Atlas Copco

Overhauling instructions
Hydraulic Rock drilling machine
COP 1140/1435

Atlas Copco Rock Drills AB

Örebro, Sweden
© Atlas Copco Rock Drills AB, 2011, All rights reserved

No. 9853 1202 01a

 © Copyright 2011, Atlas Copco Rock Drills AB, Sweden
All product names in this publication are trademarks of Atlas Copco. Any unauthorised
use or copying of the contents or any part thereof is prohibited.
Illustrations and photos may show equipment with optional extras.
No warranty is made regarding specifications or otherwise. Specifications and equipment
are subject to change without notice.
Consult your Atlas Copco Customer Centre for specific information.
Operating instructions in original

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
 Contents

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

2. Tool list............................................................................................................... 7
3. Drilling machine main parts ............................................................................. 9
4. Dismantling the drilling machine’s main parts............................................. 11
4.1 Fitting the rock drill on the assembly fixture ...................................................................... 11
4.2 Removing the front head ................................................................................................... 11
4.3 Dismantling the accumulators ........................................................................................... 12
4.4 Removing the back head and cylinder .............................................................................. 12
4.5 Dismantling the hydraulic motor ........................................................................................ 12

5. Dismantling and assembling the front head. ............................................... 13

5.1 Removing the front head ................................................................................................... 13
5.2 Inspecting and replacing parts .......................................................................................... 13
5.3 Mounting the front head .................................................................................................... 14

6. Accumulators .................................................................................................. 17
6.1 Dismantling the accumulator ............................................................................................. 17
6.2 Inspecting and replacing parts .......................................................................................... 17
6.3 Assembling the accumulator ............................................................................................. 18

7. Cylinder............................................................................................................ 19
7.1 Dismantling the cylinder .................................................................................................... 19
7.2 Inspecting and replacing parts .......................................................................................... 20
7.3 Assembling the cylinder .................................................................................................... 20

8. Gear housing................................................................................................... 23
8.1 Dismantling and inspecting the side bolts, cover plate and rotation chuck bushing.......... 23
8.2 Fitting the parts in the gear housing .................................................................................. 26

9. Fitting the drilling machine’s main parts ...................................................... 29

9.1 General.............................................................................................................................. 29
9.2 Mounting the gear housing onto the mounting plate ......................................................... 29
9.3 Mounting the hydraulic motor ............................................................................................ 29
9.4 Assembling the cylinder .................................................................................................... 29
9.5 Fitting the back head ......................................................................................................... 29
9.6 Mounting the front head .................................................................................................... 30
9.7 Mounting the accumulator ................................................................................................. 30
9.8 Charging the accumulator ................................................................................................. 31

3
Contents

10. Function test of rotation................................................................................. 33

11. Tightening torques ......................................................................................... 35
12. Hydraulic and lubricant recommendations.................................................. 37
12.1 Pneumatic tool oil ............................................................................................................. 38
12.2 Grease .............................................................................................................................. 38

4
 General 1

1. General
These instructions are intended as a guide for the
repair of your hydraulic rock drilling machine.
1.1 Layout
The instructions are preceded by safety regula-
tions, followed by a tool list for the standard and
special tools required. Following which, there is a
description of how the drilling machine’s main
parts are removed. Under each main heading
there are then detailed instructions on the
removal, checking and inspection of parts, as well
as fitting.
The instructions are concluded with sections on
how the main parts are fitted, as well as which
tests and checks that should be carried out follo-
wing repair.
The letters within brackets in the text refer to the
tool list of special tools, and figures within brackets
refer the illustrations that belong to the text.
1.6 Environment
Environmental regulations
Care for the environment!
Leaking hydraulic couplings and grease are
hazardous to the environment.
Changing oils, hydraulic hoses and various
types of filter can be hazardous to the environ-
ment.
Always collect oil residue, oil spill, oily waste
and grease residue and spill. Treat according
to applicable local regulations.
Use biodegradable hydraulic fluid and lubrica-
ting oil wherever possible.
1.7 Safety regulations
The Safety chapter contains important information
for the prevention of accidents.

1.2 Requirements for the workshop

- The workshop must be separate from grinding, Warning boxes
welding or other work that generates particles.
- The workshop must be well-cleaned, free from The manual contains warnings.
dust and dirt. Warnings are preceded by a heading (Danger,
Warning and Caution).
- The workshop should be equipped with
• suitable standard and special tools Warning boxes
• washing installations for cleaning and
degreasing Danger
• air for flushing clean Indicates an imminent risk of serious or fatal
• hydraulic press injury if the warning is not heeded.
• lifting device for min. 500 kg
Warning
1.3 In the event of leakage problems Indicates hazards or hazardous procedures
Check the source of the leak before removing the which could result in serious or fatal injury if
drilling machine from the rig. the warning is not heeded.

1.4 During dismantling Caution

Always wash the drilling machine externally using
grease solvent before starting removal.
An assembly fixture must be used when dismant-
ling the drilling machine.
Indicates hazards or hazardous procedures
which could result in personal injury or
damage to property if the warning is not
heeded.

1.5 During assembly

During all assembly operations assembly grease
must be applied to the internal parts and screws
must be lubricated unless otherwise stated.

5
General 1
The following general safety regulations must
be observed
Important!
• Read through the overhauling instruction
carefully before starting the repair. Follow the
instructions given and local regulations.
• Ensure that the hydraulic, water and air
systems are depressurised and that the elec-
trical system is de-energised prior to remo-
ving the drilling machine or starting work on
the system.
• The drilling machine must only be repaired by
personnel trained by Atlas Copco.
• Make sure that the safety labels are fitted,
clean and fully legible.
• Use approved lifting devices when handling
the drilling machine. Avoid lifting heavy
weights yourself.
• Components that could move or fall down
must be secured in order to prevent personal
injury during the repair. Always use an
assembly fixture (A), see the tool list.
• Check that hoses are of the correct quality, the
correct size, with correctly pressed connec-
tions and that the hose connections are unda-
maged and firmly tightened. Hoses that
loosen could cause serious injury.
• Always plug the hydraulic hoses immediately
after they have been detached. Use clean
protective plugs.
• Use only Atlas Copco original parts. Any
damage or malfunction caused by the use of
non-original Atlas Copco parts is not covered
by warranty or product liability.
• Do not use or intervene in the drilling machine
unless you have been trained to do so.
• Make sure that the drilling machine has been
maintained in accordance with the applicable
instructions.
• Before repositioning the rig and drilling
machine or starting to drill, make sure that
there are no personnel in the immediate vici-
nity of the drilling machine.
6
• Never attempt to carry out maintenance while
the drilling machine is in operation.
• Checks and adjustments that are necessary
when the drilling machine is in operation must
be carried out by at least two persons. One
person must then be present at the operating
station and have a good view of the work.
• Make sure that the place of work is well venti-
lated.
• Particular attention must be paid to all
warnings in the manual.
Important!
A mining machine has many components and
functions that are controlled by a hydraulic
system, directly or indirectly. Before working on
or inspecting any part of the machine, it is
important to know how the machine moves and
how its functions are controlled by the hydraulic
system.
Prior to starting work or inspecting any part it
must be physically locked/stopped to prevent it
from moving and causing bodily injury. The
mechanic must be careful not to place any body
part where a movement of the machine could
cause injury if the hydraulic system fails or is
disconnected.
There may be occasions where components
and or vehicles start moving when trapped
energy is released. Where applicable, there
must be confirmation that all measures to safe-
guard against involuntary movement have been
taken by releasing the energy and/or physically
locking/stopping the machine.
It is also incumbent on the individuals involved
to ensure that all local, national and federal
safety regulations are followed, before and
during the work or inspection.
 Tool list 2

2. Tool list

A1 A7 A13

A2 A8 A14

A3 A15
A9

A4 A10 A16

A5 A11
1250 0188 95

A6 A12

Letter Tools
A1 Plastic mallet
A2 Copper hammer
A3 Honing tool 19-70 mm
A4 U-ring spanners 10-32 mm
A5 Hexagon wrench 4-10 mm
A6 Screwdriver
A7 Punch 2-10 mm, Copper punch 20 x 250 mm
A8 Feeler gauge 0.03-0.10 mm, with 0.01 mm intervals
Feeler gauge 0.05-1.00 mm, with 0.05 mm intervals
A9 Internal lock ring pliers
A10 Torque wrenches 10-350 Nm
A11 Socket wrench set with sockets 10-32 mm for external hexagon,
Socket wrench set with sockets 4-10 mm for internal hexagon
A12 Awl
A13 T-handle with 3/4" connection bracket, Power socket 32 mm
A14 Vernier calliper
A15 Micrometer
A16 Bearing puller

7
Tool list 2

A G O

B H
P

C
L
Q
D

E M
U
1250 0402 86

F N

Letter Tools Part no.

A Assembly fixture 3115 0329 80
B Retaining plate 3115 3457 00
C Rotary actuator 9495 5916 81
D Mandrel for gear housing 9495 5917 00
E Mandrel for cylinder and front 9495 5918 00
F Mandrel for piston guide 9495 5919 00
G Mandrel for plug for cylinder 9495 5920 00
H Mandrel for front d=45 9495 5921 00
L Fitting and removal tool 3115 5251 80
M Assembly tool (M18x2) 3115 1127 00
Fitting tool (M16) 3115 1126 00
Assembly tool (M14) 3115 1627 00
Assembly tool (M20x2) 3115 1628 00
N Puller 3091 0455 90
O Wrench accessory NV 32 mm 3115 0344 00
Wrench accessory NV 24 mm 3115 0343 00
P Wrench accessory for side bolts NV 30 mm 3115 3521 00
Q Charging equipment for accumulators 3115 3425 80
U Plate 9495 5922 00

8
 Drilling machine main parts 3

3. Drilling machine main parts

600

100

200
500
1250 0407 07

300
400 7, 8

100. Front head incl. 300. Cylinder incl.

Shank adapter Cylinder liner
Stop ring Plunger
Stop washer Piston guides
Flushing head Seal holder
Steering Piston seals
Valve piston
200. Gear housing, incl. Valve covers
Cover
Drill sleeve 400. Back head
Rotation chuck bushing
Driver 500. Hydraulic motor
Gear
Damper piston 600. Accumulators
Damper piston liner Intake accumulator
Damper piston seals Damper accumulator
Bearings
7, 8. Side bolts and nuts

9
Drilling machine main parts 3

10
 Dismantling the drilling machine’s main parts 4

4. Dismantling the drilling machine’s main parts

NB! Always wash the drilling machine externally 4.2 Removing the front head
using grease solvent before starting removal.
The assembly fixture (A) must be used when
dismantling the rock drill.
In the event of leakage problems 108
• Check the source of the leak before removing
the drilling machine from the rig.
107
Important!
Observe great cleanliness when intervening 15
in the drilling machine or its hydraulic circuit.

1250 0405 51
Replacement of front head parts, shank
adapter, accumulator, hydraulic motor, bolts
and connections must be carried out on the
worksite. Other repairs must be carried out in • Remove the nipple (15) and the flushing adapter
a suitable workshop. (107).
• Remove the O-ring (108).
4.1 Fitting the rock drill on the
assembly fixture 100
236

9
113
1250 0407 13
1250 0406 79

• Remove the 4 front bolts (9).

• Remove the front head (100) by pulling the tool
shank or tapping it loose with a plastic mallet.
• Screw the rock drilling machine into the movable • Remove the guide pin (236) from the gear
assembly fixture and the support plate (B). housing and the 2 O-rings (113).

11
Dismantling the drilling machine’s main parts 4

4.3 Dismantling the accumulators 4.5 Dismantling the hydraulic motor

Caution!
All gas must be released before removal. 10
Do this by removing the protective cap (A),
undoing the valve nut (B) and opening it 2-3
turns.

There is a risk of injury if these instructions

are not observed!

1250 0402 77
B A 11
600 500
320 • Remove the nuts (11) and screws (10) and
remove the hydraulic motor (500) from gear
housing.
600
233
1250 0405 49

• Remove the accumulators (600) with the seals

(233 and 320) by undoing the bolts.

4.4 Removing the back head and

cylinder
Important!
All personnel must stand to the side of the
drilling machine when removing the back
head.

300
400
8
1250 0405 52

• Remove the back head (400) by loosening and

removing the dome nuts (8).
• If necessary, tap on the back head with a plastic
mallet and gently prize with a crowbar or similar.
• Remove the cylinder (300) by tapping with a
plastic mallet and gently prizing it loose using a
crowbar or similar tool.

12
 Dismantling and assembling the front head. 5

5. Dismantling and assembling the front head.

5.1 Removing the front head

118 E
100
101
1250 0400 58

• Remove the lock ring (118) from the front.
Caution!
The percussion mechanism must not be
enabled, when the shank adapter is dismantled.
Piston and front piston guide can be damaged.
1250 0400 60
• Press out the inner components from the front.
Use the press tool (E).
• The wide section of the press tool must be
turned towards the bushing.
5.2 Inspecting and replacing parts
Before inspection the parts must be washed clean
in grease solvent.

112
117 118
116 106 16 115 112 115
19 101
117
114
106
105
104
1250 0402 41
1250 0407 08

102

• Replace all O-rings (112), seals (115, 117) and

• Remove the shank adapter (16) and stop ring the wiper (114).
(106) from the front head (101). • Replace the stop ring (106) and flushing head
• The drill sleeve (19) detaches. (104) if they are damaged or cracked.
• Remove the spring pin (116).
• Check the internal components when replacing
the shank adapter.

13
Dismantling and assembling the front head. 5

5.3 Mounting the front head

101
A 114 102
1250 0402 85

1250 0400 50
• Replace the guide (102) if its surface has been
worn more than max. diameter 36 mm (original
35.2)
Or in the event of damage, cracks, etc.
• Check that the guide does not rotate in the front
head. • Install the scraper (114) in the guide (102).

• Press the guide (102) in at the front (101).

1,5
mm
105 106

101 117 115 112 115 117

L
1250 0407 09

1250 0400 51

104
• Replace the stop ring (106) in the event of
damage, cracks, etc., or if the surface is worn by
more than 1.5 mm.
• Use a new stop ring as a comparison template.
• Also replace if the contact surfaces on the tool
shank and stop ring are together worn more • Fit the seals (115, 117) in the flushing head
than 4 mm. (104).

• Install the O-rings (112) in the grooves on the

flushing head (104).

• Press the flushing head (104) in at the front

(101) so that the flushing hole in the flushing
head corresponds with the flushing hole at the
front.

14
 Dismantling and assembling the front head. 5

101

108
107
1250 0400 52

15

• Install O-ring (108), flushing connection (107)

and nipple (15) at the front (101).

19 101 105 112

106 118
16
1250 0407 16

• Replace the stop washer (105) in the front (101).

• Install the lock ring (118) in the front (101).

• Install O-ring (112) on the stop ring (106).

• Fit the stop ring (106) on the shank adapter (16).

• Replace the shank adapter (16) in the front

(101).

• Replace the drill sleeve (19).

15
Dismantling and assembling the front head. 5

16
 Accumulators 6

6. Accumulators
CAUTION! 6.1 Dismantling the accumulator
All gas must be released before removal. Do
this by removing the protective cap (A) and
loosening the valve nut (B) by 2-3 turns.

There is a risk of injury if these instructions

are not observed! L

600

1250 0402 87
1250 0187 04

N2 • Secure the lower section of the disassembly tool

(L) firmly in a vice.
• Fit the accumulator (600) onto the disassembly
1 2 tool (L).
• Screw in the cover plate for the disassembly tool
(L) with the nuts.
• Unscrew the accumulator’s cover plate from the
1. Read the operator’s instructions carefully before housing with a suitable spanner (A4).
service or replacement of the accumulator.
2. Must be charged with nitrogen only. 6.2 Inspecting and replacing parts
CAUTION!
Incorrect length of bolts, as well as damaged
or corroded threads on bolts, housings and
1 covers may lead to dangerous oil leakage
B
2 A and parts loosening.

Risk of personal injury

Always replace incorrect and damaged bolts

(4), housing (1) and cover plate (3). Always
1250 0406 81

replace the bolts in pairs.

613
The rock drill is equipped with two accumula- 604
tors:
• Damper accumulator (1)
• Intake accumulator (2)
602

601
1250 0407 12

233, 320

• Always replace the diaphragm (602) and valve

(604) if there is any indication of cracks or other

17
Accumulators 6

damage. Always replace the seal ring (233 and

320).
• Replace the diaphragm or the entire
accumulator if oil comes out of the valve nipple.
• Check that the duct for gas charging is not
blocked.
• Inspect the housing (601) and cover (613). If L
there are cracks or other damage, replace the
complete accumulator. 600
• Replace the housing (601) and the cover plate
(613) if the threads are damaged or highly
corroded. L

CAUTION!

1250 0402 87
Damaged or highly corroded threads on the
accumulator housing or cover could result in
a serious accident. • Position the accumulator on the lower section of
the assembly tool (L).
6.3 Assembling the accumulator • Screw on the cover plate for the assembly tool
(L) with the nuts.
Before fitting it is important that all parts are dry • Tighten the accumulator’s cover plate (600) to a
and free of oil. tightening torque of 300 Nm.
• Use the assembly tool (K) and a wrench adapter
(R) with the torque wrench.
602 613
2
604
1
1250 0407 20

601
1250 0407 14

• Check and replace the safety labels if required

(1 and 2)
• Lubricate the edge of the diaphragm with a thin
layer of silicone grease. Fit the diaphragm (602) WARNING!
in the housing (601).
• Lubricate the threads of the cover plate (613) Do not charge the accumulators before they
and housing (601) with grease, type NEVER- have been fitted onto the drilling machine.
SEEZ.
• Fit the cover (613) on the housing (601) and
screw the accumulator together by hand, parts
facing in the direction as showed in the figure.
NB! Do not turn the accumulator over before it
has been screwed together.
• Fit a new valve (604) together with the O-ring
and tighten to tightening torque 30 Nm.

18
 Cylinder 7

7. Cylinder
7.1 Dismantling the cylinder • Clean and check the rear piston guide (306).
Before inspection the parts must be washed clean • If necessary, press out the piston guide (306)
from the guide housing (307) using the press
in grease solvent. tool (F).

305
E
301
302
307 308 304
303
306
301 305

1250 0402 48
1250 0402 46
• Press out the parts 304, 303 and 302 forwards
using the tool E.
• Tap out the piston (305) backwards using a
plastic mallet.
• Parts 306, 307 and 308 come out with the piston 312
(305) from the cylinder housing (301).
• NB! Do not try to tap the piston out forwards. 316
This leads to damage to the front piston 304
guide. 314

315
308
317
313
1250 0402 49

• Remove the wiper (314), O-ring (316) and set of

1250 0402 47

seals (312) from the seal housing (304).

323
• Remove the set of seals (313), O-ring (317) and 310
wiper (315) from the seal housing (308). 301
318
309

307 F
306
1250 0402 50

317 319
311
323
• Remove the valve covers (310 and 311)
1250 0402 44

together with O-ring (318) and seal ring (319) by

removing the screws (323).
• Remove the valve (309).

• Remove the O-ring (317) from the piston guide

housing (307).

19
Cylinder 7

303
301
302
321
1250 0402 53

1250 0405 55
• Check the wear plug (321). • Check the front’s piston guide (303) and liner
NB! The wear plug (321) must only be replaced (302).
if holes are detected or if it is loose. • If there are signs of scoring and scratches then
the parts must be replaced.
7.2 Inspecting and replacing parts
Clean all ducts by flushing them thoroughly. 7.3 Assembling the cylinder
Before assembly, all parts must be lubricated with
clean hydraulic oil. All O-rings and seals must be
replaced.

301
309 323
310
301
318
309
1250 0405 53

1250 0402 50

319
• Check the cylinder housing (301), cylinder bore, 311
valve drilling, and valve piston (309). 323
• In the event of scoring or scratches, replace the
parts. • Replace the valve (309), O-ring (318), the seal
Minor scoring can be polished with a fine abra- ring (319), the valve covers (310, 311) and the
sive cloth, whetstone or honing tool. screws (323).

305
301 G

321
1250 0407 10

1250 0402 52

• Inspect the plunger (305) for scoring and • If you have to change to a new wear plug (321),
scratches. Also inspect the impact surface for it must be performed by using the tool (G).
wear and chips. NB! It is important that the tool is used in order
to avoid damage to the plug.

20
 Cylinder 7

312
316
304 307
314 F
306
317
1250 0402 49

1250 0402 44
• Fit the wiper (314), O-ring (316) and set of seals • Replace the piston guide (306) in the piston
(312) onto the seal housing (304). guide housing (307) using the press tool (F).
• NB! This should be carried out with caution as
the piston guide has thin walls.
• Replace the O-ring (317) on the piston guide
housing (307).
E
301
302 301
303 307
304
E
1250 0402 48

• Press in the liner (302) using the tool (E).

• Press in the piston guide (303) using the tool
1250 0402 54

(E).
• Press in the seal housing (304) using the tool
(E).
• Press the piston guide housing (307) into the
305 cylinder housing (301) using the tool (E).
301

315
308
317
313
1250 0402 43

1250 0402 45

• Replace the piston (305) by pushing it into the

cylinder (301).

• Fit the set of seals (313) and the wiper (315)

onto the seal housing (308).
• Fit the O-ring (317) onto the seal housing (308).

21
Cylinder 7

E 301 308
1250 0402 55

• Press the seal housing (308) into the cylinder

housing (301).

22
 Gear housing 8

8. Gear housing
8.1 Dismantling and inspecting the
side bolts, cover plate and rotation
chuck bushing

216
220
217
219

1250 0406 86
221
222
1250 0406 84

7 • Remove the needle bearing (219), the inner ring

(217), the gear (220) and the inner ring (216)
together in one package.
• Inspect and remove the side bolts (7) if they are
damaged. 216
• Loosen the motor mount (221) by removing the
screws (222).
• Tap off the motor mount using a plastic mallet
and release it with a screwdriver. 217
219
1250 0402 59

• Check the needle bearing (219) and the inner

rings (216, 217) and replace them if necessary.
1250 0406 85

Separate the inner rings during dismantling.

234 235 228

220
• Remove the seals (234) and (235).
• Remove the O-ring (228).
1250 0402 60

• Clean and check the gear (220).

• Replace in the event of signs of damage and
wear.

23
Gear housing 8

208

A16
209
215
218
1250 0406 87

1250 0407 15
• Check the needle bearing (218) that remains in • If any of the roller bearings (208, 209) on the drill
the gear housing. sleeve must be replaced, then the roller cage
• Replace if necessary. must be pressed off with the bearing removal
NB! Spacer ring (215). tool (A16).

232 211 C 211

210
1250 0402 64
1250 0406 88

• Check and replace the drill sleeve (210) in the

• Unscrew the cover plate (211) using the tool C
(seal (232) comes with the cover plate (211)
during dismantling).
event of deformation or cracks, or if the ring gear
is excessively worn, or if the contact surface for
the seals (231, 232) is worn or damaged.

209 212
210
208 m
2m

212
1250 0406 95
1250 0406 96

• Check and replace the driver (212) when the

boom width is less than 2 mm.
• Remove the drill sleeve (210) together with the
roller bearing (209) and the driver (212).
• The inner bearing race and the rollers for the
tapered roller bearing (208) come out with the
drill sleeve (210).
• Check the roller bearings for wear and damage.

24
 Gear housing 8

U
225 229
230 204224
208
231 223
207
1250 0402 66

1250 0402 81
• Remove the outer ring for the tapered roller
bearing (208) and the support ring (207).
• Remove the seal (230) and (231).
• Use the disassembly tool (u) and a brass rod to
release the liner (204).
• Remove the O-rings (223, 224 and 225) from
the liner (204).
• Check the liner (204) so that no scoring,
scratches or other damage exists. Polish minor
damage and replace if necessary.
• Remove the seal (229)
206
205
1250 0402 67

• Tap out the damper piston (5) and rotation chuck

bushing (6) using a brass mandrel.
1250 0177 30

• Check the sealing surfaces of the damper piston

and check that there is no scoring, scratches or
other damage.
• Polish minor damage.
• Check the gear housing mating face for damage
and wear.
206

1,5
1250 0402 68

• Check the rotation chuck bushing (206).

• Replace if the contact surface’s bevel is
damaged or worn more than 1.5 mm.

25
Gear housing 8

8.2 Fitting the parts in the gear

housing
Before assembly, the parts must be lubricated with
clean hydraulic oil
NB! Replace all O-rings and seals.

206
205

1250 0402 69
201
• Lubricate and replace the damper piston (205)
and rotation chuck bushing (206).
• Tap in using a soft mandrel in plastic material
229 NB! Take care not to damage the damper seals.
1250 0407 03

• Replace the seal (229). Turn it correctly in

accordance with the small figure.
208
225 207
204 224
223 230
1250 0402 70

231

• Replace the support ring (207) and the outer

ring (208) in the tapered roller bearing.
1250 0402 79

• Tap them in if required.

NB! The tapered roller bearings must be pre-
assembled on the drill sleeve without the outer
rings.
• Fit the O-rings (223, 224, 225) and the seal
(230) in the liner (204).
• Grease the liner’s outer part and the O-rings.
• Replace the seal (231)

D 201 212
204
1250 0406 97

209
210
1250 0402 80

• Fit the driver (212) in the drill sleeve (210).

• Replace the outer ring in the tapered roller
bearings (209) and replace the unit in the
machine.
• Press in the liner (204) using the tool (D).

26
 Gear housing 8

201

216
220
217
1250 0402 72

215

1250 0402 75
232 211 218

• Fit a new seal (232) in the cover plate (211).
• Replace the support ring (215) and the needle
bearing (218) in the gear housing (201).
• Fit the inner rings (216, 217) on the gear (220).
• Fit the gear (220) in the gear housing (201).
.

234

235
1250 0407 11

C 211
1250 0402 76

• Fit the cover plate (211) and set the bearing’s 234
preload using tool C. The tool must be used so 228
that the drill sleeve is rotated during assembly.
• The tool rotates the bearings, and this is • Replace the 4 seals (234) and (235).
important for bearing preload. • Fit the O-ring (228).
• Tighten the cover plate to a torque of 400 Nm.

B
A 219 263
1250 0402 78

261 222
1250 0407 05

• Assemble the motor mount (261) together with

NB! Check the following before mounting the
front head:
• Note which of the six markings A is closest
to a milled out recess B.
• Fit the spring pin (116) into the correspon-
ding hole in the front head.
the needle bearing (219) and the O-rings (263),
then replace the gear housing using the screws
(222). Tighten to a torque of 45 Nm.
• Replace the new or inspected side bolts (7).

27
Gear housing 8

28
 Fitting the drilling machine’s main parts 9

9. Fitting the drilling machine’s main parts

9.1 General 9.4 Assembling the cylinder
All parts must be thoroughly cleaned before
assembly. During fitting the parts must be lubri-
cated with clean hydraulic oil.
The O-rings must be replaced with new
intact ones and be greased with silicone
grease.
301
9.2 Mounting the gear housing onto 322
the mounting plate

1250 0405 46
• Check that the guide pin (322) is fitted in the
cylinder.
• Fit the cylinder (301) on the side bolts.

9.5 Fitting the back head

1250 0177 31

B 301
322
• Screw the gear housing securely into the 400
mounting plate (B) as shown in the figure. 8
1250 0405 47

9.3 Mounting the hydraulic motor

10
• Before assembly, apply grease to the threads,
type Never Seez.
• Check that the guide pin (322) is fitted in the
cylinder.
• Fit the back head (400) on the side bolts.
• Tighten the dome nuts (8) alternately to a
tightening torque of 250 Nm.
1250 0402 77

11
500
• Lubricate the splines on the gear housing’s
motor shaft.
• Fit the hydraulic motor (500) to the gear
housing.
• Tighten the nuts (11) and the bolts (10) to a
tightening torque of 80 Nm.

29
Fitting the drilling machine’s main parts 9
9.6 Mounting the front head
100
116 236
9 600
113
1250 0407 21
• Check that the spring pin (116) is fitted in the
correct hole in the front head.
• The spring pin (116) must correspond with the
bearing’s setting for preload.
• Check that the guide pin (236) is fitted in the
gear housing.
• Fit the O-rings (113) in the front head. Check
that they are fitted in the correct position.
• On surface rigs, replace the O-ring
(0663614900), if appropriate, in order not to
pressurise the contact surfaces.
NB! O-ring (0663614900) is not replaced on
underground rigs.
• Fit the front head (100) onto the gear housing.
• Fit the bolts (9).
NB! Lubricate threads before assembly.
• Tighten the bolts (9) alternately to a tightening
torque of 220 Nm.
• Lubricate the gear housing with COP grease.
30
9.7 Mounting the accumulator
B A
600
320
233
1250 0405 49
CAUTION!
Defective screws can cause dangerous oil
leakage, or can cause the accumulator to be
blown off.
Squirting oil can seriously injure the eyes and
skin.
Parts that come loose can cause serious
injury.
• Fit the seals (233) on the intermediate segment
and the cylinder, then replace the accumulators
(600).
• Make sure that the seals are not damaged
during the assembly.
• Replace the accumulator on the rock drilling
machine using undamaged original screws,
length 55 mm (M16 x 55 - 8.8 Fzb). NB! For the
HD accumulator, original 65 mm screws must be
used.
• Replace both screws at the same time, even if
only one of them is corroded (or damaged in any
way).
• Tighten the screws alternately to a tightening
torque of 220 Nm (160 lbf.ft).
 Fitting the drilling machine’s main parts 9

NB! Charge at the bottom if possible rather than

too high.

Damper accumulator (1) 15 bar

Intake accumulator (2) 70-100 bar*

*Maximum charge pressure 100 bar (but no more than colla-

1250 0187 04
ring pressure -40 bar).
N2 • Tighten the valve nut (B) and close the gas
valve.
• Remove the gas house and fit the protective cap
1 2 (A) to the accumulator valve again.

1. First read through the user manual carefully.

2. Charge only with nitrogen.
• Check that the accumulators (1 and 2) have the
correct safety labels and that these are not
damaged.
• Replace damaged labels!

9.8 Charging the accumulator

B
A
1
2
1250 0153 19

WARNING!
The accumulators must be charged with
nitrogen (N 2) only!

Other gases may 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 instructions

are not observed!
• Remove the protective cap (A).
• Open the valve nut (B) by 2-3 turns, and connect
the gas house.
• Open the gas valve.
• Charge the accumulators to the correct
pressure, as follows:

31
Fitting the drilling machine’s main parts 9

32
 Function test of rotation 10

10. Function test of rotation

P
1250 0164 61

• Connect the hydraulic hoses P (Pressure) and R

(return) to the hydraulic motor.
• Supply hydraulic fluid pressure to the hydraulic
motor, max. pressure 40 bar, for approximately
half a minute.
• Check that the rotation is smooth, quiet, and that
there are no leaks, as well as that the rotation
takes place in the right direction.

33
Function test of rotation 10

34
 Tightening torques 11

11. Tightening torques

608
211

602

604

9
601

107 323

8
222
11
1250 0407 04

Lubricate the threads at pos. 8, 211 and 601 with NV= Spanner size
Never-Seez Regular Grade.

Ref. Torque
Qty. Check point NV Instructions
No. Nm
8 2 Dome nut, Side bolt 250 30 Tighten the screws alternately to full
torque
9 4 Front head 220 24 Tighten the screws alternately to full
torque
11 2 Hydraulic motor 80 19 Tighten the screws alternately to full
torque
107 1 Flushing connector 220 27
211 1 Cover plate, Roller bearing 400
222 2 Motor flange 45 16 Tighten the screws alternately to full
torque
323 4 Valve cover 220 24 Tighten the screws alternately to full
torque
601 2 Accumulator housing 300 -
604 2 Valve, accumulator 30 19
608 4 Accumulator 220 24 Tighten the screws alternately to full
torque

35
Tightening torques 11

36
 Hydraulic and lubricant recommendations 12

12. Hydraulic and lubricant recommendations

Hydraulic fluid
A good hydraulic fluid provides superior protection against wear, rust and oxidisation as well as good anti-
foaming and air and water separation properties.

In order to ensure a lowest level on these properties the mineral oil based and synthetic (polyalphaolefin)
hydraulic fluids must conform to the standard ISO 11158 HM/HV or DIN 51524 HLP/HVLP.

Environmentally friendly hydraulic fluids must fulfil ISO 15380

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

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

If the viscosity is too low:

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

If the viscosity is too high:

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

The hydraulic fluid must be filtered to a purity of 20/18/15 in accordance to ISO 4406.

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

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

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

37
Hydraulic and lubricant recommendations 12

12.1 Pneumatic tool oil

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

Quantity Part number

1 can of 10 litres 3115 3125 00
48 cans of 10 litres 3115 3126 00
1 barrel of 208 litres 3115 3127 00

If COP OIL is not available then the oil should have the following properties:

• Use an oil with good lubricating properties intended for compressed air tools.
• The oil must have good adhesion capacity.
• The oil must have additives that prevent foam formation.
• Depending on ambient temperature, the oil should have the following viscosity grades if the viscosity
index (VI) is about 100:

Ambient temperature ºC Viscosity grade (ISO 3448)

-25 to 0 VG 15-32
-10 till +20 VG 32-46
+10 till +50 VG 46-68

• The oil must have an EP additive which covers the following load-bearing properties:

ASTM D 2783 Min. 250 kg

ASTM D 4172 (40 kg) Max. 0.5 mm

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

Operating
NLGI number Drop point Base oil viscosity
Temperature
1,5-3 250 ºC 400-600 mm2/s -40 to +150 ºC
at 40 ºC

38
 Hydraulic and lubricant recommendations 12

39
Always use Atlas Copco original parts. Any damage
or malfunction caused by the use of unapproved
spare parts is not covered by warranty and product
safety undertakings.
This publication only applies to the products
described.
When ordering spare parts, please specify part
number (not reference number) as well as quantity.