammer.
16
17
Fig. 49. Fitting the O-rings into the cover and gear
housing
28
Intermediate part
Disassembly
Assembly
17
56
57 Disassembly
58 Remove the check-valve poppet (57), seat (59)
59 and O-rings (17, 56, 58 and 60). Pull out the seat
with the aid of a M6 screw.
60
Pull out the coupling (48) and the spacer ring (49).
48
1250 0028 66
49
Fig. 50. Removing the check valve
47
Knock out the damper piston (47) using a hammer
and copper mandrel.
1250 0028 67
Fig. 51. Removing the damper piston
39
37
25
Carefully remove the damper-piston seals (25 and
26) with the aid of a pointed tool. Be careful not to
damage the seal grooves in the intermediate part
(37) and liner (39).
1250 0028 68
26
Fig. 52. Removing the damper-piston seals
29
U
39 Remove the front damper-piston liner (39) by pla-

cing a plate (U) in the seal groove. Then carefully
knock out the liner using a copper mandrel and a
plastic hammer.
1250 0028 69
Fig. 53. Removing the front damper-piston liner

FF
a degreasing agent.
;;;;;;;
;
1250 0028 70
Change all O-rings.
;;;;;;;
The sliding bearing (46) should not be removed un-
less it is damaged. If the sliding bearing is damaged
remove it as follows:
46 Press out the sliding bearing (46) with the aid of the
;; ;;
; ;;
press tool (FF) and circlip (AA).
AA
;;;;;;
Fig. 54. Removing the sliding bearing
42
Check the damper-piston bushing (43). Minor sco-

ring can be removed by polishing with a fine abrasi-
ve cloth, after which the bushing must be washed.
If the bushing is worn or badly damaged, it must
43 be changed.
Remove the lock ring (42) with the aid of a
screwdriver.
Knock out the bushing (43) using a copper mand-
1250 0028 71
rel and a plastic hammer. Alternatively, the bus-

hing can be removed using the extractor (N) and a
70–100 mm expander.
Fig. 55. Removing the bushing
30
39
Check the damper-piston liner (39). Minor scoring

1250 0028 72
can be removed using a fine abrasive cloth, after

which the liner must be washed. If the liner is worn
or badly damaged, it must be changed.
Carefully check the nozzle (38) in the rear face of
the intermediate part (37). Also check the holes in
Fig. 56. Checking the damper-piston liner the liner (39) and make sure that all holes are free
of dirt
97 99 Change the damper piston (97) if the seals have

worn into the piston by more than 0.1 mm. Remo-
ve minor scoring using a fine abrasive cloth.
Fas / Chamber Change the rotation chuck bushing (99) if the seals
have worn into it by more than 0.1 mm. Polish off
any minor damage.
1250 0005 62
Change the damper piston (47) if the chamfer on

the impact surface (see fig. A) is damaged or worn
down.
When the chamfer shown has a worn down, it cor-
responds to approx. 1.5 mm of wear.
Fig. 57. Checking the damper piston
Fig. 58. No illustration - no text in this instruction.
31
Assembly
I
Before assembly, all parts must be oiled with
clean hydraulic oil.
Press in the damper-piston bushing (43) using

mandrel (I) and press tool (T).
N.B. Press the bushing in carefully so that it does
42 not become deformed when it bottoms out!
Fit the lock ring (42) to retain the bushing.
T
;;
;;;; 43
;;
;;
;; ;;
;;;;
1250 0028 75
;;
;;;;
Fig. 59. Fitting the damper-piston bushing
39
40 Fit the O-rings (40 and 41) on to the damper-
piston liner (39), and smear them with oil.
;;;; ;;
41
Tap in the liner using press tool (E).
;;
; ;;
;;;;; ;;
1250 0028 76
;;;;;
Fig. 60. Fitting the damper-piston liner
32
Fit the damper-piston seals (25 and 26) as follows:
Check that the seal grooves are very clean.
Oil the O-rings and fit them into the grooves.
The seal ring may be warmed in hot water to facili-
tate assembly.
Bend the seal ring as shown in the figure. Then pla-
ce the seal on a flat surface and tap down the in-
25 ner upturned edge of the seal using a hammer.
Fit the seal ring into the groove, and press it neatly
26 into the groove using the shaft of a tool.
IMPORTANT! Make sure that the seals are turned
as shown in the figure.
1250 0028 77
Fig. 61. Fitting the damper-piston seals
BB
47
Oil the damper piston (47) and carefully tap it into

the intermediate part using the press tool (BB).
Now press out the damper piston and check that
the seals are located correctly, and that they are
not damaged.
1250 0028 78
N.B. It should be easy to press the damper piston

into the intermediate part.
Fig. 62. Fitting the damper piston
33
If the sliding bearing (46) has been removed, press
it back into place with the aid of mandrel (DD).
1250 0028 79
46
DD
Fig. 63. Fitting the sliding bearing
Check the sealing surfaces on the check-valve

37 poppet (57) and seat (59). Minor damage can be
lapped away using fine grinding paste. In the event
of more serious damage, change the parts.
61
Check that the poppet moves easily in the seat.
57
Fit the check-valve poppet (57), O-ring (58) and
seat (59) into the intermediate part (37).
1250 0028 80
58
59 Fit the coupling (48) and the spacer ring (49).
48 Smear the parts with grease so that they stick in

place when the intermediate part is fitted to the
49 cylinder later on.
Check that the guide pin (61) is in place in the inter-
mediate part (37).
Fig. 64. Inspecting and fitting the check valve
34
Cylinder, piston guides and impact piston
Disassembly
Assembly
86 75
Disassembly
Pull out the impact piston (87).
Remove the rear piston guide (86). It can usually
87 be pulled out of the cylinder (75) by hand. If this is
not possible, use the extractor (N) with a 37–46 mm
1250 0028 81
expander.
Fig. 65. Removing the rear piston guide and impact pis-
ton
Do not remove the seal housing (63) unless it is

damaged.
If the seal housing is damaged, or if leakage indica-
1250 0028 82
tes that the O-rings (65) need changing, remove

the seal housing. Press or tap out the front piston-
guide (66) and seal housing (63) with the aid of
63 tool (G).
65
66 65
Fig. 66. Removing the seal housing
82
81
1250 0005 63
Loosen the screws (82) and remove the valve co-

85 vers (81 and 84). Now press out the valve piston
84 (85).
82
Fig. 67. Removing the valve piston
35
a degreasing agent.
66
63
Change all O-rings.
Change the front piston guide (66) and seal
housing (63) if they are worn or damaged.
Change the rear piston guide (86) if it is damaged.
1250 0028 84
Check the clearance between the piston guides

and impact piston with the aid of a feeler gauge.
If the clearance is greater than 0.05 mm, the guide
86 should be replaced.
Fig. 68. Checking the piston guides
N
The front piston-guide (66) is pressed into the seal
housing (63). Do not separate these parts unless
they are damaged.
If they need to be separated, proceed as
63 follows:
– Press the piston guide out of the seal
housing with the aid of a 28–40 mm
expander (N).
66
1250 0155 02
Fig. 69. Removing the front piston guide
75
If the bore of the cylinder (75), the valve bore

1250 0028 86
or valve piston (84) show signs of scoring or

scratches, the parts must be changed. Minor
scoring can be removed using a fine abrasive
cloth, a whetstone or a honing tool (see List of
standard tools, page 3).
84
Wash out all ducts thoroughly to remove any
foreign matter.
Fig. 70. Checking the cylinder and valve piston
36
87 Inspect the impact piston (87) for scoring and
scratches. Also inspect the impact surface for
wear and chipping.
Minor scoring and scratching on the piston can be
removed using a fine whetstone.
R=1
Grinding the piston
Minor scoring or pitting on the impact surface of
the piston can be removed by face grinding. Grind
by 0.1–0.2 mm at a time, until the surface is even.
The accumulative maximum is 0.5 mm.
N.B. The length dimension given in the figure oppo-
1250 0028 87
site is the minimum permissible dimension. Further,

0.5 mm the outside and inside radii must be restored preci-
sely so that an even transition is obtained. There
must be no sharp edges.
After grinding, check carefully that there is no
cracking on the impact surface of the piston.Wash
278 mm the piston thoroughly to remove all traces of grin-
ding residue.
Fig. 71. Checking the impact piston
Assembly
82 Before assembly, all parts must be oiled with
81 clean hydraulic oil.
83
72 Fit the valve piston (85). The end with the hole
must face the cover (84) as shown in the figure
opposite. Check that the valve piston moves easily
1250 0005 65
85 in the valve bore.

83
84 Fit the valve covers (81 and 84) with new O-rings
82 (83). The valve covers should slide in easily and
should not be knocked into place.
72 Tighten the screws (82) to a torque of 220 Nm
(160 lbf. ft).
Check carefully that the four nozzles (72) are not
clogged with dirt and that they are properly tighte-
Fig. 72. Fitting the valve piston and valve covers ned.
DD
If the piston guide (66) has been removed, fit it

back into place as follows:
66 – Press the piston guide into the seal

housing (63) with the aid of mandrel (DD).
N.B. The piston guide must be fitted with the larger
diameter facing upwards, as shown in the figure
opposite.
63
1250 0155 03
Fig. 73. Fitting the piston guide
37
If the seal housing (63) has been removed, fit it
back as follows:
– Fit the O-rings (65).
– Press in the seal housing with the aid of mandrel
(DD).
63 N.B. Make sure that none of the four recesses (A)
in the seal housing locate directly in front of the
stop screw (B) in the cylinder.
1250 0028 90
B DD
65
A
Fig. 74. Fitting the seal housing
Fit the piston seals (64) into the seal housing.

(A seal kit consists of an O-ring and a Teflon ring).
Fit the O-ring into the groove. Bend the Teflon ring
as shown in the figure, and then press it into the
1250 0028 91
groove.
IMPORTANT! Make sure that the lips of the seal
64 face the direction shown in the figure opposite.
Fig. 75. Fitting the impact-piston seals
86
75
Oil the impact piston (87) and slide it into the cylin-
der (75). When the piston reaches the front piston
64
seals (64), twist the piston gently so as not to
damage the seals.
1250 0028 92
Fit the piston guide (86).

87
Fig. 76. Fitting the impact-piston and piston guide
38
Hydraulic motor
Disassembly
Assembly
Function and condition test
For exploded view of hydraulic motor, see page 43.
Disassembly
4
Clamp the hydraulic motor (51) firmly in a vice fit-
ted with copper jaw linings.
3
Using a 4 mm Allen key, loosen the screws (4). Re-
7 move the plate (3) and O-rings (2 and 7).
51
1250 0028 93
Fig. 77. Removing the plate
Lift off the cardan shaft (5).

8
Using a 4 mm Allen key, loosen the screws (6)
and remove the cog wheel set (8) from the valve
1250 0028 94
housing (19).
19
Fig. 78. Removing the cardan shaft and cog wheel set
39
19
Remove the valve drive (10) from the valve hou-

17 sing (19). Turn the valve housing upside down and
knock out the contents (11, 12, 13, 17 and 18)
18 against two blocks of wood. Be careful not to
damage the parts.
13
12
11
1250 0028 95
10
Fig. 79. Emptying the contents of the valve housing

1250 0028 96
23 Clamp the valve housing (19) firmly in the vice.

25
22 Using a 5 mm Allen key, remove the valve plugs
21 (23) and O-rings (25).
Turn the valve housing upside down and remove
the springs (22) and balls (21).
19
Fig. 80. Removing the valve plugs

All parts must be cleaned thoroughly before in-
spection.
mm Check all parts for wear and damage. Change all
0.1
worn or defective parts. Change all O-rings and
seal rings.
1250 0028 97
Check the cog wheel set for wear as shown in

the figure opposite. When the clearance between
the roller and the crest of the rotor tooth exceeds
0.1 mm, the cog wheel set must be changed.
Fig. 81. Inspecting the parts
40
Assembly
Before assembly, all parts must be cleaned tho-
roughly and then oiled with clean hydraulic oil.
When repairing or overhauling the motor, the
seal set 3115 2450 90 must always be used.
1250 0028 98
Clamp the valve housing (19) firmly in a vice fitted

23 with copper jaw linings.
25
22 Insert the balls (21) and springs (22) into the two
21 holes in the valve housing (19), and then fit the
plugs (23) and washers (24). Use a 5 mm Allen
key, and tighten the plugs to a torque of 10 Nm
(7 lbf. ft).
19
Fig. 82. Fitting the balls and springs into the valve
housing
17
13 Clamp the valve housing (19) firmly in a vice fitted

with copper jaw linings.
Place the spring ring (18) in the valve housing (19).
14
15 Grease the O-rings (15 and 16) and fit them on to
the balance plate (13).
16 Grease the balance plate and fit it into the valve
housing. The guide pin (14) must locate in the hole
in the bottom of the valve housing. Press the balan-
1250 0028 99
18
ce plate into place using a soft tool shaft.
Grease and fit the spacer pin (17). (The grease will
keep the parts in place during assembly.)
19
Fig. 83. Assembling the internal parts of the valve

housing
41
5
2
Place the cog wheel set (8) on a flat surface.
1
Grease and fit the seal ring (1) and O-rings (2 and
7) to the plate (3).
4 3
Place the cardan shaft (5) with plate (3) into the
cog wheel set (8).
7
Adjust the plate relative to the screw holes in the
1250 0029 00
cog wheel set, and then fit the screws (4).
Fig. 84. Fitting the plate
Clamp the cog wheel set (8) in a vice fitted with

10 copper jaw linings.
Fit the valve drive (10).
Make a mark on one of the tooth crests on the up-
per side (A) of the valve drive (10). The mark must
B 8 be directly opposite a clearance curve in the outer
cog circle (B) of the rotor, as shown in the figure
1250 0029 01
opposite.
Fig. 85. Fitting the valve drive
11
1250 0029 02
7 Put the channel plate (11) on the cog wheel set (8).
When placing the channel plate on the cog wheel
set, make sure that the guide pin (9) locates in the
bottom hole in the channel plate.
Now fit the O-ring (7).
8
9
Fig. 86. Fitting the O-ring and channel plate
42
12 Fit the disc valve (12) so that one of the holes (B) li-
nes up with the marking on the valve drive (10).
B Turn the disc valve anti-clockwise until the splines
10 engage.
N.B. If the disc valve is not fitted in this way, the
motor will rotate anti-clockwise.
1250 0029 04
Fig. 87. Fitting the disc valve
Place the valve housing (19) on top of the cog whe-

19 el set (8) and disc valve (12).
Fit the screws (6) and tighten to pull the valve hou-
sing and cog wheel set together.
1250 0029 05
12
Fig. 88. Fitting the valve housing
43
Hydraulic motors 3115 2450 81 (OMSU 80)
3115 2450 83 (OMSU 160)
13
14
A 15
A
16
17
18 20
19
21
22
1
2
3 9
1250 0005 78
4
5 23
6 24
25
7 26
8
7
10
11
Function and condition test of hydraulic motor
P 51
Clamp the hydraulic motor (51) firmly in a vice.

Connect up the motor as shown in the figure above
R
(P = Pressure; R = Return), and let it rotate for
about 30 seconds with a maximum flow of 10 l/min
(2.6 US gal/min). Check that the motor runs smoot-
hly and that there is no dissonance.
1250 0029 07
Fig. 89. Testing the hydraulic motor
44
Assembling the main parts of the rock drill
General Assembly sequence:

All parts must be cleaned thoroughly before fi- · Cylinder
nal assembly. Just before assembly, the parts · Hydraulic motor
must be oiled with clean hydraulic oil. · Intermediate part
All O-rings must be changed. Grease the new · Cover and gear housing
O-rings with silicone grease before fitting. · Back head
· Front head
· Accumulators
71
Cylinder
Using two M16 bolts, bolt the cylinder (71) secure-
ly to the adapter plate (R) and pivoted mounting fix-
1250 005 66
ture (A). See figure opposite.
Fig. 90. Fitting the cylinder to the pivoted mounting

fixture
Hydraulic motor
Fit the hydraulic motor to the intermediate part (37).
25 Tighten the screws (25) to a torque of 75 Nm.
51
37
1250 005 67
Fig. 91. Fitting the hydraulic motor to the intermediate part
45
Intermediate part
17 Fit the O-ring (62) into the groove in the middle of
56 the rear guide of the intermediate part (37).
71
Fit the O-rings (17, 56 and 60) into the rear face of
the intermediate part (37).
Fit the O-rings (17 and 32) in place in the front
62 60
face of the intermediate plate (37).
37
Fit the intermediate part (37) to the cylinder (71).
1250 005 68
Lightly tap the intermediate part into position using

a copper hammer.
17
32
Fig. 92. Fitting the intermediate part to the cylinder
37
18 Cover and gear housing
12 Fit the gear housing (18) to the intermediate part
(37) using the side bolts (4) to guide it into place.
If the rotation shaft (27) does not enter the coup-
1250 005 69
ling (48), insert a shank adapter into the driver (12)

and turn it.
4
48
27
Fig. 93. Fitting the gear housing to the intermediate part
3
Fit the rear washers (3) and nuts (2). Tighten the
rear side-bolt nuts (2) alternately to a torque of
300 Nm (220 lbf. ft). Use the wrench adapter (K)
for the torque wrench.
Fit the bolts (5). Tighten the bolts to a torque of
220 Nm (160 lbf. ft).
1250 0005 58
N.B. Before assembly, smear the threads with gre-

ase of type NEVER-SEEZ.
5
Fig. 94. Fitting the bolts
46
Back head
Grease the O-rings (88) and fit them into the groo-
90 ves on the back head (89).
61
89 Check that the guide pin (61) is fitted into the back
88 head.
Carefully fit the back head to the cylinder. Take
1250 0005 70
care not to damage the impact piston or the piston

seals.
Tighten the six screws (90) for the back head
alternately to a torque of 220 Nm (160 lbf. ft).
Fig. 95. Fitting the back head to the cylinder
2 Front head
1 Fit the front head (1) over the side bolts (4).
Fit the washers (3) and nuts (2).
N.B. Before assembly, smear the threads with gre-
1250 0029 13
ase of type NEVER-SEEZ.

4 Tighten the nuts (2) alternately to a torque of 350 Nm
3 (260 lbf. ft).
2
Fig. 96. Fitting the front head

1250 0027 86
2 3 4 8
Fit the flushing adapter (5) and plug (8) together

with the O-rings (2 and 3) and support rings (4).
Now tighten the flushing adapter and plug to a
torque of 300 Nm (220 lbf. ft).
2
3
4
5
6
Fig. 97. Fitting the plug and flushing adapter to the front
head
47
Accumulators
CAUTION
· Mount the accumulators to the rock drill
using undamaged original screws.
Each accumulator must have two screws
(4) of length 70 mm.
Change both screws at the same time,
even if only one of them is corroded (or
damaged in some other way).
Defective screws can cause dangerous oil
leakage, or can cause the accumulator to
be blown off.
71 95
64 63
95
37 64 91
92
95
1250 0005 55
64
Place the sealings (64) into the grove on the inter-
mediate part (37) and the cylinder (71).
Fig. 98. Fitting the accumulators Fit the accumulators (63 and 92) to the cylinder
(71), and the accumulator (91) to the intermediate
part (37).
Tighten the screws (95) alternately to a torque of
220 Nm (160 lbf. ft).
= Read the instruction book carefully

before servicing or changing
1250 0020 91
Make sure that the accumulators (67, 91, 92) have

the correct safety labels, and that the labels are
not damaged.
= Must be charged with nitrogen only
Replace any damaged safety labels!
67
92
91
1250 0029 15
Fig. 99. The accumulator safety labels
48
Charging the accumulators
WARNING
· The accumulators must be charged with
nitrogen (N2) only!
Other gases can cause an explosion.
CAUTION
· Do NOT charge the accumulators until
they have been fitted to the rock drill.
There is a risk of injury if these instruc-
tions are not observed!
Throule shooting
To high charged accumulator damage the diap-
hragm and gives heavy marks under neath.
The accumulators must be charged before the drill
rig is started up.
The intake accumulator (67) is located on the left-
B hand side of the rock drill.
The return accumulator (92) is located on the right-
hand side of the rock drill, and the damper accumu-
92 lator (91) is on the intermediate part.
67 All stated pressures must be read at the rock drill
91 with the hydraulic oil at operating temperature.
1. Unscrew and remove the protective cap (A).
2. Open the valve nut (B) by 2–3 turns.
A 3. Fit the charging equipment.
4. Adjust the regulator to the lowest possible pres-
1250 0115 56
sure.
5. Open the gas valve (C).
4
6. Charge the accumulators to the right pressures,
as given below:
0
20
0 0
15 25
0
10
R
BA
0
0
20
0 0
15 25
0
10
R
BA
0
a. Damper accumulator (91): 20- 25bar

0
20
0 0
15 25
0
10
R
BA
0
C
b. Intake accumulator (67): 30 - 40 bar below
the collaring pressure.
N.B. It is better to undercharge rather than
overcharge the accumulators.
c. Return accumulator (92): to half the value
of the percussion return pressure.
7. Tighten the valve nut (B) and shut the gas val-
ve (C).
Fig. 100. Charging the accumulators 8. Remove the charging equipment and fit back
the protective cap (A).
N.B. In order to avoid the risk of leakage, it is N.B. The reading on the pressure gauge in the
recommended that the charging nipples be re- cab (or on the panel) is approx. 5 bar higher
placed after they have been opened/closed 3 ti- than the reading obtained at the rock drill, de-
mes. pending on the lengths of the hoses and the ty-
pes of valves that may be fitted between the
cab/panel and the rock drill
49
Greasing the gear
20 19 Remove the plug (19) with washer (20) and fill the
gear housing with a heat-resistant grease via the
nipple (21). Fill until grease comes out through the
hole (A). See the section "Recommended hydraulic
oils and lubricants".
A Fit back the plug (19) with washer (20) and tighten.
1250 0029 20
21
Fig. 161. Greasing the gear
Recommended hydraulic oils and lubricants

Lubricant Recommendation
Hydraulic oil · Use a mineral-base or synthetic (polyalpha-olefin or diester based) hydraulic oil with good anti-wear, anti-rust,
anti-oxidation and foam inhibiting properties, and with good air and water separation characteristics. Choose an
oil with viscosity grade (VG) and viscosity index (VI), in accordance with the table below. An oil with a high
viscosity index is less sensitive to the effects of temperature.
Hydraulic oil temperature in tank oC ( oF) Viscosity Viscosity

Normal operating temp. Min. starting temp. Max. temp. grade VG index VI
(viscosity 25–50 cSt) (viscosity min. 1000 cSt) (ISO 3448)
+50 to +70 (122 to 158) +5 (41) 80 (176) ISO VG 100 Min. 100
+45 to +60 (113 to 140) –5 (23) 75 (167) ISO VG 68 Min. 100
+35 to +50 (95 to 122) –10 (14) 65 (149) ISO VG 46 Min. 100
+25 to +40 (77 to 104) –15 (5) 55 (131) ISO VG 32 Min. 100
+10 to +25 (50 to 77) –25 (–13) 35 (95) ISO VG 15 Min. 100
Air tool oil · Use a mineral base air tool oil.

Ambient temperature oC ( oF) Viscosity grade (ISO 3448)
–30 to 0 (–22 to +32) ISO VG 32–68
–10 to +20 (14 to 68) ISO VG 68–100
+10 to +50 (50 to 122) ISO VG 100–150
Grease · IMPORTANT! Because of the operating temperature in the rock drill gear housing (see "Greasing the gear"),
always use a high-temperature grease containing an ashless thickening agent and additives that give
resistance to oxidation and rust. The grease should also have good resistance to water.
Grease properties NLGI-number 2 Base oil viscosity 110 cSt at 40 oC (104 oF)
Dropping point 250 oC (480 oF) Operating temp. –20 to +150 oC (–4 to 300 oF)
50
Testing the rotation and percussion functions
Testing the rotation function
Connect the hydraulic hoses P (pressure) and R
P (return) to the hydraulic motor. Switch on the hyd-
raulic pressure (max. 40 bar/580 psi) to the motor
for about half a minute.
Check that the rotation motor operates smoothly,
without dissonance or leakage, and in the correct
direction.
1250 0005 72
P R
Fig. 102. Testing the function of the hydraulic motor
Testing the percussion function

Connect the hydraulic hoses P (pressure), and
P R (return) as shown in the figure. Apply a hydraulic
pressure (max. pressure 30 bar) to the percussion
circuit for approx. half a minute.
Check that the percussion mechanism functions
properly, and that there is no external oil leakage.
1250 0005 73
Fig. 103. Testing the function of the percussion mechanism
51
Tightening torques
4 5
5
5
8
3
5
1
6
7
1250 0115 54
3
2 10
9
N.B. Tighten item Nos. 1–3 in the prescribed order.
Ref.No. Qty. Check point Torque Instructions

Nm lbf.ft
1 2 Side bolts 300 220 Tighten the rear nuts

2 2 Front bolts 220 160 Tighten the front bolts
3 2 Side bolts 350 260 Tighten the front nuts
4 6 Back head 220 160 Tighten the screws alternately to full torque
5 6 Accumulators 220 160 Tighten the screws alternately to full torque
6 4 Hydraulic motor 75 Tighten the screws alternately to full torque
7 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque
8 6 Valve covers 220 160 Tighten the screws alternately to full torque
9 1 Flushing connection 300 220
10 1 Flushing plug 300 220
52
Rock drill COP 1532 61
88
87
2
3
83
81
82
95
CO
P 1 (71)
532 90
89 (71) 63
71
Intake accumulator / Return accumulator A 72
ROTATION 180∞
66 64
55 91 85
53 49 (91) 83 86
62 84 (71)
48 (37) (71)
46 64 64
92
100 103 82
101 26
1 CO 70
P 1 (37) 66 107
A 102 5 106
2 32 68 104
14 105 (71)
A 25 69 70
12 70 97 65
3
93 99 67
37 (18) 52
9
96 18 (18)
10 11 6
10
5
(6) 4
8 (6) (20)
13 9
7 5
4 1 (20)
6
A (20) 17
16
4 36 15
17 3 (20)
5 2 14
= SEAL KIT 1250 0068 51 61 (18)
CO
56 4 12
P 1 57
58 13
532 59 11
1250 0005 80
3
60 2
(37)
Damper accumulator
11
Front head
7 15
14
1250 0005 77
1
10 9 8
2 13
1250 0068 45
12
3
11
10
6 12 10
4 9
13
1
5
13 2 3 4 8
Atlas Copco, 2003

Printed in Sweden
2
3
4
7 5
53

9853 1090 01b Overhauling Instructions COP 1532

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Overhauling instructions for

Hydraulic COP 1532

List of contents Page

ATLAS COPCO ROCK DRILLS AB

indicates hazards or hazardous procedures which COULD

indicates hazards or hazardous procedures which COULD

The following safety rules must also be observed:

Honing tool ø 20–50 mm

Feeler gauge, 0.03–0.10 mm, with 0.01 mm

Internal circlip pliers

Torque wrenches, torque range 10–350 Nm

Socket set with:

T-handle with 3/4" square drive

A 3115 0329 80 Pivoted mounting Disassembly, assembly and

B 3115 1902 80 Press Basic tool for use with other

D 3115 1019 00 Mandrel Removal and fitting of guide,

and driver (figs. 13, 15, 16,

E 3115 2750 00 Press tool Fitting of seal rings and

F 3115 2751 00 Press tool Fitting of tapered roller

bearings (fig. 45).

G 3115 2753 00 Mandrel Removal of front seal hou-

sing with piston guide (fig.

H 3115 0313 00 Mandrel Assembly of gear housing

I 3115 0314 00 Mandrel Fitting of bushing for damper

piston (fig. 59).

J 3115 1877 00 Assembly and Assembly and disassembly of

disassembly tool accumulators (figs. 19, 22).

K 3115 0344 00 Wrench adapter Adapter for use with torque

(32 mm) wrench when tightening up

L 3115 2859 80 Assembly and Assembly and disassembly of

M 3115 1627 00 Assembly tool Fitting of thread inserts into

3115 1126 00 Assembly tool

N 3091 0455 90 Extractor + See figs. 34, 55, 65, 69.

O 3115 2754 00 Mandrel Fitting of needle bearing,

P 3115 3425 80 Charging Equipment for charging of ac-

R 3115 2747 00 Adapter plate Used in conjunction with

for disassembly, assembly

S 3115 2756 00 Mandrel Removal of washers, needle

bearing, guide sleeve and

T 3115 2163 00 Sleeve Fitting of bushing into inter-

U 3115 1594 00 Plates Removal of damper piston

liner (fig. 53).

V 3115 2755 00 Spacer ring Removal of needle bearing,

X 3115 1899 00 Sleeve Removal and fitting of

AA 0335 2141 00 Circlip ø 46 mm Removal of slide bearing

BB 3115 2749 00 Press tool Removal of guide sleeve

Fitting of damper piston

CC 3115 2846 00 Mandrel Removal of needle bearing,

spacer ring and seal ring

DD 3115 2752 00 Press tool Fitting of slide bearing into

Fitting of piston guide (fig.

EE 3115 2844 00 Extension sleeve Fitting of seal ring (fig. 39).

FF 3115 2757 00 Press tool Removal of slide bearing

GG 3115 2918 80 Bottle regulator Reducing valve with 16-bar

1. Front head, incl. 5. Accumulators

4. Intermediate part, incl.

N.B. Always wash down the outsides of the

Take off the accumulators (63, 91, 92) together

Fig. 5. Removing the accumulators

Back head and impact piston

Fig. 6. Removing the back head

3 Cover and gear housing

Fig. 10. Removing the intermediate part