Reg.

code
ASB TAB 43
COP 1838
1999–08

Overhauling instructions for

Hydraulic COP 1838ME
Rock drills COP 1838HE
1250 0021 33

B versions

The following overhauling instructions apply only to

COP 1838ME/HE rock drills that have serial numbers
ending with the letter B.

List of contents Page

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main parts of the rock drill . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembling the rock drill into its main parts . . . . . . . . . . 9
Disassembly, inspection, replacement of parts
and assembly of:
– Front head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– Back head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
– Cover and gear housing . . . . . . . . . . . . . . . . . . . . . . . . . 25
– Intermediate part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
– Cylinder, piston guides and impact piston. . . . . . . . . . . . 45
– Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Function- and condition test of hydraulic motor . . . . . . . . . 58
Assembling the main parts of the rock drill . . . . . . . . . . . . 59
Charging the accumulators . . . . . . . . . . . . . . . . . . . . . . . . 64
Greasing the gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Testing the rotation and percussion functions . . . . . . . . . . 66
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Recommended hydraulic oils and lubricants . . . . . . . . . . . 68
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

ATLAS COPCO ROCK DRILLS AB

ÖREBRO • SWEDEN
© Atlas Copco Rock Drills AB, 1999. All rights reserved.

No. 9853 0968 01b

 SAFETY INSTRUCTIONS
• Important safety information is given at various points in these instructions.
• Special attention must be paid to the safety information contained in frames and accompanied by a war-
ning symbol (triangle) and a signal word, as shown below:

indicates hazards or hazardous procedures which COULD

WARNING result in serious or fatal injury if the warning is not observed.

indicates hazards or hazardous procedures which COULD

CAUTION result in injury or damage to equipment if the warning is not
observed.

The following safety rules must also be observed:

• Carefully read through the overhauling instruc- • When lifting the rock drill, use approved lifting
tions before disassembling the rock drill. Fol- equipment only. Avoid lifting heavy weights
low the instructions given and also observe manually.
any local regulations. • To avoid injury when repairing or overhauling
• Before loosening or disconnecting hoses and the rock drill, any components that could pos-
removing the rock drill from the drill rig, always sibly move or drop when disconnected, expo-
make sure that there is no pressure in the hyd- sed or removed must be secured safely.
raulic, water and air systems. Also check that Always use the pivoted fixture A (see List of
the electrical system is dead. Tools, page 4).
• Repair or overhauling of the rock drill is restric- • Check that the hoses used are of the right qua-
ted to personnel who have received the neces- lity, and that all hose connections are in good
sary training from Atlas Copco. condition and properly tightened.
• Make sure that all safety labels remain in pla- • Use Atlas Copco genuine parts only. Any
ce, and that they are kept clean and fully legib- damage or malfunction caused by the use of
le. See the spare parts list for details of label unauthorized parts is not covered by Warranty
locations and part numbers. or Product Liability.

General
The following instructions are intended as a guide for Workshop standards
service personnel involved in the overhauling of the
COP 1838ME and COP 1838HE hydraulic rock drills. Workshops for the overhauling of hydraulic
machines must be:
For rock drills equipped with an extractor unit
(i.e. COP 1838MEX and COP1838HEX), see also • Isolated from all dust- and particle-generating
activities such as grinding, welding etc.
printed matter No. 9853 0939 01.
• Very clean, i.e. free of dust and dirt.
• Equipped with
Layout of these instructions – all necessary standard and special tools
– washing facilities for cleaning and degreasing
These instructions begin with the safety instructions,
components
followed by a list of the standard and special tools
– compressed air for blow cleaning components
needed. This is followed by instructions on how to
– a hydraulic press
disassemble the rock drill into its main parts. Then,
– hoisting facilities with a minimum capacity of
under the respective main headings, detailed in-
500 kg.
structions are given on the further disassembly,
checking, inspection of parts and re-assembly.
The instructions end with a section describing how
the main parts of the rock drill are put back together,
followed by the tests and checks that must be carried
CAUTION
out after the machine has been overhauled.
• Never intervene in the rock drill, connec-
The letters enclosed in brackets in the instructions tions or hoses when the hydraulic system
refer to the list of special tools on pages 4–6. The is pressurized.
numbers enclosed in brackets in the instructions re- Hydraulic oil at high pressure and high
fer to the exploded views of the machine on pages temperature can squirt out with great force.
57 (hydraulic motor) and 69 (rock drill). Risk of injury to eyes and skin.

2
 List of tools / Standard tools

Plastic hammer

Copper hammer

Honing tool ø 19–70 mm

Combination spanners
Spanner widths: 10–32 mm, 46 mm

Allen keys
Width across flats: 4–10 mm
Width across flats: 3/16"

Screwdrivers

Punches, 2–10 mm
Copper punch, 20 x 250 mm

Feeler gauge, 0.03–0.10 mm, with 0.01 mm

increment
Feeler gauge, 0.05–1.00 mm, with 0.05 mm
increment

Internal circlip pliers

Torque wrenches, torque range 10–350 Nm

(7–260 lbf. ft)

Socket set with:

– sockets for external hexagon, 10–32 mm
– sockets for internal hexagon, 4–10 mm
– socket for internal hexagon, 3/16"

Awl

T-handle, with 3/4" square drive

Impact socket 32 mm
1250 0022 43

Vernier calliper
Micrometer, 0–25 mm

3
List of tools / Special tools and test equipment
Tool Part number Name Use

A 3115 0329 80 Pivoted mounting Disassembly, assembly and

fixture testing of rock drill (figs. 2, 137)
1250 0024 27

B 3115 1902 80 Press Basic tool for use with other

press tools (figs. 58, 64, 66,
67, 69)
1250 0024 28

C 3115 0318 00 Extension sleeve For use with press B

(figs. 64, 67)
1250 0024 29

D 3115 1019 00 Mandrel Removal and fitting of guide

(figs. 14–17, 65)
1250 0024 30

E 3115 1113 00 Press tool Fitting of seal rings and

damper liner (figs. 58, 67, 86).
1250 0024 31

Fitting of shims (fig. 69)

F 3115 1903 00 Press tool Fitting of tapered roller

bearings (fig. 66)
1250 0024 32

G 3115 0312 00 Mandrel Fitting of piston guides

(figs. 96, 126)
1250 0024 33

4
List of tools / Special tools and test equipment
Tool Part number Name Use

H 3115 0313 00 Mandrel Assembly and disassembly of

gear housing (figs. 46, 59–61,
1250 0024 34

63)

I 3115 0314 00 Mandrel Fitting of piston seal housing

1250 0024 35

(figs. 38, 83).

Fitting of bushing for damper
piston (fig. 85)

J 3115 1877 00 Assembly and Assembly and disassembly of

disassembly tool accumulators (figs. 20–32)
1250 0024 36

K 3115 0343 00 Wrench adapter Adapters for use with torque

(24 mm) wrench when tightening up
1250 0024 37

3115 0344 00 Wrench adapter the machine (figs. 69, 124, 127)
(32 mm)

L 3115 2859 80 Assembly and Assembly and disassenbly of

disassembly tool, accumulators (figs. 16–22)
consisting of: (COP 1032 - 1850)
3115 2859 00 Ass. tool
3115 2860 00 Stud ( 2pcs )
3115 2861 00 Ring
0266 2114 00 Nut ( 2pcs )
1250 0045 44

M 0462 7010 34 Assembly tool Fitting of thread inserts into

(M12) intermediate part and cylinder
3115 1627 00 Assembly tool
1250 0024 39

(M14)
3115 1126 00 Assembly tool
(M16)
3115 1628 00 Assembly tool
(M20)

N 3091 0455 90 Extractor + See figs. 37, 50, 57, 78

1250 0024 40

adapters

O 3115 0284 00 Washer Locking of valve plunger

1250 0024 41

when condition testing per-

cussion mechanism (fig. 137)

5
List of tools / Special tools and test equipment
Tool Part number Name Use

P 3115 1821 80 Charging hose Hose for charging of accumu-

lators (fig. 133)
1250 0024 42

– 3115 0642 00 – Nipple

– 3115 2075 00 – Adapter

Q 3115 0646 00 Gas-cylinder Pressure regulator for charg-

regulator ing of accumulators (fig. 133)
1250 0024 43

– 3115 0644 00 – Nipple

– 3115 0978 00 – Pressure gauge

R 3115 2263 00 Ring spanner Nuts for hydraulic motor

1250 0024 44

(figs. 12, 121)

S 3115 1897 00 Fixture Assembly and testing of hy-

draulic motor (figs. 97–119)
1250 0024 45

T 3115 1896 00 Plate Fitting of bushing into rota-

tion chuck (fig. 64)
1250 0024 46

U 3115 1594 00 Plates Removal of damper piston

1250 0024 49

liner (fig. 75)

V 3115 1899 00 Sleeve Removal and fitting of guide

(figs. 14, 16, 17).
1250 0024 50

X 3115 2163 00 Sleeve Fitting of bushing into inter-

mediate part (fig. 85)
1250 0024 51

Y 3115 2519 00 Tensioning tool Disassembly and gripping of

diaphragm support
1250 0024 52

(figs. 21, 24, 25)

6
List of tools / Special tools and test equipment
Tool Part number Name Use

AA 3115 2471 00 Guide ring Shimming of roller bearings

(fig. 69)
1250 0024 53

BB 0686 4249 00 Plug Removal of guide sleeve

(fig. 45)
1250 0024 58

7
Main parts of the rock drill

Fig. 1. Hydraulic rock drill COP 1838, main parts

1. Front head incl. 5. Accumulators

• Shank adapter • Intake accumulator
• Connection plate • Damper accumulator
• Stop ring • Return accumulator
• Flushing head
• Guide
6. Cylinder, incl.
2. Cover • Impact piston
• Piston guides
3. Gear housing, incl.
• Valve piston
• Regulator plug
• Rotation chuck bushing
• Rotation shaft
• Rotation chuck
• Driver 7. Back head, incl.
• Gear • Rear piston seals

4. Intermediate part, incl.

• Damper piston 8. Hydraulic motor
• Damper-piston liner
• Front piston seals
• Damper-piston seals
• Check valve

8
Disassembling the rock drill into its main parts
The pivoted mounting fixture (A) must be used when disassembling the COP 1838.

Disassembly sequence:
IMPORTANT
• Front head
• Always observe a high standard of cleanli- • Accumulators
ness when opening up the rock drill or its • Back head and impact piston
connections. • Cover and gear housing
• Only the front-head parts, shank adapter, • Intermediate part
accumulators, hydraulic motor, bolts and • Cylinder
connections may be changed at the work- • Hydraulic motor
site. All other repairs must be carried out
in a suitable workshop.

N.B. Always wash down the outsides of the

rock drill using a degreasing agent before di-
sassembly begins.

Bolt the rock drill securely to the pivoted mounting

fixture (A).

Fig. 2. Fitting the rock drill to the pivoted mounting fixture

Front head
Take off the connection plate (2) with its nipple (6)
by removing the screws (5) together with the
washers (4).
Remove the cup seal (3).

Fig. 3. Removing the nipple, connection plate, screws

and cup seal

Remove the front side-bolt nuts (2) and washers

(3). Remove the front head (1B) by tugging the
shank adapter (20 or 21).
Take out the cylindrical pin (9).

Fig. 4. Removing the front head

9
 Accumulators

CAUTION
• All gas must be released from the accumu-
lators before they are removed from the
rock drill.
To release the gas, remove the protective
cap (A) and loosen the valve nut (B) by
2–3 turns.
Failure to follow this procedure can result
in injury.

Take off the accumulators (52 and 92) together

Fig. 5. Removing the accumulators
with the O-rings (34) by removing the screws
(4 or 7 and 93).

16
HE/HEX Surface drill rigs
14 Remove the return accumulator (94) by removing
A the nuts (15), screws (14), screw (16) and retainer
12
(12). Pull off the clamp (13) and unscrew the ac-
13
cumulator from the nipple A.
HE/HEX
17
15
94
18 ME/MEX Underground drill rigs
16 94 Remove the return accumulator (94) by removing
14 the nuts (17), screws (16), screw (18) and retainer
1250 0061 40

15 (14). Pull off the clamp (15) and unscrew the ac-
13 cumulator from the pressure screw (10).
ME/MEX 9
17 12

10

Fig. 6. Removing the return accumulator

Back head and impact piston

Remove the back head (83) by loosening and re-
moving the screws (84).
If necessary, tap the back head with a copper
hammer and carefully prizing it free with the aid of
a parting tool or similar implement.

Fig. 7. Removing the back head

10
 79
77
1250 0031 33

Pull out the impact piston (77) together with the

rear piston guide (79). Put the impact piston in a
safe place where it will not be scratched or dama-
ged.

Fig. 8. Removing the impact piston and rear piston guide

Cover and gear housing

Remove the rear side-bolt nuts (2) and washers
(3). Remove the side bolt (4).

Fig. 9. Removing the side bolts

Tap free the gear housing (17) and cover (6) using
a copper hammer, and pull them off with the aid of
the side bolts (5).
The rotation shaft (26) usually comes out with the
gear housing. If it does not, pull out the rotation
shaft separately.

Fig. 10. Removing the cover and gear housing

11
 Intermediate part
Tap free the intermediate part (36) using a copper
hammer. If the intermediate part sticks on the
lower guide, use a parting tool or similar imple-
ment, to prize it free.

Fig. 11. Removing the intermediate part

1250 0031 34

74 95 72 Hydraulic motor
Remove the nuts (75) using the ring spanner (R),
and remove the hydraulic motor (74).
Remove the gasket (95).
Pull out the coupling (72).
R 75

Fig. 12. Removing the hydraulic motor

12
 Front head
Disassembly
Inspection, replacement of parts
Assembly

Disassembly
Pull out the shank adapter (20 or 21).

Fig. 13. Removing the shank adapter

Press out the guide (7 or 14), flushing head (10 or

16) and stop ring (12 or 18). Use the mandrel (D)
to remove the 38 mm guide. Use the mandrel (D)
plus the sleeve (V) to remove the 52 mm guide.

Fig. 14. Removing the guide

13
 Inspection, replacement of parts
Before inspection, all parts must be washed
clean in a degreasing agent.
Change the guide (7 or 14) if its inside diameter is
greater than 39 mm (or 53 mm).
Change the flushing head (10 or 16) in the event of
serious damage, cracks etc.
Change the stop ring (12 or 18) if the surface is
worn down by more than 1 mm. Use a new stop
ring as a gauge for comparison.
Change all O-rings and cup seals.
IMPORTANT! The cup seals must face the direc-
tions shown in the figure opposite.

Fig. 15. Checking the guide, O-rings, seal rings, flushing

head and stop ring

Assembly
Before assembly, the parts must be oiled with
V clean hydraulic oil.
Press in the guide (7) with the aid of mandrel (D).
A Press in the guide (14) with the aid of mandrel (D)
plus sleeve (V).
7 Check that the lubricating duct (A) is not blocked.
14 To do this, blow through it with compressed air.
1250 0024 61

Fig. 16. Fitting the guide

14
 Press in the flushing head (10) with the aid of
mandrel (D). Alternatively, press in the flushing head
(16) with the aid of mandrel (D) and sleeve (V).
N.B. The flushing head must be fitted so that the
lubricating grooves are on the top.
See figure opposite.
Also make sure that the flushing hole in the flus-
hing head lines up with the corresponding hole (A)
in the front head.

Fig. 17. Fitting the flushing head

Fit the stop ring (12 or 18) with O-ring (9 or 19),

O-ring (13) and shank adapter (20 or 21) into the
front head (1).

Fig. 18. Fitting the stop ring and shank adapter

15
 Accumulators
Disassembly
Inspection, replacement of parts
Assembly

= Read the instruction book carefully

before servicing or changing

1250 0020 91
= Must be charged with nitrogen only

The rock drill is equipped with three accumulators:

– the intake accumulator (52)
– the damper accumulator (92)
– the return accumulator (94)
There are two different intake accumulators (52):
– part number 3115 2391 81 (larger model)
for COP 1838HE
– part number 3115 1763 82 (smaller model)
Fig. 19. The accumulators on the rock drill for COP 1838ME

Intake accumulator
4
3115 2391 81 (52)
3 Disassembly

J
CAUTION
• All gas must be released from the ac-
cumulator before it is removed from the
52 rock drill.
To release the gas, remove the protective
cap (A) and loosen the valve nut (B) by
A B
2–3 turns.
Failure to follow this procedure can result
1250 0045 45

in injury.
L

Clamp the tool (L) firmly in a vice.

Place the accumulator (52) on tool (L).
Place tool (J) on the accumulator. Fit ring (3) and
tighten the nuts (4) by hand. Ring (3) serves to
keep tool (J) in place when high torque is applied.
Now, with the aid of a 32 mm impact socket and
long T-handle with 3/4" square drive, unscrew the
housing from the accumulator cover.
125 0045 46

If necessary, strike the top of the drive with a cop-

per hammer to help loosen the thread.
Fig. 20. Disassembling the accumulator

16
 J Place the tensioning tool (Y) in the cover (6).
Place a used diaphragm (5) over the tool.
2 Tighten the housing (1) with the tool (J) so that the
4 nut (2) is pressed upward.
1 Try to unscrew the nut (2). If it does not loosen,
saw off the shaft of the diaphragm support (4) just
6 below the nut.
5
Disassemble the housing (1) and other compo-
nents.
Y
1250 0045 47

Fig. 21. Disassembling the diaphragm support

Inspection, replacement of parts

Fig. 22. Intake accumulator 3115 2391 81 Change the diaphragm (5) if it shows signs of
cracking or other damage.
When changing the diaphragm, make sure that no
CAUTION bits of rubber have lodged in the valve (12) or in
the test valve (8).
• Screws of incorrect length, as well as rus-
ted or damaged threads on the screws, Blow clean the gas ducts in the cover (6) with
housing or cover can lead to dangerous compressed air.
oil leakage and can cause the compo-
nents to loosen. Change the valves (8 and 12) if they are damaged.

Risk of injury to personnel. Always change the O-rings (9, 10 and 14) if the val-
ves have been disassembled.
• Always change the screws (7), housing
(1) or cover (6) if they are corroded, worn, Always change the diaphragm support (4) and the
defective or damaged. Always change nut (2) if they have been disassembled.
BOTH screws at the same time.
Change the screws (7) if they are rusted or dama-
ged.
Change the housing (1) and cover (6) if the thre-
ads are damaged or badly rusted.
Change the spring (3) if it is shorter than 25.5 mm.

17
 Assembly
Before assembly, it is important that all parts
are clean, dry and free of oil.
Fit the compression spring (3) on to the diaphragm
support (4). Press the end of the diaphragm sup-
port through the housing (1), and thread on the nut
(2) by hand.

Fig. 23. Fitting the diaphragm support

J Clamp the tool (L) firmly in a vice.

On to the tool (L) put:
– the cover (6)
2 4 – the tool (Y)
– a used diaphragm (5)
5 1
– the housing (1)
6 – the tool (J).
Tighten the housing hard enough to prevent the
diaphragm support (4) from rotating when the nut
125 0045 48

Y
(2) is tightened later.

Fig. 24. Holding the diaphragm support

2
4
1
5 Remove the nut (2) and clean the threads.
Put a drop of "Loctite 270" locking compound on
the thread and tighten the nut using a 10 mm fixed
Y spanner. Make sure that none of the locking com-
pound runs down and locks the diaphragm support
(4) in the housing (1).
Now lock the nut further by means of four punch
marks.
Remove the housing (1), the old diaphragm (5)
and tool (Y).
Check that the diaphragm support (4) is still mov-
125 0045 49

able after the locking compound has hardened.

Fig. 25. Locking the nut

18
 Place a perfect diaphragm (5) in the cover (6).
Smear the edges of the diaphragm with a thin lay-
J
er of silicone grease.
Smear the threads of the accumulator cover (6)
1 and housing (1) with grease of type NEVER-SEEZ.
5 Tighten the housing to a torque of 300 Nm
(220 lbf. ft) using the tool (J) and a torque wrench.

6
125 0045 50

Fig. 26. Fitting the diaphragm and housing

Fit the valve plunger (11) together with O-rings (9

and 10), and fit the valve body (8). Tighten to a
torque of 45 Nm (33 lbf. ft).
Fit the valve (12) together with O-ring (14). Tighten
to a torque of 45 Nm (33 lbf. ft).

Fig. 27. Fitting the valves

Inspect the safety labels (15, 16), and change

them if necessary.
N.B. Do not charge the accumulator until it has
been fitted securely to the rock drill.

Fig. 28. The accumulator safety labels

19
Intake accumulator 3115 1763 82 (52)
Damper accumulator 3115 2395 80 (92)
Disassembly

CAUTION
4 • All gas must be released from the ac-
cumulator before it is removed from the
rock drill.
3 To release the gas, remove the protective
cap (A) and loosen the valve nut (B) by
2–3 turns.
Failure to follow this procedure can result
J in injury.
50
52
Clamp the tool (L) in a vice.
67
Place the accumulator (52 or 92) on tool (L).
91
Place tool (J) on the accumulator. Fit ring (3) and
92
A B
tighten the nuts (4) by hand. Ring (3) serves to
L keep tool (J) in place when high torque is applied.
Unscrew the housing from the cover with the aid of
1250 0047 45

tool (J). Use a 32 mm impact socket and extended

T-handle with a 3/4" square drive.
If necessary, strike the top of the drive with a
copper hammer to help loosen the thread.

Inspection, replacement of parts

(see also fig. 31)
Change the diaphragm (2) if it shows signs of
cracking or other damage.
When changing the diaphragm, make sure that no
Fig. 29. Disassembling the accumulator bits of rubber have lodged in the valve (9 or 4) or
in the test valve (5 or 7).
Blow clean the gas ducts in the cover (3) with
compressed air.
Change the valves if they are damaged.
Always change the O-rings (6, 7, 11 or 6, 8, 9) if
the valves have been disassembled.
Change the screws (4 or 93) if they are rusted or
damaged.
Change the housing (1) and cover (3) if the thre-
ads are damaged or badly rusted.

CAUTION
• Screws of incorrect length, as well as rus-
ted or damaged threads on the screws,
housing or cover can lead to dangerous
oil leakage and can cause the compo-
nents to loosen.
Risk of injury to personnel.
• Always change the screws (4 or 93), hou-
Fig. 30. Checking the diaphragm, valve housing and cover sing (1) or cover (3) if they are corroded,
(Illustration shows intake accumulator worn, defective or damaged. Always
3115 1763 82) change BOTH screws at the same time.

20
 Assembly (see also fig. 30)
Before assembly, it is important that all parts
are clean, dry and free of oil.
Place the diaphragm (2) in the housing (1) and gre-
ase the edges of the diaphragm with a thin layer of
silicone grease.
Smear the threads of the accumulator cover (3)
and housing (1) with grease of type NEVER-SEEZ.
Fit the cover (3) on to the housing (1) and thread
the accumulator together by hand.
Do not turn the accumulator upside down until it
has been screwed together.
Fit the valve plunger (10 or 8) together with O-
rings (8, 9 or 6, 7), and fit the valve body (7 or 5).
Tighten to a torque of 45 Nm (33 lbf. ft).
Fit the valve (4 or 9) together with the O-ring (6 or
11), and tighten to a torque of 45 Nm (33 lbf. ft).
Fig. 31. Fitting back the diaphragm and cover into the
housing
(Illustration shows damper accumulator)

J
Now place the accumulator on the assembly tool
(L).
1
Tighten the housing (1) to a torque of 300 Nm
(220 lbf. ft) using the assembly tool (J) and a
L torque wrench.
1250 0045 53

Fig. 32. Tightening the housing

21
 Inspect the safety labels (12, 13 and 11, 12), and
change them if necessary.
N.B. Do not charge the accumulators until they
have been fitted securely to the rock drill.

Fig. 33. The accumulator safety labels

19
11
1 2
8 18
16
20
1250 0041 46

14

12

15
17 10 9 7 6 5 4 3 13

Fig. 34a. Return accumulator

3115 2615 90 HE/HEX Surface drill rigs

7 1

18
16
10
12
9 14
11
13
8
1250 0052 63

2 6 5 4 3 15
17
Fig. 34b. Return accumulator
3115 2615 91 ME/MEX Underground drill rigs

Return accumulator (94)

Disassemble the return accumulator and check all parts. If the diaphragm (1) shows signs of cracking or ot-
her damage, it must be changed.
Change all O-rings.
When assembling the accumulator, smear the edges of the diaphragm with a thin layer of silicone grease or
similar lubricant.
Fit the plug (11) together with the O-ring (8).
Tighten to a torque of 45 Nm (33 lbf. ft).Fit the tube (2) in such a way that the plug (11) is accessible for
checking the accumulator diaphragm (see fig. 132).

22
 Back head
Inspection, replacement of parts
Assembly

Inspection, replacement of parts

Before inspection, all parts must be washed in
a degreasing agent.
Check the piston seals (81) for damage or wear.
To check the wear of the piston seals, slide the im-
pact piston (77) into the back head (83). Then pull
the piston upwards, whereupon the back head
should stick to the piston.

Fig. 35. Checking the piston seals

If the piston seals (81) need to be changed, they

can be removed carefully with the aid of a pointed
tool. Take care not to damage the grooves in the
seal housing (80).

Fig. 36. Removing the piston seals

23
 It is not necessary to remove the seal housing (80)
unless it is damaged, or if leakage indicates that
the O-ring (82) must be changed.
If it is necessary to remove the seal housing, this is
done as shown in the figure. Use the extractor (N)
with a 37–46 mm expander.

Fig. 37. Removing the seal housing

Assembly
Before assembly, all parts must be oiled with
clean hydraulic oil.
If the seal housing (80) has been removed, it must
be fitted back into the back head as follows:
First fit a new O-ring (82). Then press the seal hou-
sing into place with the aid of mandrel (I).

Fig. 38. Fitting the seal housing into the back head

Fit the piston seals (81) as shown in the figure.

(A seal kit consists of an O-ring and a Teflon ring).
Bend the Teflon ring as shown in the figure, and
then press it into the groove.
N.B. The lips of the seals must face the direction
shown in the figure!

Fig. 39. Fitting the piston seals

24
 Cover and gear housing
Disassembly
Inspection, replacement of parts
Assembly

Disassembly
Remove the side bolts (5) and rotation chuck
bushing (25).

Fig. 40. Removing the side bolts and rotation chuck bus-
hing

Tap loose the cover (6) using a copper hammer.

Carefully prize the cover off the gear housing with
the aid of two screwdrivers or something similar.

Fig. 41. Removing the cover

Pull out the rotation shaft (26).

If the shaft sticks, tap it out using a punch
(ø approx. 7 mm) inserted through the hole in the
front end of the gear housing. If a thicker punch is
used, there is a risk of damaging the needle bea-
ring (27).

Fig. 42. Removing the rotation shaft

25
 Remove the rotation chuck (14) together with the
shims (11) and outer rings (12 and 16) of the bea-
rings from the gear housing by tapping the rotation
chuck with a copper hammer.
Now take out the gear-wheel (33) from the gear
housing.

Fig. 43. Removing the rotation chuck and shims, bearing

rings and gear-wheel from the gear housing

Using a punch (ø 10 mm), tap out the rotation

shaft’s front needle bearing (27) and two
washers (23 and 28) from the gear housing.

Fig. 44. Removing the rotation shaft’s front needle

bearing and washers

Remove the guide sleeve (32) as follows:

– Thread the plug (BB) into the guide sleeve.
– Place the gear housing (17) on two blocks of
wood as shown in the figure opposite.
– Knock out the guide sleeve with the aid of a drift
(12x200 mm).

Fig. 45. Removing the guide sleeve

26
 Knock out the sleeve (30) with needle bearing (29)
using the mandrel (H).

Fig. 46. Removing the sleeve and needle bearing

Inspection, replacement of parts

Before inspection, all parts must be washed in
a degreasing agent.
Change all O-rings.
Change the side bolts (4 and 5) if they are badly
rusted or if they show signs of crack formation.
Change all side bolts after every 400 hours of
operation. Never mix new and old side bolts.

Fig. 47. Checking the side bolts

Change the shank adapter (20 or 21) if the thread

is worn out, or if the impact surface is upset or chip-
ped.
Change the driver (13) when the spline width is
less than 2 mm.

Fig. 48. Checking the driver and shank adapter

27
 Check the wear between the rotation chuck (14)
and the driver (13) using a feeler gauge. If the clea-
rance exceeds 0.04 mm, the driver or rotation
chuck should be changed.
Check the bushing (15). If the internal diameter is
greater than 64.0 mm the bushing should be
changed.

Fig. 49. Checking the wear

If the driver (13) needs to be changed, it can be re-

moved with the aid of the extractor (N) and a
37–46 mm expander. See figure.

Fig. 50. Removing the driver

28
 If the bushing (15) needs to be changed, split it
with the aid of a screwdriver. Be careful not to
damage the rotation chuck.

Fig. 51. Removing the bushing

A
16 14 12 11 Change the rotation chuck (14) if it shows signs of
deformation or cracking, if the gear ring is badly
worn, or if the depth of the lubrication grooves (A)
is less than 1.0 mm.
Change the roller bearings (12 and 16) in the
1250 0026 53

event of dissonance or damage.

Change the shims (11) if they show signs of damage.

Fig. 52. Checking the rotation chuck, roller bearings,

seals and shims

If either of the roller bearings (12 or 16) on the rota-

tion chuck needs to be changed, the roller cage
must be broken up with a screwdriver.
Place the rotation chuck vertically on a dolly that
has a smaller diameter than the inside diameter of
the bearing (so that the inner rings can drop down)
and then remove the inner rings of the roller bea-
ring by heating them rapidly.
N.B. Try not to heat the rotation chuck – especially
the gears!
Alternatively, cut through the inner rings of the bea-
ring using a grinder.

Fig. 53. Removing the inner rings of the bearings

29
 Check the seal rings (7 and 21) in the cover and
gear housing for wear and damage.
If the seals need to be changed, remove the cir-
clips (8 and 22) and knock out the seals using a
punch.

Fig. 54. Removing the seal rings from the gear housing
and cover

Change the rotation chuck bushing (25) if its surfa-

ce against the shank adapter is worn by more than
1 mm. Use a new rotation chuck bushing as a gau-
ge.
N.B. The minimum permissible length of the rota-
tion chuck bushing is 78 mm.
Polish or change the rotation chuck bushing if the
surface that faces the damping piston is scored.

Fig. 55. Checking the rotation chuck bushing

Change the needle bearings (27 and 29) of the ro-

tation shaft in the event of dissonance or damage.
Change the gear-wheel (33) if it shows signs of de-
formation or cracking, or if the gear ring is badly
worn.
Change the cup seal (31).

Fig. 56. Checking the rotation-shaft needle bearings,

gear-wheel and cup seal

30
 If the rear needle bearing (29) needs to be
changed, remove it from the sleeve (30) with the
aid of the extractor (N) and a 23–30 mm expander.
See figure opposite.

Fig. 57. Removing the rear needle bearing from the sleeve

Assembly
Before assembly, all parts must be oiled with
clean hydraulic oil.

Fit the seal ring (21) into the gear housing (17)
with the aid of the press (B) and press tool (E).
Fit the circlip (22).

Fig. 58. Fitting the seal ring in the gear housing

Fit the washer (23) and needle bearing (27) with its
inner ring and washer (28). Use mandrel (H).

Fig. 59. Fitting the washers and needle bearing

31
 Fit the needle bearing (29) without the inner ring
into the sleeve (30). Use the mandrel (H).

Fig. 60. Fitting the needle bearing into the sleeve

Insert the gear-wheel (33) into the gear housing to

act as a spacer.
Fit the sleeve (30) into the gear housing, with the
needle bearing turned toward the gear-wheel. Use
mandrel (H).
Now remove the gear-wheel (33).

Fig. 61. Fitting the sleeve

Fit the outer ring of the roller bearing (16). Use a

copper mandrel.

Fig. 62. Fitting the outer ring of the roller bearing

32
 Fit the inner ring of the needle bearing (29).
Fit the gear-wheel (33).
Fit the guide sleeve (32) with new cup seal (31).
Use mandrel (H).

Fig. 63. Fitting the inner ring of the needle bearing,

gear-wheel and guide sleeve with cup seal

T
Fit the bushing (15) into the rotation chuck (14).
Use the press (B) with extension sleeve (C) and
15 plate (T).
N.B. Press the bushing in carefully so that it does
14 not become deformed when it bottoms out!

B
1250 0062 48

Fig. 64. Fitting the bushing into the rotation chuck

33
 Fit the driver (13) into the rotation chuck (14). Use
the mandrel (D) and a plastic hammer.

Fig. 65. Fitting the driver

Fit the roller bearings (12 and 16) on to the rotation

chuck (14).
Use the press (B) and press tool (F).

Fig. 66. Fitting the roller bearing

Fit the seal ring (7) into the cover (6). Use the
press (B) with extension sleeve (C) and press tool
(E).
Fit the circlip (8).

Fig. 67. Fitting the seal ring into the cover

34
 Preloading the bearings in the
gear housing by means of shims
N.B. During the preloading exercise, all parts must
be free of grease and oil.
Do not fit any O-rings into the gear housing or co-
ver for the preloading exercise.

Fit the rotation chuck (14) into the gear housing

(17).
Fit the outer ring of the front roller bearing (12).
Tap it into place with the aid of a punch.
Place the shims (11) on the outer ring of the bea-
ring. Choose the thickness and quantity of shims
so that a definite "gap" is created between the
gear housing (17) and the cover (6) when the latter
is assembled later.
Fit the cover (6).

Fig. 68. Fitting the rotation chuck, outer ring and shims
into the gear housing for the preloading exercise

Place the gear housing on the press (B) and guide

ring (AA).
Place the press tool (E) on the cover (6).
Rotate the rotation chuck 2 - 3 turns.
Tighten to a torque of 200 Nm (150 lbf. ft) using
the adapter wrench (K).
Release the tension and tighten again, this time to
a torque of 20 Nm (15 lbf. ft).
Use a feeler gauge to measure the clearance be-
tween the gear housing and the cover. Measure
to an accuracy of 0.05 mm.
Remove the cover (6) and reduce the number
of shims (11) until a measured clearance of
0.15–0.20 mm is obtained. This will give the
roller bearings a preloading of 0.15–0.20 mm when
the rock drill is finally pulled together by the side
bolts.
N.B. It is important that the bearings are preloa-
ded correctly, and also that the tightening
torque is correct. After a period of drilling, the
seats of the bearings can become bedded in.
When this happens, it is important that preloa-
ding of the bearings does not cease, which
could result in damage to the roller bearings
Fig. 69. Checking the preloading of the bearings and shims.

35
 Grease all parts, especially the roller bearings.
See grease recommendations on page 68.
Fit the O-ring (10) into the cover (6). Place the O-
ring (24) in the gear housing (17). First smear the
O-rings with grease, so that they stick in place
during assembly.
Fit the guide pin (9) into the gear housing, and
then fit the cover (6).
If necessary, tap down the cover using a plastic
hammer.

Fig. 70. Fitting the O-rings into the cover and gear
housing

Fit the rotation shaft (26) into the gear housing

(17). Use a plastic hammer to tap the shaft down
to the bottom.
Fit the rotation chuck bushing (25) into the rotation
chuck (14).

Fig. 71. Fitting the rotation shaft into the gear housing,
and the chuck bushing into the rotation chuck

36
 Intermediate part
Disassembly
Inspection, replacement of parts
Assembly

Disassembly
Remove the check-valve poppet (89), seat (91)
and O-ring (90). Pull out the seat with the aid of a
M6 screw.

Fig. 72. Removing the check valve

Knock out the damper piston (35) using a hammer

and copper mandrel.

Fig. 73. Removing the damper piston

Carefully remove the damper-piston seals (46 and

47) with the aid of a pointed tool. Be careful not to
damage the seal grooves in the intermediate part
(36) and liner (41).

Fig. 74. Removing the damper-piston seals

37
 Remove the front damper-piston liner (41) by pla-
cing a plate (U) in the seal groove. Then carefully
knock out the liner using a copper mandrel and a
plastic hammer.

Fig. 75. Removing the front damper-piston liner

Inspection, replacement of parts

Before inspection, all parts must be washed in
a degreasing agent.
Change all O-rings.
Check the impact-piston seals (54) for wear and
damage.
To measure the wear, carefully slide the impact pis-
ton (77) through the seals. If the seals give a firm
resistance to the passage of the piston, they do
not normally need to be changed. Compare with
the procedure for checking the impact-piston seals
in the back head.
Fig. 76. Checking the impact-piston seals

If the impact-piston seals (54) need to be changed,

carefully remove them with the aid of a pointed
tool. Be careful not to damage the grooves in the
seal housing (53).

Fig. 77. Removing the impact-piston seals

38
 The seal housing (53) should not be removed un-
less it is damaged. If the seal housing is damaged or
if leakage indicates that the O-ring (55) needs to be
replaced, the seal housing should be removed as
shown in the figure opposite. Use the extractor (N)
and a 37–46 mm expander.

Fig. 78. Removing the seal housing

Check the damper-piston bushing (45). Minor sco-

ring can be removed by polishing with a fine abrasi-
ve cloth, after which the bushing must be washed.
If the bushing is worn or badly damaged, it must
be changed.
Remove the lock ring (44) with the aid of a
screwdriver.
Knock out the bushing (45) using a copper mand-
rel and a plastic hammer. Alternatively, the bus-
hing can be removed using the extractor (N) and a
70–100 mm expander.

Fig. 79. Removing the bushing

39
 Check the damper-piston liner (41). Minor scoring
can be removed using a fine abrasive cloth, after
which the liner must be washed. If the liner is worn
or badly damaged, it must be changed.

Fig. 80. Checking the damper-piston liner

Change the damper piston (35) if the seals have

worn into the piston by more than 0.1 mm. Remo-
ve minor scoring using a fine abrasive cloth.

Fig. 81. Checking the damper piston

Carefully check the nozzles (37, 37A) in the rear

and front faces of the intermediate part. Also check
the holes in the liner (41) and make sure that all ho-
les are free of dirt. Check that the nozzles are pro-
perly screwed in, and locked with LOCTITE 243 or
542.
In surface drilling, the oil flow to the parting surfa-
ces of the rock drill can be reduced (if necessary)
by changing the nozzle (37A).
N.B. In underground drilling, all nozzles must
Fig. 82. Checking the intermediate part always be open (1.7 mm).

40
 Assembly
Before assembly, all parts must be oiled with
clean hydraulic oil.

If the seal housing (53) has been removed, it

should be re-fitted as follows:
Fit the O-ring (55).
Press the seal housing into place with the aid of
mandrel (I).

Fig. 83. Fitting the seal housing

Fit the impact-piston seals (54). (A seal kit consists

of an O-ring and a Teflon ring.) The seals are fitted
as follows:
Check that the seal grooves are very clean. Oil the
O-ring and fit it into the groove.
Insert the seal ring into the seal housing, and then
press it neatly into the groove using, e.g. the shaft
of a tool.
IMPORTANT! Make sure that the lips of the seal
face the direction shown in the figure opposite.

Fig. 84. Fitting the impact-piston seals

41
 Press in the damper-piston bushing (45) using
mandrel (I) and sleeve (X).
N.B. Press the bushing in carefully so that it does
not become deformed when it bottoms out!
Fit the lock ring (44) to retain the bushing.

Fig. 85. Fitting the damper-piston bushing

Fit the O-rings (42 and 43) on to the damper-

piston liner (41), and smear them with oil.
Tap in the liner using press tool (E).

Fig. 86. Fitting the damper liner

42
 Fit the damper-piston seals (46 and 47) as follows:
Check that the seal grooves are very clean.
Oil the O-ring and fit it into the groove.
Bend the seal ring as shown in the figure. Then pla-
ce the seal on a flat surface and tap down the in-
ner upturned edge of the seal using a hammer.
Fit the seal ring into the groove, and press it neatly
into the groove using the shaft of a tool.
IMPORTANT! Make sure that the seals are turned
as shown in the figure.

Fig. 87. Fitting the damper-piston seals

Oil the damper piston (35) and press it into the in-
termediate part.
N.B. This must be done with the greatest of care!
Now press out the damper piston and check that
the seals are located correctly, and that they are
not damaged.
Fit back the damper piston. Take care not to
damage the seals!
Fig. 88. Fitting the damper piston

43
 Check the sealing surfaces on the check-valve
poppet (89) and seat (91). Minor damage can be
lapped away using fine grinding paste. In the event
of more serious damage, change the parts.
Check that the poppet moves easily in the seat.

Fit the check-valve poppet (89), O-ring (90) and

seat (91) into the intermediate part.
Smear the parts with grease so that they stick in
place when the intermediate part is assembled.

Fig. 89. Inspecting and fitting the check valve

44
Cylinder, piston guides and impact piston
Disassembly
Inspection, replacement of parts
Assembly

Disassembly
Remove the front piston guide (57) by inserting the
impact piston (77) and knocking out the guide care-
fully.
Check that the contact surfaces (A) of the piston
Fig. 90. Removing the front piston guide guides in the cylinde (66).
Burnish the surfaces if necessary.

Remove the screws (62) that hold the valve covers

(60 and 61), and press out the valve piston (59).
Remove the regulating plug (63) and washers (64)
by unscrewing the nut (65).

Fig. 91. Removing the valve piston and regulating plug

Inspection, replacement of parts

Before inspection, all parts must be washed in
a degreasing agent.
Change all O-rings.
Change the piston guides (57 and 79) if they show
signs of serious cavitation damage.
If the clearance is greater than 0.06 mm, the gui-
des should be replaced.
Insert the impact piston and measure the clearan-
ce using a feeler gauge.

Fig. 92. Checking the piston guides

45
 If the bore of the cylinder (66), the valve bore
or valve piston (59) show signs of scoring or
scratches, the parts must be changed. Minor
scoring can be removed using a fine abrasive
cloth, a whetstone or a honing tool (see List of
standard tools, page 3).
Wash out all ducts thoroughly to remove any
foreign matter.

Fig. 93. Checking the cylinder and valve piston

Inspect the impact piston (77) for scoring and

scratches. Also inspect the impact surface for
wear and chipping.
Minor scoring and scratching on the piston can be
removed using a fine whetstone.

Grinding the piston

Minor scoring or pitting on the impact surface of
the piston can be removed by face grinding. Grind
by 0.1–0.2 mm at a time, until the surface is even.
The accumulative maximum is 0.5 mm.
N.B. The length dimension given in the figure oppo-
site is the minimum permissible dimension. Further,
the outside and inside radii must be restored preci-
sely so that an even transition is obtained. There
must be no sharp edges.
After grinding, check carefully that there is no
cracking on the impact surface of the piston. Wash
the piston thoroughly to remove all traces of grin-
Fig. 94. Checking the impact piston ding residue.

46
 Assembly
Before assembly, all parts must be oiled with
clean hydraulic oil.
Fit the valve piston (59) into the valve bore.
The valve piston is symmetrical, so it can be inser-
ted either way. Check that the valve piston moves
easily in the valve bore.
Fit the valve covers (60 and 61) with new O-rings
(34).
The valve covers should slide in easily and should
not be knocked into place.
Tighten the screws (62) to a torque of 145 Nm
(105 lbf. ft).
Fit the regulating plug (63) and seal rings (64).
Tighten the nut (65) to a torque of 80 Nm (60 lbf. ft).

Fig. 95. Fitting the valve piston and valve covers

77 58 57 G
1250 0032 26

Slide the impact piston (77) into the cylinder. Fit

the O-ring (58) on to the front piston guide (57).
Now fit the piston guide using the impact piston as
a guide. Tap the piston guide into place using the
mandrel (G).
Fig. 96. Fitting the piston guide
Then remove the impact piston from the cylinder.

47
 Hydraulic motor
Disassembly
Inspection, replacement of parts
Assembly
Function and condition test

For exploded view of hydraulic motor, see page 57.

Disassembly
Clamp the fixture (S) firmly in a vice. Screw the
hydraulic motor firmly to the fixture. Using a 3/16"
Allen key, remove the two plugs (28) and the
washers (29).
Use a 17 mm socket to remove the four screws
(24) which hold the motor together. Lift off the val-
ve housing (22) and turn it upside down so that the
springs (27) and balls (26) can be removed.

Fig. 97. Removing the plugs and screws

Remove the spacer pin (20) and valve drive (13).

Fig. 98. Removing the spacer pin and valve drive

48
 Lift off the cog wheel set (11). Remove the cardan
shaft (9) and the O-ring (10), which remains in the
intermediate plate (6).

Fig. 99. Removing the cog wheel set and cardan shaft

Take off the intermediate plate (6).

Fig. 100. Removing the intermediate plate

Take out the seal ring (4) and O-ring (5) from the
intermediate plate (6).

Fig. 101. Removing the seal ring and O-ring

49
 Turn the bearing housing (1) upside down and
knock out the splined shaft (3) using a plastic ham-
mer.

Fig. 102. Removing the splined shaft

Remove the seal rings (2 and 25) using a socket

with an outside diameter of 36 mm and a plastic
hammer.

Fig. 103. Removing the seal rings

50
 Knock out the contents of the valve housing (22)
by striking the housing against two blocks of wood.
Be careful not to damage the parts.

Fig. 104. Emptying the contents of the valve housing

Inspection, replacement of parts

All parts must be cleaned thoroughly before in-
spection.
Check all parts for wear and damage. Change all
worn or defective parts. Change all O-rings and
seal rings.
Check the cog wheel set for wear as shown in
the figure opposite. When the clearance between
the roller and the crest of the rotor tooth exceeds
0.1 mm, the cog wheel set must be changed.

Fig. 105. Inspecting the parts

51
 Assembly
Before assembly, all parts must be cleaned tho-
roughly and then oiled with clean hydraulic oil.
When repairing or overhauling the motor, the
seal set 3115 1010 93 must always be used.

Use a socket with an outside diameter of 50 mm

and a short extension piece to fit the seal ring (2).

Fig. 106. Fitting the seal ring

Fit the seal ring (25) as shown in the figure opposi-

te.
Use a socket with an outside diameter of 42 mm to
fit the seal ring.

Fig. 107. Fitting the seal ring

52
 Clamp the fixture (S) firmly in a vice. Screw the be-
aring housing (1) to the fixture.
Tap down the splined shaft (3) into the bearing
housing using a plastic hammer.
N.B. Make sure that the spacer sleeve centrali-
zes between the bearings.
Fit the O-ring (5) on to the bearing housing.

Fig. 108. Fitting the splined shaft

Grease the seal ring (4) and place it in the interme-

diate plate (6) with the larger diameter of the seal
against the intermediate plate.

Fig. 109. Fitting the seal ring into the intermediate plate

53
 Fit the intermediate plate (6) and fill the bearing
housing (1) with hydraulic oil.
Put the cardan shaft (9) in place and fit the O-ring
(10).
N.B. In the OMS 315 hydraulic motor, the cardan
shaft (9) must be fitted with the conical part facing
downward.

Fig. 110. Fitting the intermediate plate and the cardan

shaft and O-ring

Place the cog wheel set (11) on top of the interme-

diate plate (6) and make sure that the guide pin
(12) is in place.
Also check that the drainage duct (A) in the cog
wheel set lines up with the duct (B) in the interme-
diate plate.

Fig. 111. Fitting the cog wheel set

54
 Fit the valve drive (13).
Make a mark on one of the tooth crests on the up-
per side (A) of the valve drive (13). The mark must
be directly opposite a clearance curve in the outer
cog circle (B) of the rotor, as shown in the figure
opposite.

Fig. 112. Fitting the valve drive

Grease the O-ring (10) and stick it to the channel

plate (14). Put the channel plate on the cog wheel
set (11).
When placing the channel plate (14) on the cog
wheel set, make sure that the guide pin (12) loca-
tes in the bottom hole in the channel plate.

Fig. 113. Fitting the O-ring and channel plate

55
 Fit the valve disc (15) so that one of the holes (B) li-
nes up with the marking on the valve drive (13).
Turn the valve disc anti-clockwise until the splines
engage.
N.B. If the valve disc is not fitted in this way, the
motor will rotate anti-clockwise.

Fig. 114. Fitting the valve disc

Place the spring ring (21) in the valve housing (22).

Grease the O-rings (18 and 19) and fit them on to
the balance plate (16).
Grease the balance plate and fit it into the valve
housing. The guide pin (17) must locate in the hole
in the bottom of the valve housing. Press the balan-
ce plate into place using a soft tool shaft.
Grease and fit the spacer pin (20). (The grease will
keep the parts in place during assembly.)

Fig. 115. Assembling the internal parts of the valve housing

56
 Fit the valve housing (22) and tighten the screws
(24) gradually and alternately to a torque of 50 Nm
(37 lbf. ft).

Fig. 116. Fitting the valve housing

Insert the balls (26) and springs (27) into the two
holes in the valve housing (22), and then fit the
plugs (28) and washers (29). Use a 3/16" Allen
key, and tighten the plugs to a torque of 10 Nm
(7 lbf. ft).

Fig. 117. Fitting the balls and springs into the valve housing

57
 3115 1010 80 (05 - OMS 100)
Hydraulic motors 3115 1010 81 (07 - OMS 160)
3115 1010 83 (10 - OMS 315)
3115 1010 84 (09 - OMS 250)

1
25 2

4 7
5
8
6
12
9
10

17

11 23
10 13
22
14
15
16 24
18
19
20
21 27
28
1250 0074 90

26
29
Function and condition test of hydraulic
motor

Connect up the motor as shown in the figure oppo-

site (P = Pressure; R = Return), and let it rotate for
about 30 seconds with a maximum flow of 10 l/min
(2.6 US gal/min). Check that the motor runs smoot-
hly and that there is no dissonance.

Fig. 118. Testing the hydraulic motor

Clamp the fixture (S) firmly in a vice and fit the hyd-
raulic motor so that the splined output shaft is
locked. See figure opposite. Connect the hydraulic
hoses (P = Pressure; R = Return) and adjust the
hydraulic pressure to 40 bar (580 psi). Measure
the leakage flow from the motor. It must not exceed
2–3 l/min (0.53–0.79 US gal/min).

Fig. 119. Checking the flow of leakage oil

58
 Assembling the main parts of the rock drill

General Assembly sequence:

All parts must be cleaned thoroughly before fi- • Cylinder
nal assembly. Just before assembly, the parts • Hydraulic motor
must be oiled with clean hydraulic oil. • Intermediate part
All O-rings must be changed. Grease the new • Cover and gear housing
O-rings with silicone grease before fitting. • Back head and impact piston
• Front head
• Accumulators

Cylinder
Put the pivoted mounting fixture (A) in the horizon-
tal position.
Using two M16 bolts, bolt the cylinder (66) securely
to the mounting fixture, with the front part of the
cylinder facing into the workbench.

Fig. 120. Fitting the cylinder to the pivoted mounting

fixture

Hydraulic motor
Make sure that the circlip (73) is fitted in the coup-
ling (72).
66
Smear the splines of the coupling with grease, and
slide the coupling on to the output shaft of the hyd-
1250 0062 41

74 73 72
raulic motor (74).
R
Fit a new gasket (95) to the end face of the cylin-
der (66).
Fit the hydraulic motor to the cylinder (66).
95
75 Tighten the nuts (75) to a torque of 65 Nm
(50 lbf. ft) using the ring spanner (R).
Fig. 121. Fitting the hydraulic motor to the cylinder

59
 Intermediate part
Put the pivoted mounting fixture into the vertical
position.
Fit the O-ring (56) into the groove in the middle of
the rear guide of the intermediate part (36).
Fit the O-ring (50) into the rear face of the interme-
diate part (36). (First smear some grease into the
groove, so that the O-ring sticks in place during as-
sembly.)
Fit the intermediate part (36) to the cylinder (66).
Lightly tap the intermediate part into position using
a copper hammer. Make sure that the check valve
(91) stays in place.

Fig. 122. Fitting the intermediate part to the cylinder

Cover and gear housing

Put the pivoted mounting fixture into the horizontal
position.
Grease and fit the O-ring (34).
Fit the gear housing (17) to the intermediate part
(36). If the rotation shaft (26) does not enter the
36 17 coupling (72), insert a shank adapter into the driver
72 26 (13) and turn it.
1250 0061 37

13

34

Fig. 123. Fitting the gear housing to the intermediate part

60
 Fit the side bolts (5). Fit the rear washers (3) and
nuts (2). Tighten the rear side-bolt nuts (2) alterna-
tely to a torque of 300 Nm (220 lbf. ft). Use the
wrench adapter (K) for the torque wrench.
Fit the bolt (4). Tighten the bolt to a torque of 300 Nm
(220 lbf. ft).
N.B. Before assembly, smear the threads with gre-
ase of type NEVER-SEEZ.

Fig. 124. Fitting the side bolts

Back head and impact piston

Oil the impact piston (77) with clean hydraulic oil.
Slide the impact piston into the cylinder bore.
When the piston reaches the front piston seals,
twist the piston gently through the seals. If the pis-
ton is knocked through the seals, there is a risk of
damaging the seals.

Fig. 125. Fitting the impact piston

Fit the rear piston guide (79) with a new O-ring (58).
Tap in the piston guide with the aid of mandrel (G).

79 58
1250 0024 62

Fig. 126. Fitting the rear piston guide

61
 Fit the O-ring (78) into the cylinder. Fit the O-ring
(76) into the groove on the cylinder. (First grease
the O-ring so that it sticks in place.)
Fig. 127. Fitting the back head to the cylinder
Before fitting the back head, check that the piston
(77) can be moved back and forth in the cylinder
bore with a rotary motion.
Carefully fit the back head to the cylinder. Take
care not to damage the impact piston or the piston
seals.
Tighten the three screws (84) for the back head
alternately to a torque of 220 Nm (160 lbf. ft). The
two lower screws should be tightened to the final
torque before the upper screw.
Use the wrench adapter (K) for the torque wrench.

Front head
Fit the pin (9) into the cover. Fit the front head (1B)
over the side bolts (5).
Fit the washers (3) and nuts (2).
N.B. Before assembly, smear the threads with gre-
ase of type NEVER-SEEZ.
Tighten the nuts (2) alternately to a torque of 350 Nm
(260 lbf. ft).

Fig. 128. Fitting the front head

Fit the cup seal (3) into the flushing head.

Fit the connection plate (2) to the front head using
the washers (4) and screws (5). Tighten the
screws (5) to a torque of 90 Nm (65 lbf. ft). Fit the
nipple (6) to the connection plate, and tighten the
nipple to a torque of 300 Nm (220 lbf. ft).

Fig. 129. Fitting the connection plate to the front head

62
 Accumulators

CAUTION
• Fit the accumulators to the rock drill using
undamaged original screws.

The intake accumulator (52) [i. e. the larger

model for COP 1838HE] must have two
screws (7), 100 mm in length.
The intake accumulator (52) [i. e. the smaller
model for COP 1838ME] must have two
screws (4), 70 mm in length.
The damper accumulator (92) must have
two screws (93), 70 mm in length.
Change both screws at the same time,
even if only one of them is corroded or
damaged in some other way.
Defective screws can cause dangerous oil
leakage, or can cause the accumulator to
be blown off.

CAUTION
• Charge the accumulators AFTER they
have been fitted to the rock drill.
Failure to follow this procedure can result
in injury.
Fig. 130. Fitting the accumulators

Fit the O-rings (34) on to the accumulators (52 and

92), and then fit the accumulators to the interme-
diate part (36).

= Read the instruction book carefully Fit the damper accumulator (92) to the left-hand
before servicing or changing side of the rock drill, and the intake accumulator
(52) to the right-hand side of the rock drill, i.e. the
hose side. Tighten the screws (93 and 4 or 7) alter-
nately to a torque of 220 Nm (160 lbf. ft).

Make sure that the accumulators (52, 92) have the

correct safety labels, and that the labels are not
damaged.
Replace any damaged safety labels!

= Must be charged with nitrogen

Fig. 131. The accumulator safety labels
1250 0024 63

16
14
Fit the return accumulator (94) to the nipple (17 on
underground drill rigs) or (A on surface drill rigs)
and tighten in such a way that the plug (11) is ac-
12 cessible for checking the accumulator diaphragm.
11
13 A
Thread on the clamp (13) and fit the retainer (12)
using the screws (14, 16) and nuts (15).
17
15 94
Fig. 132. Fitting the return accumulator

63
 Charging the accumulators

WARNING
• The accumulators must be charged with
nitrogen (N2) only!
Other gases can cause an explosion!

CAUTION
• Charge the accumulators AFTER they
have been fitted to the rock drill.
Failure to follow this procedure can result
in injury.

The intake accumulator (52) and damper accumu-

lator (92) must be charged before the drill rig is
started up. The return accumulator (94) must not
be charged.
The intake accumulator (52) is located on the right-
hand side of the rock drill, by the oil intake nipple.
The damper accumulator (92) is located on the left-
hand side of the rock drill.

Fig. 133. Charging the accumulators

Take off the protective cap (A) from the accumula-

tor valve.
Open the valve nut by 2–3 turns.
Fit the regulator (Q) into the gas cylinder, and con-
nect the charging hose (P) between the regulator
and the accumulator valve.
Adjust the regulator to the lowest possible pressu-
re, and then open the valve on the gas cylinder.
Charge the intake accumulator (52) to a pressure
of 30 bar (435 psi) below the collaring pressure,
max. 110 bar (1595 psi).
Close and tighten the valve nut, close the valve on
the gas cylinder, and disconnect the charging hose
(P) from the accumulator. Fit the protective cap (A)
back on to the accumulator valve.
Now charge the damper accumulator (92) to a
pressure of 20–25 bar (290–360 psi) by following
the same procedure as outlined above.

64
 Greasing the gear
Remove the plug (18) and fill the gear housing with
a heat-resistant grease via the nipple (20). Fill until
grease comes out through the hole (A). See the
section "Recommended hydraulic oils and lubri-
cants" on page 68.
Fit the plug (18) with washer (19) and tighten.

Fig. 134. Greasing the gear

65
Testing the rotation and percussion functions

Testing the rotation function

Connect the hydraulic hoses P (pressure) and R
(return) to the hydraulic motor. Switch on the hyd-
raulic pressure (max. 40 bar/580 psi) to the motor
for about half a minute.
Check that the rotation motor operates smoothly,
without dissonance or leakage, and in the correct
direction.

Fig. 135. Testing the function of the hydraulic motor

Testing the condition of the

percussion mechanism
For the condition test, the hydraulic hoses
must be connected as shown in the figure op-
posite.

Remove the valve cover (61) from the right-hand

side of the machine.
Fig. 136. Testing the condition of the percussion Insert the washer (O), which must be very clean,
mechanism and fit back the valve cover.
Switch on the hydraulic pressure to the percussion
function and adjust the pressure regulator in the
test equipment until the pressure gauge reads
100 bar (1450 psi).
Depress the "low" scale button on the flow meter,
and take the reading.
The leakage flow for a new machine is 2–3 l/min
(0.53–0.79 US gal/min). Leakage flows of more
than 5 l/min (1.32 US gal/min) are not acceptable,
and indicate some kind of fault in the impact pis-
ton–bore, the valve piston–bore, piston guides
or reflex damper.
N.B. Do not forget to remove the washer (O) after
the test.
Fit back the valve cover (61). Now run the rock drill
at low pressure (5-15 bar) and check that the pis-
Fig. 137. Checking the flow of leakage oil in the ton moves back and forth.)
percussion mechanism

66
Tightening torques

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
3A 2 Side bolts (ME/HE) 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 torque
10 1 Plug 45 33
11 4 Valve covers 145 105 Tighten the screws alternately to full torque
12 2 Connection plate 120 90 Tighten the screws alternately to full torque
13 1 Flushing connection 300 220
14 4 Inlet, flushing medium 90 65 Tighten the screws alternately to full torque

67
Recommended hydraulic oils and lubricants
Lubricant Recommendation

Hydraulic oil • Use a mineral-base (polyalpha-olefin or diester based) hydraulic oil with good anti-wear, anti-rust, anti-oxidation
and foam inhibiting properties, and with good air and water separation characteristics. Choose an oil with viscosity
grade (VG) and viscosity index (VI), in accordance with the table below. An oil with a high viscosity index is less
sensitive to the effects of temperature.
Hydraulic oil temperature in tank oC ( oF) Viscosity Viscosity
Normal operating temp. Min. starting temp. Max. temp. grade VG index VI
(viscosity 25–50 cSt) (viscosity min. 1000 cSt) (ISO 3448)
+50 to +70 (122 to 158) +5 (41) 80 (176) ISO VG 100 Min. 100
+45 to +60 (113 to 140) –5 (23) 75 (167) ISO VG 68 Min. 100
+35 to +50 (95 to 122) –10 (14) 65 (149) ISO VG 46 Min. 100
+25 to +40 (77 to 104) –15 (5) 55 (131) ISO VG 32 Min. 100
+10 to +25 (50 to 77) –25 (–13) 35 (95) ISO VG 15 Min. 100

Air tool oil • Use a mineral base air tool oil.

Ambient temperature oC ( oF) Viscosity grade (ISO 3448)
–30 to 0 (–22 to +32) ISO VG 32–68
–10 to +20 (14 to 68) ISO VG 68–100
+10 to +50 (50 to 122) ISO VG 100–150

Grease • IMPORTANT! Because of the operating temperature in the rock drill gear housing (see "Greasing the gear"),
always use a high-temperature grease containing an ashless thickening agent and additives that give
resistance to oxidation and rust. The grease should also have good resistance to water.
Grease properties NLGI-number 2 Base oil viscosity 110 cSt at 40 oC (104 oF)
Dropping point 250 oC (480 oF) Operating temp. –20 to +150 oC (–4 to 300 oF)

68
Hydraulic rock drills COP 1838
Intake accumulator HE/HEX (52) Intake accumulator ME/MEX (52) Damper accumulator (92)
3115 2391 81 3115 1763 82 3115 2395 80
1 2 3 1 2
3
2 1 11
3 4 5
6 10
13
9 7
12 8
11 9
14
10
7
4

1250 0029 95
1250 0041 45

1250 0029 96
11
6 D
10 15
16 8
9 7 12 13 4
8
6
5 5 12

18
Return accumulator HE / HEX (94) 19
3115 2615 90
17
19 1A 21 22 25
11
1 2
8 18
16
20
4
9
1250 0041 46

14

12
10 7 8 11 12 13 15 14 16
24
20
17 10 9 7 6 5 4 3 13
15 6
1B

2 3

23 27 28 33 29 30 31 32 34 26
5

Return accumulator ME / MEX (94) 85 86 62

49
1250 0058 09

3115 2615 91 52 48 61 63 64 65
50 94
39 34 3 2
7 1
40 84
59
18
51
16
34 87 88
10
12 37 66
9 14 35 46 47 37 53 55 57 76
11
13
8
1250 0052 63

37
50 54 56 58 77 78 58 79 81 80 82 83
2 6 5 4 3 15
67
17 70
89 90 91
36 34
69 34
93
92 68 72 73 95 74
60
71 75
41 42 43 44 45 62

69
Hydraulic rock drills COP 1838

Front head ME/HE (1B)

7 8 9 10 9 8 11 9 12 13
20
1250 0058 10

22 1

3
2
4
5

14 15 9 16 9 15 17 19 18 13 21
6

35
34
Front head MEX/HEX 19 33
32
31
14 15

20 21
37
1 36
23 38
16 17
36

22

39
2 3 4 5 6 10 7 9 8 7
22

12 29
11 13
1250 0058 11

Atlas Copco, 1999

Printed in Sweden
26 27 28 27 26 24 25

70