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Reg. codeAIB TAB 43COP 16382007–08Maintenance instructions forHydraulicRock drill COP 16381250 0021 33ATLAS COPCO ROCK DRILLS AB ÖREBRO · SWEDEN© Atlas Copco Rock Drills AB, 2007. All rights reserved.No. 9852 1653 01c SAFETY REGULATIONS·Important safety information is given at various points in these instructions.·Special attention must be paid to the safety information contained in frames and accompanied by a war-ning symbol (triangle) and a signal word, as shown below:indicates hazards or hazardous procedures which COULDresult in serious or fatal injury if the warning is not observed.indicates hazards or hazardous procedures which COULDresult in injury or damage to equipment if the warning is notobserved.The following safety rules must also be observed:·Carefully read through all operating- and main-tenance instructions for the drill rig and rockdrill before putting the rock drill to use. Alwaysfollow the instructions given.·Do not use or intervene in the rock drill unlessyou have been trained to do so.·The rock drill may only be used for the pre-scribed purposes.·Make sure that the drill rig has been maintai-ned in accordance with the current instructions.·Make sure that all safety labels remain in pla-ce, and that they are kept clean and fully legib-le. See the spare parts list for details of labellocations and part numbers.·Always wear a safety helmet and ear protec-tors during drilling. Any local regulations thatexist must also be observed.·Before moving the drill rig or starting to drill,make sure that there are no personnel in theimmediate vicinity of the drill rig.·Use Atlas Copco genuine parts only. Anydamage or malfunction caused by the use ofunauthorized parts is not covered by Warrantyor Product Liability.·Never attempt to carry out maintenance whilethe drill rig is in operation.·Those checks and adjustments that must bemade while the drill rig is in operation must becarried out by at least two persons. One per-son must man the control station and keep astrict watch over the work.·To prevent injury during service and mainte-nance, all components that could possiblymove or drop must be supported safely onblocks or trestles, or secured by means ofadequately dimensioned slings.·Before starting work on any of the systems,make sure that the hydraulic, air and water sys-tems are without pressure, and that the electri-cal system is dead.·Check that the hoses used are of the right qua-lity, and that all hose connections are in goodcondition and properly tightened.WARNINGCAUTIONContents PageSafety regulations . . . . . . . . . . . . . . . . 2Action list . . . . . . . . . . . . . . . . . . . . . 3Hose connections . . . . . . . . . . . . . . . . 4Tightening torques . . . . . . . . . . . . . . . . 5Accumulators . . . . . . . . . . . . . . . . . . 6– Charging the accumulators . . . . . . . . . . 6– Checks in the event of hose vibration . . . . . 7– Changing the accumulators . . . . . . . . . . 8– Changing the return accumulator . . . . . . . 9Changing the hydraulic motor . . . . . . . . . . 9Filling with lubricating oil and bleeding the syst. 10Setting of ECL lubricating system . . . . . . . 10Lubrication of gear . . . . . . . . . . . . . . . 11Setting the damper pressure . . . . . . . . . . 11Removing the front head . . . . . . . . . . . . 12Checking the front head . . . . . . . . . . . . 13Changing the flushing head and driver . . . . 14Mounting the front head . . . . . . . . . . . . 14Slinging . . . . . . . . . . . . . . . . . . . . 15Long-term storage . . . . . . . . . . . . . . . 15Recommended hydraulic oils and lubricants . 162 Action listBefore starting up a new- ornewly overhauled rock drill: Page·Connect up the hoses . . . . . . . . . . . . 4·Charge the accumulators . . . . . . . . . . . 6·Select a suitable hydraulic oil and lubricant . 16·Fill the lubricating system with oil . . . . . . . 10·Adjust and set the lubricating system . . . . 10·Set the damper pressure . . . . . . . . . . . 11Every shift·Check that air and lubricating oil come out between the shank adapter and front guideand also out of the hole in the front head . . 13·Check that the damper-pressure gauge on the drill rig shows the normal value. In case of deviation, adjust the damper pressure . . . 11·Check that the shank-adapter threads are not damaged . . . . . . . . . . . . . . . . . 13·Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulators . . 7·Check that there is no leakage from the rockdrill. If the flushing medium leaks out of the overflow hole in the front head, change the seals and O-rings . . . . . . . . . . . . . . . 13·When changing the shank adapter or remov-ing the front head, check the internal compo-nents, including the visible parts of the piston,driver and rotation chuck bushing . . . . . . 13In the event of defect, remove to a suitable workshop for repair or replacement.After the first shift when using a new- or newly overhauled rock drill·Tighten all threaded unions . . . . . . . . . 5After every 40th percussion-hour·Grease the gear . . . . . . . . . . . . . . . 11·Tighten all threaded unions . . . . . . . . . 5·Check the safety labels on the accumulators. Replace them if they are damaged or illegible . 6·Check the return accumulator . . . . . . . . 7Every 400th percussion-hour:·Remove the rock drill from the drill rig and send it to a suitable workshop for over-hauling*.* The rock drill should be overhauled at suitable intervals, based on local conditions. The characteristics of the rock will have a great influence on the rate of wear, and thus on the required frequency of overhauling.IMPORTANT·Observe great cleanliness when interve-ning in the rock drill or its hydraulic cir-cuit.·The following parts may be changed at theworksite in accordance with the instruc-tions given:– shank adapter– driver– front head parts– accumulators– hydraulic motor– screws– connections.Other repairs must be carried out in a sui-table workshop in accordance with theWARNING·Before starting any maintenance work,make sure that the electrical system isdead.There is a risk of injury if these instructionsare not observed!CAUTION·Take care during rod jointing and whenhandling the drill bit. Mind your fingers!·Keep your clothing away from rotating machine parts.Carelessness can lead to serious injury.·Always use ear protectors during drilling.High noise levels damage hearing.·Never attempt maintenance or intervenein the rock drill, connections or hoses whi-le the hydraulic, lubrication or flushingsystems are pressurized. Air or oil can squirt out at high pressureand high temperature, with the risk of serious injury to the eyes and skin.3 Hose connections 1. Drainage 2. Rotation to the left 3. Rotation to the right 4. Percussion mechanism, return 5. Percussion mechanism, intake 6. Flushing air/water 7. Lubricating air 8. Damper, intake Connecting the hoses·Clean the hose connections on the rock drill be-fore removing the protective plugs (or caps).·Never remove a protective plug until the hose isready to be connected.·Always store the rock drill with all hose connec-tions plugged. Use suitable protective plugs orcaps, and make sure that they are clean.CAUTION·Never attempt maintenance or intervenein the rock drill, connections or hoses whi-le the hydraulic, lubrication or flushingsystems are pressurized. Air or oil can squirt out at high pressureand high temperature, with the risk of serious injury to the eyes and skin.·Pressure hoses with an internal diameterof 19 mm (3/4") or more are rated SAE 100R9R (i.e. high-pressure hose with four lay-ers of spirally wound steel-wire reinforce-ment). See spare parts list for drill rig.For safety reasons, these hoses must not,under any circumstances, be replacedwith hoses of a lower rating. There is a risk of injury if these instruc-tions are not observed!1250 0147 2318723456AIR4 Tightening torquesN.B. Tighten item Nos. 1–3 in the prescribed order. Ref.No. Qty. Check point Torque Instructions Nm lbf.ft 1 2 Side bolts 300 220 Tighten the rear nuts 2 1 Front bolt 300 220 Tighten the front bolt 3 2 Side bolts 350 260 Tighten the front nuts 4 3 Back head 220 160 Tighten the screws alternately to full torque (uppermost screw last) 5 1 Regulating plug 80 60 6 4 Accumulators 220 160 Tighten the screws alternately to full torque 7 4 Hydraulic motor 65 48 Tighten the nuts alternately 8 2 Clamping attachment,return accumulator 30 22 9 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque10 1 Plug 45 3311 4 Valve covers 145 105 Tighten the screws alternately to full torque12 2 Connection plate 120 90 Tighten the screws alternately to full torque13 1 Flushing connection 300 22014 4 Inlet, flushing medium 90 65 Tighten the screws alternately to full torque15 1 Intake, extractor unit 120 9016 1 Return, extractor unit 120 901250 0147 2445167891011126913314325 AccumulatorsThe accumulators are fitted with safety labels asshown in the figure below.1. Damper accumulator2. Intake accumulator3. Return accumulator4. Protective cap5. Valve nut6. Gas valveCharging the accumulators1. Remove the protective cap (4).2. Open the valve nut (5) by 2–3 turns, and con-nect the gas hose.3. Open the gas valve (6).4. Charge the accumulators to the correct pressure, as follows:– Damper accumulator (1): 20–25 bar (290–360 psi)– Intake accumulator (2): 30- 40 bar below the collaring pressure (435 - 580 psi)5. Tighten the valve nut (5) and close the gas val-ve (6).6. Remove the gas hose and fit back the protecti-ve cap (4) to the accumulator valve.The return accumulator (3) must not be charged.WARNING·The accumulators must be charged withnitrogen (N2) only!Other gases can cause an explosion.CAUTION·Do NOT charge the accumulators untilthey have been fitted to the rock drill.There is a risk of injury if these instruc-tions are not observed!= Read the instruction book carefully before servicing or changing= Must be charged with nitrogen only1250 0027 191250 0020 91 0001051002052RAB0001051002052RAB0001051002052RAB1250 0175 942345616 Checking the accumulators in the event of hose vibrationDamper accumulator (1) and Intake accumulator (2)1. Press in the pin on the test valve (7). If the ac-cumulator is charged, the pin will stick out by4.5 mm and give a firm resistance when pres-sed in.N.B. The damper-accumulator pin is somewhateasier to press in.If it is easy to press in the pin, it means that the-re is no gas pressure (diaphragm damaged).2. Change the accumulator if it is not functioningproperly (see page 8).3. After fitting a new accumulator, charge it with nitrogen.N.B. The seat of the charging valve can easilybecome deformed when opened and closed re-peatedly. The charging valve should thereforebe changed regularly.Return accumulator (3) (Check every 40th percussion-hour)1. Put the rock drill in the horizontal position, asshown in the figure.2. Remove the plug with O-ring (8). If oil comesout, the diaphragm is damaged.3. Change the diaphragm if necessary.4. If the diaphragm is touching the outer pipe,press down the diaphragm using a blunt, cylindrical mandrel (ø 7–9 mm). See fig. A.For the correct diaphragm position, see fig. B.5. Fit back the plug and O-ring.1. Damper accumulator2. Intake accumulator3. Return accumulator7. Test valve8. Plug with O-ringAB1250 0175 953882717 Changing the accumulatorsRemovalRemove the accumulators (1 and 2) together withthe sealings (3) by removing the screws (4 and 5 or 6).Now send the accumulators to a workshop foroverhauling!MountingMountingFit the sealings (3) into the grove in the intermedia-te part (7) and then fit the accumulators (1 or 2) tothe intermediate part (7)Make sure that the sealings dont get damagedduring the assembly. Fit the damper accumulator (1) to the left-handside of the rock drill. Fit the intake accumulator (2)to the right-hand side of the rock drill, i.e. the hoseside. Tighten the screws (4 and 5, or 6) alternatelyto a torque of 220 Nm (160 lbf.ft).Now charge the accumulators with nitrogen (N2).See page 6.CAUTION·Release all gas before removing the ac-cumulators from the rock drill.To do this, remove the protective cap (A),loosen the valve nut (B) and open it by 2–3 turns.There is a risk of injury if these instruc-tions are not observed!CAUTION·Mount the accumulators to the rock drillusing undamaged original screws.The intake accumulator (2) for COP 1638must have two screws (4) of length 70 mm.The damper accumulator (1) must havetwo screws (5) of length 70 mm.Change both screws at the same time,even if only one of them is corroded (ordamaged in some other way).Defective screws can cause dangerous oilleakage, or can cause the accumulator tobe blown off.Squirting oil can seriously injure the eyesand skin.Parts that come loose can cause seriousinjury.1250 0147 2542337BA15BACAUTION·Do not fit the seals on the accumulator.8 Changing the return accumulatorRemovalDisconnect the hydraulic hose (8) from the returnaccumulator (3).Remove the return accumulator (3) by removingthe nuts (2), screws (1). Pull off the clamp (5) and unscrew the accumulatorfrom the nipple (7 on surface drill rigs) or (9 on underground drill rigs).Now send the accumulator to a workshop for over-hauling!MountingFit the return accumulator (3) to the nipple (7 or 9)and tighten in such a way that the plug (10) is ac-cessible for checking the accumulator diaphragm. Slide the clamp (5) on to the accumulator, by me-ans of the screws (1) and nuts (2).Connect the hydraulic hose (8) to the return accumulator (3).Changing the hydraulicmotorRemovalDisconnect the hydraulic hoses (1).Remove the return accumulator (3).Remove the nuts (2) and take off the hydraulic mo-tor (3).Pull out the coupling (4).MountingMake sure that the circlip (5) is fitted into the coup-ling (4).Grease the splines inside the coupling, and slidethe coupling on to the output shaft of the hydraulicmotor (3).Fit the hydraulic motor (3) with gasket (7) to the cylinder (6). Change the gasket if it is damaged.Tighten the nuts (2) to a torque of 65 Nm (48 lbf.ft).Connect the hydraulic hoses (1). Check that themotor rotates in the correct direction.CAUTION·Before intervening in the hydraulic, wateror air systems, make sure that there is nopressure in the systems.·Pressure hoses with an internal diameterof 19 mm (3/4") or more are rated SAE 100R9R (i.e. high-pressure hose with four lay-ers of spirally wound steel-wire reinforce-ment). See spare parts list for drill rig.For safety reasons, these hoses must not,under any circumstances, be replacedwith hoses of a lower rating. There is a risk of injury if these instructionsare not observed!1250 0027 231250 0027 221582397109 Filling with lubricating oil and bleeding the system·Check the oil level in the lubricating-oil container(1) once a shift. Observe a high standard of cle-anliness and fill with oil of the right quality (seepage 19). The lubricating-oil container holds 5litres.1. Open the electrical cabinet.2. Start the lubricating system (see the operator’sinstructions for the drill rig).3. Check the lubricating air pressure at the rockdrill (11) using a pressure gauge (A). The pres-sure should be 2–3 bar. If the pressure is toolow, clean the restrictor (9) or increase the dia-meter of the restrictor.Underground drill rigs4. Check that the green light emitting diode (G) indicates power on.5. Adjust the screw (T1) so that the light emittingtime of the yellow diode (R) is 0.5 seconds.6. Observe the yellow diode (R) and adjust thelubricating oil dosage to 35–40 pulses/min (13a)and 20-25 pulses/min (13b), by means of thescrew (T2). After making the respective setting, check the LED(F) on the lubricating pump to ensure that the rightpulse frequency has been obtained. Check alsothat oil comes out of the hole (B) in the front headand between the shank adapter and front guide.·If the lubricating system has been empty of oil, itmust be bled after filling. This is done as follows:– Loosen the cap (7) and let the lubricating oil escape until all air has been discharged from the lubricating oil pump. Now tighten the cap.– Start the lubricating system and loosen the hose connection at pressure gauge (8), so that all air is released from the system. Now tighten the hose connection.– Disconnect the lubricating-air hose (12) from the nipple (11) on the rock drill.– Start the lubricating pump and let it pump until oil comes out of the plastic hose (10). When re-starting (after standstill), oil must come out of the plastic hose directly when the lubricating pump is started.– Check that the plastic hose (10) for lubricating oil is of the correct length. It must not protrude into the machine. – Re-connect the lubricating-air hose (12). 1. Lubricating-oil container 2. Filler cap 3. Pulse relay 7. Cap, bleeding 8. Pressure gauge 9. Restrictor10. Plastic hose11. Lubricating-air connection12. Lubricating-air hose13a. 3217 8667 5013b. 3217 8667 52A. Pressure gaugeF. Light-emitting diode (LED)G. Green LEDR. Yellow LEDT1. Adjustment screw, light-emitting timeT2. Adjustment screw, pulse frequencyIMPORTANT·Use the recommended lubricating-air pres-sure and the recommended lubri-cating oil.Certain moving parts of the rock drill arelubricated by means of oil-mixed compres-sed air. It is important that these parts re-ceive good lubrication.CAUTION·Never intervene in the lubricating systemwhile it is pressurized.Lubricating oil can squirt out, with therisk of injury to the eyes and skin.Setting of ECL lubricating system24 V+_87F12911BBBA103T1GRT221Min. oljenivÂMin. oil levelGS13bF71250 0145 5813a10 [...]... spli- · · · nes of the driver (5) If the splines are less than 2 mm in width, the driver must be changed (see page 14) Fit a new driver with the aid of a suitable mandrel and a copper hammer If the rotation chuck bushing (2) is worn by more than 1 mm, or if the striking surface of the impact piston (12) is damaged in any way, the rock drill must be sent to a suitable workshop for overhauling See the... (1) Check that the pin (6) is fitted into the cover Fit the front head (1) on to the side bolts (5) 1250 0027 37 Fit the washers (2) and nuts (3) N.B Before assembly, smear the threads with grease (type NEVER-SEEZ) Check the tightening torques of the rear side-bolt nuts and front side bolt (see 1–2, page 5) Now tighten the nuts (3) alternately to a torque of 350 Nm (260 lbf.ft) Fit the cup seal (4)... +60 (113 to 140) –5 (23) +35 to +50 (95 to 122) –10 (14) +25 to +40 (77 to 104) –15 (5) +10 to +25 (50 to 77) –25 (–13) Air tool oil Grease · Use a mineral base air tool oil Ambient temperature oC ( oF) –30 to 0 (–22 to +32) –10 to +20 (14 to 68) +10 to +50 (50 to 122) Max temp 80 (176) 75 (167) 65 (149) 55 (131) 35 ( 95) Viscosity grade VG (ISO 3448) ISO VG 100 ISO VG 68 ISO VG 46 ISO VG 32 ISO VG 15... torque of 90 Nm (65 lbf.ft) 1250 0027 38 Change the seal washer (7) if it is damaged Fit the nipple (2) to the connection plate, and tighten to a torque of 300 Nm (220 lbf.ft) Connect the flushing hose (5) and tighten the coupling nut After assembly, check that air and lubricating oil come out of the hole in the front head and also between the shank adapter and the front guide 14 1250 0027 40 Slinging... pressure in the systems 1250 0027 30 There is a risk of injury if these instructions are not observed! N.B Always clean the outside of the rock drill before disassembly COP 1638 Remove the flushing hose (5) Remove the connection plate (1) and nipple (2) by removing the screws (3) and washers (6) Remove the cup seal (4) Remove the front side-bolt nuts (3) with their washers (2) 1250 0027 31 Remove the front . clamp (5) and unscrew the accumulatorfrom the nipple (7 on surface drill rigs) or (9 on underground drill rigs).Now send the accumulator to a workshop for. VG 46 Min. 100+25 to +40 (77 to 104) –15 (5) 55 (131) ISO VG 32 Min. 100+10 to +25 (50 to 77) –25 (–13) 35 ( 95) ISO VG 15 Min. 100 Air tool oil·Use a