Atlas Copco

Repair Instruction
Hydraulic Rock drills
COP 1840,1840EX

Atlas Copco Rock Drills AB

Örebro, Sweden
©Atlas Copco Rock Drills AB, 2009, All rights reserved

No. 9853 1002 01c

 ©Copyright 2009, Atlas Copco Rock Drills AB, Sweden
Any unauthorised use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and draw-
ings.

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
 Innehåll

INNEHÅLL
1. GENERAL .......................................................................................................... 5
1.1 Layout.................................................................................................................................. 5
1.2 Requirements for the workshop ......................................................................................... 5
1.3 Environment ........................................................................................................................ 5

2. SAFETY REGULATIONS................................................................................... 6
2.1 Warning boxes .................................................................................................................... 6
2.2 The following general safety rules must be observed ......................................................... 6

3. TOOL LIST.......................................................................................................... 7
4. ROCK DRILL MAIN PARTS............................................................................. 10
5. DISMANTLING THE ROCK DRILL’S MAIN PARTS ....................................... 11
5.1 Fitting the rock drill on the pivot plate................................................................................ 11
5.2 Dismantling the front head (COP 1840) ............................................................................ 11
5.3 Removing the extractor unit’s front head (COP 1840EX).................................................. 11
5.4 Dismantling the accumulators ........................................................................................... 12
5.5 Removing the back head and plunger............................................................................... 12
5.6 Removing the side bolts, Cover and gear housing (COP 1840) ....................................... 13
5.7 Removing the extractor’s Cover and gear housing (COP 1840EX) .................................. 13
5.8 Removing the intermediate section ................................................................................... 14
5.9 Dismantling the hydraulic motor ........................................................................................ 14

6. DISMANTLING, INSPECTING AND ASSEMBLING THE FRONT HEAD

(COP 1840)........................................................................................................ 15
6.1 Removing the shank adapter and guide............................................................................ 15
6.2 Inspecting and replacing parts .......................................................................................... 15
6.3 Fitting the guide, flushing head, stop ring and adapter ..................................................... 15

7. DISMANTLING, INSPECTING AND ASSEMBLING THE EXTRACTOR’S FRONT

HEAD (COP 1840EX) ........................................................................................ 17
7.1 Removing the shank adapter, piston, seals, guide and bushing ....................................... 17
7.2 Inspecting and replacing parts .......................................................................................... 18
7.3 Fitting the guide, bushings and piston............................................................................... 18

8. REMOVING, INSPECTING AND FITTING THE EXTRACTOR UNIT’S COVER .

(COP 1840EX) ................................................................................................... 20
8.1 Removing the side bolts, flushing intake union, seal and flushing head ........................... 20
8.2 Inspecting and replacing parts .......................................................................................... 20
8.3 Fitting the sealing ring, flushing head and side bolts......................................................... 21

9. ACCUMULATORS ........................................................................................... 22
9.1 Safety labels...................................................................................................................... 22
9.2 Dismantling the intake accumulator .................................................................................. 22
9.3 Inspecting and replacing parts .......................................................................................... 23
9.4 Fitting the diaphragm, cover, housing and labels.............................................................. 24
9.5 Dismantling the damper accumulator................................................................................ 25
9.6 Inspecting and replacing parts .......................................................................................... 26
9.7 Fitting the diaphragm, cover, housing and labels.............................................................. 26
9.8 Dismantling and assembling the return accumulator ........................................................ 27

10. BACK HEAD .................................................................................................... 28

10.1 Inspection and replacement of piston seals and seal housing .......................................... 28
10.2 Fitting the seal housing and piston seal ............................................................................ 28

3
Innehåll

11. COVER, EXTENSION PIECE AND GEAR HOUSING..................................... 30

11.1 Removing the side bolts, cover, rotation chuck bushing, rotation shaft, gears, guide sleeve 30
11.2 Inspecting and replacing parts.......................................................................................... 31
11.3 Fitting the parts in the gear housing ................................................................................. 33
11.4 Shimming the bearings in the gear housing ..................................................................... 35

12. INTERMEDIATE SECTION.............................................................................. 37

12.1 Remove the non-return valve, damper piston, seals and liners........................................ 37
12.2 Inspecting and replacing parts.......................................................................................... 37
12.3 Fitting the seal housing, seals, bushing, liner and damper piston .................................... 39

13. CYLINDER, PISTON GUIDE AND PLUNGER ................................................ 41

13.1 Removing the piston guide, valve piston and regulating plug .......................................... 41
13.2 Inspecting and replacing parts.......................................................................................... 41
13.3 Fitting the valve piston, valve end plates and piston guide .............................................. 42

14. FITTING THE ROCK DRILL’S MAIN PARTS .................................................. 43

14.1 General ............................................................................................................................. 43
14.2 Fitting the cylinder on the pivot plate ................................................................................ 43
14.3 Assembling the hydraulic motor and intermediate section on the cylinder ....................... 43
14.4 Fitting the gear housing, side bolts and cover .................................................................. 44
14.5 Fitting the plunger and back head .................................................................................... 44
14.6 Assembling the front head (COP 1840)............................................................................ 45
14.7 Assembling the extractor unit’s front head (COP 1840EX) .............................................. 46
14.8 Assembling the accumulators........................................................................................... 46
14.9 Accumulator safety labels................................................................................................. 46
14.10 Assembling the return accumulator ................................................................................. 47
14.11 Charging the accumulator................................................................................................ 47

15. FUNCTION TEST OF ROTATION AND PERCUSSION.................................. 48

16. TIGHTENING TORQUES ................................................................................. 50
16.1 Tightening the side bolts................................................................................................... 51
16.2 Retightening an assembled rock drill................................................................................ 51

17. LUBRICATION ................................................................................................. 52

17.1 Lubrication the gear .......................................................................................................... 52

18. HYDRAULIC AND LUBRICANT RECOMMENDATIONS................................ 53

18.1 HYDRAULIC FLUID ......................................................................................................... 53
18.2 PNEUMATIC TOOL OIL ................................................................................................... 54
18.3 GREASE........................................................................................................................... 54

4
 General 1

1. GENERAL 1.3 ENVIRONMENT

These instructions are intended as a guide for the
repair of your hydraulic rock drill.
1.1 LAYOUT
The instructions are preceded by safety regula-
tions, followed by a tool list for the standard and
special tools required. This is followed by how the
main parts of the rock drill are dismantled. Under
each main heading there are then detailed instruc-
tions 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.
ENVIRONMENTAL REGULATIONS
Think of 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 residues, oil spillage, oily
waste and residues and spilt grease. Deal
with according to local provisions.
Use biodegradable hydraulic and lubricating
oils where possible.

1.2 REQUIREMENTS FOR THE

WORKSHOP
- The workshop must be separate from grinding,
welding or other work that generates particles.
- The workshop must be well-cleaned, free from
dust and dirt.
- The workshop must be equipped with
• suitable standard and special tools
• washing installations for cleaning and
degreasing
• air for flushing clean
• hydraulic press
• lifting device for min. 500 kg

5
Safety regulations 2
2. SAFETY REGULATIONS
The Safety chapter contains important information
for the prevention of accidents.
2.1 WARNING BOXES
The manual contains warnings.
Warnings are preceded by a heading (Danger,
Warning and Caution).
WARNING BOXES
Danger
Indicates an imminent risk of serious or fatal
injury if the warning is not heeded.
Warning
Indicates hazards or hazardous procedures
which could result in serious or fatal injury if
the warning is not heeded.
Caution
Indicates hazards or hazardous procedures
which could result in personal injury or
damage to property if the warning is not
heeded.
6
2.2 THE FOLLOWING GENERAL
SAFETY RULES MUST BE
OBSERVED
IMPORTANT!
• Read through the repair instructions carefully
before starting the repair. Follow the instruc-
tions 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 rock drill or starting work on the
system.
• The rock drill 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 rock drill. Avoid lifting heavy weights your-
self.
• Components that could move or fall down
must be secured in order to prevent personal
injury during repair. Always use a pivot plate
(A), see the tool list.
• Check that the hoses used are of the right
quality, and that all hose connections are in
good condition and properly tightened. Hoses
that loosen could cause serious injury.
• 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 rock drill unless
you have been trained to do so.
• Make sure that the rock drill has been main-
tained in accordance with the applicable
instructions.
• Before moving the rig and rock drill or starting
to drill, make sure that there are no personnel
in the immediate vicinity of the drill rig.
• Never attempt to carry out maintenance while
the rock drill is in operation.
• Checks and adjustments that are necessary
when the rock drill is in operation must be
carried out by at least two persons. One
person must then be present at the operating
station and have a good view of the work.
• Make sure that the place of work is well venti-
lated.
• Particular attention must be paid to all
warnings in the manual.
 Tool list 3

3. TOOL LIST

A1 A7 A13

A2 A8 A14

A3 A9 A15

A4 A10

A5
A11

A6
1250 0217 00

A12

Letter Tools Part no.

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 Drift 2-10 mm, Copper drift 20x250 mm
A8 Feeler gauge 0.03-0.10 mm, with 0.01 mm intervals
Feeler gauge 0.05-1.00 mm, with 0.05 mm intervals
A9 Internal lock ring pliers
A10 Torque 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 Punch
A13 T-handle with 3/4" connection bracket, Power socket 32 mm
A14 Vernier gauge
A15 Micrometer 0-25 mm

7
Tool list 3

A G M

B H N

C I,II O

P
D J

E R
K
1250 0188 96

F
L

Letter Tools Part no.

A Pivot plate 3115 0329 80
B Press tool consisting of: 3115 1902 80
-Guide plate 3115 1902 00
-Nut 3115 2734 00
-Bolt 3115 0317 00
-Bolt (EX) 3115 2420 00
C Extension 3115 0318 00
D Drift 3115 1019 00
E Press tool 3115 1113 00
F Press tool 3115 1903 00
G Drift 3115 3003 00
H Drift 3115 0313 00
I Drift 3115 0314 00
II Drift 3115 3004 00
J Fitting and removal tool 3115 1877 00
K Key set (24 mm) 3115 0343 00
Key set (32 mm) 3115 0344 00
L Fitting and removal tool 3115 2859 80
Fitting tool 3115 2859 00
Pin (x 2) 3115 2860 00
Ring 3115 2861 00
Nut (x 2) 0266 2114 00
M Fitting tool (M12) 0462 7010 34
Fitting tool (M14) 3115 1627 00
Fitting tool (M16) 3115 1126 00
Fitting tool (M20) 3115 1628 00
N Puller + accessories 3091 0455 90
O Washer 3115 0284 00
P Charging equipment 3115 3425 80
R Ring spanner 3315 2263 00

8
 Tool list 3

S BB JJ

CC
T HKK

DD
U LL

EE
V MM

FF
X
NN

GG
Y
OO

HH
1250 0199 21

AA

Letter Tools Part no.

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

9
Rock drill main parts 4

4. ROCK DRILL MAIN PARTS

8 7 5 4 2a 1a

COP 1840

9 6

4 3 2b 1b
7 5
8

COP 1840EX
12500217 03

9 6

1a. Front head incl. 5. Intermediate section incl.

Shank adapter Damper piston
Connecting plate Damper piston liner
Stop ring Front piston seals
Flushing head
Guide 6. Accumulators
Intake accumulator
1b. Extractor unit’s front head incl. (EX) Damper accumulator
Shank adapter Return accumulator
Piston
Guide 7. Cylinder incl.
Plunger
2a. Cover Piston guides
Valve piston
2b. Extractor unit’s cover incl. Regulating plug
Flushing head
Flushing connector 8. Back head incl.
Rear piston seals
3. Extension piece
9. Hydraulic motor
4. Gear housing, incl.
Rotation chuck bushing
Drill sleeve
Driver
Rotation shaft

10
 Dismantling the rock drill’s main parts 5

5. DISMANTLING THE ROCK

DRILL’S MAIN PARTS 162
172
NB! Always wash the rock drill externally using
grease solvent before starting removal.
The pivot plate (A) must be used when dismant-
ling the rock drill.
In the event of leakage problems
• Check the source of the leak before removing

the rock drill from the rig.
IMPORTANT!
Observe great cleanliness when intervening
in the rock drill or its hydraulic circuit.
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
a suitable workshop.
1250 0217 06
300
252 251
• Loosen the front side bolt nuts (251) with the
washers (252). Remove the front head (172) by
pulling the shank adapter (300).
• Pull out the cylindrical pin (162).

5.1 FITTING THE ROCK DRILL ON THE 5.3 REMOVING THE EXTRACTOR
PIVOT PLATE UNIT’S FRONT HEAD (COP
1840EX)

162

A
1250 0217 04

1250 0217 07

188 252 251

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

• Loosen the front side bolt nuts (251) with the
washers (252). Remove the front head (162) by
5.2 DISMANTLING THE FRONT HEAD pulling the shank adapter.
(COP 1840) • Pull out the cylindrical pin (188).
1250 0217 05

180

179
178
173 177
• Remove the connecting plate (177) with the
union (173) by undoing the bolts (178) with
washers (179).
• Remove the seal (180).

11
Dismantling the rock drill’s main parts 5

5.4 DISMANTLING THE ACCUMULA- 5.5 REMOVING THE BACK HEAD AND
TORS PLUNGER
CAUTION! CAUTION!
All gas must be released before removal. All personnel must stand to the side of the
Do this by removing the protective cap (A), rock drill when removing the back head.
undoing the valve nut (B) and opening it 2-3
turns.
There is a risk of injury if these instructions
are not observed!

94
D 92
BA
82 221

1250 0217 10
1250 0217 08

82
211 BA • Remove the back head (92) by undoing and
removing the bolts (94).
• If necessary, tap with a copper hammer and
C carefully prize with a crowbar or similar.
• Remove the accumulators (211,221) with the
seals (82) by loosening the bolts (C and D)

29
21

23
1250 0217 11

21
1250 0217 09

14
24 231
• Pull out the piston (21), together with the rear
piston guide (29), and place the piston where it
cannot be scratched or damaged.
• Remove the return accumulator (231) by
removing the nuts (24) and the bolts (23). Pull
away the clip (21) and unscrew the return
accumulator from the union (14).

12
 Dismantling the rock drill’s main parts 5

5.6 REMOVING THE SIDE BOLTS, 5.7 REMOVING THE EXTRACTOR’S

COVER AND GEAR HOUSING COVER AND GEAR HOUSING
(COP 1840) (COP 1840EX)

251 252 251 252

199 153
1250 0217 12

1250 0217 14
133
133

• Undo the rear side bolt nuts (251) with washers • Undo the rear side bolt nuts (251) with washers
(252). (252).
• Undo the side bolt (133). • Undo the bolt (133).
• Tap loose the cover (153) with a copper
hammer.
• Remove the O-ring (199).

103 141 153

103 141

161
1250 0217 13

1250 0217 15

130
• Tap loose the gear housing (103), together with
the extension piece (141) and the cover (153)
using a copper hammer and pull them out using
the side bolts (161).
In normal cases the rotation shaft (130) is
removed together with the gear housing. Other-
wise, pull out the rotation shaft.
130
• Tap loose and pull out the gear housing (103),
together with the extension piece (141) using a
copper hammer.
In normal cases the rotation shaft (130) is
removed together with the gear housing. Other-
wise, pull out the rotation shaft.

13
Dismantling the rock drill’s main parts 5

5.8 REMOVING THE INTERMEDIATE

SECTION

53
1250 0217 16

• Tap loose the intermediate section (53) with a

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

5.9 DISMANTLING THE HYDRAULIC

MOTOR

241 247 248

1250 0217 17

246
R

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

and remove the hydraulic motor (241).
• Remove the gasket (247).
• Pull out the coupling (248).

14
 Dismantling, inspecting and assembling the front head (COP 1840) 6

6. DISMANTLING, INSPEC- 6.2 INSPECTING AND REPLACING

TING AND ASSEMBLING PARTS
Before inspection the parts must be washed clean
THE FRONT HEAD (COP in grease solvent.
1840)
6.1 REMOVING THE SHANK
ADAPTER AND GUIDE
1m
190 176 185 193 m
173 175 174
300 192 175 195

1250 0217 20
53 mm
1250 0217 18

• Replace the guide (173) if the inside diameter

exceeds 53 mm.
• Replace the flushing head (174) if major
damage, cracks or similar have arisen.
• Replace the stop ring (185) if the surface is worn
• Pull the shank adapter (300) from the front by more than 1 mm. Compare with a new stop
head. ring.
• Replace all O-rings and U-sleeves.
NB! The sleeves must be turned in accordance
with the figure.
D
6.3 FITTING THE GUIDE, FLUSHING
V HEAD, STOP RING AND ADAPTER
Before fitting the parts must be lubricated with
173 clean hydraulic oil.
174
D
1250 0217 19

185 V
• Press out the guide (173), the flushing head A
(174) and the stop ring (185). Use the drift (D)
and the socket (V) to remove the guide. 173
1250 0217 21

• Press in the guide (173) using the drift (D) and

the sleeve (V).
• Check that the lubricating duct (A) is open by
blowing with compressed air.

15
Dismantling, inspecting and assembling the front head (COP 1840) 6

174
1250 0217 22

• Press in the flushing head (174) using the drift

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

172

300
1250 0217 23

185
193 195

• Fit the stop ring (185) with the O-ring (193), O-

ring (195) as well as the adapter (300) in the
front head (172).

16
 Dismantling, inspecting and assembling the extractor’s front head (COP 1840EX) 7

7. DISMANTLING, INSPEC-
TING AND ASSEMBLING
THE EXTRACTOR’S FRONT
HEAD (COP 1840EX)
7.1 REMOVING THE SHANK
ADAPTER, PISTON, SEALS,
GUIDE AND BUSHING 167

1250 0217 26
300 168
• Remove the piston seals (167 and 168) carefully
using a narrow pointed tool.
• Exercise caution so that the sealing grooves are
not damaged.
1250 0217 24

NB! Leave the O-ring remaining in the grooves

as support for the circlip when the bushings (164
and 165) are pressed out later on.

B
• Pull the shank adapter (300) from the front
head.
• Drain any hydraulic oil from the front head.
EE
163

262 181
1250 0217 27

FF
B
1250 0217 25

• Press out the guide (163) using press tools (B,

EE and FF).
• Alternatively, the guide (163) can be pressed out
using a hydraulic press, drift (D) and socket (V).

• Press out the piston (181) using a copper drift or B

carefully blow compressed air via the union
(262).
1250 0217 28

162

DD
165
GG
AA B
• Press out the bushing (165) from the front head
(162) by positioning the circlip (AA) diameter
120 mm, in the seal groove and use press tools
(B, C, DD and GG).
• Remove the O-ring(170-172) from the bushing
(165).

17
Dismantling, inspecting and assembling the extractor’s front head (COP 1840EX) 7

7.3 FITTING THE GUIDE, BUSHINGS

B AND PISTON
Before fitting the parts must be lubricated with
AA clean hydraulic oil.
C B
CC
163 C

EE
1250 0217 29

166 163
B 162

1250 0217 31
HH
• Remove the lock ring (166) using lock ring pliers
for the internal lock ring. B
• Then remove the bushing (163) by positioning
the circlip (AA), Ø100 mm, in the seal groove
and used the press tools (B, C and CC). • Press in the guide (163) in the front head (162)
• Remove the O-ring (169) from the bushing using the special tools (B, C, EE and HH).
(163).
B
7.2 INSPECTING AND REPLACING
PARTS
Before inspection the parts must be washed clean C 166
in grease solvent.
DD 167
167 166 165 171
169 164 1811 m 170 168 172 162 164
m
1250 0217 32

169
HH
B
163 • Align the lower O-ring (169) on the bushing
300 (164) in accordance with the figure.
53 mm
1250 0217 30

T45 • Fit the sealing ring (167) with the O-ring in the
T51 bushing (164) in accordance with the figure.
• Then press in the bushing (164) using the press
tools (B, C, DD) and the guide (HH).
• Fit the lock ring (166).
• Replace the guide (163) if the inside diameter
exceeds 53 mm.
• Replace the O-rings (169-172) and the sealing
rings (167,168).
• Replace the piston (181) in the event of
significant wear, max. 1 mm.
• Replace the bushings (164,165) if there has
been significant scoring damage. Minor damage
can be polished with abrasive cloth.
• Replace the shank adapter (300) if the thread is
worn out or the impact surface is warped or
chipped.

18
 Dismantling, inspecting and assembling the extractor’s front head (COP 1840EX) 7

B 170
171
168
FF 181
165
162
162
1250 0217 33

1250 0217 34
HH 172
B

• Align the lower O-ring (172) on the bushing
(165) in accordance with the figure.
• Fit both of the other O-rings (170,171) on the
bushing (165).
• Fit the sealing ring (168) with the O-ring in the
bushing (165) in accordance with the figure.
• Then press down the bushing (165) using the
special tools (B, C, FF and HH).
• Lubricate the piston (181) and press it into the
front head (162).
NB! This must be carried out with the greatest
caution.
• Then press out the piston and check that the
seals are correctly positioned and that they are
not damaged.
NB! The piston must be easy to fit.

19
Removing, inspecting and fitting the extractor unit’s cover (COP 1840EX) 8

8. REMOVING, INSPECTING
AND FITTING THE
EXTRACTOR UNIT’S 155
COVER (COP 1840EX)
8.1 REMOVING THE SIDE BOLTS,
FLUSHING INTAKE UNION, SEAL
AND FLUSHING HEAD
154

1250 0217 37
153
153 186 252 251
187
• Undo the circlip (155) with strong internal lock
ring pliers.
1250 0217 35

• Prize out the seal (154) from the cover (153)

using a crowbar.

186

• Remove the stud screws (186) from the cover

(153) by first screwing on a nut (252) against a 153
side bolt nut (251) on each respective stud
screw.
1250 0217 38

• Then remove the side bolts (187) in the same 182

way as the stud screws.

263
183 • Press out the flushing head (182) from the cover
(153).
184
197
198 8.2 INSPECTING AND REPLACING
PARTS
Before inspection the parts must be washed clean
1250 0217 36

in grease solvent.

195 185 182 185 195

• Undo the unions (263,183) from the cover.
• Remove the O-rings (197,198) and the support
ring (184).
1250 0217 39

• Replace all O-rings (195) and seals (185).

• Replace the flushing head (182) if major
corrosion damage, cracks or wear have arisen.

20
 Removing, inspecting and fitting the extractor unit’s cover (COP 1840EX) 8

186 252 251 194

195 185
182
196 185
187 197
153 183 263

1250 0217 42
1250 0217 40

133 198
197 184

• Replace the side bolts (133,187), the washers
(252) and the stud bolts (186) in the event of
significant rusting or cracks.
• Also check the threads in the domed nuts (251).
• Replace the side bolts in pairs every 400
operating hours. Never mix new and old bolts.
8.3 FITTING THE SEALING RING,
FLUSHING HEAD AND SIDE
BOLTS
Before fitting the parts must be lubricated with
clean hydraulic oil.
B
• Fit the O-rings (194-197) and the seals (185) in
the flushing head (182).
NB! The seals (185) must be turned in accor-
dance with the figure.
• Fit the flushing head (182) in the cover (153) and
tap it down with a copper hammer. Check
carefully that the flushing intake in the cover is
aligned with the hole in the flushing head.
• Fit the O-rings (197,198) and the support ring
(184) on the union (183).
• Tighten the union (183) to tightening torque 300
Nm.
• Fit the union (163).
• Tighten the nut on the union (163) to 180 Nm.

E 187 186 252 251

155
154

153
1250 0217 41

1250 0217 43

186

• Fit the sealing ring (154) in the cover (153) using

press tools (B and E).
• Fit the circlip (155) in the cover’s groove using • Fit the side bolts (187) and the stud screws
strong internal lock ring pliers. (186) by using the nut (252) and a side bolt nut
(251) on each respective screw.

21
Accumulators 9

9. ACCUMULATORS
9.1 SAFETY LABELS
L
L
J

1250 0217 46
211
1250 0217 44

AB
L
1 2

1. Read the instruction book closely before servi-

cing or replacement.
2. Must be charged with nitrogen only.
1250 0217 45

1250 0217 47
221

• Tighten the tool (L) in a vice.

231
• The rock drill is equipped with three
accumulators.
• Intake accumulator (211)
• Damper accumulator (221)
• Return accumulator (231)
• Fit the accumulator (211) on the tool (L).
211 • Fit the tool (J) onto the accumulator (211), add
the ring (L) and screw on the nuts (L) by hand.
The ring (L) holds the tool (J) in place at high
torque.
• Screw apart the accumulator with the tool (J).
Use a 32 mm power socket and extended T-
handle with 3/4" connection bracket.
• Add the socket bracket to facilitate removal.

9.2 DISMANTLING THE INTAKE

ACCUMULATOR

CAUTION!
All gas must be released before removal. Do
this by removing the protective cap and
opening the valve nut 2-3 turns.
There is a risk of injury if these instructions
are not observed!

22
 Accumulators 9

9.3 INSPECTING AND REPLACING

PARTS
J
5
4
2 5 2 14 4 3 1
1 16
3 15 9
Y

1250 0217 49
1250 0217 48

7 8
6

• Place the tensioning tool (Y) in the cover (1).

• Place a used diaphragm (3) over the tool.
• Tighten the housing (2) with the tool (J) so the
nut (5) is pushed up. CAUTION!
• Try to undo the nut (5). If it’s not possible, cut off
the diaphragm support’s (4) shaft just below the Incorrect length of bolts, as well as damaged
nut. or corroded threads on bolts, housings and
• Dismantle the housing (2) and other covers may lead to dangerous oil leakage
components. and parts loosening.
Risk of personal injury
Always replace incorrect and damaged bolts,
housings and covers. Always replace the
bolts in pairs.
• Replace the diaphragm (3) if there is any
indication of cracks or other damage.
• When replacing the diaphragm, check that there
are no pieces of rubber stuck in the valve (9) or
in the control valve (8).
• Replace the valves if they are damaged.
• Blow clean the gas ducts in the cover (1).
• Always replace the O-rings (6,7,15) if the valve
has been removed.
• Always replace the diaphragm support (4) and
the nut (5) if dismantled.
• Replace the spring (14) if its length is less than
25.5 mm.

23
Accumulators 9

9.4 FITTING THE DIAPHRAGM,

COVER, HOUSING AND LABELS
Before fitting it is important that all parts are dry
and free of oil.

5
2
5 2 14 4 3
Y 4

1250 0217 53
1250 0217 51

• Remove the nut (5) and clean the threads.

• Fit the pressure spring (14) on the diaphragm
support (4).
• Press the end of the diaphragm support through
the housing (2) and screw on the nut (5) by
hand.
J when the locking fluid has hardened.
• Place a drop of locking fluid, "Loctite 270", on
the thread and tighten the nut with a 10 mm
spanner . Make sure that no locking fluid runs
down and locks the diaphragm support (4) in the
housing (2).
• Lock the nut further with four centre punch
marks.
• Dismantle the housing (2), the old diaphragm (3)
and the tool (Y).
• Check that the diaphragm support (4) can move

5 4
3 2
1
Y
J
2
1250 0217 52

3
L
1250 0217 54

• Tighten the tool (L) in a vice.
• Fit the cover (1), a used diaphragm (3) the
housing (2) and tool (J).
• Tighten the housing enough so that the
diaphragm support (4) rotates when the nut (5)
is later tightened.
1
• Place a good diaphragm (3) in the cover (1).
Lubricate the edge of the diaphragm with a thin
layer of silicone grease.
• Lubricate the accumulator cover (1) and
housing (2) threads with grease, type Never
Seez.
• Tighten the housing with a torque of 300 Nm.
Use tool (J) and a torque wrench.

24
 Accumulators 9

9.5 DISMANTLING THE DAMPER

ACCUMULATOR
1
16

15 9 L
L

J
1250 0217 55

221

1250 0217 57
7 8
6 L
• Fit the valve plunger (8) with the O-rings (6,7)
and the valve body. Tighten with a torque of 45
Nm.
• Fit the valve (12) with the O-ring (14). Tighten
with a torque of 30 Nm.

221
1250 0217 58
1250 0217 56

13 13 • Tighten the tool (L) in a vice.

• Fit the accumulator (221) on the tool (L).
• Fit the tool (J) onto the accumulator (221), add
the ring (L) and screw on the nuts (L) by hand.
• Check and replace the safety labels if required The ring (L) holds the tool (J) in place at high
(13). torque.
• Screw apart the accumulator with the tool (J).
Use a 32 mm power socket and extended T-
WARNING handle with 3/4" connection bracket.
• Add the socket bracket to facilitate removal.
Do not charge the accumulators before they
have been fitted onto the rock drill.

25
Accumulators 9

9.6 INSPECTING AND REPLACING 9.7 FITTING THE DIAPHRAGM,

PARTS COVER, HOUSING AND LABELS
Before fitting it is important that all parts are dry
and free of oil.
1 2 3
1 2 3
7
6 5
4 67
1250 0217 59

5
11
9

1250 0217 60
11
10 9
10
CAUTION!
Incorrect length of bolts, as well as damaged • Fit the diaphragm (2) in the housing (1) and
or corroded threads on bolts, housings and lubricate the edge of the diaphragm with a tin
covers may lead to dangerous oil leakage layer of silicone grease.
and parts loosening. • Lubricate the threads of the cover (3) and
Risk of personal injury housing (1) with grease, type NEVER-SEEZ.
• Fit the cover (3) on the housing (1) and screw
Always replace incorrect and damaged bolts, the accumulator together by hand.
housings and covers. Always replace the NB! Do not turn the accumulator over before it
bolts in pairs. has been screwed together.
• Replace the diaphragm (2) if there is any • Fit the valve plunger (5). Tighten to tightening
indication of cracks or other damage. torque 45 Nm.
• When replacing the diaphragm, check that there • Fit the valve (9) and tighten to tightening torque
are no pieces of rubber stuck in the valve (9) or 30 Nm.
in the control valve (5).
• Replace the valves if they are damaged.
• Flush clean the gas ducts in the cover (3) with
air.
• Always replace the O-rings (6,7,11) if the valve
has been removed.
• Replace the bolts (4) if the threads are corroded
or damaged. J
• Replace the housing (1) and the cover (3) if the
threads are damaged or highly corroded. 1
L
1250 0217 61

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

Tighten the housing (1) to tightening torque 300
Nm. Use the fitting tool (J) and a torque wrench.

26
 Accumulators 9

12

1250 0217 62

12

• Check and replace the safety labels if required

(12).
WARNING
Do not charge the accumulators before they
have been fitted onto the rock drill.

9.8 DISMANTLING AND ASSEMBLING

THE RETURN ACCUMULATOR

10 2 11
12
1250 0217 63

23

24
25 4 6 3 8 9 14 21
13

• Dismantle the return accumulator and check the

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

27
Back head 10

10. BACK HEAD

10.1 INSPECTION AND REPLACE-
MENT OF PISTON SEALS AND
SEAL HOUSING
Before inspection the parts must be washed clean
N
in grease solvent.

21 25

1250 0217 66
27

• The seal housing (25) only needs to be removed

92 if it is damaged or if leakage indicates that the O-
26 ring (27) must be replaced.
1250 0217 64

• When removing, use a puller with expander 37-

46 mm (N).

10.2 FITTING THE SEAL HOUSING

• Check whether the piston seals (26) are AND PISTON SEAL
damaged or worn. Before fitting the parts must be lubricated with a
• Check the wear of the piston seals by inserting clean hydraulic oil.
the plunger (21) in the back head (92). Then lift
in the piston. The back head should then follow.

25 25
27
1250 0217 67

26
1250 0217 65

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

fitting takes place as follows:
• Fit a new O-ring (27). Press the seal housing
• If the piston seals (26) need to be replaced, first into place with a drift (I).
remove them carefully with a pointed object to
avoid damage to the seal housing (25) grooves.

28
 Back head 10

26
1250 0217 68

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

figure. (A seal kit consists of an O-ring and a
Teflon ring).
• Bend the Teflon ring in accordance with the
figure and press the seal into the groove.

29
Cover, extension piece and gear housing 11

11. COVER, EXTENSION

PIECE AND GEAR
HOUSING
141
11.1 REMOVING THE SIDE BOLTS, 132
COVER, ROTATION CHUCK
BUSHING, ROTATION SHAFT,
GEARS, GUIDE SLEEVE

1250 0217 73
161

• Remove the rotation chuck bushing (132).

• Tap loose the extension piece (141) with a
copper hammer. Carefully prize with two
crowbars or similar.
1250 0217 70

• Remove the side bolts (161) (COP 1840HE).

130 126
1250 0217 74

153

• Pull out the rotation shaft (130).

• If the shaft is stuck then it can be tapped out with
1250 0217 72

a drift of about 7 cm through the hole in the front

end of the gear housing. If a thicker drift is used
there is a risk of damage to the needle bearing
(126).
• Tap loose the cover (153) with a copper
hammer. Carefully prize with two crowbars or
similar (COP 1840HE). 137
138
121 117 122 139
1250 0217 75

123

• Remove the drill sleeve (117) together with the

shims (137-139) and bearing outer races
(121,122) from the gear housing by tapping on
the drill sleeve with a copper hammer.
• Then remove the gear (123) from the gear
housing.

30
 Cover, extension piece and gear housing 11

11.2 INSPECTING AND REPLACING

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

109
1250 0217 76

133 161

1250 0217 79
124
125

• Tap loose the rotation shaft’s front needle

bearing (124) and the two washers (109,125) in
the gear housing using a drift of about 10 mm.
• Replace all O-rings.
• Replace the side bolts (133,161) in the event of
significant rusting or cracks.
• Replace the side bolts in pairs every 400
operating hours. Never mix new and old bolts.

103
300

300
1250 0217 77

129 KK
131
2m
• Remove the guide sleeve (129) as follows: m
1250 0217 80

• Screw a plug (KK) into the guide sleeve.

• Fit the gear housing (103) onto two wooden
blocks in accordance with the figure.
• Tap out the guide sleeve using a drift (12x200
mm).
• Replace the shank adapter (300) if the thread is
worn out or the impact surface is warped or
chipped.
• Replace the driver (131) when the boom width is
less than 2 mm.
H

131
1250 0217 78

127 117
126
1250 0217 81

• Tap out the sleeve (127) with needle bearing

(126). Use a drift (H).
118

• Check the wear between the drill sleeve (117)

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

31
Cover, extension piece and gear housing 11

play exceeds 0.2 mm then the driver or drill
sleeve must be replaced.
• Check the bushing (118). If the inner diameter
exceeds 64.0 mm then the bushing must be
replaced.
significantly worn or if the depth of the
lubricating grooves (A) is less than 1.0 mm.
• Replace the roller bearings (121,122) in the
event of noise and damage.
• Replace the shims (137-139) if there is any
indication of damage.

121
131
122

1250 0217 85
1250 0217 82

• If the driver (131) needs to be replaced then use

the puller and an expander 37-46 mm (N). • If any of the roller bearings (121,122) on the drill
sleeve must be replaced, then the roller cage
must be split open with a crowbar.
• Set the drill sleeve vertically on a drift with a
diameter smaller than the inner diameter of the
bearing (so that the inner races can fall down)
and then remove the inner races from the roller
bearings using a puller.
• The bearing races can also be split with a
grinder.
1250 0217 83

118
1250 0217 86

• If the bushing (118) needs to be replaced, break

it open with a screwdriver. Exercise caution, so
that the drill sleeve is not damaged.

107 154
108 155
121 122 137
A 138
117 139 • Check the sealing rings (1254,107) in the cover
and gear housing respectively with regard to
wear and damage.
• If the seals need to be replaced then this takes
place by means of undoing the lock rings (155
1250 0217 84

and 108 respectively), after which the seals are

knocked out with a drift.

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

deforming or cracks, or if the ring gear is

32
 Cover, extension piece and gear housing 11

11.3 FITTING THE PARTS IN THE

GEAR HOUSING
Before fitting, the parts must be lubricated with
clean hydraulic oil.
m 132
1m
1250 0217 87 E

107
103
66 mm 108

1250 0217 90
B
• Replace the bushing (132) if the surface against
the adapter is worn by more than 1 mm.
Compare with a new one.
• Polish or replace the rotation chuck bushing if
the surface to the damper piston has scoring • Fit the sealing ring (107) in the gear housing
marks. (103) using the press tools (B and E).
NB! Minimum length 66 mm. • Fit the lock ring (108).

H
125
124
1250 0217 88

109
1250 0217 91

124 123 126 128

• Replace the rotation shaft needle bearings • Fit the washer (109), the needle bearing (124)
(124,126) in the event of noise or damage. with its inner race, and washer (125). Use a drift
• Replace the gear (123) in the event of (H).
deforming, if cracks have arisen or if the ring
gear is significantly worn.
• Replace the sleeve gasket (128).

N 126
1250 0217 92
1250 0217 89

127
126
129
• Fit the needle bearing (126) without inner race in
the sleeve (127). Use a drift (H).

• If the rear needle bearing (126) needs to be

replaced, remove it from the sleeve (129) using
a puller and an expander 23-30 mm (N).

33
Cover, extension piece and gear housing 11

H
C

127 T
118
117

1250 0217 96
1250 0217 93

123 B

• Fit the gear (123) as spacer in the gear housing. • Fit the bushing (118) in the drill sleeve (117).
• Fit the sleeve (127) with needle bearing turned Use press tool (B), extension (C) and plate (T).
to the gear. Use a drift (H). NB! Press carefully so that the bushing is not
• Remove the gear (123). deformed when it reaches the bottom.

131
1250 0217 94

1250 0217 97

121
117

• Fit the roller bearing (121) outer race. Use a • Fit the driver (131) in the drill sleeve (117). Use
copper drift. the drift (D) and a plastic mallet.

H
F
129 MM 121
128 122
117
1250 0217 98
1250 0217 95

126 123

• Fit the needle bearing (126) inner race. • Fit the roller bearing (121,122) on the drill sleeve
• Fit the gear (123). (117). Use press tool (B, F and MM).
• Fit the guide sleeve (129) with a new circlip
sleeve (128). Use a drift (H).

34
 Cover, extension piece and gear housing 11

C FF
LL
E
155 141

154
1250 0217 99

1250 0219 32
153 JJ
B
B
• Fit the sealing ring (154) in the cover (153). Use • Fit the gear housing onto the press tool (B) and
press tools and extensions (B, C and E). the guide (JJ).
• Fit the lock ring (155). • Fit the press tool (FF) and spacer tube (LL) onto
the extension piece (141).
• Rotate the drill sleeve 2-3 turns.
11.4 SHIMMING THE BEARINGS IN • Tighten to tightening torque 200 Nm. Use a key
THE GEAR HOUSING set (K) or a 32 mm socket.
• Unload the tension and retighten to tightening
torque 20 Nm.
141 • Measure the clearance between the gear
housing and the extension piece with a feeler
gauge. Measure with an accuracy of 0.05 m.
137 • Remove the extension piece (141) and reduce
138 the number of shims until a measured clearance
139 of 0.15-0.20 mm is obtained. In this way a
tension for the roller bearings of 0.15-0.20 mm is
132 obtained when the rock drill is finally assembled
with the side bolts.
122 NB! It is important that the bearing tension is
1250 0219 31

103 correct as well as that the tightening torque is

121 correct. After drilling for a while the bearing
seats can settle, so it is important that the
bearing tension does not stop, which could
• During fitting, the tension of the gear housing’s involve damage to roller bearings and shims.
roller bearings (121,122) must always be
checked.
NB! During shimming all parts must be free from
grease and oil. No O-rings should be fitted in the 141
gear housing or cover. 143
• Fit the drill sleeve (132) down into the gear
housing (103). 162
• Fit the front roller bearing (122) outer race. Tap 134
it into place using a drift.
• Add shims (137-139) in against the outer race.
Select dimension and quantity so that a gap with 103
a safety margin is formed between gear housing
1250 0219 33

(103) and extension piece (141).

• Fit the extension piece (141).

• Grease in all parts, in particular the roller

bearings and O-rings. See the chapter,
Lubricant recommendations.
• Fit the O-ring (143) in the extension piece (141).
• Fit the O-ring (134) in the gear housing (103).
• Fit the guide pin (162) in the gear housing and
then fit the extension piece (141).
• If necessary, tap down the extension piece with
a plastic mallet.

35
Cover, extension piece and gear housing 11

103
132 117
1250 0219 34

130

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

(103).
• Tap in the shaft with a plastic mallet.
• Fit the rotation chuck bushing (132) in the drill
sleeve (117) with the lubricating grooves
backwards.

153
164
1250 0219 35

(COP 1840HE)
• Fit the O-ring (164) in the cover (153). Use
grease on the O-ring so that it remains in place
during fitting.
• Fit the cover (153).
• If necessary, tap down the cover with a plastic
mallet.

36
 Intermediate section 12

12. INTERMEDIATE SECTION

12.1 REMOVE THE NON-RETURN
VALVE, DAMPER PISTON,
SEALS AND LINERS 66

1250 0219 39
• Remove the front damper piston liner (66) by
1250 0219 36

placing a plate (U) in the sealing groove. Then

tap out the liner carefully using a copper drift and
a plastic mallet.
76 78 77
• Remove the non-return valve’s cone (77), seat 12.2 INSPECTING AND REPLACING
(76) and O-ring (78). Pull out the seat using an PARTS
M6 bolt.
Before inspection the parts must be cleaned in
grease solvent.

16
86 21
1250 0219 37

1250 0219 40

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

and copper drift. • Replace all O-rings.
• Check the plunger’s seals (16) with regard to
wear and damage.
• The wear is measured by carefully inserting the
plunger (21). If the piston moves stiffly then the
piston seals do not normally need to be
53 replaced. Compare with the back head.

85
66

84
1250 0219 38

• Remove the damper piston’s seals (84,85)

carefully with a pointed object so that the sealing
grooves in the intermediate section (53) and the
liner (66) are not damaged.

37
Intermediate section 12

69

16 70

1250 0219 44
66
15

1250 0219 41

• If the plunger’s seals (16) need to be replaced,
first remove them carefully with a pointed object
to avoid damage to the seal housing (15)
grooves.
• Check the damper piston liner (66). Polish minor
scoring using fine abrasive cloth and wash
clean. If the liner is worn or has major damage
then it must be replaced.
• Replace the O-rings (69,70).

N 86
0,1 mm

15

1250 0219 45
17
1250 0219 42

• The seal housing (15) must not be removed if it

is not damaged. If the seal housing is damaged • Replace the damper piston (86) if the seals have
or if leakage indicates that the O-ring (17) must worn by more than 0.1 mm.
be replaced, use the puller and an expander 34- • Polish minor damage.
46 mm (N).

Bø1,7 mm
A ø1,7 mm
A ø1,7 mm
1250 0219 46

67 66
1250 0219 43

(ø2,0 mm)

68
• Check the damper piston’s bushing (67). Polish
minor scoring using fine abrasive cloth and
wash clean. If the bushing is worn or has major
damage then it must be replaced.
• Remove the lock ring (68) with a screwdriver.
• Either knock out the bushing (67) with a copper
drift and a plastic mallet or used the puller (N)
and an expander 70-100 mm.
• Carefully check the nozzles (A and B) in the
intermediate section’s rear and front edges, and
the same with the holes in the liner (66), so that
all holes are free from dirt. Check that the
nozzles are firmly screwed in and locked with
Loctite 243 or 542.
• For surface drilling (if necessary) the oil flow to
the machine’s mating face can be reduced by
replacing the nozzle (B).

38
 Intermediate section 12

NB ! For underground drilling all nozzles must

always be open 1.7 mm.

12.3 FITTING THE SEAL HOUSING,

SEALS, BUSHING, LINER AND II
DAMPER PISTON 68 X
Before fitting the parts must be lubricated with
clean hydraulic oil. 67
II

1250 0219 49
15
17 • Press in the damper piston bushing (67) using
the drift (II) and the socket (X).
NB! Press carefully so that the bushing is not
deformed when it reaches the bottom.
1250 0219 47

• Fit the bushing’s lock ring (68).

E
• Fit the O-ring (17).
• Press the seal housing (15) into place using the 66
drift (II).
67
70
1250 0219 50

16 15
1250 0219 48

• Fit the O-rings (67,68) on the damper piston

liner (66) and lubricate them.
• Tap in the liner with the press tool (E).

• Check that the sealing grooves in the seal

housing (15) are well cleaned.
• Lubricate the O-ring and fit it in the sealing
groove.
• Insert the sealing ring in the seal housing (15)
and then press the ring into the sealing groove
with a tool shank for example.
NB! The seal lips must be turned in accordance
with the figure.
(A seal kit consists of 1 x O-ring and 1 x Teflon
ring)

39
Intermediate section 12

46
1250 0230 24

1250 0219 53
47
76 78 77
• Check that the sealing grooves in the damper • Check the sealing surfaces on the non-return’s
piston are well cleaned. valve cone (77) and seat (76). Minor damage
• Lubricate the O-ring and fit it in the sealing can be touched up with emery paste. The parts
groove. must be replaced in the event of major damage.
• Check that the cone is running smoothly in the
seat.
• Fit the non-return valve’s cone (77), O-ring (78)
and seat (76) in the intermediate section.
• Lubricate the parts with grease so that they
OO NN remain in place when the intermediate section is
fitted.
1250 0230 25

NB! The seals must be turned, in accordance

with the figure.
• Bend the sealing ring, in accordance with the
figure with tool (NN).
• Insert the sealing ring in the groove and then
press the ring in with tool (OO).

86
1250 0219 52

• Lubricate the damper piston (86) and press it

into the intermediate section.
NB! This must be carried out with the greatest
caution.
• Then press out the damper piston and check
that the seals are correctly positioned and that
they are not damaged.
NB! The damper piston must be easy to fit.

40
 Cylinder, piston guide and plunger 13

13. CYLINDER, PISTON GUIDE 13.2 INSPECTING AND REPLACING

AND PLUNGER PARTS
Before inspection all parts must be cleaned in
grease solvent.
13.1 REMOVING THE PISTON GUIDE,
VALVE PISTON AND REGULA-
TING PLUG

29 19
29
21

1250 0219 56
1250 0219 54

• Replace all O-rings.

• Replace the piston guides (19,29) if they show
signs of significant cavitation damage.
• If the clearance is greater than 0.06 m then the
• Remove the front piston guide (29) by moving in
guide must be replaced.
the piston (21) and tapping carefully. • Move the piston in and measure the clearance
with a feeler gauge.
34
32 35 37 36
47
31 3

31
1250 0219 55

1250 0219 57

47
32
34
• Undo the bolts (34) holding the valve end plates
(32) and press out the valve piston (31).
• If the cylinder (3) (the cylinder bore or valve
• Remove the regulating plug (35) and washers bore) and valve piston (31) show signs of
(37) by undoing the nut (36). scoring or scratches, then the parts must be
replaced. Minor scoring can be polished with
fine abrasive cloth, whetstone or honing tool.
• Clean all ducts of impurities by washing them
thoroughly.

41
Cylinder, piston guide and plunger 13

13.3 FITTING THE VALVE PISTON,

21 VALVE END PLATES AND
PISTON GUIDE
Before fitting all parts must be lubricated with
clean hydraulic oil.
34
32 35 37 36
R=1 47
31
R=1
1250 0219 58

0,5 mm

1250 0219 55
• Check the plunger (21) for scoring and
scratches as well as the impact surface with 47
regard to wear and chipping. 32
• Minor scoring and scratches on the piston can 34
be polished with fine whetstone.
• Minor damage to the piston’s impact surface can • Fit the valve piston (31).
be rectified using grinding. Grind down 0.1-0.2 • The valve piston is symmetrical and can be
mm at a time until the surface is smooth. In total turned. Check that the valve piston is running
a maximum of 0.5 mm may be ground down. smoothly.
NB! The stated length dimension must not be • Fit the valve end plates (32) with new O-rings
less than L=428.5 mm. External and internal (47).
radiuses must be restored so that an even chan- • The end plates must slide smoothly and must
geover (without sharp edges) is obtained. not be tapped in.
• Following grinding, check that the impact • Tighten the bolts (34) to tightening torque 145
surface is free from cracks. Clean the piston Nm.
thoroughly so that all grinding residue is • Fit the regulating plug (35) and the sealing rings
removed. (64). Tighten the nut (36) to tightening torque 80
Nm.

21 46 29 G

1250 0219 59

• Insert the plunger (21) into the cylinder. Fit the

O-ring (46) on the front piston guide (29). Fit the
piston guide with the plunger as a guide.
• Tap the guide into place with the drift (G).
• Then remove the plunger from the cylinder.

42
 Fitting the rock drill’s main parts 14

14. FITTING THE ROCK 14.3 ASSEMBLING THE HYDRAULIC

DRILL’S MAIN PARTS MOTOR AND INTERMEDIATE
SECTION ON THE CYLINDER
14.1 GENERAL
All parts must be thoroughly cleaned before fitting.
During fitting the parts must be lubricated with
clean hydraulic oil. 3

1250 0219 61
The O-rings must be replaced with new intact 241 130 249
ones and be greased with silicone grease. R

14.2 FITTING THE CYLINDER ON THE

PIVOT PLATE 248
246

3
• Make sure that the groove ring (130) is fitted in
the coupling (248).
• Lubricate the coupling’s splines with grease and
fit the coupling onto the hydraulic motor (241).
• Fit a new gasket (248) to the cylinder’s (3) end
A plate.
• Fit the hydraulic motor onto the cylinder (3).
1250 0219 60

• Tighten the nuts (246) to tightening torque 65

Nm. Use the ring spanner (R).

• Align the pivot plate (A) horizontally. 53

• Bolt in the cylinder (3) with two M16 bolts on the
pivot plate with the front head inwards in relation 81
to the workbench.
83

3
1250 0219 62

• Align the pivot plate (A) vertically.

• Fit the O-ring (83) in the groove on the
intermediate section (53) rear guide.
• Fit the O-ring (81) in the intermediate section’s
(53) rear face. Add grease in the groove so that
the O-ring remains in place during fitting.
• Fit the intermediate section (53) onto the
cylinder (3). Tap lightly with a copper hammer.
• Make sure that the non-return is held in position.

43
Fitting the rock drill’s main parts 14

14.4 FITTING THE GEAR HOUSING,

SIDE BOLTS AND COVER

53 251 252
199 153

132
130 135 103
1250 0219 63

1250 0219 65
A

133
132
COP 2540EX
(COP 1840HEX)
• Align the pivot plate (A) horizontally. • NB! Before assembly, grease must be applied
• Fit the O-ring (135) in place using grease. to the threads, type NEVER-SEEZ.
• Fit the gear housing (103) on the intermediate • Fit the O-ring (199).
section (53). If the rotation shaft (130) does not • Fit the cover (153) and the side bolt (133). Fit the
change the coupling (148), insert a shank rear washers (252) and nuts (251).
adapter in the driver (132) and turn. • Tighten the rear side bolt nuts (251) alternatingly
to tightening torque 300 Nm. Use key set (K) for
the torque wrench.
• Then tighten the side bolt (133) to tightening
torque 300 Nm.
161
14.5 FITTING THE PLUNGER AND
BACK HEAD
133
21
1250 0219 64

251 252

(COP 1840HE)
1250 219 66

NB! Before assembly, grease must be applied

to the threads, type NEVER SEEZ.
• Fit the side bolts (161). Fit the rear washers
(252) and nuts (251). Tighten the rear side bolt
nuts (251) alternately until tightening torque 300
Nm has been reached. Use key set (K) for the
torque wrench. • Lubricate the plunger (21) with clean hydraulic
• Fit the side bolt (133). Tighten the bolt to oil.
tightening torque 300 Nm. • Insert the piston in into the cylinder bore. When
the piston reaches the front piston seals, turn
the piston in. The piston seals could be
damaged if the plunger is tapped in.

44

29 46
1250 0219 67
G
• Fit the rear piston guide (29) with new O-ring
(46). Tap in the piston guide using a drift (G).
93 38
94
1250 0219 68
• Fit the O-ring (93) in the back head. Place the
seal ring (38) in the groove on the cylinder. Use
grease so that the O-ring remains in position.
• Before fitting the back head, check that the
piston can be moved forward and back with a
rotating motion.
• Fit the back head carefully on the cylinder so
that the plunger or piston seals are not
damaged.
• Tighten the three bolts (94) for the back head
alternately to tightening torque 220 Nm. The two
lower bolts must be tightened before the upper
one.
• Use key set (K) for the torque wrench.
45
Fitting the rock drill’s main parts 14
14.6 ASSEMBLING THE FRONT HEAD
(COP 1840)
162
172
1250 0219 69
161 252 251
• Fit the pin (162) in the cover. Align the front head
(172) on the side bolts (161).
• Fit the washers (252) and nuts (251).
NB! Before assembly, grease should be applied
to the threads, type NEVER-SEEZ.
• Tighten the nuts (251) alternatingly to tightening
torque 350 Nm.
150 0219 70
180
179
178
173 177
• Fit the cup seal (180) into the flushing head.
• Fit the connecting plate (177) on the front head
with washers (179) and bolts (178). Tighten the
bolts (178) to tightening torque 90 Nm.
• Fit the union (173) on the connecting plate.
Then tighten to tightening torque 300 Nm.
Fitting the rock drill’s main parts 14

14.7 ASSEMBLING THE EXTRACTOR

UNIT’S FRONT HEAD (COP D
1840EX) BA
82 221

186 162

1250 0217 08
82
211 BA
1250 0219 71

188 252 251

C
• Fit the sealing rings (82) into the grooves in the
intermediate. Check carefully that the seal (82)
is not damaged when assembling.
• Fit the cylindrical pin (188). • Fit the damper accumulator (221) on the left-
• Fit the front head (162) onto the screw studs
hand side of the rock drill and the intake
(186). accumulator (211) on the right-hand side (hose
• Fit the washers (252) and nuts (251). side). The bolts (C,D) must be tightened
NB! Before assembly, grease should be applied
alternately to tightening torque 220 Nm.
to the threads, type NEVER-SEEZ.
• Tighten the nuts (251) alternatingly to tightening
torque 300 Nm. 14.9 ACCUMULATOR SAFETY
LABELS
14.8 ASSEMBLING THE ACCUMULA-
TORS
CAUTION! 211 221
Fit the accumulators onto the rock drill using
undamaged original bolts.
The intake accumulator must have two bolts
with a length of 100 mm.
The damper accumulator must have two
1250 0219 72

bolts with a length of 70 mm.

Replace the bolts in pairs even if only one
bolt is corroded or damaged in some other
way.
Defective bolts may lead to dangerous oil
leakage or the accumulator working loose. • Check that the accumulators (211,221) have the
correct safety labels and that these are not
damaged.
• Replace damaged labels.
CAUTION!
The accumulators must be fitted on the rock
drill before charging.
There is a risk of injury if these instructions
are not observed!

46
 Fitting the rock drill’s main parts 14

14.10 ASSEMBLING THE RETURN union. The damper accumulator (221) is located
ACCUMULATOR on the left-hand side of the rock drill.
• Remove the protective cap (A) on the
accumulator valve.
• Open the valve nuts 2-3 turns.
• Connect the regulator at the lowest possible
pressure and open the valve on the gas bottle.
• Charge the intake accumulator (211) to 30-40
23 bar under collaring pressure. Normally 80-100
bar. Max 100 bar.
NB! Charge at the bottom if possible rather than
21 11 too high.

1250 0219 73
• Tighten the valve nut and close the valve on the
14 gas bottle.
• Undo the filler hose (P) and screw in the
24 231 protective cap (A) on the accumulator valve.
• Charge the damper accumulator (221) with 20-
25 bar.
• The return accumulator (231) must not be
• Bolt the return accumulator (231) onto the union charged.
(14) so that the plug (11) is accessible for
checking the accumulator’s diaphragm.
• Thread on the clamp (21) and fit the bolts (23)
and nuts (24).

14.11 CHARGING THE ACCUMU-

LATOR
WARNING
The accumulators must only be charged with
nitrogen gas (N 2)
Any other gas could cause an explosion.

CAUTION!
The accumulators must be fitted on the rock
drill before charging.

221
231
211
P
A Q
1250 0219 74

• The intake accumulator (211) and damper

accumulator (221) must be charged before
starting up the drill rig.
• The intake accumulator (211) is located on the
right-hand side of the rock drill, by the intake

47
Function test of rotation and percussion 15

15. FUNCTION TEST OF

ROTATION AND PERCUS-
SION

1250 0219 77
P
O
R
33
34
1250 0219 75

• During the condition test the hydraulic hoses

must be connected as illustrated in the figure.
• Undo the valve end plate (33) on the right-hand
side of the machine.
• Connect the hydraulic hoses P (Pressure) and R • Add the washer (O) fully cleaned and refit the
(Return) to the hydraulic motor. Supply hydraulic end plate.
oil pressure to the hydraulic motor, max. • Supply hydraulic oil pressure to the percussion
pressure 40 bar for about half a minute. function and adjust the reducing valve on the
• Check that the rotation runs smoothly, without test equipment until the pressure gauge reads
noise and external leakage, and in the right 100 bar.
direction. • Press the button for low scale on the flow gauge
and read.
• The leakage flow for a new rock drill is 2-3 l/
minute. Leakage flow of more than 5 l/minute is
unacceptable and indicates that there is a defect
in plunger bore, valve piston bore, piston guides
D or reflex dampers.
NB! Do not forget to remove the washer (O)
after the test.
P • Refit the valve protection (33) with the screws
R (34) and check that the piston moves forward
1250 0219 76

and back by operating the rock drill at low

hydraulic pressure (5-15 bar).

48
 Function test of rotation and percussion 15

49
Tightening torques 16

16. TIGHTENING TORQUES

6
5 1
4

3A 3A 2
14
9
13
6
12
7 11 3B
8 9 10 15
16
1250 0210 54

2
13

• Smear the threads and the contact surfaces of

nuts and washers with Never-Seez Regular
Grade.

Ref. Torque
Qty. Check point Instructions
No. Nm
1 2 Side bolts 300 Tighten the rear nuts
2 1 Front bolt 300 Tighten the front bolt
3A 2 Side bolt 350 Tighten the front nuts
3B 3 Side bolts EX 300 Tighten the front nuts
4 3 Back head 220 Tighten the bolts alternately to full torque,
top bolt last
5 1 Regulating plug 80
6 4 Accumulator 220 Tighten the bolts alternately to full torque
7 4 Hydraulic motor 65 Tighten the nuts alternately
8 2 Clamping bracket, return accu- 30
mulator
9 4 Rock drill mounting 250 Tighten the bolts alternately to full torque
10 1 Plug 45
11 4 Valve end plates 145 Tighten the bolts alternately to full torque
12 2 Connecting plate 120 Tighten the bolts alternately to full torque
13 1 Flushing connector 300
14 4 Intake, flushing medium 90 Tighten the bolts alternately to full torque
15 1 Intake, extractor unit 120
16 1 Return, extractor unit 120

50
 Tightening torques 16

16.1 TIGHTENING THE SIDE BOLTS

1
1250 0219 79

2 3B

2 3A
• Inspect the side bolts, nuts and washers
regarding cracks, scoring or corrosion. Replace
damaged parts.

• Smear the threads and the contact surfaces of

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

• Tighten the rear nuts (1) with tightening torques.

• Tighten the side bolt (2) with tightening torques.

• Tighten the front nuts (3A or 3B) with teghtening

torques.

16.2 RETIGHTENING AN ASSEMBLED

ROCK DRILL
If the rock drill is a non-extractor version
• Undo the front nuts (3A) just enough to release
the tension in the front end of the side bolts.

If the nuts tend to bind in the thread: undo them

completely, clean the threads, smear with
Never-Seez Regular Grade.

Put the washers and nuts back again by hand

without tightening them.
Both versions
• Tighten the rear nuts (1) with tightening torques.

• Tighten the side bolt (2) with tightening torques.

• Tighten the front nuts (3A or 3B) with tightening

torques.

51
Lubrication 17

17. LUBRICATION
1
3
1250 0210 87

17.1 LUBRICATION THE GEAR

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

52
 HYDRAULIC AND LUBRICANT RECOMMENDATIONS 18

18. HYDRAULIC AND LUBRICANT RECOMMENDATIONS

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

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

Environmentally friendly hydraulic fluids must fulfil ISO 15380

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

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

IF THE VISCOSITY IS TOO LOW:

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

IF THE VISCOSITY IS TOO HIGH:

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

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

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

THE HYDRAULIC FLUID MUST BE CHANGED AT REGULAR INTERVALS. FACTORS INFLUENCING

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

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

53
HYDRAULIC AND LUBRICANT RECOMMENDATIONS 18

18.2 PNEUMATIC TOOL OIL

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

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

Operating
NLGI number Drop point Base oil viscosity
Temperature
1.5 250 ºC 400-600 mm2/s -40 to +150 ºC
at 40 ºC

54
HYDRAULIC AND LUBRICANT RECOMMENDATIONS 18

55
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.