COP Training Student Binder 1838 GB 061114

Subject Content Page
GENERAL-ABOUT-ROCK DRILLS
- Product presentation 3
- Product presentation DHR 13
- Competitors 25
- Repowring 1632 29
- Repowring 1132 55
- Shock wave theory 73
- Percussion Data 81
- Principals Tophammer Rock drill 89
- Rock Mechanics 93
ROCK-DRILL-FUNCTION-and-PRINCIPALS
- Percussion circuit 97
- Damper circuit 107
- Extractors 121
- Feed circuit 125
- Rotation circuit 127
- Rock drill CONTROL FUNCTIONS 133
- Flushing circuit 139
- Lubrication system 143
- Principles for a percussive rockdrill 147
- Function descriptions 153
OVERHAULING – DISASSEMBLE
- Overhauling instructions COP 1838 165
TROUBLE SHOOTING
- Fault & Causes 237
- Secoroc Trouble shooting guide 257
OVERHAULING – ASSEMBLE
- Overhauling instructions COP 1838 165
OPERATION AND MAINTENANCE

289
- Maintenance instructions COP 1838
311
- Setting the COP 1838 ME
312
- How to use COP 1838 HF
QUESTIONS & MISCELLANEOUS

- How to find PMI DB 315
- How to find Rock Drill database 319
- How to find Service report DB 323
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•Åke Eklöf
Hydraulic Rock Drills

Programme overview 2006
Fredrik Öberg / 2006-01-26
Copyright, 1996 © Dale Carnegie & Associates, Inc.
Designation KEY
Following designations appear in this presentation:
4 HF High Frequency
4 HD Hydraulic drill for Drifting
4 HB Hydraulic drill for Benching
4 ME or M Medium Energy
4 X or EX Extractor
4 LP Low Pressure
4 LE Low Energy
4 HE High Energy
4 CR COPROD
4 TED Tube Extracting Device
4 U Underground version of front head
COP 1019 / 1019HF

3.5/4.5 kW, D=23-35 mm, H19, Rel. 1994
Application:
4 DSI-drilling
•Borrmaskiner+Diarot •1
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•Åke Eklöf
COP 1022 / 1022HF

4/5 kW, D=27- 41 mm, H22, Rel. 1979
Application:
4 DSI-drilling
COP 1025
4,5 kW, D=30-41 mm, H25, Rel. 1981
Application:
4 DSI-drilling
COP 1028HD
5,5 kW, D=33-45 mm, R28, Rel. 1983
Application:
4 Bolting
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•Åke Eklöf
COP 1132
11 kW, D=33-51 mm, R28, R32, Rel. 2005
Applications:
4 Bolting
4 Drifting
COP 1238 ME / 1338 MEX

12 kW, D=45-89 mm, R32, T38, T45, Rel. 1983
Applications:
4 Drifting
4 Long Hole Drilling
4 Benching
COP 1338 MEX

COP 1238 ME
COP 1238 LP (low pressure)

12 kW, 130-230 bar, D=45-89 mm, R32, T38, T45, Rel. 1983
Applications:
4 Drifting
4 Benching
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•Åke Eklöf
COP 1532
15 kW, D=33-64 mm, R32, T38, Rel. 2002
Applications:
4 Drifting
4 Bolting
4 Long Hole
Drilling
4 (Benching)
COP 1638
16 kW, D=33-76 mm, R32, T38, Rel. 2004
Application:
4 Drifting
4 Bolting
4 Long-hole drilling
COP 1638
COP 1838 LE
16 kW, D=48-76 mm, R32, T38, Rel. 2003
Application:
4 Benching
COP 1838 LE
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•Åke Eklöf
COP 1838 ME/MEX

18 kW, D=45-89 mm, R32, T38, T45, Rel. 1991
Applications:
4 Drifting
4 Long Hole
Drilling
4 Benching
COP 1838 MEX COP 1838 ME
COP 1838 HF
22 kW, D=43-76 mm, R38, T38, T45, Rel. 2000
Application:
4 Drifting
COP 1838 HF
COP 1838 HE/HEX

18 kW, D=76-102 mm, T45, T51, Rel. 1989
Applications:
4 Benching,
COP 1838 HEX

COP 1838 HE
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•Åke Eklöf
COP 1838 CR
18 kW, D=90-105 mm, CR76, Rel. 1993
Application:
4 Benching
®
Function of the COPROD -system
COPROD 89 D= 105 - 127 mm
COPROD 102 D= 115 - 140 mm
COPROD 127 D= 140 - 165 mm
Tube adapter COPROD COPROD

-section head
COPROD® system
COPROD® section
COPROD® head
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•Åke Eklöf
Tube Extracting Device TED
COP 1840 HE/HEX

18 kW, D=76-102 mm, T45, T51, Rel. 1995
Applications:
4 Benching
COP 1840 HEX
COP 2160 / 2160 EX

21 kW, D=89-127 mm, T45, T51, Rel. 2005
Application:
4 Benching
COP 2160 EX
COP 2160
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•Åke Eklöf
COP 2150 CR
21 kW, D=105-127 mm, CR89, Rel. 2002
Application:
4 Benching
COP 2560 / 2560 EX

25 kW, D=89-127mm, T45, T51, Rel. 2005
Application:
4 Benching
COP 2560 EX
COP 2560
COP 2550 UX
25 kW, D=89-127mm, (T45), T51, ST 58 Rel. 2004
Application:
4 Long Hole drilling
COP 2560 UX
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•Åke Eklöf
COP 2550 CR
25 kW, D=105-127 mm, CR89, Rel. 2002
Application:
4 Benching
COP 3038
30 kW, D=43-64 mm, T38, Rel. 2004
Application:
4 Drifting
COP 4070 ME/MEX

40 kW, D=89-127 mm, T51, T60 Thunder Rod Rel. 2005
Applications:
4 Benching
COP 4070 MEX
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•Åke Eklöf
COP 4050 MUX

40 kW, D=89-127 mm, T51, TDS 76, TDS87, Rel. 2002
Application:
COP 4050 ME CR
40 kW, D=105-140 mm, CR 89, CR 102, Rel. 1998
Application:
4 Benching
COP 4050 HE CR
40 kW, D=140-165 mm, CR 127, CR140, Rel. 1999
Application:
4 Benching
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Rotation units
DHR
3 gear house sizes
DHR 48 Family DHR 56 Family

DHR 45 Family
Name Code
Example: DHR 45A
Suitable Air driven (A) or
Down Hole Rotation
for 4-5” hammer Hydraulically driven (H)
DHR 34A DHR 45A DHR 45H DHR 48H DHR 48W DHR 48RC
DHR 45 Family DHR 48 Family

DHR 56A
DHR 56 Family
Designation key
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DHR versions – P/N Key
Rotation units – Surface
4 ROC F6 with DHR

45H and
floating sub
4 ROC L8 with DHR
48H and
fix sub
4 ROC 460 with DHR 45

4 ROC 460 HF with DHR A and floating sub
56 A and floating sub
Rotation units – Underground
El Soldado Mine, Chile
SIMBA M6C with DHR 48H
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Rotation units – Underground
SIMBA W469 with DHR 48 W LKAB, Kiruna, Sweden
Air powered rotation units DHR(A)
Hydraulic powered rotation units DHR(H)
DHR DHR DHR DHR DHR

45H 48H45 48H56 48H68 48RC [1]
Length [2] mm 685/842 528/882 534/888 550/904 696 / -
Weights 2 kg 111/124 163/239 164/240 166/242 178 / -
Drill tube connection
API Reg Female 2 3/8” 2 3/8” 2 3/8” 2 3/8” 4” Metzke
3 ½” 3 ½” Long pin
Male
Qty of drive motors :1 2 2 2 2
Performance at drilling[3]
Max torque (Nm) 2200 3000 3900 5100 5100
Max pressure drop (bar) 175 210 210 175 175
Max speed [4] (rpm) 80 136 107 68 68

Max flow (l/min) 75 150 150 150 150
[1] To be used for Reverse Circulation Drilling with components from Metzke Enginnering,
Air swivel not incl. rotary head.
[2] With fixed adapter / floating adapter
[3] With mineral oil. For other oils ask for information.
[4] Not in combination with max torque.
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DHR 34/45A with fix sub
DHR 34/45A with floating sub
Floating sub of DHR 34/45
4
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Vane motor with planetary gear to
DHR 34/45/56A
Air motor shuttle valve
Air vane motor to DHR 34/45/56A
5
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Air vane motor to DHR 34/45/56A
Planetary gear to DHR 34/45/56 A
DHR 56A
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DHR 45H with floating and fix subs
DHR 48H with floating and fix sub
DHR 48H Basic parts
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DHR 48H with fix and floating sub
Fix sub
Floating sub
DHR 48 RC
DHR 48 RC at L8 RC
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BBX 280
Rotation unit to comply with new

demands:
• Higher airpressure 35 bar
• Higher torque: Max 6 kNm
• Higher serviceability
• Modularisation; same main
components for all versions.
BBX 280 with floating sub
BBX 280 Replaceble spare sleeves
Spare sleevs
Inlet air seal
Hyd drain seal
on motor pinion
shaft
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BBX 280 Air inlet
Air inlet seal with leakage drain channel.
Two seals between inlet seal and gear box.
BBX 280
General improvements – improved seal replaceability
by use of the sleeve
BBX 280
General improvements – hyd seal leakage check hole.
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DHR
END
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Chapter 5.5
Competitors
Bench drilling - Tunnel driving - Roof bolting - Reaming - Production drilling - LRD
Andreas Nordbrandt / 2004-11-10
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HYDRAULIC TOP HAMMERS – ATLAS COPCO and COMPETITORS
SURFACE DRILLING
DSI Construction Construction Construction Constr/
Constr/Quarry Constr/
Constr/Quarry Quarry Quarry
23-
23-41 mm -51 mm -64 mm 76-
76-89 mm 89-
89-102 mm 102-
102-115 mm 115-
115-127 mm 105-
105-165 mm
COP 1032
COP 1019/HF COP 1028 COP 1238 ME COP 1800-ser. COP 2150 COP 2550 COP 4050
COP 1238 ME
COP 1022/HF COP 1838 LE COP 1800-ser. COP 2150 COP 2550 COP 4050
ROC D3 ROC D5 ROC D7 ROC F7 ROC F9, F9 CR ROC L7

Example on rig ROC D5 ROC D7 ROC F7 ROC F9 ROC L7 ROC L7 CR
HL 510, HL X5,
HE 119 HE 122, HE 122, HE X1 HL 300 HL 600 HL 700, HL 800T HL 1000 HL 1500
HL 600 HL 700,
HE / HL X1 HL X1, HL 300 HL 510 HL 800T HL 700, HL 800T HL 1000 HL 1500
Quarry Commando, Commando 120 Commando 300, CHA 550, CHA 660 Ranger & Scout 6 / 7/800 Pantera 800, Pantera 1100 Pantera 1500
Example on rig Dino 4/500, CHA 550,
Trimmer, Liner Commando 300 Ranger K5/500 & Scout 500 Ranger/K/Scout 5/6/7/800 Pantera 800 900 & 1100 Pantera 1500
HC150, HC160
YH 70, HC 50 YH70, YH80, HC80, HC 105, HC120 HC160, HC 170 HC 160, HC 200A
HC 170, HC200,
HC 105, HC120 HC150, HC 160 HC 200A
YH100, YH135
Example on rig ECM 470 ECM 470, ECM 580, ECM 635, ECM 645, ECM 670, ECM 680, ECM 690, ECM 710, ECM 690, ECM 720
ECM 590, ECM 635 ECM 660 MkII ECM 690, ECM 710 ECM 720
HPR 45 HPR 45, HPR 45,

HPR2-C HPR2-C
HPRH HPR1H-ATW, HPRH HPR1H-ATW
SD 250 SD 250, SD 250 C SD 345, SD 345C SCH 5000C, GD 402 SCH 5000C DTH-rig
Example on rig
Cubex Chimera TH Cubex Chimera TH
HD 606 MkII HD 709 HD 709, HD 712 HD 712, HD 715 HD 715 HD 715
HCR 600 HCR 900 HCR 900, HCR 1200 HCR 1200, HCR 1500 HCR 1500 HCR 1500 DTH-rig
Example on rig
H 410, H420, H 528 H 538 H 751 H 751 H 751

H 460, H522
Example on rig Perfora DSI-rigs

MIG 45 (Demoroc)
HD 1704 HD 125 HD 125 HD 155 HD 165

HD 155
Example on rig
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HYDRAULIC TOP HAMMERS – ATLAS COPCO and COMPETITORS
UNDERGROUND DRILLING
PRODUCTION DRILLING DRIFTING BOLTING
Small Medium Large X Small Small Medium Large
51-
51-76 mm 76-
76-102 mm 102-
102-127 mm
33-64 mm 38-64 mm 38-64 mm 28-45 mm 28-45 mm 28-45 mm 28-51 mm
COP 1532
COP 1532, COP 1838 COP 4050MUX
COP 1238ME COP 1238ME COP 1238ME COP 1028 COP 1532 COP 1532 COP 1532
COP 2550UX COP 1838ME/HF COP 1838HF COP 1032
COP 1238ME COP 1838ME/HF
SIMBA H 157 SIMBA M-ser. SIMBA L-ser. BOOMER S1L, 104 BOOMER M2-ser. BOOMER L3-, BOLTEC SL BOLTEC MD-ser. BOLTEC LC-ser.
Example on rig SIMBA H 250 SIMBA H 1250 281, 282,L1, L1 DH BOOMER L2-ser. WL3- and XL3 ser. BOLTEC H235 BOLTEC MC-ser. BOLTEC LD-ser.
H-star 350, HL 700 S, HL 1000S, X2F, HL 510 S HLX5, HFX5 HLX5, HFX5 HSX, HL X1, Hydrastar 200B, HL 300S HL 300S
X2 L, HL 510 S HL 1000 S HL 1500 S HL 560 Super HL 560 Super Hydrastar 200B HL300S, HL510B HL 510B HL 510B
/ SECOMA HL 510 T
Quasar L, Mercury L, Cabolt 520
SOLO/MATIC 700 SOLO/MATIC 1000 Axera LP Axera 7 Axera T10-T12 Robolt XLP, Robolt 06 Robolt 320
Example on rig SOLO/MATIC 500
SOLO/MATIC 1000 Axera D 04-06 Axera T 08 Robolt 310 Cabolt 530
SOLO 05 SOLO/MATIC 1500 Robolt 05
HC 50 HC 50 HC 50 HC 80 HC 50 HC 50
HC 80 HC 107E
MTI 1SB, 1SXB MTI 2SB Robodrill MTI Drift MTI Drift
Example on rig MTI - VRLH
Robodr. Pantofor Robofor
Robodr.Mini-Panto Runner Bolter Runner Bolter
ECM 690, ECM 720
HPR1H-ATU HPR 45 HPRH-A/AF HPRH-D HPR1-JTW

HPRH-CU HPR2-C HPRH-D HPRH1-D
Example on rig Cubex Aquila / B, Cubex Aquila / B, Mine King Mine King Mine King
Cubex LH1 Cubex LH1 MK10-35 MK35-45 MK45-65
HD 150
HD 90 HD 90 HD 90
HD 90 HD 190
HD 150 HD 210
Example on rig JTH2A-90 JTH2RS-XX JTH3RS-XX MacLean Bolter MacLean Bolter
H 751 H 751 H 528 H 528 H 528

H 538 H 538 H 528 H 528
H 538 H538 H 538
Example on rig
HD 155 HD 155 HD 65 HD 155 HD 155 HD 65 HD 65 HD 65 HD 65

HD 165 HD 155 HD 155 HD 155
Example on rig Stopemaster Stopemaster Facemaster Facemaster Facemaster Roofmaster Roofmaster Roofmaster
TH 400
TOYO TH 800
TH 900
TH 400
TH 800
TH 800
TH 900
THMJ-28/2900
Example on rig THMJ-2400 THMJ-34/38/3900
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COP 1638
-the new 16 kW Rock Drill
Andreas Nordbrandt, 2004-09-14
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COP 1638 in brief
A new 16 kW rock drill for Face- and Long
hole drilling Underground
Can be used on 45 kW electrical motor power
pack
Gradually replaces COP 1238 ME
Developed from COP 1838 ME, and has
therefore many COP 1838 features
Suitable as Repower rock drill. There is a big
Repowering potential, replacing used COP
1238 MEs and used Tamrock HL 500/510s
Technical data, COP 1638 vs COP 1238 ME
COP Rock Drill 1238 ME 1638

Impact power, max [kW] 12 16
Weight, [kg] 150 170
Max impact pressure [bar] 230 200
(at the hammer)
Impact energy, [J] 240 266
Impact frequency [Hz] 50 60
Damper, type Hydraulic single Hydraulic, double
Hole range [mm] 33-89 33-76
Shank adapters R32, R/T38 R32, R/T38
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COP 1638, features and benefits
Feature - Atlas Copco double dampening system
Benefits
- Provides good bit-rock contact which gives high penetration
rate
- Gentle to the drill steel and rock drill, absorbs harmful recoil
energy and tightens drill steel thread joints

Feature – Pressurized mating surfaces between the parts
Benefit – There is a 2-3 bar air pressure inside the drill,

which prevents dirt and moist from entering. This results in
longer service life of the parts and more trouble free
operation.
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Feature (optional) – Front head designed for ultra-corrosive
environments – AW-version!
Benefits –
Minimized risk of water inside the drill
Longer service life on drill housing and shank
Longer service life on front guide
Feature and benefit – The Impact piston design

emulates the size of the drill steel. This feature gives
minimum drill steel stress.
Drillers who have tested the COP 1638 say it is very

easy to adapt to different rock or bit conditions
What is AW version?
AW is an option to COP 1638 or 1838ME with a special front
head, aimed for sites where the environment is medium to very
corrosive.
For those not familiar with the COP 1638, it is the optimal choice
for upgrading old rigs with COP1238/DCS, COP1432/DCS14 or
similar class competitor rockdrills, to provide higher productivity
and better drilling economy.
The AW design provides mainly:
– Minimised risk of water intrusion into the rock drill and
hydraulic system
– Longer service life on the front head (corrosion resistant
material) and its comprised parts
– Longer service life of the shank adapter (zinc phosfated
surface is option)
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What is AW version?
AW version is available for dia 38 mm shank adapters as part of
complete rock drill or as a kit for retrofitting.
The AW design is tested in corrosive environment in Poland and
Australia in more than 1.500.000 drill meters
AW, BOM and feature numbers

3
4
2 6
1
5
5
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Features 1 to 3
1 The flushing head is made from a high quality black polymere,
which can not corrode. As the backhammer feature is desired
also in the AW version, we do not allow the stop ring to hammer
on the flushing head. Therefore a spacer (pos 114) is
introduced.
2 Due to the space required between the two rear flushing seals,
the AW shank adapter is 20 mm longer than a standard shank
adapter (which means that an AW rock drill is 20mm longer than
a standard 1638 or 1838 ME rock drill).
A zinc-phosphate coated shank adapter is available to increase

its service life.
3 AW version front head has a much larger cross sectional areas
for evacuation of the flushing water when a flushing seal is worn.
There are 4 radial holes for the front seal and 4 large grooves
for the rear seal. Neglecting change of a worn seal therefore
reduces the risk of water inside the drill and its hydraulic
system
Features 4 to 6
4 The AW design has incorporated the water inlet connection
plate
5 The AW design has 2 wipers around the front guide, to protect
the lubrication system from dirt and water.
The front wiper protects the drill from cuttings and the rear wiper
protects the lubrication system from flushing water
6 There a 3 flushing seals with the same P/N
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Part numbers
As part of complete rock drill, the designation AW is
added to a normal designation of a rock drill, for
instance: COP 1838 ME-AW-T38/05 has P/N 8311
1247 57. You find all P/N in the price list in the RDE
Rock Drills Database.
Retrofit kit P/N is 3115 3018 80, it comprises all
included in the BOM list excluding the shank adapters
which has following P/N:
T38 male, L=455mm, SECOROC NR.435-09108,00
R38 male, L=455mm, SECOROC NR.404-09108,00
R38 male, L=455mm, SECOROC NR.404-09108,30 (zinc-phosphated)
COP 1638 field tests summary

3 field tests have been carried out in Australia,
Canada and Poland, replacing COP 1238 ME
on used eqipment
Totally 2309 impact hours
Successful tests, no problems are reported
Shank adapter service life was increased by
in average 23% vs COP 1238 ME
All field test sites report an increase in
productivity.
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Field Test #1, Beaconsfield Mine, Australia
Rig: Used Boomer 322 . AVO 96A021 with Feed BMHT 6314-08, compressor LE
55, DCS-12-45-2. Rig was originally equipped with COP 1238 ME
3 pc of test COP 1638 were run 512 , 571 and 626 impact hrs between 2003-08 and
2004-04
Reported shank adapter average service life: COP 1238; 714 m, with COP 1638
814 m. This equals 15% improvement despite scaling with the rock drill (which is
the reason for the overall short lives) .
Average reported penetration rate: COP1238 1.2m/min, COP 1638 1.6m/min.
Improvement by 33%.
Current draw (1000 V system):
COP 1238 : appr 32,5A (full drilling) => 44,5 kW el power.
COP 1638 : appr. 33Amp (full drilling) =>45 kW el power.
No rock drill problems are reported
Shank adapter life [m], Beaconsfield Penetration rate [m/min], Beaconsfield
900 2
1,9
850 1,8
1,7
800
+15% 1,6
750 1,5 +33%
1,4
700 1,3
1,2
650
1,1
600 1
COP 1238 ME COP 1638 COP 1238 ME COP 1638
Field Test #2, Agnico Eagle Mine , Canada

Rig: Used Boomer 282 , equipped with 1 COP1238ME (left boom) and 1 COP1638 (right
boom), serial no AVO 95A113 with Feed BMH 1314 and compressor LE8UV. Power pack
DCS-12-45-2.
Drill steel used: Secoroc T38-H35-SR35 , 14 feet long with semi-ballistic button bits, dia 48
mm and reaming holes dia 102mm. Regrinding is made every 20 meters. Bit life is 800-
1000 feet
Start up was 2004-03-04 , and per 2004-05-06 the COP 1638 had run 202 imp hrs .
COP 1638 has an average penetration rate which is appr. 8-10% higher than COP 1238
ME. All reaming holes were drilled with COP 1638. Average penetration rate for COP 1638
is 2,15 m/min.
Average shank adapter service life was 21% better with COP 1638 than with COP1238ME
(from 2075 to 2520 m)
Current draw @ 575 V, 60 Hz
COP 1238 : 46Amp (collaring) and 51Amp (full drilling) => 40kW el. power
COP 1638 : 51Amp (collaring) and 55Amp (full drilling) => 43 kW el. power
No rock drill problems are reported
Shank adapter life [m], Agnico Eagle Penetration rate [m/min], Agnico Eagle
2700
2,5
2,4
2500 2,3
+21% 2,2
2300 2,1
+15%
2
2100
1,9
1900 1,8
1,7
1700 1,6
1,5
1500
COP 1238 ME COP 1638
COP 1238 ME COP 1638
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Field Test #3, Polkowice , Poland
Rig: used Boomer 281LP with serial no AVO 99A032, Feed BMH 2337L, compressor LE 55
10UV and equipped with drill system DCS-12-45-1. .
Test object: COP 1638 R38-05-AW with stainless steel front head, replacing COP 1238ME.
Drill steel: Boart R38-H35-R32 , 10 feet , semiballistic button bit, diameter 51 and 64 mm .
Between 2004-04-01 and 2004-08 200 impact hrs have been drilled @ an average penetration
rate of 4.3 m/min with COP 1638.
One face is drilled 10 min faster (from 40 min to 30 min) compared to COP1238ME, which
means appr. 25% faster average peneration rate.
Average shank adapter average service life is 2750m with COP 1638, which is 34% higher
than COP 1238ME (2050 m)
No rock drill problems are reported.
Shank adapter life [m], Polkowice Penetration rate [m/min], Plokowice

4,6
2900
4,4
2700
+34% 4,2 +25%
2500
4
2300
3,8
2100 3,6
1900 3,4
1700 3,2
1500 3
COP 1238 ME COP 1638 COP 1238 ME COP 1638
COP 1638 P/N

COP 1638 has now following P/N (GAC 10 B, PGC 108, Rate group K6)
8311 1249 53 COP 1638-T38E-07

8311 1249 54 COP 1638-R38-05
8311 1249 55 COP 1638-T38-05
8311 1249 56 COP 1638-T38-07
8311 1249 57 COP 1638-AW-R38-05
8311 1249 58 COP 1638-AW-T38-05
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COP 1638 Pricing
IP price (2004-08, kSEK)

600
500
400
300 IP price (kSEK)
200
100
0
COP 1238 ME COP 1638 COP 1838 ME
COP 1638, Market Introduction on rigs

COP 1638 will be the main rock drill alternative on
following rigs, with start Q4 2004:
Boomer 104
Boomer 281 / Boomer 282
Boomer S1L
Boomer M2C / Boomer M2D
Boomer L2D
Boomer 195
Boomer 352 / Boomer 353
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Questions and answers I
How much is common between COP 1838 ME and
COP 1638?
Although COP 1638 might look like a COP 1838 ME, the
interior parts are new in order to give best performance
at 16 kW impact power, and all the well known
properties of COP 1838 ME are provided in COP 1638.
Which are the main benefits for a customer?
Compared to a COP 1238ME or a similar rock drill, the
COP 1638 provides a better drill steel and spare parts
economy.
When will COP 1638 be introduced on the market?
Release will take place in MineExpo in Las Vegas in
September 2004. It will be the main rock drill alternative
on DCS Boomers from Q3 2004.
Questions and answers II

Could old rigs be repowered by COP 1638?
So called repowering is one main target with COP 1638,
replacing old COP 1238 MEs but also competitors drills.
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Suitable rigs/recommendations replacing COP 1238 with COP 1638
BOOMER REMARK / RECOMMENDATION MANUF. VOLUME

195 -All versions Compressor with 24 l/s or 25-30 in operation
better is recommended (Japan)
281 -BMH 2000 recommended >160 (not incl. RB 281)
-DCS 12-45 kW required Not all rigs fulfil the
-Water pump CR4 or better recommended recommendations (~25%
-Compressor with 8 l/s or better is or ~40 units have)
recommended, LE 55 for instance
282 -BMH 2000 is recommended >300 (not incl RB 282)

-DCS 12-45 kW is required Not all rigs fulfil the
-Water pump CR4 or better is recommendations
recommended (~25% or 75 units have)
-Compressor with 15 l/s or better is
recommended, for instance LE 75
322 -All versions ~30
352/353 -All versions with DCS 12 261 (B352) / 138 (B353)

(Compressor with 15l/s (352) / 24l/s (353) or
better is recommmended, for instance LE 75 )
COP 1638 P/N

For URE (Underground), COP 1638 has now following P/N
8311 1249 53 COP 1638 T38E 07

8311 1249 54 COP 1638 R38 05
8311 1249 55 COP 1638-T38-05
8311 1249 56 COP 1638-T38-07
8311 1249 57 COP 1638 R38-05 AW
8311 1249 58 COP 1638 T38-05 AW
8311 1249 61 COP 1638 R32E-07
8311 1249 62 COP 1638 R32-05
AW-version (Aggressive Water) is an alternative when the
flushing water causes excessive corrosion. See the following
slides
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COP 1638
-Repowering
Andreas Nordbrandt / RD, 2004-08-17
Repowering instruction COP 1638

This Repowering instruction, includes:
•Why COP 1638 repowering?
•Targeted repowering rigs (AC)
•COP 1638 P/N available
•Pricing
•Installation of damper oil supply kit
•Hose connections
•Tightening torques
•Setting instructions
•COP 1638 Functional description
•COP 1638 Dimension sketch
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What do we mean by Repowering?
4 Change of Rock Drill on customers rig, no matter origin

manufacturer
4 Change the Rock Drill on an Atlas Copco rig
All in order to improve the performance of the rig!!
Today Tomorrow?
Why Repowering at all?

From the Customer´s point of view
4 Change of drilling conditions (hole diameter, work site etc)
4 Having low penetration rate
4 Increased (or average high) drill steel and service costs
4 Facing reduced MTBF (Mean Time Between Failure)
From the SC´s point of view

4 High Gross Profit on the product (sale of separate Rock
Drill)
4 Increased turn over
4 Increased sales of spare parts
4 (Better?) contact with the customer for future sales
4 Other opportunities such as drill steel and spare parts
contracts
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COP 1638 is suitable to replace COP 1238 ME.
- WHY so?
- Developed from COP 1838 ME and has therefore ”COP 1800 technique”
technique”.
- Drills faster than COP 1238ME and provides better drill tool life
life
- In about 4 hrs, the COP 1638 can be run
COP 1638 is suitable to replace COP 1238 ME.

- WHY so?
COP 1638 can be used on 45 kW power pack, which is standard
with COP 1238 ME Underground
”COP 1800 technique”, giving following benefits vs COP 1238
− Double damper => longer drill tools life
– Pressurized mating surfaces => longer service life on parts
– Aggressive water (”stainless steel”) front head optional
− Minimized risk of water inside the drill
− Longer service life on drill housing
− Longer service life on front guide
There is a big repowering potential with high profitability

– Replacing a COP 1238 ME on an Atlas Copco rig only takes 4h,
only the damper supply circuit has to be added. Such kits are
available
– Replace HL 500/510 on Tamrock Face drilling rigs
From case to case, AC must help the customer to evaluate the

benefits and estimate the pay-off time
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BOOMER REMARK / RECOMMENDATION MANUF. VOLUME

195 -All versions Compressor with 24 l/s or 25-30 in operation
better is recommended (Japan)
281 -BMH 2000 recommended >160 (not incl. RB 281)
-DCS 12-45 kW required Not all rigs fulfil the
-Water pump CR4 or better recommended recommendations (~25%
-Compressor with 8 l/s or better is or ~40 units have)
282 -BMH 2000 is recommended >300 (not incl RB 282)

-DCS 12-45 kW is required Not all rigs fulfil the
-Water pump CR4 or better is recommendations
recommended (~25% or 75 units have)
recommended, for instance LE 75
322 -All versions ~30
352/353 -All versions with DCS 12 261 (B352) / 138 (B353)

(Compressor with 15l/s (352) / 24l/s (353) or
better is recommmended, for instance LE 75 )
Flow requirements for COP 1638
Impact pressure available, recommended [bar] 210

(at the pump)
Impact flow required [l/min] 75

Rotation flow recommendation [l/min] 75
Rotation pressure available min [bar] 80
Damper flow available [l/min] 8-10
Damper supply pressure, min [bar] 130
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Assembly instruction
Install the damper supply kit P/N 9106 1826 20. Follow the
hydraulic drawing 9106 1826 23 enclosed. Note, it is a general
drawing
Connect the constant flow regulator, 3217 9193 01, close to the
main pump.
Connect the dampening gauge, at the operator.
Connect all hoses according to the hydraulic drawing.
Adjust the damper, same procedure as COP 1838, accumulator
and regulator according to the enclosed instructions.
Installation of damper supply kit - Preparation
Use the hydraulic kit 9106 1826 20, suitable for replacement of COP 1238 on
Boomer 281 or 282, drilling system DCS 12 – 45 kW.
Kit P/N 9106 1826 20, included parts:
P/N Part Qty.

9106 1826 23 DRAWING 1
3217 9193 01 REGULATOR 1
3177 3032 00 PRESSURE GAUG 1
3177 3070 00 NIPPLE 1
9106 1300 03 ATTACHMENT 1
0147 1247 03 SCREW, HEX HE 2
0301 2321 00 PLAIN WASHER 2
0291 1128 15 LOCK NUT 2
3176 6126 00 PLATE 1
9106 1826 21 HOSE SET 1
9106 1826 22 NIPPLE SET 1
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Principal schematic, damper oil supply
Start to assembly the constant-flow valve, 3217 9193 01, find a suitable place close
to the pump or the operator.
Regulator
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Assembly the damper pressure gauge, 3177 3032 00, find a suitable place close to
the operator.
Assembly the COP 1638 on the existing COP 1238 cradle, ensure that the bolts are
correctly righted and correct in length.
Note, rear right bolt is longer than standard for COP 1238.
Use bolt 0147 1483 03, M6S 16x70 – 8,8 Fzb.
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COP 1638 hose connections
Assembly the extra hoses for the dampening function, note that the hose set, 9106 1826 21,
may have to be complemented with other hoses due to different feed lengths.
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COP 1638 tightening torques
21
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22
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Important !!
23
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Important !
24
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COP 1638 - Recommended initial settings
25
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COP 1638 – Printed matters
Following printed matters can be found in the PMI-database
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Feature - Atlas Copco double dampening system
Benefits
- Provides good bit-rock contact which gives high penetration
rate
- Gentle to the drill steel and rock drill, absorbs harmful recoil
energy and tightens drill steel thread joints
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Feature – Pressurized mating surfaces between the parts
Benefit – There is a 2-3 bar air pressure inside the drill,

which prevents dirt and moist from entering. This results in
longer service life of the parts and more trouble free
operation.
COP 1132 P/N

For URE (Underground), COP 1132 has now following P/N
8311 1280 00 COP 1132 R32-02 Male L=410mm

8311 1280 01 COP 1132 R32E-02 Male L=500mm
8311 1280 02 COP 1132 R28-02 Male L=410mm
8311 1280 03 COP 1132 SR28-02 Male L=410mm
8311 1280 04 COP 1132 SR28E-02 Male L=500mm
8311 1280 05 COP 1132 R32F-02 Female L=280mm
8311 1280 06 COP 1132 R32E-06 Male L=500
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COP 1132
-Repowering
Peter Almer 2006-09-01
COP 1132 is suitable to replace COP 1032 HD.

- WHY so?
COP 1132 can be used on 45 kW power pack.
”COP 1132 technique”, giving following benefits vs COP 1032

− Double damper => longer drill tools life
– Pressurized mating surfaces => longer service life on parts
– Lower weight
– Higher power
– Higher frequency. Better penetration, especially in soft to medium hard rock.
There is a big repowering potential with high profitability

– Replacing a COP 1032 on an Atlas Copco rig only takes 6 h. only the
damper supply circuit has to be added. Such kits are available
– Replace Hydrastar 200B on Tamrock Face drilling rigs.
From case to case, AC must help the customer to evaluate the benefits and
estimate the pay-off time
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REMARK / RECOMMENDATION
BOOMER -BMH 2000 recommended

-DCS 12-45 kW required
-Water pump CR4 or better recommended
BOLTEC All types
SIMBA H157
Flow requirements for COP 1132
•Impact pressure available, recommended [bar] 200
•Note Max impact pressure Female shank. [bar] 180
•Impact flow required [l/min] 65

•Rotation flow recommendation [l/min] 35-40
•Rotation pressure available min [bar] 140
•Damper flow available [l/min] 6
•Damper supply pressure, Setting [bar] 18-20
•Damper supply pressure drilling [bar] ~80
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Assembly instruction
Install the damper supply kit P/N 9106 1826 20. Follow the
hydraulic drawing 9106 1826 20 enclosed. Note, it is a general
drawing
Connect the constant flow regulator, 3217 9193 06, close to the
main pump.
Connect the dampening gauge, at the operators panel.
Connect all hoses according to the hydraulic drawing.
Adjust the damper, same procedure as COP 1838, accumulator
and regulator according to the enclosed instructions. Note that
the damper pressure should be 20 bar for COP 1132.
Installation of damper supply kit - Preparation
Use the hydraulic kit 9106 1826 20, suitable for replacement of COP 1022
The hydraulic kit is for repowering COP 1638 and COP 1132.
Kit P/N 9106 1826 20, included parts:
P/N Part Qty.

9106 1826 23 DRAWING 1
3217 9193 06 REGULATOR 1
3177 3032 00 PRESSURE GAUG 1
9106 1300 03 ATTACHMENT 1
0147 1247 03 SCREW, HEX HE 2
0301 2321 00 PLAIN WASHER 2
0291 1128 15 LOCK NUT 2
3176 6126 00 PLATE 1
9106 1826 21 HOSE SET 1
9106 1826 22 NIPPLE SET 1
3115 0212 00 STRAP 20
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Principal schematic, damper oil supply
COP 1132
Start to assembly the constant-flow valve, 3217 9193 06, find a suitable place close
to the hydraulic pump.
Regulator
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COP 1132
Assembly the damper pressure gauge, 3177 3032 00, find a suitable place close to
the operator.
COP 1132 Adapter plate 3128 3174 46
If you use male shank
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COP 1132 Adapter plate / Male shank
COP 1132 Adapter plate / Male shank
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COP 1132 Adapter plate 3128 3176 94
If you use Female
COP 1132 Adapter plate / Female shank
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COP 1132 Adapter plate / Female
COP 1132 Feed compare 1132 / 1032
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COP 1132 hose connections
COP 1132
Assembly the extra hoses for the dampening function, note that the hose set, 9106 1826 21,
may have to be complemented with other hoses due to different feed lengths.
Picture from a Boltec MC
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12
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COP 1132 Accumulators
COP 1132 Accumulators
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Setting of ECL lubricating system
COP 1132 Lubricant pump old / new
New model: Part nr 3217 8667 52

20-25 pulses/min. (0.07 ml / Puls)
Old model: 3217 8667 50

35-40 pulses/min. (0.04 ml / Puls)
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COP 1132 Damper pressure setting
Hydraulic oils and lubricants
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COP 1132 Important !
COP 1132 Dimensions male shank
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COP 1132 Dimensions female shank
COP 1132 – Printed matters

Following printed matters can be found in the PMI-database
Note that the PMI-database are updated freqvently.
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18
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Modul 1
Shock wave theory
M1. Purpose
4 Tension wave recoil

4 Compression wave recoil
4 Frequency
4 Impact energy
4 Power
4 Impact velocity
4 Stroke length
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M1. Introduction
M1. Basic
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M1. Shock waves
1 2 3 4 5 6 7
c
v c
c Δ
2L
M1. Recoil – stuck end
”Stuck” end
Compression wave recoil
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M1. Recoil – free end
Free end
Tension wave recoil
M1. Recoil – optimum
Optimum
No recoil if
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M1. Relative Drilling Force– Frel
Compressio n wave recoil Tension wave recoil
M1. Shock wave form
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M1. Principles for a perc. rock drill stroke length
The same impact power can be achieved with…….
OR
M1. Rock drill stroke length
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M1. Example
Customer
-I changed from Cop 1838 ME to Cop 1838 HF to get more
penetration rate out of this soft rock. I used to set the ME on 180
bar and that worked perfect. When I set the HF on 180 bar it
works much worse. What’s wrong with this rock drill?
M1. Cop 1838 ME/HF
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M1. Summary
4 Tension wave recoil

4 Compression wave recoil
4 Frequency
4 Impact energy
4 Power
4 Impact velocity
4 Stroke length
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Percussion data
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COP 1838 ME/HF
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COP 1838 HE / 1838 HEX / 1840 HE / 1840 HEX
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COP 1838 HE / 1838 HEX / 1840 HE / 1840 HEX
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COP 1238ME
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COP 2550 / 2550 EX
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Exercise
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Principle for topphammer rockdrills
Flushing
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Rotation
Impact (Percussion)
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Feed
Damper
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Ecl Lubrication
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Chapter 1.3
Rock Mechanics
Bench drilling - Tunnel driving - Roof bolting - Reaming - Production drilling
Gunnar Wijk / Maria Pettersson

Modified by Andreas Nordbrandt / 2003-08-13
1.3 Rock mechanics – Percussive drilling
Rock Parameters
• Compressive strength σc 60 - 400 MPa
• Stamp strength σST 600 - 4000 MPa
• Indexation parameter 2RST 5 - 10 mm
• Stamp crater volume VST mm3
• Rock brittleness index κ 1-3
• Cerchar Abrasivity Index CAI 1-6
• Density ρ 2000 - 5000 kg/m3
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1.3 Rock mechanics – Compressive strength
Compressive strength test
Fc
F
σ = c
c
πd 2
d 4
d = 20 mm standard
2d
ROCK TYPICAL σc
Sandstone 100 MPa
Limestone 150 MPa
Fc Granite 250 MPa
1.3 Rock mechanics – Stamp load test

Stamp load test
Fb 2b Bohus granit, b=5 mm
150
Rock
sample
Fb [kN]
Concrete Fb< FST xb
0
1.12 1.00 0.79 1.05
1.02 0.87 0.85
Fb= FST xST
Bohus granit, b=2 mm
standard
40
ST [k
VST
FSTF[kN]
20
0
0 100 200
VST [mm3]
4
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1.3 Rock mechanics – Stamp load test
Results from the Stamp Load test
F
σ = ST
• Force : ST πb2 ⇒ Need of Contact (Impact) force
• Penetration : xST ⇒ when is maximal force needed

• Volume of crater : VST ⇒ penetration rate
• Width of crater : 2RST ⇒ indexation between blows
1.3 Rock mechanics – Brittleness and CAI

Rock Brittleness
FST VST
κ= 1<κ < 3
800 b 4 x ST σ c
VST
κ∝ Brittle rock: large volume and less penetration => large κ
x ST
Cerchar Abrasivity Index, CAI
Edge of steel is scrathed on a rock surface, wear ⇒ CAI 1 < CAI < 6
Sandstone CAI ≈ 4-5

Limestone CAI ≈ 1
Granite CAI ≈ 5
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1.3 Rock mechanics – Calculations from s. l. t.
Calculations with help from data from the Stamp Load Test
Piston Penetration rate NVST

weight m B≈ f
πD 2
Impact velocity v 4
Impact rate f Minimum rpm 2R
n ≈ ST f
πD
Stamp load F x
Impact energy mv 2 E ST = ST ST
E= energy 2
2 mv 2
Impact power P = Ef E= ≥ NE ST
2
Impact energy P = Ef
Drill bit Impact power

diameter D
Number of buttons N
Wear flat radius a
Bohus granite example
Rock
FST=30 kN, xST=0.8 mm, vST=60 mm3
Stamp force FST
Penetration xST D=76 mm, N=12, f=50Hz ⇒
Volume of crater VST
Radius of crater RST B=48 cm/min, n=75 rpm, P=7.5 kW
7
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Chapter 2.1
Percussion
mechanism/circuit
Bench drilling - Tunnel driving Roof bolting - Reaming - Production drilling
Gunnar Wijk
2.1 The percussion mechanism – COP 1838

Strength with the principle:
¾ Efficiency
¾ ”Good” piston shape
Weakness with the principle:

¾ Limited in frequency
¾ Complicated valve
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2.1 The percussion mechanism – COP 1532
Strength with the
principle:
¾ Short design
¾ Less risk of
cavitation
¾ ”Good” piston
shape
¾ High power
potential
Weakness with the principle:

¾ Efficiency
¾ Large channels
¾ Sensitive to impact
position
2.1 The percussion mechanism

When the piston has moved through roughly half the stroke length (or slightly more),
depending on whether the return drive area is the same size or smaller than the
power-stroke drive area, the front edge of the return drive-area land uncovers a duct
in the cylinder. It is through this duct that working pressure is able to reach one of
the spool-switching drive areas, i.e. the one that acts against the holding area that is
keeping the spool in its end position just at that moment.
Just before this, the front edge of the power-stroke drive-area land has uncovered
another duct in the cylinder, through which the oil behind the other switching drive
area of the spool is able to drain out via the space between the lands on the impact
piston. The switching drive areas of the spoof are normally 2 - 3 times larger than
their holding areas. This means that the lightweight spool will move rapidly over to
its other end position. A typical spool velocity is 2 m/s and a typical spool stroke
length is 4 mm. This means that it takes the spool about 1 ms to reach the centre
position.
During this time, the impact piston is typically moving at a velocity of 7 m/s. In other
words the impact piston will have travelled at least 7 mm after its position has
initiated the so-called "roof switching" sequence of the valve spool. When the spool
passes its centre position, the working pressure is re-direct from the return drive
area of the impact piston to the power-stroke drive area. When this happens, the
working pressure on the spool-switching drive area disappears. At the same time,
however, the working pressure changes to the other spool holding area which is
what drives the spool all the way to the opposite end position.
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Since the working pressure is now acting on the power-stroke drive area. the backward
movement of the impact piston is braked, and the piston turns to begin its power stroke at the
correct stroke-length distance from the drill steel. The piston is now accelerated toward the
drill steel.
Just before the piston strikes, the rear edge of the front piston land uncovers a duct in the
cylinder, through which the oil behind the first switching drive area of the spool is able to
drain out. Immediately after this. the rear edge of the rear piston land uncovers another duct
in the cylinder, through which working pressure is able to reach the drive area of the spool to
initiate the so called "shank switching" sequence.
In a perfectly tuned machine, the spool passes the centre position just as the piston strikes
the drill steel. Since the spool needs about the same time to reach the centre position in the
shank switching sequence as in the roof switching sequence, i.e. about 1 ms, and the piston
velocity is now about 10 m/s the duct through which the shank switching sequence is initiated
should ideally be uncovered when the impact piston has about 10 mm to go before striking
the drill steel.
If the spool passes the centre position after the impact piston has struck the shank adapter,
there is a danger that the piston will bounce away from the shank adapter without any
working pressure acting on its return drive area. The machine is then said to be switched too
late. When a machine is switched too late, there is a risk of cavitation on the return drive area
and neighbouring surfaces in the lower cylinder chamber.

If the spool passes the centre position before the impact piston strikes the shank adapter,
working pressure will act on the return drive area during the final stage of the power stroke,
which means that the piston will be braked, thus losing part of the potential impact force.
When this happens, part of the potential penetration rate will obviously be lost as well .
When it comes to the risk of cavitation on the return drive area of the impact piston, however,
this is in principle eliminated in a machine that is switched too early.
Nearly all competitor machines keep a permanent working pressure on the return
drive area of the piston, partly to enable simpler ducting in the cylinder, but perhaps also
because they are afraid of the risk of cavitation. The disadvantage of keeping a permanent
working pressure behind the return drive area is that the power-stroke drive area must be
made larger compared with a machine that has alternating working pressure on the return
drive area, since the permanent pressure on the return drive area has to be overcome during
the entire power stroke of the piston.
This means that oil has to be "run-pumped” from the return drive area to the power-stroke
drive area during the power stroke. This causes internal flow losses in the machine, which
do not exist in machines that have alternating pressure on the return drive area. It follows
therefore, that a machine with permanent working pressure on the return drive area has, in
principle, lower efficiency compared with a machine with alternating pressure on the return
drive area.
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The description above concerns a hydraulic percussive rock drill, but the principle is the
same for a pneumatic machine, although there is no cavitaion in the latter. Modern
pneumatic machines, in particular In-The-Hole hammers only have one moving part in the
percussion mechanism and are hence called ”valve-less”. This is not an adequate name
since there are grooves and ducts in the cylinder and/or the striker, so that the striker also is
the valve spool.
A requirement for such machines is that the working medium is compressible so that the
energy can be used in an (ideally) adiabatic expansion-and-compression cycle.
Hydraulic oil is also compressible but the stiffness is so great that the ”valve-less” principle is
not very good for hydraulic machines Nevertheless several such machines have been
developed mainly in the USA, which is a young continent with relatively soft rock.
Characteristic for "valveless hydraulic percussion mechanisms is low impact energy and high
impact frequency, typically half the impact energy and twice the impact frequency of a
machine with a valve, the same piston mass and the same impact power. The generally soft
rock in the USA probably duped machine manufacturers into investing in a combination of
low impact energy and high impact frequency. When these machines subsequently
encountered hard and/or abrasive rock, the regrinding intervals for the drill bits became
unacceptably short. Whatever the real reasons, most of these "valve less" hydraulic rock
drills were in the market for a short time only.
2.1 The percussion mechanism - accumulator
In the ”centre” => charge to

half working pressure
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2.1 The percussion mechanism - accumulators

Efficiency and accumulators
Hydraulic rock drills are driven by hydraulic pumps. The “simplest” pumps deliver a constant
flow of oil. The rock drill consumes a certain average flow, which increases with the selected
working pressure. The constant-flow pump must therefore be chosen so that its flow will be
sufficient for the highest permissible working pressure of the rock drill. If the machine has to
work at a lower working pressure due to the rock conditions, then the excess flow from the
pump is drained back to the tank via a pressure relief valve.
The leakage through a hydraulic rock drill is proportional to the tolerances (between the
cylinder and impact piston, and in the valve) to the third power. This means that if one rock
drill has an all-round minimum clearance of 0.05 mm, while another machine has an all-round
maximum clearance of 0.10 mm, then leakage through the latter machine will be greater by a
factor of (0.10/0.05)3 = 8. Within the framework for the production tolerances therefore, the
accepted maximum leakage flow through the machine is typically half the displaced (= useful)
flow, which is given by the impact frequency, stroke length and the power-stroke drive area,
the latter reduced by the return drive area in a machine that maintains a permanent working
pressure on the return drive area.
It must be accepted therefore, that different machines of the same type will show rather large
differences in oil consumption, which is one more reason why the constant flow pump must
be combined with a pressure relief valve to the tank. This means that the system's primary
power consumption is independent of the oil consumption of the particular machine, and is
determined by the selected working pressure only.
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With a so-called "pressure compensated" pump, the pump is regulated continuous, to deliver
the oil flow needed to maintain the working pressure of the system, which is selected by
means of a regulating device on the pump. The primary power consumption is therefore
reduced through both a reduced working pressure and smaller tolerances in the machine, i.e.
system efficiency increases considerably compared with a constant-flow pump used in
combination with a pressure relief valve, even when the (small) internal oil flow in the
pressure compensated pump (which is needed for the function of the regulating device) is
taken into consideration.
The displaced (= useful) oil flow through the machine is consumed with large variations in
time. Immediately after the impact against the drill steel, and also when the piston is at the
turning point, the piston velocity is very low, i.e. the piston movement draws no oil. The
pump must be able to deliver an almost constant oil flow if it is to "feel good", and if the hoses
between the pump and the rock drill are not to vibrate excessively. When the piston
movement stops drawing oil momentarily, the entire pump delivery flows into the high
pressure accumulator and presses against the flexible diaphragm, so that the gas pressure
on the other side of the diaphragm rises.
When the piston moves with the greatest velocity, i.e. just before impact, there is a
momentarily displaced flow, i.e. the product of piston velocity and the effective power-stroke
drive area (= the actual power-stroke drive area reduce by the return drive area in a machine
with a permanent working pressure on the return drive area) that is typically five times
greater than the average flow.

During these periods of peak demand, oil is taken from the accumulator into the piston
movement, which means that the gas pressure on the other side of the diaphragm
decreases.
The function of the high pressure accumulator is therefore to even-out the rock drill's demand
for oil, and thereby relieve the pump from large momentary fluctuations in demand. A rock
drill with a piston mass of 5 kg will typically have a power-stroke drive area A = 4 cm2, stroke
length S = 4 cm, impact velocity v = 10 m/s and impact frequency 50 Hz. The useful flow of
the machine is therefore fAS 48 dm3/min, with the momentarily greatest displaced flow being
vA 240 dm3/min. The effectiveness of the pressure stabilizing function of the hiqh pressure
accumulator increases with the volume of gas behind the diaphragm, but a certain variation
at the working pressure inlet to the percussion mechanism is unavoidable. An estimate of the
pressure variation can be obtained if we assume that the entire oil consumption of the piston
per stroke, i.e. the volume AS, is taken from the accumulator, without the pump having to fill
the void. In the above example, we get AS = 16 cm3, which should be compared with the
accumulator's gas volume in a working situation.
When the machine is not working, the diaphragm is pressed against the bottom of the
accumulator chamber and the gas pressure is given by the charging pressure, which should
be about half the working pressure of the percussion mechanism.
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In the example above, a typical gas volume is then U = 160 cm3. At the working pressure, to
which the gas is in principle compressed isothermically, the gas volume is therefore about U/2 =
80 cm3. This volume is considerably greater than the theoretically greatest volume AS = 16 cm3
which can be drawn from the accumulator momentarily. This means that the variation in gas
pressure in the accumulator is considerably smaller than the average working pressure. In
practice, the greatest volume that is drawn from the accumulator is typically less than half of the
theoretically greatest volume, i.e. AS/2 < 8 cm3 so that a representative value of the difference
between maximum and minimum pressures, i.e. the pressure variation, at the working pressure
inlet to the percussion mechanism is less than AS/U= 10% of the average working pressure.
It should be noted that from the moment roof switching takes place to the moment at which the
piston reaches its turning point, the power-stroke drive area of the impact piston actually
"pumps" oil into the high pressure accumulator together with the pump itself. In other words,
during this phase of the impact cycle, the displaced flow of the impact piston is in fact “negative”.
The velocity variation in the piston movement means in principle that the return flow from the
rock drill varies with time, in the same way as on the high pressure side. To even-out the flow in
the return hose and there thereby eliminate hose vibration and pressure peaks which could wear
out the return filter (if fitted), a return accumulator is needed. The return accumulator should be
charged to about half the return pressure that is needed to "pump" the oil through the return
hose, the return fitter, and back to the tank.
It can be said therefore. that the rock drill accumulators are needed for the system to "feel
good" before and after the percussion mechanism. However, the accumulators are also
needed for the rock drill itself to function well and not be subjected to damage.
It is impossible to drill with a ruptured high-pressure accumulator diaphragm, owing

to the hose pulsations and rig vibrations that would occur. In the case of a ruptured
diaphragm - in the low pressure accumulator, however, it is sometimes possible to drill
without visible problems or even latent damage. This has led many engineers to regard the
low pressure accumulator as unnecessary - at least engineers who have been fortunate
those enough not to have had to repair a rig suffering from problems caused by the absence
of a low pressure accumulator.
The situation arises partly due to difficulties experienced in charging the return accumulator
to the correct pressure, which is normally 3 - 5 bar. The return accumulator is often
overcharged (because it surely needs gas too), and if everything continues to go well,
worksite personnel soon begin charging the low pressure accumulator to the same pressure
as the high pressure accumulator.
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The accumulators should be charged with nitrogen to about half their working pressure so
that the diaphragm is kept roughly in the middle of the accumulator chamber during drilling.
Provided that the return accumulator is always correctly charged, i.e. not charged at too high
a pressure, the machine can have a common return- and drainage line.
However, if the accumulator is charged at too high a pressure, most of its pressure-stabilizing
function will be lost, resulting in uncontrolled pressure peaks on the return side of the circuit.
This will interfere with the spool function and cause the machine to operate unevenly. By
fitting a separate drainage line from the percussion mechanism, machine operation will be
much less affected by a ruptured diaphragm in the
return accumulator.
It is obviously very important that the return accumulator is not charged to too great a pressure,
or the diaphragm will almost always be pressed against the bottom of the accumulator chamber,
leaving it only when large pressure peaks occur on the return side. Under such conditions, the
function of the return accumulator would be lost and the diaphragm would wear out quite
rapidly, ultimately resulting in rupture.

Presumably, the ill-founded idea is to have a ready-charged spare accumulator handy in
case the diaphragm in the real high pressure accumulator should rupture (an expected
service life of a diaphragm is IN AN IDEAL OPERATING SITUATION 400 Impact hrs ). In
terms of the rock drill, the risk incurred by a non-functioning low pressure accumulator is that
expensive components in the rock drill will gradually become victims of cavitation damage,
e.g. the cylinder bore and valve bore.
In terms of training therefore, it is almost more important to emphasize the low pressure
accumulator rather than the high pressure accumulator.
In principle, pneumatic rock drifts have the same type of accumulator functions as hydraulic
rock drills, but obviously no diaphragm is needed in the accumulator, since the
compressibility of the compressed air is exploited. It is, however, equally important to design
the machine with a generously proportioned compressed-air chamber between the
compressed air inlet and the valve spool, in order to obtain an even air consumption from the
compressor, i.e. no hose vibrations and high efficiency in the percussion mechanism just in
the same way as a generous high-pressure accumulator is essential for hydraulic rock drills.
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2.1 Oil consumption range
Oil consumption range
The flow of hydraulic oil to 411
COP 1238 ME during final testing
in the production department in
1988. The vertical lines indicate the
theoretical maximum and minimum
limits on the basis of the drawing
tolerances.
The test working pressure is 200

bar, at which the impact frequency
is f = 50 Hz. The upper piston-drive
area is A2 = 3.8 cm². At stroke
position Il the stroke length is S 44
mm, which means that the
piston-displaced flow is fSA2 - 50
dm3/min.
The spool-displaced flow is about 2

dm3/min. The minimum leakage is
therefore 56 - 52 - 4 dm3/min and
the maximum leakage 76 - 52 = 24
dm3/min.
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106 of 326
Chapter 2.2
Damper mechanism/circuit
Gunnar Wijk / Maria Pettersson /

2.2 The damper mechanism - why?
RECOIL DAMPENING.
Long drill steel life

High penetration rate
Most of the Atlas Copco rock drills are equipped with the so-called double damper system.
A built-in recoil dampener:
•Absorbs shock reflexes from the drill steel

•Reduces vibrations of the drill rods
•Reduces stress on rock drill feed and boom system.
The damper also ensures that good contact is maintained between the drill bit and the rock. This is of
great significance to penetration rate and drill steel economy.
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2.2 The damper mechanism – more in detail
Reflex damper
When the impact piston strikes the shank adapter, there is a momentary shock-wave movement
of the shank adapter, in the order of 1 mm. -With a high feed force behind the machine, the rock
drill is pressed against the drill steel via the rear faces of the shank adapter splines at the
moment of impact. But this contact is broken momentarily upon impact. The feed force will
then press the rock -drill towards the shank adapter to resume contact.
At the same time, however, penetration of the drill bit into the rock causes reflected
compressional shock waves in the drill steel to reach the shank adapter, which cause the shank
adapter to strike the machine via the rear faces of the splines with impact forces that,
theoretically at least, can be nearly as large as those imparted to the drill steel by the impact
piston. To protect the rock drill from this kind of impact, the modern rock drill is equipped with a
reflex damper to transmit the feed force from the rock drill to the drill steel.
Without a reflex damper, the function of the rock drill could be described as follows. When the
working pressure drives the impact piston backwards, it drives the rock-drill housing forwards,
and vice versa. This means that a rock drill without a reflex damper can be regarded as two
pistons which strike the drill steel alternately, i.e. firstly the impact piston with a typical mass m =
5 kg and typical stroke length S = 4 cm, which strikes with a typical impact velocity of v = 10
m/s; and secondly the rock-drill housing with a typical mass of M = 150 kg and typical stroke
length mS/A= 1.3 mm, which strikes with a typical impact velocity of mv/M - 0.3 m/s.
Without a reflex damper, i.e. with only a shock-transmitting axial bearing between the rock drill
and e drill steel, all that really happens is that the drill steel is shock-fed against the bottom of
the drill hole.
2.2 The damper mechanism – more in detail

In this context, the situation could be compared with that of a motor-car. The reflex damper in
a rock drill is the equivalent of the suspension and shock absorbers of a car. A rock drill
without a reflex damper is like a car in which the shock absorbers have been replaced with
rigid steel rods. If this were the case, it would be of no help at all to keep the suspension. As
long as the car is driven on an absolutely flat. asphalted road without bumps, pot-holes or any
other irregularities, things would go reasonably well. But sooner or later the car would be
subjected to devastating damage, initiated by shocks and vibrations from the wheels contact
with the ground, in spite of the fact that pneumatic tyres have a certain shock-damping
function.
The reflex damper serves not only to protect the rock drill from the impacts from the shank
adapter (described above), but also gives improved feeding of the drill steel against the
bottom of the hole. In other words, the shock-feeding characteristic is replaced with more
continuous feeding. This also makes it easier for the rotation motor to keep the joint in the
drill string tight, since they have a tendency to loosen as the impact energy from the piston is
transmitted through the joints. Different types of reflex damper are described below in more
detail.
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2.2 The hydraulic damper mechanism - principle
4Reflected shock
waves are absorbed
+ drill steel
+ rock drill
feed force 4Drilling
position of
shank adapter
+ controlled drilling force
floating
position + stable rotation torque
2.2 Different hydraulic damper principles
4 Hydraulic damper, ”fixed” 4 Hydraulic double damper,

”floating”
COP 1032, COP 1238
4 Hydraulic damper, ”floating”

COP 1432
COP 1532
COP 1800
COP 2150
COP 2550
COP 4050
COP 1440, COP 1550
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2.2 Different hydraulic damper principles
4 Arrangement 1, Hydraulic damper, 4 Arrangement 3, Hydraulic
”fixed” double damper, ”floating”
4 Arrangement 2, Hydraulic damper,

”floating” Features
of arrangement
1, 2 and 3
Protects the rock drill
from rock recoils
2 and 3 Provides good rock-bit
contact
3 only Absorbs the energy of the
recoils
2.2 The damper mechanism, COP 1238

COP 1238 (single hydraulic damper, see figure):
Damper piston area Ad = 12 cm2
The damper is supplied with oil by the percussion pressure p=200 bar,
which means that the thrust of the damper piston is pAd = 24 kN.
The recoil force R during drilling is given by the impact piston's mass m, impact velocity v and
impact frequency f, Which means that R = mvf. If m = 5 kg, v = 10 m/s and f = 50 Hz, the
impact power would be mv2/2 = 12.5 kW, in which case the recoil force R would be R = 2.5
kN.
In horizontal drilling with a normal feed force of F = 8 kN, the
force F – R = 5.5 kN should be transmitted to the drill steel via
the damper piston. Since the ratio of this force to the damper-
piston force is 5.5/24 = 0.23, the damper piston will be in
contact with the shank adapter during only 23% of the impact
cycle time. It is during this contact time that the feed force presses the drill bit against the
rock, and therefore enables the torque generated by the rotation motor to tighten the joints in
the drill string.
The damper piston pressure p is reduced via leakage in the gaps, and thereafter through the
restrictor ' just below she front piston-seal housing, which means that the normal pressure on
the damper-piston seals is about half the percussion pressure, i.e. p/2. 'With greater
clearance between the damper piston and cylinder, greater pressure is obtained on the
damper seals. In other words, the real damper-piston seal pressure depends on the
production outfall for the gaps in front of the damper-piston seals.
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2.2 The damper mechanism, COP 1238
The flow through the damper is between 0.5 and 2.0 dm 3/min
depending on the production outfall for the gaps in front of the damper-piston seals.
The damper piston is “almost” always pressed against the rotation chuck. When large
compressional-wave reflexes come from the drill bit, the damper piston "bounces" backward -
say by 0.5 mm at the most - after which it returns to strike the shank adapter at practically the
same velocity it had when it bounced off the shank adapter, i.e. without significant energy
loss. The movements are so small that the damper piston can be housed directly in the steel
of the intermediate part, without the occurrence of any scoring tendencies worth mentioning.
2.2 The damper mechanism, COP 1440/1550

COP 1440/1550 (single hydraulic floating damper, see figure)
Same damper piston area as for COP 1238
The damper is fed with a constant flow Qd = 7 dm3/min via a constant-flow valve, which is
adjusted to give a damper pressure (measured at the rock drill) of pd = 30 bar (which is
equivalent to about 35 bar measured on the pressure gauge at the operator's station). The
damper pressure is set while the drill bit is NOT pressed against the rock, so that the damper
piston is located in the most forward position, and presses the rotation-chuck bushing against
the rotation chuck. This position is about 4 mm in front of the impact position, which is shown
in the figure, which means that the piston stroke-position controlling holes in the front damper-
piston guide are completely open. The damper pressure pd = 30 bar is what is needed to
force the damper flow Qd through the restrictor located just beneath the front piston-seal
housing.
During drilling, the damper-piston flow shares the return hose with the larger percussion-
mechanism flow. which means that the pressure drop in the hose typically goes up to approx.
5 bar. When the feed force presses the damper piston into the rock drill, the pressure rises
when the stroke-position controlling holes are shut off. The machine therefore locates itself in
the correct stroke position within an interval less than, say 0.5 mm, forward of the rear edges
of the stroke-position controlling holes. This applies to all combinations of recoil force R and
feed force F.
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Since the machine itself sets the correct damper pressure pd = (F- R)/Ad ,the damper piston
will "always" be in contact with the shank adapter, thereby transmitting the. force F - R to the
drill bit, thus enabling thread tightening to take place. Contact is only broken immediately after
the impact piston has struck the shank adapter, since this causes a shock-wave movement in
the order of 1 mm. The damper piston force needs a period of about 0.8 ms to pitch the
damper piston and rotation-chuck bushing forward, so that contact with the shank adapter is
resumed. This period of time is small compared with the impact cycle time which for f = 70
Hz corresponds to l/f = 14 ms.
The pressure an the damper-piston seals is less compared with the COP 1238, since the
damper pressure itself is less. This gives longer service life to the damper-piston seals, at
least in respect of wear caused by the pressure between the seals and the damper-piston
surface.
The damper-piston movements are greater than in the COP 1238, especially since the
damper piston and rotation-chuck bushing follow the shank adapter "immediately after blows
from the impact piston. This leads to greater wear. It has not yet been ascertained whether
the combined effect of lower seal pressure and larger damper-piston movements gives
reduced or increased seal service life, although the indications point strongly in favour of the
latter. It must also be mentioned that the larger damper-piston movements in the COP
1440/1550 require the damper piston to be borne in bronze bushings. Reflected compression
shock waves from the drill bit pitch the rotation-chuck bushing and the damper piston
backward in the same way as in the COP 1238.
These components are then turned around to strike at roughly the same velocity which they
received in the first place, i.e. without significant energy loss. This means that any shock
wave energy in the drill steel that has not been utilized for rock destruction will remain in the
drill steel, gradually being converted to heat in the friction surfaces of the drill steel, i.e. at the
threads in the joints.
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2.2 The damper mechanism, COP 700 / 900
COP 700 / 900 (floating pneumatic damper):
In terms of function-, this damper is identical to the damper in the COP 1440/1550, but
instead of using hydraulic oil and a diaphragm to connect the gas pressure in the hydraulic
machine's reflex-damper accumulator to the damper piston area Ad, the gas pressure in the
"reflex-damper accumulator" of the pneumatic machine acts directly on the damper-piston
area.
The reflex damper is permanently connected to the lubricating-air pressure (6bar) via a
pressure regulator. If the pressure in the reflex damper falls below 4 bar, the lubricating air
fills the shortfall in the damper immediately. In normal drilling work, the feed force
compresses the reflex-damper gas, so that the damper pressure is typically 10 bar. If some
of the-air leaks out of the damper during drilling (even though such leakage seems to be
extremely rare), the damper pressure will momentarily fall below 4 bar when the feed force is
released on completion of the drill hole. When and if this happens, however, the lubricating
air will immediately recharge the damper to the correct pressure.
In underground mines, the air pressure can sometimes be considerably higher than normal,
for example at the start of a shift when very few machines are working and the air flow
through the network is low. At times like this, the reflex damper in COP 700/900 would
receive an excessive charging pressure. To prevent this from happening, the lubricating air to
such machines must be taken via a pressure regulator, adjusted to 6 bar.
2.2 The damper mechanism, hydr. double damper

COP 1800/2000/4050 (hydraulic double damper, see figure):
The damper in the COP 1838 is similar to the one in the COP 1440/1550, but has an "extra
cylinder" and corresponding diameter change on the damper piston. When reflected
compressional shock waves from the drill bit pitch the rotation-chuck bushing and damper
piston backward, the pressure rises rapidly in the "extra cylinder". When this happens, the oil
volume in the "extra cylinder" is jetted out, mainly forward, around the edges of the "extra
damper piston".
This oil jetting consumes the movement energy of the rotation-chuck bushing and damper
piston. When the damper piston and rotation-chuck bushing are then pressed forward again
by the pressure on the damper piston's outer ring area, the components return to the shank
adapter at a velocity that is typically around 30% of the velocity they received from the
compressional shock-wave reflexes from the drill bit. This means that about 1 - 0.32 = 90% of
the energy in the compressional shock-wave reflexes will have left- the drill steel. to be
"cooled away" in the oil cooler on the rig.
The temperature of the return oil is typically 6 ‘C higher than the temperature of the incoming
pressure oil in the COP 1440/1550, because the efficiency is not 100%. The efficiency of the
COP 1838 is about the same. The extra "power" that has to be cooled away due to the double
damper in the COP 1838 corresponds, therefore, to a return-oil temperature that is typically
max. 8 °C higher than the temperature of the incoming pressure oil.
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2.2 The damper mechanism, hydr. double damper
When the damper piston is "pulled" out of a "extra cylinder" by pressure on the damper
piston's outer ring area, cavitation damage would occur in the "extra cylinder" if it were not
filled with oil at exactly the same rate as the piston is pulled out. This filling function is
achieved by means of a "super-fast" check valve with seat sealing to prevent cavitation.
The damage on the rear damper-piston seal, the seal is pressurized to the damper pressure.
Leakage in the rear annulus around the damper piston therefore takes place in the opposite
direction compared with the leakage in COP 1238/1440/1550. This means that the damper
flow Od is smaller in the COP 1838 than in COP 1440/1550, but the difference is marginal.
In principle, the damper in the COP 4050 is identical to the double damper in COP 1838.
2.2 The hydraulic double damper - function
4 Reference position
Constant
flow
Feed
force
Impact ”floating”
position position
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4 TheImpact - The shank adapter is

pushed towards the rock
Constant
flow
Feed
force
Impact
position

4 The damper piston and the rotation chuck bushing
are pressed towards the shank adapater, The
impact piston starts a new stroke
Constant
flow
Feed
force
Impact
position
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4 The rock drill body moves forward due to the feed

force. The ”equilibrium” is reestablished.
Constant
flow
Feed
force
Next impact
position

4 A recoil comes and forces the damper piston to the right. High inner stage
damper pressure. The recoil energy is absorbed and transferred into heat.
Constant
flow
Feed
force
Next impact
position
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4 Thedamper piston is pushed forward. The check

valve opens.
Constant
flow
Feed
force
Next impact
position
4 Thedamper piston stops at the ”equilibrium”

point. After the stroke, see slide ”no 1” again.
Constant
flow
Feed
force
Next impact
position
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2.2 The hydraulic double damper - Advantages
4The oil in the damper is an axial bearing
+ the service life of the rock drill, vibrations from 40 G
⇒4G
4Efficient contact between rock and bit
+ penetratin rate
+ good joint-thread tightening
+ reduced need of feed force (see next slide)
+ the service life of the shank adapter
+ the service life of the drill steel
+ hole straightness
4Correct stroke position

+ controlled impact velocity
4Energy from the recoils is transferred into heat
+ the service life of the shank adapter
+ the service life of the drill steel
2.2 Examples of service life
Surface shank adapter life typical rod service life

[m] rod 1 [m]
Customer 1 COP1238 2500 - 4000 2000 - 3000

COP1838 ~12000 7000 - 8000
Customer 2 COP1238 ~ 3000 x
COP1838 ~ 9000 x
Customer 3 COP1238 3500 - 4000 2000 - 3000
COP1838 > 8000 > 4000
Underground
Customer 4 COP1238 2000 - 3500 600 - 1000
COP1838 3500 - 4500 1000 - 1500
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2.2 The hydraulic double damper – Feed force
Button bit Ø51

COP1838ME II 230 bar
HL550 Super 210 bar
HL550 Super 230 bar
2,6 2,3
2,5 2,2
Kin [mm³/Joule]
2,1
P e n ra t e [ m /m in ]
2,4 2,0
2,3 1,9
2,2 1,8
2,1 1,7
2,0 1,6
1,9 1,5
1,8 1,4
1,7 1,3
1,6 1,2
4 5 6 7 8 9 10 11 12 13 14 15
4 5 6 7 8 9 10 11 12 13 14 15
Feed force [kN] Feed force [kN]
In this chart, COP1838, was run at This is a more fair comparisation as

lower Impact power than HL 550. the ”rock penetration efficiency” vs
No correct comparisation. the feed force is plotted.
2.2 The damper mechanism, soft/hard damper

The figures to the right show the results of shock-wave
measurements taken on a prototype version of the COP
1440 (which corresponds to the "soft damper” case), as well
as the results from a modification of the machine to make its
reflex damper the same as that in the COP 1238 ME, i.e. the
“hard damper” case.
The arrows in the figures indicate the primary shock waves

generated by blows from the impact piston to tide shank
adapter. The reflected primary shock waves from the drill bit
come about 1 mm later in' the figure's time scale. In the
case of the 'hard damper", the reflected primary shock waves
are often (but not always) almost pure tensile waves, in
contrast to the primary compressional shock waves that are
sent to the drill bit.
A reflected tensile shock wave indicates that the drill bit was
not in contact with the rock when the primary compressional
shock wave arrived at the drill bit. The consequence of this
is not only a reduced penetration rate, but also reduced drill-
steel life. With the "soft damper", the reflected primary shock
wave always has only a small initial tensile element, and
terminates with a small compressional element, which
indicates that the drill bit has always been in good contact
with the rock.
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2.2 The damper mechanism, soft/hard damper
This in turn indicates that most of the energy in the primary

shock waves has been consumed in the penetration of the
drill bit into the rock.
Since the rock-drill operation is a little uneven, the

amplitudes of the primary compressional shock waves vary
quite a lot. This is because the measurements were taken on
prototype machines, i.e. not fully trimmed rock drills.
14
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Chapter 2.8
Extractors
Gunnar Wijk
2.8 Extractors
HYDRAULIC DRILL STEEL EXTRACTOR

- No lost drill steel
- Higher production
This feature is optional for almost all Atlas Copco rock drill models designed for Bench
drilling or Long hole drilling underground.
The hydraulic extractor unit is engaged automatically during reverse feeding. The device
gives a back-hammering effect equal to about 20% of the rock drill impact power.
As a result, the risk of the drill steel remaining stuck in the hole after jamming is virtually
non-existent.
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2.8 Extractors
2.8 Extractors
The rock drill shown above is equipped with an extractor unit. The oil-filled space around the
extractor piston is connected to a constant-flow valve, which supplies the extractor with an oil
flow of 8 dm3/min. When the feed force is directed into the rock, the return line from the
extractor unit is shut off, so that the constant--flow valve is fully open. The constant-flow valve is
supplied with oil by the percussion pump. During normal drilling therefore, the extractor piston
and stop ring are held against the cover (i.e. the part between the extractor housing and the
gear housing) by the machine's working pressure.
When the drill steel is to be pulled out of the hole, the direction of feed is reversed. When this
happens, the return line from the extractor unit is opened automatically. A restrictor in the return
line causes the extractor flow of 8 dm3/min to build up to a pressure of 30 - 40 bar inside the
extractor unit. If the drill steel jams in the hole, the flange on the extractor shank is pulled toward
the stop ring, which in turn butts up against the extractor piston.
The extractor piston is then moved to the left in the figure, whereupon the left edge of the piston
head shuts off two holes in the same way as the edge of the damper piston in the floating reflex
damper shuts off the stroke-position controlling holes when the feed force presses the rock drill
against the drill steel.
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2.8 Extractors
The extractor pressure is therefore able to rise up to the percussion pump pressure. When the
percussion is started (sufficient extractor power can usually be, obtained by operating the
percussion at collaring pressure) the impact piston strikes the extractor piston via the stop ring,
whereupon about half the impact energy enters the drill steel in the form of a compressional
sock wave, while the other half throws the extractor piston up to the left. The extractor piston
turns after a movement of 5 - 8 mm, and returns to strike the extractor-piston flange from the
left. In doing this, it generates a tensile shock wave in the drill steel, which is very effective at
freeing the jammed drill steel.
Rock drills without extractor units also have a stop ring that butts up against the front head,
either directly or via the flushing head. A certain "extraction effect" is also obtained in this case,
when the rock drill pulls on the drill steel with the percussion mechanism running. The stroke
position is then moved forward by a few centimetres in the machine, which means that the
impact piston enters the front end-position damping zone before it is able to strike the shank
adapter.
Most of the impact energy is lost when the oil is squeezed out of the front end-position damping
zone, which is essential if vital components such as the stop ring, flushing head, front head and
side bolts are to be able to withstand the effects of idle percussion during so-called "back
hammering". However, the effectiveness of this kind of "extraction effort" is obviously not nearly
as good. If the system behind the rock drill does not have effective automatic anti-jamming
protection, and jamming is a common occurrence, then the rock drill must be equipped with an
extractor unit if drilling economy is to be acceptable.
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Chapter 2.3
Feed circuit
2.3 The feed circuit

Feed Force
The purpose of the feed is to maintain the drill bit in close contact against the rock and
create a rotation torque, enough to tighten the drill steel joints.
However, the bit must still be able to rotate. The feed force must always be matched to
the percussion pressure. The figure below illustrates this relationship.
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Chapter 2.4
Rotation mechanism/circuit
Gunnar Wijk
2.4 The rotation mechanism
This is a schematic
showing the principle of
the rotation devices in a
percussive rock drill
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HIGH TORQUE ROTATION, PURPOSE:

- Prevents drill steel jamming
- Properly tightened drill steel joints
A powerful, independent and reversible hydraulic rotation motor gives high torque and
enables great control possibilities for efficient drilling.
The "rota-control" system, which includes RPCF (Rotation Pressure Control of Feed force)
and anti-jamming functions, enables the output of the percussion mechanism to be
exploited fully, with minimal risk of jamming.
The drill string is given a certain rotation torque to ensure proper shock wave movement
over the contact areas of the rods. The rotation motor is available in seven different sizes
through the Atlas Copco rock drill range, from 16 cc to 315 cc.

Rotation devices
A separately rotated rock drill has a rotation motor which is (normally) a bought-in component in
the case of hydraulic machines, but is source-manufactured in the case of pneumatic machines.
Via a shaft and a gear, the rotation motor drives a so-called "driver", which in turn transmits
rotation to the shank adapter via a splined union or, in the case of the COP 700/900, a polygon
bushing. The gear usually has just one straight step with a ratio in the order of 2 to 3.
Hydraulic and pneumatic rotation motors have different characteristics. The hydraulic rotation
motor is fed with a constant
flow Qr and gives a constant speed n in rev/min. The constant flow gives an off-load rotation
pressure pr,i when the drill bit is rotated
without contact with the rock. With increasing feed force, however, an increasing torque is
obtained in the drill steel, along with a
corresponding rotation-pressure increase pr,r so that the rotation pressure becomes
pr, = pr,i + pr,r.
The pneumatic rotation motor is fed with a constant air pressure pr

and gives an off-load rotation speed ni when the drill bit is rotated without contact with the rock.
With increasing feed force, the speed n decreases, so that n < ni, at the same time as the
torque in the drill steel increases. The air consumption Qr decreases somewhat with
increased load.
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In hydraulic machines, it is often possible to choose between

rotation motors of differing displacement, e.g. 80, 100, 160, 250 or 315 cm, with the larger
motors being chosen for combinations of high torque and low rotation speed.
The final gear-wheel in the gear is called the "rotation chuck", which is borne in roller bearings in
the gear housing. In the case of almost ail competitor machines, the rotation chuck is borne in
plain bearings. In our machines, the roller bearings are preloaded by means of shims and
precise tightening of the rock-drill side bolts. With the correct amount of shims, the service life of
the roller bearings is quite exceptional.
There is reason to believe, however, that our competitors have been forced to use plain
bearings because all of their machines, with one exception, do not have reflex dampers.
Without the reflex damper's elimination of reflected compression shock waves from the drill bit,
the service life of roller bearings is probably unacceptably short.
The roller bearings are grease or hydraulic oil lubricated. The grease should be filled at intervals
of 40 impact-hours and the oil lubricated gears need no separate filling as they are connected to
the hammers hydraulic system, which also has the effect of cooling the bearing. The bearing
friction effect in a grease-lubricated roller bearing is usually so small that special cooling is not
necessary. Instead, a "hot" gear housing is an indication that something is wrong, e.g. that the
machine's lubricating-oil supply has stopped working.
The rotating and shock-wave loaded shank adapter is borne partly in the driver, which is made
of bronze and guides the shank adapter via the crests of the adapter splines, and partly in a
nose bushing, also made of bronze. These bearings are lubricated by means of oil-mixed
compressed air, which will be described later, section 2.7.
The damper piston transfers feed force to the shank adapter via the rotation-chuck bushing,
which means that these components do to some extent "follow" the rotation of the shank
adapter. The lubricating air lubricates the contact surfaces each time a clearance appears in
conjunction with the blows from the impact piston. This means that the average rotation speed
of the damper piston is certainly significantly lower than that of the shank adapter. Also, rotation
of the damper piston is "braked" by friction against the damper-piston seals.
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The rotation in hand-held and light, rig-mounted pneumatic rock drills is connected to the action
of the impact piston, i.e. such machines have an integrated percussion- and rotation
mechanism. Rotation is achieved with the aid of either a ratchet wheel around the front end of
the piston, or by a rifle bar in the rear of the piston. Normally, the drill steel is rotated during the
piston's return stroke, as inclined grooves in the piston are forced to follow inclined splines in
the ratchet wheel or rifle bar. See the pictures below.
BBC 34 BBD 94
C=Rifle bar D=Ratchet wheel

The ratchet wheel or rifle bar is prevented from rotating in the other direction by spring-loaded
pawls. By means of straight grooves in the front end of the piston, the rotating piston turns a
driver nut which is press-fitted into the rotation chuck. The rotation chuck with its female
hexagonal chuck transmits the rotation to the drill steel shank. When the impact piston turns into
the power stroke, it moves toward the shank without rotation, since the pawls do not prevent the
ratchet wheel or rifle bar from rotating in the same direction as that in which the piston rotated
during the return stroke.
Since the inertia of the ratchet wheel or rifle bar is much smaller than that of the impact piston,
driver nut, rotation chuck and drill steel, it is the ratchet wheel or rifle bar that rotates during the
power stroke of the piston.
Rock drills with piston-operated rotation have automatic anti-jamming protection, since the
piston stalls when rotation ceases, and vice versa. Since the rotation speed decreases as the
torque increases, the operator often has time to notice that jamming is about to take place, and
can take evasive action by reducing the feed force.
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Down-the-hole hammers, which are located directly behind the drill bit in the hole, are rotated by
drill tubes, which are threaded to the hammer just behind the percussion mechanism. The drill
tubes are rotated by a hydraulic or pneumatic rotation motor outside the hole.
Atlas Copco Secoroc COP 64 Gold
®
Function of the COPROD -system
COPROD 89 D= 105 - 127 mm
COPROD 102 D= 115 - 140 mm
COPROD 127 D= 140 - 165 mm
Tube adapter COPROD COPROD

-section head
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Chapter 2.5
Rock Drill Control Systems
2.5 Control systems – Basic demands
4 Keepthe joint-threads well tightened -

RPCF
4 Good collaring
4 Low feed force when risk for jamming
4 High impact pressure allowed only
when the damper is in ”floating” position
with (at a certain damper pressure) -
DPCI
4 Ramping of the impact and feed
pressures
4 Lubrication air flow supervision control
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2.5 RPCF (Rotation Pressure Controlled Feed)
Purpose:
The main purpose of the RPCF system is to give an even rotation torque. This will prevent over-
tightening of coupling joints and also prevent the couplings from running open. Over tightened
couplings will cause difficulty in undoing the joints when picking up the rods, and it may also
cause premature breakage of the rods due to increased rotation torque.
Coupling joints that are not tight enough will be damaged in a short time. Heat will be built up in
the lose joint and cause severe pittings in the thread and will most definitely cause thread
breakage in a very short time.
The couplings (Speedrods or standard) is not dimensioned to take the stress caused when
drilling with open joints. The coupling will split longitudinal or transversal.. This is due to the fact
that the impact energy (shock wave) will be transferred over the threads instead of at the ends
of the rods. It will also have a negative influence on the net penetration since impact energy is
lost on its way to the drill bit.
The ideal RPC-F setting is when constantly engaged, which means that the feed pressure will
fluctuate and the rotation pressure (and therefore the coupling-tightening torque) is more or less
stable.
4 Minimum - maximum torque
7 Mainly from friction from the
bit-hole bottom
4 Rotation pressure
7 Idle rotation pressure
7 Rotation pressure increase
2.5 RPCF (Rotation Pressure Controlled Feed)
Function:
The RPCF valve constantly monitors the rotation pressure and tries to keep it at the same level.
If the rotation pressure exceeds a certain value (The “RPCF setting” typically 45-50 bar), it will
then start to decrease feed pressure until rotation pressure drops below the “RPCF setting”
value again.
Great hole deviation can sometimes cause the RPCF system to be adjusted due to the majority
of the rotation torque is caused from friction between the hole wall and the rods and not
between the rock and the bit.
4 Minimum - maximum torque

7 Mainly from friction from the
bit-hole bottom
4 Rotation pressure
7 Idle rotation pressure
7 Rotation pressure increase
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2.5 Good collaring
4 Stable rig setup

4 Low feed speed
4 Low feed pressure
4 Low impact pressure
2.5 Anti jamming-purpose and function

The purpose of the anti jamming system is to prevent the rods from getting jammed in the hole
when drilling in demanding rock conditions through voids and cracks.
The anti-jamming system will reverse the feed direction when it is activated.
The more difficult it is to rotate the bit in the hole, the higher the rotation pressure will be. This
comes from the friction between the bit and the hole bottom plus the hole walls. Great hole
deviation may also be a possible cause for a anti jamming activation.
Function:
A soon as the rotation pressure exceeds a certain value, a signal is sent to the feed circuit to
reverse the feed for a certain period and until the rotation pressure have dropped below the
alarm level again. The most sohpisticated Atlas Copco drilling systems start over with a
collaring phase instead of full drilling.
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2.5 Anti jamming – no/limited flushing (surface)
Purpose:
The purpose of the flush air anti-jamming system is to prevent the bits from getting clogged
when drilling in very soft rock formations or through clay sections. The anti-jamming system will
reverse the feed direction when it is activated.
Function:
The system is measuring pressure difference (airflow) over a large restriction in the flush air-line
to the rock drill. If the pressure difference becomes less than the preset value (normally 20-30
mbar) it will then send a signal to the PLC or control computer which sends a signal to the feed
circuit to reverse the feed for a certain period and until the pressure difference is greater than
the preset value.
Note: Drilling in very soft rock with high penetration rates may sometimes cause false
activations due to the weight and amount of cuttings being transferred in the hole. This may be
overcome by either decreasing feed and impact pressure which will then reduce the penetration
rate, or alternatively reduce the setting on the pressure differential switch closer towards zero,
this may cause blockage of the drill bit but will maintain penetration rates.
2.5 DPCI (Damper Pressure Control of Impact)

Purpose:
The main purpose is to protect the rock drill and the consumables from premature failures by
cutting off or reducing impact pressure in case the dampening pressure drops below preset
values. The dampening pressure is a direct reflection of the feed force in the rod (giving
coupling tightening torque) together with ground conditions in front of the bit. The higher the
dampening pressure gets the harder and more homogenous the rock is (more stress wave
reflections), the lower it gets, the softer and more fractured the rock is (less stress wave
reflections). Less impact energy is normally required to penetrate soft formations.
Additional to this it will also cut off impact pressure completely if a cavity is reached..
Function:
When the dampening pressure is above idle pressure (typically 35 bar), it will only allow for
reduced impact. As the dampening pressure increases to typically 50 bar it will allow for high
impact pressure to be used. All this happens automatically during drilling. Dampening pressure
below 35 and above a certain limit (typically 120 bar) will cut off impact completely since too low
or high dampening pressures could be harmful for the rock drill.
Note:
A faulty or incorrect RPC-F setting may also cause the impact pressure to fluctuate a lot since
the dampening pressure more or less is directly proportional to feed pressure, I.e. if the rotation
pressure increases above 45-50 bar the feed pressure will start to drop and as a direct result of
this the dampening pressure will also drop. This may then cause the impact pressure to drop to
reduced impact pressure.
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2.5 DPCI – 4 different modes
Damper pressure
[bar]
typical values
120
50
35
Drilling mode
1 2 3 4
1 Low damper pressure. No drilling allowed, something is probably wong with the
damper oil supply
2 Rock contact, but not sufficient for full drilling, which would damage the drill steel
3 Full drilling allowed. Good rock contact
4 Too high damper pressure caused by too high feed force or clogged restriction in the rock drill. No
drilling allowed as there is risk of damage on the dampering piston and its surrounding environment
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Chapter 2.6
Flushing circuit
Gunnar Wijk
2.6 The flushing circuit
SEPARATE FLUSHING VIA STAINLESS-STEEL COMPONENTS

- Enables high flushing pressures
- Long service life
Effectively sealed separate flushing permits high flushing pressures, which keeps the hole
clean of drill cuttings at all times.
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Flushing arrangements
The cuttings that are broken off the rock underneath the drill bit are flushed out of
the hole with the aid of a flushing medium that is led to the drill bit via a hole in the
drill steel. The flushing medium is usually compressed air in surface drilling
applications, and, water in underground drilling applications. In smaller rock drills,
the flushing medium is usually led into the drill steel via a central flushing tube, which
runs axially through the impact piston and enters the shank of the drill steel.
On larger rock drills, the flushing medium is usually led into the drill steel from the
side, via a flushing head. The flushing head must be made of a stainless material, in
order to withstand corrosion when water flushing is used.
The flushing head cannot rotate, since the flushing inlet has a pipe and a seal that
enter the flushing head from the outside. The flushing head is subjected to shock
waves from the stop ring in conjunction with idle percussion or back hammering,
which must be resorted to if
the drill steel jams in the hole when using machines that are not equipped with a so-
called "extractor unit" .
The flushing head is sealed against the shank adapter by means of double seals,
between which there are squirt holes. If flushing water is seen squirting out of any of
the holes, then the flushing seals must be changed at the earliest opportunity.
If the outer of the two rear flushing seals is defective, then the flushing water, the pressure of
which is always several times greater than that of either the lubricating air or the return hydraulic
oil in the rock drill, will first fill the spaces in the rock drill that are normally air filled, and then
force its way into the return hydraulic oil via the seals in the impact-piston seal housing, which
are turned to seal against pressure from the oil side, but not from the other side The flushing
water can sometimes be very aggressive, quickly. subjecting the shank adapter to corrosion
attack, which gives it a rough surface.
Such a surface will quickly wear out the flushing water seals. If this happens so often that the
operator is obliged to continue drilling for a while with a defective inner flushing-water seal, it
may be advisable to turn the outer impact-piston seals in the two seal housings. This will
minimize the risk of water forcing its way into the hydraulic oil, which would sooner or later
require that the entire volume of hydraulic oil in the system be changed.
If the flushing water is very aggressive, the flushing system of the rig should be equipped with a
dry-blowing function, so that all flushing water in the rock drill can be blown out prior to longer
stoppages between drillings, e.g. when there is a change of shift. The reason why this action is
recommended is because corrosion attack is very much more intensive when the space
between the shank adapter and the flushing head is filled not only with water, but also partly
with air.
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The required flushing speed will depend on: specific gravity – material having a
density of 2 t/cu m requires at least 10 m/sec, whereas iron ore, for example,
having a density of 4 t/cu m, requires an air speed of 25-30 m/sec; particle size
– the larger the particles, the higher flushing speed required; particle shape –
spherical particles require more speed than flaky, leaf shaped particles.
2.6 The flushing media
With water flushing the drill bit obtains efficient cooling so that high rotation rate can be used
without too fast wear of the drill bit. With air flushing the rotation rate must normally be chosen
to be only about half as big if drill bit wear shall not be too fast.
Rock destruction (or drilling rate) is reduced with water flushing since the drill bit must rapidly
(with about the same velocity as that of the striker impacts) push away the water in front of it
when the buttons penetrate the hole bottom. The advantage of a greater rotation rate with water
flushing as compared to air flushing is almost cancelled due to this effect. In practice the two
flushing alternatives are almost never compared since other circumstances determine that air
flushing is used in surface drilling and water flushing is used in underground drilling.
Flushing of horizontal holes is in principle more difficult than flushing of vertical holes since the
flow along the drill steel in a horizontal hole cannot lift the rock debris against gravity. Flushing
of horizontal holes is helped via the rotation of the drill steel, which gives the flushing medium a
circular movement. The average value of this circular velocity component is about half of the
velocity of the rotating surface of the drill steel.
Accordingly there is a lifting force on one side of the drill steel so that the axial flow can get hold
of the debris and carry them to the hole entrance as if it was “screwed” like from an Auger steel.
Thus it is understood that rotation (and flushing) must not be stopped before the drill bit has
been extracted from the hole.
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2.6 The flushing media
In drifting underground, with one big hole at the center and many small holes over the rest of
the tunnel front, the rotation rate with the big bit must be much smaller than with the smaller bits
if the wear rate shall be low and the drilling efficiency shall be good, at least as far as the rock
destruction under the buttons is concerned.
The reduced rotation rate does however correspond to bad flushing efficiency for the big hole.
Thus it is important that the big hole, if possible, is drilled with some upward inclination so that a
flow of debris from the hole is achieved. Furthermore it is recommendable to interrupt the drilling
frequently and mechanically scratch debris out of the hole with the drill bit before the
accumulated amount of debris is too large. If the bit nevertheless seems to become stuck, then
the greater rotation rate for the small hole drilling can be turned on and allowed to work for say
half a minute before a new attempt to extract the bit is started.
Water mist, which mostly is used to stabilize the hole walls, is giving penetration rates closer
To if with air flushing than water flushing.
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Chapter 2.7
Lubrication system
Gunnar Wijk
2.7 The lubrication circuit

The surfaces between moving parts must be lubricated if the components are
to have a good service life. The percussion mechanism and rotation motor in a
hydraulic rock drill are obviously lubricated by hydraulic oil, but in the case of
pneumatic rock drills, lubricating oil must be added to the compressed air that
drives the machine.
This applies to both the percussion mechanism and the rotation motor. There
is always a certain overpressure in all the inner spaces in a pneumatic rock
drill, relative to the atmosphere, which means that air continuously blows out
through the various slots and holes. This movement of air effectively prevents
dust and other impurities from entering the machine. Sometimes, however, the
rotation motor is switched off while the drill hole is blown clean. During such
operations, it is possible that drill cuttings can enter the rotation motor, with
devastating effect.
To prevent dirt and water from entering hydraulic rock drills, all spaces in the
machine that are not filled with oil must be given a certain overpressure relative
to the surrounding atmosphere. This is achieved by supplying the machine with
a flow of compressed air, which is mixed with a suitable quantity of oil. In
underground drilling applications, it is important that ALL external mating
surfaces are supplied with pressurized lubricating air, since it is technically
impossible to create effective sealing surfaces without the use of gaskets.
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Gaskets do have the desired effect, but suffer from short service life, which is why internal
pressurization of the machine is a much better alternative. In surface drilling applications, the
ingress of impurities is almost negligible, and "sweating" around mating surfaces that are
internally pressurized by lubricating air can have negative consequences.
On surface machines therefore, it must be made possible to easily switch off pressurization of
the mating surfaces. Lubricating oil is needed primarily at two places in a hydraulic rock drill,
namely between the splines of the driver and shank adapter, and between the nose bushing
and neck of the shank adapter. Traditionally we have a generous amount of air blowing out
around the nose bushing, in order to prevent the ingress of dirt in both surface and underground
drilling applications.
In surface drilling, the hole diameters are usually larger, which means that higher torque have to
be transmitted via the shank adapter. For this reason, it is especially important that the dosage
of lubricating oil is correct, in terms of both. quantity and quality.
Lately, it has become an issue in surface drilling to reduce this amount to zero.
Almost all our surface rock drills are prepared to collect the lubrication oil and lead it back to the
rig if desired.
Under no circumstances should the lubricating oil be too thin, otherwise the flow of lubricating
air will simply blow it off the surfaces to which it is supposed to stick.
The dirt is especially important to keep away in upward-directed drilling, when flushing water
and drill cuttings from the hole shower down continuously over the machine. Different types of
drill collars are available to lead the cuttings and water away from the rock drill front.
In underground drilling applications using water flushing, the shank adapter splines are well-
cooled by the flushing water streaming into the adapter, even though the heat has to travel
forward somewhat through the adapter steel in order to reach the water-cooled surfaces. In
surface drilling applications, the cooling properties of
air flushing are much less efficient.
We normally call the lubrication circuit the ”ECL-system” – Electrically Controlled Lubrication. In
our system, a fixed displacement piston pump delivers an amount of oil in proportion to how
many electrical pulses the coil of the pump is set to.
In DTH or CR applications, the amount of oil that pump delivers is not sufficient. Therfore there
is the HECL pump (Heavy –ECL) which is electrically-hydraulically operated and delivers 6-9
times as much lubrication oil as the ECL pump
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2.7 Pressurized mating surfaces
PRESSURIZED MATING SURFACES, SIDE RODS AND FRONT HEAD

- Prevents contaminants and dirt from entering the rock drill
- Simpler Maintenance
Constant ”over pressure” from mixed oil/air in the machine gives good lubrication and
prevents the ingress of dirt, moisture and water. This ensures long service life for the
shank adapter and components of the machine.
A rock drill with this feature can safely be used in dirty, corrosive environments; the
system contributes particularly high reliability and long life.
If desired, the lubrication air to the contact (mating) surfaces can be cut-off by fitting a plug
into the intermediate part from outside the rock drill (preferred on Surface drilling).
All newer rock drill models from Atlas Copco has this feature
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Principles for a percussive
rock drill
Gunnar Wijk
1.2 Principles for a percussive rock drill
Percussive rock drills are used to drill holes with diameters

from a few centimetres to several decimetres. Inside the
machine there is an impact piston that is accelerated
pneumatically or hydraulically toward the drill steel at impact
velocities of 8 - 11 m/s. Different impact pistons,
all with the same piston mass.
The piston acceleration stretch can be anything from a few

centimetres to a decimetre or so in length. The-impact piston
in a medium-heavy rock drill weighs about 5 kg. To obtain the
desired impact velocity, the pneumatic or hydraulic-pressure p
acts on a piston drive area.
A normal pneumatic pressure is p = 6 bar, while a normal

hydraulic could be anywhere between p = 120 bar and p=230 Theoretical. shock waves for
bar. It follows that a much larger drive area is needed behind the same impact velocity, i.e.
the same impact energy.
the impact piston in a pneumatic rock drill compared with that
in a hydraulic rock drill, which consists "only" of a narrow "ring"
around the piston. Typical impact pistons with the same piston
mass, but for different working pressures, are shown in the
figure to the right.
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Different impact pistons,

all with the same piston mass.
Theoretical. shock waves for

the same impact velocity, i.e.
the same impact energy.

When the impact piston is accelerated toward the drill steel, the
working pressure pushes the rock drill over the piston in the
opposite direction. To keep the rock drill pressed against the drill
steel, therefore, a feed force is needed behind the rock drill.
Consequently, the size of this feed force must be in the order of

the working pressure multiplied by the piston-drive area. Upon
impact, a shock wave is generated in the drill steel. The shape of
the shock wave resembles a somewhat distorted n mirror image"
of the impact piston, which can also be seen in the figure below .
The maximal shock wave stress in the drill steel must not exceed
the fatigue strength of the drill steel. It can be said therefore, that
a slimmer piston can strike the drill steel with a greater impact
velocity.
This means that, with a given drill bit, a slimmer piston will enable
faster drifting in a given rock type without overloading the drill
steel. at the same time as the drill bit can be drilled to a higher
degree of wear before regrinding. In addition to this, a greater
impact velocity means that the impact piston completes the
impact cycle in a shorter time, i.e. the impact frequency is greater,
which also results in faster penetration.
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In pneumatic rock drills the impact velocity is normally 8 - 9 m/s. Pneumatic rock drills are almost always
designed to work at the pressures normally found in compressed-air networks, i.e. they have working
pressures of 6 - 7 bar.
The exception is in so-called down-the-hole (DTH) rock drills, in which the percussion mechanism is located
in the hole, directly behind the drill bit. In this case, the drill string is lengthened by jointing drill pipes behind
the rock drill until the desired hole depth is obtained.
This means that the drive area of the impact piston in a DTH rock drill has to be smaller than the cross-
sectional area of the drill hole. Higher working pressures normally 16 - 25 bar - are therefore needed in
order to obtain reasonable impact power and hence a reasonable penetration rate with DTH rock drills.
In the case of hydraulic rock drills, which have a more favourable piston geometry in terms of
drill-steel stress levels, the maximal impact velocity is usually 10 - 11 m/s. With hydraulic
percussion mechanisms, it is easy to regulate the working pressure to a value corresponding to the
maximum permissible stress level in the drill steel or impact piston.
Similarly, it is not unusual for the acceleration stretch of the impact piston (usually called the stroke length) to
be changeable between a few different values. This is achieved by means of alternative valve-spool
switching ducts in the impact-piston cylinder, which can be blocked or opened to give the desired stroke
length. This means for example that, when drilling in softer rock formations which do not require so much
impact energy for the drill bit to break the rock efficiently, a shorter stroke length and a higher working
pressure can be selected. This will give the same impact energy needed for efficient drilling, at a higher
impact frequency compared to that which is obtained with a longer stroke length. Since the impact energy
under these conditions is the same for both stroke lengths. the penetration rate with the shorter stroke length
will be greater in proportion to the higher impact frequency.
Experimental shock waves generated by impact from pistons in hydraulic

rock drills. The shock waves have been deformed during transmission
through the shank-adapter joint, but the differences in amplitude
and duration remain.
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If a hydraulic rock drill exploits all the strength of the drill steel using an impact
velocity of 11 m/s, then a pneumatic rock drill with the same piston mass will typically be
able to strike the drill steel at an impact velocity of 9 m/s to give the same drill-steel stress
level.
This means that the hydraulic machine strikes with (11/9)^2=1.5 times more impact
energy and 11/9 = 1.2 times higher impact frequency, i.e. with 1.5 x 1,2= 1.8 times more
impact power.
This means that it will drill nearly twice as fast, because the shape of the shock wave from
the hydraulic machine is also considerably more favourable in terms of rock destruction .
There is a great deal of energy in the narrow "shock-wave point", but this energy is difficult
to utilize in rock drilling.
An Example:
The fiqure below shows a general cut up picture for a modern ATLAS COPCO rock drill,
type COP 4050MUX. Most of the components described in the following slides can be
found in the figure. The machine weighs about 485 kg. It has an impact piston with a
mass of 13 kg. The maximum impact power of 40 kW is obtained at an efficiency rate of
approx 60%.
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1.2 Principles for a perc. rock drill-stroke length
STROKE LENGTH POSITIONER WITH TWO OR MORE STROKES
Easily adapted to various rock conditions together with different Impact Pressure,
gives ptimum penetration rate and drill steel economy
The stroke positioner is controlling the stroke length of the impact piston, position I gives
a shorter stroke length than position II etc. Not all Atlas Copco models have three stroke
lengths, but at least two.
A lower stroke position gives a higher frequency and is a suitable setting in soft rock
formations or when drilling with small bit diameters, drilling with higher frequency & lower
impact energy.
A higher stroke position can be used when drilling in hard rock formations or when
drilling with large bit diameters, drilling with lower frequency & higher impact energy.
On COP 4050 models, the stroke lengths are hydraulically remotely controlled!
1.2 Principles for a perc. rock drill stroke length
The same impact power can be achieved with…….
OR
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1.2 Principles for a perc. rock drill stroke length
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Function description
1532/1838CR/2150EX/2150CR/4050T51/
4050CR
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COP 1838
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COP 1838CR
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COP 1638
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COP 1532
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COP 2150/EX
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COP 2150CR/2550CR
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COP 4050MEX
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COP 4050T51
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COP 4050CR
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Function of Percussion
4COP 1238/1838
after impact
4COP 1238/1838
piston accelerating
towards impact
1
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4COP 4050 ME/MEX

function after impact
P
4COP 4050 ME/MEX

function piston accelerating
towards impact
P
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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

165 of 326
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
166 of 326
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
167 of 326
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
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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)
(M16)
(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
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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
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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
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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
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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
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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
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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
175 of 326
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
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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
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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
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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
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Accumulators
Disassembly
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
A B
2–3 turns.
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
180 of 326
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

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
181 of 326
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
182 of 326
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
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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
2–3 turns.
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.

(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
184 of 326
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
185 of 326
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.
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
186 of 326
Back head
Assembly

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
187 of 326
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
188 of 326
Disassembly
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
189 of 326
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
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Knock out the sleeve (30) with needle bearing (29)
using the mandrel (H).
Fig. 46. Removing the sleeve and needle bearing

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
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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
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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
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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
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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
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
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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
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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
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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
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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
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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
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Intermediate part
Disassembly
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
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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

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
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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
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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
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Assembly
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
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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
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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
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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
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Cylinder, piston guides and impact piston
Disassembly
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

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
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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
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Assembly
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
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Hydraulic motor
Disassembly
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
212 of 326
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
213 of 326
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
214 of 326
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

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
215 of 326
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
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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
217 of 326
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
218 of 326
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
219 of 326
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
220 of 326
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
221 of 326
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
222 of 326
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
223 of 326
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
224 of 326
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

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
225 of 326
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
226 of 326
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).
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
227 of 326
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.
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

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
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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.
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
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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
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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
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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
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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
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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 54 58
50 56 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
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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
11 12 13 29
1250 0058 11
Atlas Copco, 1999

Printed in Sweden
26 27 28 27 26 24 25
70
235 of 326
236 of 326
Different fault causes
Different Fault Causes
Atlas Copco Rock Drills AB

Copying prohibited
It is prohibited to copy this document or any part
of it without permission from Atlas Copco Rock
Drills AB
V3 2005 06
237 of 326
Too high a charge pressure in the accumulator 1 (2)
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Too high a charge pressure in the accumulator 2 (2)
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Cracked accumulator cover
The accumulator has probably run without gas for a period of time.
This leads to high pressure peaks in the oil, and thus higher stress in the steel, which may create a crack
in the bottom of the thread.
Please note: We do not recommend to check the accumulator pressure unless some difference in the
performance is noted, such as changed sound from the rock drill/ reduced penetration/ increased
vibration in the impact hoses etc. (Many reports about cracked accumulators state that this has
happened short after a regular check of the pressure).
The accumulators should never be overcharged. Recommended pressures:
Intake accumulator: 30 - 40 bar below the impact collaring pressure.
Max 110 bar
Damper accumulator: 20 - 25 bar
We recommend to change the filling valve in connection with overhaul of the accumulator, since it
may be a cause for gas leakage if opened and closed too many times.
Overtightening of the cover may create stresses, which can lead to a start of cracks.
Cracked accumulator cover is not considered to be a product safety risk, which also the product safety
committee has stated.
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Extractor
The extractor is designed to be used to help getting loose in stuck drill string situations.
When the rock drill is pulled backwards the shank adapter forces the extractor piston to the balance
position. When the piston hits the shank adapter some of the impact energy goes down the drill
string and some is transmitted to the extractor piston, which is pushed forward. The hydraulic oil in
front of the piston acts as a spring and the piston bounces backwards and hits the shank adapter.
During this cycle the striking piston, shank adaprot and extractor forms a system with no axial contact
with the housing parts of the rock drill, and thus the extractor method of coming loose is very gentle
to the rock drill compared to the old way with backhammering.
Hydraulic connections:
COP 1838/1840/2150/2550 surface applications:
During normal drilling the extractor is not pressurized and the extractor piston is in its forward
position. This is to avoid that the shank adapter accidentally hits the extractor piston during normal
drilling, especially when drilling in fractioned or soft rock.
COP 1838/1840/2150/2550 Underground applications. COP 4050 all applications:
During normal drilling the extractor is pressurized and the extractor piston is pushed backwards
towards the mechanical stop. The pressure line is always open.
The reason for the difference is that the extractor might damage the front head if it would be allowed to
move without control when drilling in different directions
Possible problems:
Leakage from the extractor; Normally caused by the O-ring in front end of the front bushing damaged.
Extractor piston seized; Normally caused by contaminated hydraulic oil
Front head damaged; The extractor has been run without pressure in underground or 4050 applications
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Flushing head
The flushing head locates the flushing seals in correct position and supports the stop ring. As the impact
forces from the stop ring are transferred through the flushing head it is made of a high strenght corrosion
resistant steel grade.
We have seen a few reports about cracked flushing heads. The cause is primarily excessive impact
system running with no feed force (backhammering), but there are two circumstances that can make the
situation worse.
Firstly, high strength and good corrosion resistance can not be combined for steel. This means that the
material in the flushing head can corrode if aggressive flushing water is used. The corrosion causes
cracks, and finally fatigue failure. If the front head is corroded, the flushing head can move forwards in
the front head and impact forces from the stop ring will be transferred to the stem of the connection
plate rather than the stud in front head as intended. This leads to unfavourable stress distribution around
the hole for the connection plate in the flushing head, and can cause cracks.
Good status of the shank, flushing seals and connection plate is essential in order to avoid corrosion of
the front head and the failures this corrosion may cause.
Minimizing impact system running with low, or no, feed force, especially with high impact pressure,
also improves the life of the flushing head.
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Front head
The front head supports the front guide and the flushing head, and carries all loads transferred through
these parts.
The worst load case happens when the impact is being run with too low, or no feed force or with
reversed feed (backhammering). The impact forces from the piston are transferred through the stop ring
and the flushing head and creates stress peaks in the front head. It is thus important to minimize
backhammering, especially if performed with full impact pressure.
In cases where the front head is corroded internally, the corrosion initiates cracks that grow slowly by
the action of the stress peaks until the front part of the head separates from the rest. This happens mainly
in underground applications and gets worse with corrosive flushing water.
The only way to improve the situation is to keep shank, flushing seals and the connection plate in good
shape.
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Piston broken in piston guide area
The most common case with broken pistons is seizure in one of the piston guides. For some reason the
piston has got a too hard contact with the guide. The piston surface is then locally heated up to some
hundred degrees, causing small heat cracks to develop. The crack gives a
big stress concentration and initiates a fatigue crack, which grows inwards through the piston.
Reasons for the hard contact can be as follows:
Contaminated hydraulic oil
Broken side bolt or uneven tightening of side bolts
Corroded mating surfaces, or dirt between mating faces causing misalignment
Dirt between cylinder and piston guide causing misalignment
Dirt between the seal housing and the back head or piston guide causing misalignment
Uneven tightening of the back head screws (screws not retightened at specific intervals)
244 of 326
Cavitation on the piston
With the pulsating operation of rock drills there is always some cavitation, how much depending on the
running conditions.
On pistons some cavitation usually occurs on the mantel surface at the front and rear driving areas and at
the switching area between the piston lands. As long as the cavitation only result in greyish colour of the
mantel surface no harm is done. Also a rough surface created by cavitation is acceptable, as long as the
damage is kept outside the sealing areas.
When the rough surface start to reach the sealing areas, or if the ends of the piston lands are too much
affected, it is time to replace the piston. If the piston has run more than 1000 impact hours when this
happens it can be regarded as an acceptable wear out time.
If severe cavitation on the piston occurs after short running time, one can assume that the running
conditions have been abnormal.
Long time running with too low feed force can lead to cavitation damages. With too low feed force the
damping piston will move forward, which means that the striking position for the piston is also moved
forward and the piston stroke gets longer. The timing between piston and valve piston will then not be
matched as the rock drill is designed for.
Frequent back hammering or running with faulty charged, or broken, accumulator would also cause
faster cavitation wear on the piston.
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Piston broken/ damaged in land area
10
Breakage of the piston in the lands is normally caused by seizure between piston lands and cylinder. As
a seizure here is between steel parts this may cause that the piston gets stuck, and the impact will stop
before the crack has propagated through the piston.
The reason for the seizure can be dirt in the oil or particles from the rock drill coming between piston
lands and cylinder. It can also be caused by misalignment because of faulty tightened side bolts, or by
worn out piston guides.
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Piston damaged in the striking face
11
This type of breakage is normally caused by one of the following reasons:

Salt corrosion: f the machine is in salt water environment for a period of time, even if the machine is not running, you get
salt corrosion in the metal. This can decrease the fatigue strength to one third of the normal strength .With the normal stress
on the piston, it will then break within a few hours when running.
There is no material usable for pistons that will stand up to salt water. The only way to get some life length of the piston is to
keep water out of the rock drill, and also during storing of pistons and rock drills.
Erosion damage: If there is liquid present between piston and adapter during running, erosion groves will occur on the
striking face of the piston. The groves may cause fatigue cracks with a break down as a result.
The piston can be regrind and put in service again if the damage has not gone too far. Instruction for grinding the striking
face of the piston can be found in the overhauling instructions.
The following faults can cause water or oil leak to the piston area:
Flushing seals or seal for connection plate worn out or damaged
Flushing head damaged
O-ring around flushing head damaged
Corrosion in front head O-ring groves
Valves for air blowing corroded or malfunctioning so that water from flushing is entering the lubricating system
Malfunctioning drainage valve in air receiver
Insufficient lubrication air pressure
Piston and damping pistons seals worn out or damaged
Front guide worn out allowing shank to wobble, which will lead to that even new seals will leak prematurely.
247 of 326
Piston guides damaged or cavitated
12
Piston guides can be damaged as a secondary damage at a piston seizure or a piston break.
Now and then we get reports about cavitation on the piston guides.
If severe cavitation on the piston guides occur after a short running time
it is normally caused by abnormal running conditions, such as long time running with too low or no feed
force.
With too low feed force the damping piston will move forwards, which means that the striking position
for the piston also moves forwards and you get a longer piston stroke. The timing between piston and
valve piston will the not be matched in the way the rock drill is designed for which may cause cavitation
on both front and rear piston guides.
Long time back hammering (without extractor) means that the piston hits the adapter and recoils back
when it is in the dampening area, which will cause cavitation on the front piston guide.
Running with broken or faulty charged accumulator could also cause cavitation on both piston guides.
With the varying conditions for a rock drill some cavitation on the piston guides is normal. If a piston
guide has cavitation marks on the end planes, but is not damaged at the inner, guiding, surface, there is
no need to replace it. Normally the cavitation is at one side of it, the guide can then be turned a bit so the
following cavitation starts on a fresh surface.
248 of 326
Rock drill rotation- Bearings
13
Appropriate amount of preload of the bearings is essential. If the preload is too small, the rollers in the
bearings will deviate from the intended rolling direction and damage the bearing. In particular rock drills
with simple dampers - COP 1032/1238/1440 - are sensitive for low preload. The simple dampers in
these rock drills hammers on the rotation chuck, the vibrations cause the rollers in the bearings to
deform the bearing cages, which finally cracks into two pieces.
Two much preload overloads the bearings and causes premature wear out.
Whenever a gearbox is dismantled, preload of the bearings must be done, according to instructions,
when it is reassembled.
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Rotation chuck bushing
14
The rotation chuck bushing transmits the reflected chock waves from the shank adapter to the damping
piston.
There are normally two possible reasons for breakage of the chuck bushing - poor lubrication or fatigue.
Sufficient lubrication is essential for good performance of the chuck bushing. High feed force and large
diameter drill bit will raise the demands for proper lubrication. Discoloration of the bushing near the
ends is a sign of high temperatures caused by insufficient lubrication.
In severe case this may cause the bushing may break into pieces, which normally causes very
expensive secondary damages to the rock drill.
The rotation chuck is a wear part, and wear limits are stated in the overhauling instructions. However,
we recommend to exchange the bushing in connection with the regular 400 hrs interval to prevent
from break down caused by fatigue.
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Side bolts
15
The side bolts are intended for keeping the parts of the rock drill safely attached to each other. They are
subjected to high pulsating stresses due to the heavy vibrations that are created when drilling. To avoid
fatigue failures, the side bolts always have to be properly tightened.
Side bolt breakage is most often caused by the fact that the side bolts have not been properly retightened
at specified intervals.
Another reason for the bolts not being properly preloaded may be dirt and/ or corroded threads causing
seizure between nut and bolt. The tightening torque will, in such a case, not create enough preload in the
side bolt, and thus cause a fatigue failure.
Damages like dents and corrosion pits can cause cracks, which can start a fatigue failure.
Side bolts should be changed if they are badly rusted or if they show signs of crack formations.
We recommend to change side bolts, dome nuts and washers in connection with every overhaul of the
rock drill, to prevent from possible, expensive secondary damages. New and old side bolts should never
be mixed.
The life length of the side bolts varies a lot in different applications.
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Stop ring
16
The most common problem with the rock drill is caused by intense backhammering or drilling with too
low or no feed force.
The impact velocity of the piston will be reduced by a damping device in the cylinder when the piston
reaches the front part of the rock drill. However, to be able to loosen a stuck drill steel the piston must
have some residual impact velocity when it reaches the shank in its forward position. The impact forces
are then also received by the stop ring.
In order to resist the impact and wear from the rotation the stop ring is carefully heat treated.
The stop ring should be inspected in connection with change of shank adapter and it should be
exchanged if it has some damages or if the wear is higher than what is stated in the Maintenance
Instructions.
It is a wear part and we recommend to change it at least every 400 hrs, even if it looks good, to prevent
from breakage because of fatigue.
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Driver
17
Driver
The most common reported problem with drivers is premature wear, which normally is caused by:
•No, or insufficient lubrication
•Wrong type of lubrication oil
•Drilling with larger diameter than the rock drill is designed for
In some cases extreme heat may build up in the driver, causing the shank adapter to crack in the splines
area, which may lead to serious secondary damages
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Driver
18
Driver
Another problem that may occur is broken splines in the driver. This is normally caused by the guide in
the front head being too much worn.
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Driver
19
Driver
If the driver is cracked, this is normally caused by wrong tolerance between driver and rotation chuck
i.e. the clearance outside the driver is too big.
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256 of 326
Trouble
Shooting
257 of 326
258 of 326
Contents
Cross/X-bits, integral drill steel ................ 4–15
Extension equipment ............................. 16–19
Button bits ........................................... 20–23
DTH ..................................................... 24–27
COPROD®-system ................................. 28–29
If you experience a premature failure on a rock drilling

tool, this booklet will help you codify the damage for
identification and possible remedy.
It is also important to us as manufacturer to receive
reports about premature failures as it will help us to
improve our products.
Main types of damage:

Cross/X-bits, integral drill steels, button bits
S Damage to the insert
L Brazing-joint damage with loss of whole
insert or part of it
F Steel damage near the carbide insert
Extension equipment
A Wear damage
B Cracks. Pieces broken loose
C Damage through upsetting
259 of 326
3
Cross/X-bits, integral drill steel
Type of failure
S1 Transversal crack S2 Crushed insert corner
Cause Remedy Cause Remedy

• Bad grinding (e.g deep • Control and adjust your • Too sharp edge on the • Control grinding procedure;
4
grinding scratches due to grinding procedure, change to corners after grinding chamfer the edge
use of wrong grinding wheel) the correct grinding wheel • Anti-taper • Insert must be reground when
• Too sharp edge after • Chamfer the edge after • Snakeskin anti-taper exceed recommen-
grinding grinding dations:
• Careless collaring – Crossbits/X-bit max 6 mm
• Wrong (too acute) insert
angel after grinding – Integrals max 8 mm
• Remove snakeskin (shorter
intervals between regrinding)
• Reduce impact force when
collaring
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Type of failure
S3 Crushed insert edge S4 Entire cutting edge crushed

• Small edge angel • Control grinding procedure; • Small edge angel • Control and adjust your grinding
• Poor chamfering after chamfer the edge • Bad grinding (e.g deep procedure, change to the correct
5
grinding • Inserts must be reground when grinding scratches due to grinding wheel
• Snakeskin anti-taper exceeds recommen- use of wrong grinding wheel • Chamfer the edge after grinding
dations: • Control grinding procedure;
– Crossbits/X-bit max 6 mm chamfer the edge
– Integrals max 8 mm
• Inserts must be reground when
• Remove snakeskin (shorter anti-taper exceeds recommen-
intervals between regrinding) dations:
• Reduce impact force when – Crossbits/X-bit max 6 mm
collaring – Integrals max 8 mm
• Remove snakeskin (shorter
collaring
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Type of failure
S5 Longitudinal crack S6 Corner crushed, longitudinal cracks

• Overheating of the insert • Control and adjust your grinding • Anti-taper • Check the taper after regrinding
during grinding procedure, change to correct • Snakeskin • Control grinding procedure;
6
• Plastic deformation grinding wheel chamfer the edge

• Snakeskin • Chamfer the edge after grinding • Inserts must be reground when
• Control grinding procedure; anti-taper exceeds recommen-
chamfer the edge dations:
• Inserts must be reground when – Cross bits/X-bits max 6 mm
anti-taper exceeds – Integrals max 8 mm
recommendations: • Remove snakeskin (shorter
– Cross bits/X-bits max 6 mm intervals between regrinding)
– Integrals max 8 mm
• Remove snakeskin (shorter collaring
collaring
262 of 326
Type of failure
S7 Ridge shaped fracture surface S8 Crack across edge of insert

• Anti-taper • Check the taper after regrinding • When a crack is located • Check the taper after regrinding
• Control grinding procedure; high up on the insert, anti- • Control grinding procedure;
7
chamfer the edge taper causes it. chamfer the edge

• Chisel bits must be reground • When a crack has • Chisel bits must be reground
when anti-taper exceeds 8 mm developed close to the when anti-taper exceeds 8 mm
bazing joint, it may be
• Remove snakeskin (shorter brazing defect • Remove snakeskin (shorter
intervals between regrinding) intervals between regrinding)
• Reduce impact force when • Reduce impact force when
collaring collaring
263 of 326
Type of failure
S11 Insert crushed between L1 Whole insert vanished
transversal cracks

8
Rare kind of failure: • Control and adjust your • If the insert has vanished • Regrind the drill steel even if
• Bad grinding (e.g deep grinding procedure, change to before the first grinding, this the insert is not worn, as fatigue
grinding scratches due to correct grinding wheel may be due to brazing in the brazing often starts from
use of wrong grinding wheel) • Chamfer the edge after failure the tip of the insert, thereby
grinding • The insert can also leave causing the possibility of failure
• Too sharp edge after
grinding its place after a lengthy
drilling cycle in non-abrasive
• Wrong (too acute) insert rock.
angel after grinding This is not due to a
manufacturing defect but
fatigue of the brazing joint
264 of 326
Type of failure
L2 Part of insert vanished L3 Insert chipped at base

Starting same as S1 • Control and adjust your Rare kind of failure. Probably: • Check the taper after regrinding
• Bad grinding (e.g deep grinding procedure, change to –Anti-taper • Control grinding procedure;
9
grinding scratches due to correct grinding wheel chamfer the edge

–Snakeskin
use of wrong grinding wheel) • Chamfer the edge after • Inserts must be reground when
grinding • When a crack is located
• Too sharp edge after high up on the insert, it is anti-taper exceeds recommen-
grinding caused by anti-taper dations:
• Wrong (too acute) insert –Cross bits/X-bits max 6 mm
• When a crack has –Integrals max 8 mm
angel after grinding developed close to the
brazing joint. It may be a • Remove snakeskin (shorter
brazing defect intervals between regrinding)
collaring
265 of 326
Type of failure
L4 Front completely damaged L11 Insert crushed close to solid centre.
Slot partly stripped of carbide

10
Started as another failure: • Control and adjust your grinding Started as another failure: • Control and adjust your grinding
• Small edge angel procedure, change to the correct • Small edge angel procedure, change to the correct
grinding wheel grinding wheel
• Bad grinding (e.g deep • Bad grinding (e.g deep
grinding scratches due to use • Chamfer the edge after grinding grinding scratches due to use • Chamfer the edge after grinding
of wrong grinding wheel) • Control grinding procedure; of wrong grinding wheel) • Control grinding procedure;
chamfer the edge
chamfer the edge
• Inserts must be reground when
• Inserts must be reground when anti-taper exceeds
anti-taper exceeds recommendations:
8 mm –Cross bits/X-bits max 6 mm
• Remove snakeskin (shorter –Integrals max 8 mm
intervals between regrinding) • Reduce impact force when
• Reduce impact force when collaring
collaring 266 of 326
Type of failure
Breakage rod Riveted striking face, lugs, splines
or collar

• From inside, most probably • Clean and oil equipment before • Worn-out bushing • Repair the rock drill and change
11
due to corrosion on used steel storage • Insufficient lubrication of the worn parts
after storage shank • Check the lubricator
• Handle equipment with care, use
• From wrench flat, as above proper wrenches and tools, not • Deformed striking face of the
or blow mark sledge-hammers piston
• From corner, blow mark
267 of 326
Type of failure
F1 Part of flank F2 Part of insert and flank missing F3 One flank missing
missing
12
F4 One flank and F5 Both flanks F6 Longitudinal

whole insert and flank breakage of insert
missing missing and one flank missing
268 of 326
F1–F6
Cause Remedy
Starting as another failure. • Control and adjust your grinding
Probably: procedure, change to correct
• Bad grinding (e.g deep grinding wheel
grinding scratches due to use • Chamfer the edge after grinding
of wrong grinding wheel) • Check the taper after regrinding
• Too sharp edge after grinding • Control grinding procedure;
• Wrong (too acute) insert chamfer the edge
angel after grinding. • Chisel bits must be reground
• When a crack is located up when anti-taper exceeds
on the insert, it is caused by
13
recommendations:
anti-taper • Cross bits/X-bits max 6 mm
• When a crack has developed • Integrals max 8 mm
close to the brazing joint. It • Remove snakeskin (shorter
may be a brazing defect intervals between regrinding)
collaring
269 of 326
Integral drill rods and tapered rods
Damage indication
N = Shank breakage
Side Joint 2
14
K = Bit breakage
C2= Upset shank striking face Top
u = Fracture starting from flat
h = Fracture starting from corner Base
i = Fracture starting from Side joint 1 Bottom joint
flushing hole
x = Starting point of fracture
cannot be determined
Flushing
hole
Please always indicate location of

”fatigue rose” if this can be determined.
If not, mark with x for example: N370x.
270 of 326
Examples:
N160 u = Fracture initiated by
outside force, 160 mm from shank
striking face.
N30i = Starting point of fracture i
in the wall of the flushing hole, 30 u
mm from shank striking face.
15
K70h = Starting point of fracture C2

at a corner, 70 mm from base of h
carbide insert or tapered end
A4 = The bit is squared

A4 B4
A10 = The solid centre is worn
A11 = The solid centre plugged (riveted)
B4 = Pieces missing in the skirt of the bit
C1 = Riveted threads
A10 A11 C1 K K20u =
271 of 326
Skirt broken, starting from outside and 20 mm
from bottom of insert
Extension equipment
Speedrod
C2
B2
N K
TAC Tubes
16
C2
B2
N K
Extension rods
C2
N K
272 of 326
Coupling sleeves
C1
B1 = Transversal crack
Machine
Bit
B2 = Longitudinal cracks
C1 = Riveted thread
K, N = The position of breakage
B2 B1 unknown
N
17
Shank adapters
N
Machine
Bit
A = See thread wear
C1 = Riveted thread
C2 C3 A C1 C2 = Riveted striking surface
Machine
C3 = Riveted splines of collar

Bit
K, N = The position of breakage

unknown
N K 273 of 326
Extension equipment
Type of failure
Damages to the bit body Thread or rod damages
A4 B4
C2 N K
Machine
Bit
A10 A11 C1 K
18
A4 = The bit is squared N50 = Thread broken 50 mm from end surface

A10 = The solid centre is worn nearest to rock drill
A11 = The solid centre plugged (riveted) K200a = Rod broken 200 mm from end surface
nearest to drill bit starting from a notch
B4 = Pieces missing in the skirt of the bit
N, K = The position to breakage unknown
C1 = Riveted threads
C2 = Riveted striking surface
K20u = Skirt broken, starting from outside and 20 mm
from bottom of insert
274 of 326
Wear of threads Breakage of rods
Degree of thread wear A-damages to threads Damage indication

A1 = Thread slightly worn Please always indicate location of ”fatigue rose” if this
A2 = Thread half-worn can be determined.
A3 = Thread worn out u = Fracture starting from flat
h = Fracture starting from corner
i = Fracture starting from flushing hole
A1 cannot be determined
u
19
A2 i i
u
A3 h
275 of 326
Button bits
Type of failure
S3 S4
S7
S1
20
S7u
S1 Button cracked S4 Top of button crushed on same

S3 Button crushed level as surrounding steel
S7 Top of button torn loose on same
level as surrounding steel
S7u Button broken-off inside the
276 of 326 bitbody
Type of failure
S1, S7 S3, S7u S4
Cause Cause Cause
• Overdrilling • Overdrilling • The button is too protruding due to high

• Wrong regrinding method or equipment • Wrong regrinding method or equipment wear of the surronding steel
• Snakeskin • Snakeskin • Careless collaring
• If gauge buttons are crushed the cause is
anti-taper
Remedy Remedy Remedy

21
• Reduce intervals between regrinding • Reduce intervals between regrinding • Lower the button to normal height, make
• Use proper equipment and technique for • Use proper equipment and technique for sure the height of the buttons are even
regrinding regrinding • Reduce the impact rate and feed force
• Regrind despite the button not being • Regrind despite the button not being when collaring
worn. Microscopic cracks in the carbide will worn. Microscopic cracks in the carbide
develop into failures will develop into failures
277 of 326
Button bits
Failure definitions Position definitions
CB GB
L1
F5
F1
22
F3
F1b
F4
CB Centre button
GB Gauge button
278 of 326
Type of failure Cause Remedy
• F1 • Overdrilled gauge button • Shorten grinding intervals
Crack close to gauge button • Damage caused by external object • Shorten grinding intervals and make
• Overdrilled gauge button. Repeated sure that the clearance angle is
• F1b overdrilling. correct
Crack in the flank starting from bottom of • Overdrilled gauge button in combination • Use caution when loosening the bit
button hole with anti-taper
• F3
Button undamaged but surrounding flank
partly missing
• F4
23
Button and part of surrounding flank

missing
• F5
Button and whole surrounding flank missing
• L1
Button loose
279 of 326
DTH Hammers
Driver Chuck
B2 = Longitudinal crack
Splines damage
A1 = 1–25 % worned out splines
A3 = >50 % worned out splines
24
Cylinder
K = Distance from chuck end
N = Distance from top sub end
280 of 326
Piston
B4 = Breakage on the end portion
C2 = Striking face
K, N = Distance from striking face
and end portion of piston
Control Tube Top sub

25
B1 = Transversal crack B1 = Transversal crack

K, N = Distance from front B2 = Longitudinal crack
and end portion of control tube K = Cylinder thread
281 of 326 N = Tube thread
DTH
DTH bits Drill Pipes
m B4 = Piece or pieces broken from
N mm Km striking face
N,K = Distance from striking
B1 surface or bit front
B2
B2
B4
B1
26
N K
Splines
Damage indication A-damage
u = Fracture starting from A1 = No wear 0–1 mm
outside of shank h i A2 = Wear 1– mm
h = Fracture starting at A3 = Wear >2 mm
corner of splines
i = Fracture starting from A
flushing hole
not localized
Please always indicate location of u 282 of 326
”fatigue rose” if this can be determined.
Bit damages
S1 CB GB
S4 L1
S3
S7 F1 F5
S7u
27
F1b F3
S1 Button cracked
F4
S3 Button crushed
S4 Top of button crushed on same CB Centre button
GB Gauge button
S7 Top of button torn loose on same
S7u Button broken-off inside the
bitbody 283 of 326
COPROD®-system
COPROD® -section complete

2 Tube
N = Fracture from rock drill end (mm)
K = Fracture from bit end
1
Rod
28

C2 = Upset striking face
End piece
Tube driver, complete N = Fracture from rock drill end (mm)
N = Fracture from rock drill end (mm) 2 K = Fracture from bit end
1
284 of 326
COPROD® –head complete
2 Bit tube
B1 = Transversal cracks
1
2 Bit rod
C2 = Upset striking face
1
Bit chuck
29

B1 = Transversal cracks
Bit driver
A3 = >50 % worned out splines
COPROD® –bit
Bit damage, see DTH bits, N,K= Distance from striking surface or bit front
page 26–27 B1 = Transversal cracks
285 of 326 B4 = Piece or pieces broken from striking face
Notes
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
286 of 326
30
287 of 326
Atlas Copco Secoroc AB
SE-737 25 Fagersta, Sweden
Tel +46 223 461 00 • Fax +46 223 461 01
www.secoroc.com
288 of 326
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Reg. code
AIB TAB 43
COP 1838
2002–02
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© Atlas Copco Rock Drills AB, 2002. All rights reserved.
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291 of 326
6$)(7<5(*8/$7,216
• 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 &28/'

:$51,1* result in serious or fatal injury if the warning is not observed.
indicates hazards or hazardous procedures which &28/'

&$87,21 result in injury or damage to equipment if the warning is not
observed.
The following safety rules must also be observed:
• Carefully read through all operating- and main- • Use Atlas Copco genuine parts only. Any
tenance instructions for the drill rig and rock damage or malfunction caused by the use of
drill before putting the rock drill to use. Always unauthorized parts is not covered by Warranty
follow the instructions given. or Product Liability.
• Do not use or intervene in the rock drill unless • Never attempt to carry out maintenance while
you have been trained to do so. the drill rig is in operation.
• Those checks and adjustments that must be
• The rock drill may only be used for the pre- made while the drill rig is in operation must be
scribed purposes. carried out by at least two persons. One per-
son must man the control station and keep a
• Make sure that the drill rig has been maintai- strict watch over the work.
ned in accordance with the current instructions.
• To prevent injury during service and mainte-
• Make sure that all safety labels remain in pla- nance, all components that could possibly
ce, and that they are kept clean and fully legib- move or drop must be supported safely on
le. See the spare parts list for details of label blocks or trestles, or secured by means of
locations and part numbers. adequately dimensioned slings.
• Always wear a safety helmet and ear protec- • Before starting work on any of the systems,
tors during drilling. Any local regulations that make sure that the hydraulic, air and water sys-
exist must also be observed. tems are without pressure, and that the electri-
cal system is dead.
• Before moving the drill rig or starting to drill, • Check that the hoses used are of the right qua-
make sure that there are no personnel in the
lity, and that all hose connections are in good
immediate vicinity of the drill rig.
condition and properly tightened.
&RQWHQWV 3DJH
Safety regulations . . . . . . . . . . . . . . . . 2 Setting of ECL lubricating system . . . . . . . 10

Action list . . . . . . . . . . . . . . . . . . . . . 3 Lubrication of gear . . . . . . . . . . . . . . . 11
Hose connections . . . . . . . . . . . . . . . . 4 Setting the damper pressure . . . . . . . . . . 11
Tightening torques . . . . . . . . . . . . . . . . 5 Setting the extractor-unit pressure (MEX/HEX) 11
Accumulators . . . . . . . . . . . . . . . . . . 6 Removing the front head . . . . . . . . . . . . 12
– Charging the accumulators . . . . . . . . . . 6 Checking the front head . . . . . . . . . . . . 13
– Checks in the event of hose vibration . . . . . 7 Changing the flushing head and driver . . . . 14
– Changing the accumulators . . . . . . . . . . 8 Mounting the front head . . . . . . . . . . . . 16
– Changing the return accumulator . . . . . . . 9 Slinging . . . . . . . . . . . . . . . . . . . . 18
Changing the hydraulic motor . . . . . . . . . . 9 Long-term storage . . . . . . . . . . . . . . . 18
Filling with lubricating oil and bleeding the system....10
............ Recommended hydraulic oils and lubricants . 19
2
292 of 326
:$51,1* $FWLRQOLVW
• %HIRUHVWDUWLQJDQ\PDLQWHQDQFHZRUN %HIRUHVWDUWLQJXSDQHZRU
PDNHVXUHWKDWWKHHOHFWULFDOV\VWHPLV
GHDG QHZO\RYHUKDXOHGURFNGULOO 3DJH
7KHUHLVDULVNRILQMXU\LIWKHVHLQVWUXFWLRQV • Connect up the hoses . . . . . . . . . . . . 4
DUHQRWREVHUYHG • Charge the accumulators . . . . . . . . . . . 6
• Select a suitable hydraulic oil and lubricant . 19
• Fill the lubricating system with oil . . . . . . . 10
• Adjust and set the lubricating system . . . . 10
&$87,21 • Set the damper pressure . . . . . . . . . . . 11
• 7DNHFDUHGXULQJURGMRLQWLQJDQGZKHQ • Set the extractor-unit pressure (MEX/HEX) . 11
KDQGOLQJWKHGULOOELW0LQG\RXUILQJHUV
• .HHS\RXUFORWKLQJDZD\IURPURWDWLQJ (YHU\VKLIW
PDFKLQHSDUWV
• Check that air and lubricating oil come out
&DUHOHVVQHVVFDQOHDGWRVHULRXVLQMXU\ between the shank adapter and front guide
and also out of the hole in the front head . . 13
• $OZD\VXVHHDUSURWHFWRUVGXULQJGULOOLQJ
+LJKQRLVHOHYHOVGDPDJHKHDULQJ • Check that the damper-pressure gauge on
the drill rig shows the normal value. In case
• 1HYHUDWWHPSWPDLQWHQDQFHRULQWHUYHQH of deviation, adjust the damper pressure . . . 11
LQWKHURFNGULOOFRQQHFWLRQVRUKRVHVZKL
OHWKHK\GUDXOLFOXEULFDWLRQRUIOXVKLQJ • Check that the shank-adapter threads are
V\VWHPVDUHSUHVVXUL]HG not damaged . . . . . . . . . . . . . . . . . 13
$LURURLOFDQVTXLUWRXWDWKLJKSUHVVXUH • Keep an eye on the hydraulic hoses. If they
DQGKLJKWHPSHUDWXUHZLWKWKHULVNRI vibrate too much, check the accumulators . . 7
VHULRXVLQMXU\WRWKHH\HVDQGVNLQ • Check that there is no leakage from the rock
drill. 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 . . . . . . 13
In the event of defect, remove to a suitable
workshop for repair or replacement.
$IWHUWKHILUVWVKLIWZKHQXVLQJD
QHZRUQHZO\RYHUKDXOHGURFNGULOO
• Tighten all threaded unions . . . . . . . . . 5
$IWHUHYHU\WKSHUFXVVLRQKRXU
,03257$17
• Grease the gear . . . . . . . . . . . . . . . 11
• 2EVHUYHJUHDWFOHDQOLQHVVZKHQLQWHUYH • Tighten all threaded unions . . . . . . . . . 5
QLQJLQWKHURFNGULOORULWVK\GUDXOLFFLU • Check the safety labels on the accumulators.
FXLW Replace them if they are damaged or illegible . 6
• 7KHIROORZLQJSDUWVPD\EHFKDQJHGDWWKH • Check the return accumulator . . . . . . . . 7
ZRUNVLWHLQDFFRUGDQFHZLWKWKHLQVWUXF
WLRQVJLYHQ
±VKDQNDGDSWHU (YHU\WKSHUFXVVLRQKRXU
±GULYHU • Remove the rock drill from the drill rig and
±IURQWKHDGSDUWV send it to a suitable workshop for over-
±DFFXPXODWRUV hauling*.
±K\GUDXOLFPRWRU
±VFUHZV
±FRQQHFWLRQV
* The rock drill should be overhauled at suitable intervals,
2WKHUUHSDLUVPXVWEHFDUULHGRXWLQDVXL based on local conditions. The characteristics of the rock will
have a great influence on the rate of wear, and thus on the
WDEOHZRUNVKRSLQDFFRUGDQFHZLWKWKH required frequency of overhauling.
3
293 of 326
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&$87,21 • Clean the hose connections on the rock drill be-
fore removing the protective plugs (or caps).
• 1HYHUDWWHPSWPDLQWHQDQFHRULQWHUYHQH
LQWKHURFNGULOOFRQQHFWLRQVRUKRVHVZKL • Never remove a protective plug until the hose is
OHWKHK\GUDXOLFOXEULFDWLRQRUIOXVKLQJ ready to be connected.
V\VWHPVDUHSUHVVXUL]HG • Always store the rock drill with all hose connec-
$LURURLOFDQVTXLUWRXWDWKLJKSUHVVXUH tions plugged. Use suitable protective plugs or
DQGKLJKWHPSHUDWXUHZLWKWKHULVNRI caps, and make sure that they are clean.
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• 3UHVVXUHKRVHVZLWKDQLQWHUQDOGLDPHWHU
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COP 1838ME/HE/HF COP 1838MEX/HEX
3B
3A 2 2
N.B. Tighten item Nos. 1–3 in the prescribed order.
5HI1R 4W\ &KHFNSRLQW 7RUTXH ,QVWUXFWLRQV

1P OEIIW
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/HF 350 260 Tighten the front nuts
3B 3 Side bolts (MEX/HEX) 300 220 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
15 1 Intake, extractor unit 120 90
16 1 Return, extractor unit 120 90
5
295 of 326
$FFXPXODWRUV
The accumulators are fitted with safety labels as = Read the instruction book carefully
shown in the figure below. before servicing or changing
1250 0020 91
'DPSHUDFFXPXODWRU
,QWDNHDFFXPXODWRU = Must be charged with nitrogen only
5HWXUQDFFXPXODWRU
1250 0027 19
&KDUJLQJWKHDFFXPXODWRUV
:$51,1* 1. Remove the protective cap (4).
• 7KHDFFXPXODWRUVPXVWEHFKDUJHGZLWK 2. Open the valve nut (5) by 2–3 turns, and con-
QLWURJHQ 1 RQO\ nect the gas hose.
2WKHUJDVHVFDQFDXVHDQH[SORVLRQ 3. Open the gas valve (6).
4. Charge the accumulators to the correct
pressure, as follows:
– Damper accumulator (1): ±EDU
±SVL
&$87,21 – Intake accumulator (2): EDU
EHORZWKHFROODULQJSUHVVXUH
• 'R127FKDUJHWKHDFFXPXODWRUVXQWLO SVL
WKH\KDYHEHHQILWWHGWRWKHURFNGULOO 5. Tighten the valve nut (5) and close the gas val-
7KHUHLVDULVNRILQMXU\LIWKHVHLQVWUXF ve (6).
WLRQVDUHQRWREVHUYHG
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.
6
296 of 326
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'DPSHUDFFXPXODWRU DQG
,QWDNHDFFXPXODWRU
1. Press in the pin on the test valve (7). If the ac-
cumulator is charged, the pin will stick out by
4.5 mm and give a firm resistance when pres-
sed in.
1% The damper-accumulator pin is somewhat
easier 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 functioning
properly (see page 8).
3. After fitting a new accumulator, charge it with
nitrogen.
N.B. The seat of the charging valve can easily
become deformed when opened and closed re-
peatedly. The charging valve should therefore
be changed regularly.
5HWXUQDFFXPXODWRU
(Check every 40th percussion-hour)
1. Put the rock drill in the horizontal position, as
shown in the figure.
2. Remove the plug with O-ring (8). If oil comes
out, 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.
1250 0027 20
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&$87,21 &$87,21
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Remove the accumulators (1 and 2) together with 7KHGDPSHUDFFXPXODWRU PXVWKDYH
the sealings (3) by removing the screws (4 and 5 WZRVFUHZV RIOHQJWKPP
or 6). &KDQJHERWKVFUHZVDWWKHVDPHWLPH
HYHQLIRQO\RQHRIWKHPLVFRUURGHG RU
Now send the accumulators to a workshop for GDPDJHGLQVRPHRWKHUZD\
overhauling! 'HIHFWLYHVFUHZVFDQFDXVHGDQJHURXVRLO
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Fit the sealings (3) to accumulators (1 or 2), and

then fit the accumulators to the intermediate part
(7).
Fit the damper accumulator (1) to the left-hand
side of the rock drill. Fit the intake accumulator (2)
to the right-hand side of the rock drill, i.e. the hose
side. Tighten the screws (4 and 5, or 6) alternately
to a torque of 220 Nm (160 lbf.ft).
Now charge the accumulators with nitrogen (N2).
See page 6.
8
298 of 326
&KDQJLQJWKHUHWXUQDFFXPXODWRU &KDQJLQJWKHK\GUDXOLF
1250 0027 22 PRWRU
8 5
10
1250 0027 23
9
3
2
5HPRYDO 5HPRYDO
Disconnect the hydraulic hoses (1).
&$87,21 Remove the return accumulator (3).
• %HIRUHLQWHUYHQLQJLQWKHK\GUDXOLFZDWHU Remove the nuts (2) and take off the hydraulic mo-
RUDLUV\VWHPVPDNHVXUHWKDWWKHUHLVQR tor (3).
SUHVVXUHLQWKHV\VWHPV
Pull out the coupling (4).
• 3UHVVXUHKRVHVZLWKDQLQWHUQDOGLDPHWHU
RIPP RUPRUHDUHUDWHG6$(
55 LHKLJKSUHVVXUHKRVHZLWKIRXUOD\
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PHQW 6HHVSDUHSDUWVOLVWIRUGULOOULJ
)RUVDIHW\UHDVRQVWKHVHKRVHVPXVWQRW
XQGHUDQ\FLUFXPVWDQFHVEHUHSODFHG 0RXQWLQJ
ZLWKKRVHVRIDORZHUUDWLQJ
Make sure that the circlip (5) is fitted into the coup-
7KHUHLVDULVNRILQMXU\LIWKHVHLQVWUXFWLRQV ling (4).
DUHQRWREVHUYHG
Grease the splines inside the coupling, and slide
the coupling on to the output shaft of the hydraulic
Disconnect the hydraulic hose (8) from the return motor (3).
accumulator (3).
Fit the hydraulic motor (3) with gasket (7) to the
Remove the return accumulator (3) by removing cylinder (6). Change the gasket if it is damaged.
the nuts (2), screws (1).
Tighten the nuts (2) to a torque of 65 Nm (48 lbf.ft).
Pull off the clamp (5) and unscrew the accumulator
from the nipple (7 on surface drill rigs) or Connect the hydraulic hoses (1). Check that the
(9 on underground drill rigs). motor rotates in the correct direction.
Now send the accumulator to a workshop for over-
hauling!
0RXQWLQJ
Fit 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).
9
299 of 326
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• If the lubricating system has been empty of oil, it
&$87,21 must be bled after filling.
This is done as follows:
– Loosen the cap (7) and let the lubricating oil
• 1HYHULQWHUYHQHLQWKHOXEULFDWLQJV\VWHP escape until all air has been discharged from
ZKLOHLWLVSUHVVXUL]HG
/XEULFDWLQJRLOFDQVTXLUWRXWZLWKWKH the lubricating oil pump. Now tighten the cap.
ULVNRILQMXU\WRWKHH\HVDQGVNLQ – 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.
,03257$17 – Disconnect the lubricating-air hose (12) from
the nipple (11) on the rock drill.
• 8VHWKHUHFRPPHQGHGOXEULFDWLQJDLUSUHV – Start the lubricating pump and let it pump until
VXUHDQGWKHUHFRPPHQGHGOXEUL oil comes out of the plastic hose (10).
FDWLQJRLO When re-starting (after standstill), oil must
&HUWDLQPRYLQJSDUWVRIWKHURFNGULOODUH come out of the plastic hose directly when the
OXEULFDWHGE\PHDQVRIRLOPL[HGFRPSUHV lubricating pump is started.
VHGDLU,WLVLPSRUWDQWWKDWWKHVHSDUWVUH – Check that the plastic hose (10) for lubricating
FHLYHJRRGOXEULFDWLRQ oil is of the correct length. It must not protrude
into the machine.
– Re-connect the lubricating-air hose (12).
• 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 (see
page 19). The lubricating-oil container holds 5
litres.
6HWWLQJRI(&/OXEULFDWLQJV\VWHP
1. Open the electrical cabinet. underground-
drill rigs
surface-
drill rigs
2. Start the lubricating system (see the operator’s 10

3 4 A
instructions for the drill rig).
R 6
3. Check the lubricating air pressure at the rock T1 T2
drill (11) using a pressure gauge (A). The pres- 5 B
G
sure should be ±EDU If the pressure is too
low, clean the restrictor (9) or increase the dia- B
2 1
meter of the restrictor.
8QGHUJURXQGGULOOULJV B
Min. oil level
4. Check that the green light emitting diode (G) 11
indicates power on. 7
F 12
5. Adjust the screw (T1) so that the light emitting
time of the yellow diode (R) is 0.5 seconds.
6. Observe the yellow diode (R) and adjust the
lubricating oil dosage to ±SXOVHVPLQ, by 9
1250 0027 77
+ _
means of the screw (T2). 8
24 V
6XUIDFHGULOOULJV
4. Observe the relay window (5) and adjust the
lubricating oil dosage to ±SXOVHVPLQ, by /XEULFDWLQJRLOFRQWDLQHU /XEULFDWLQJDLUFRQQHFWLRQ
means of the potentiometer (6). )LOOHUFDS /XEULFDWLQJDLUKRVH
3XOVHUHOD\ $3UHVVXUHJDXJH
After making the respective setting, check the LED 3XOVHUHOD\
(F) on the lubricating pump to ensure that the right )/LJKWHPLWWLQJGLRGH /('
5HOD\ZLQGRZ **UHHQ/('
pulse frequency has been obtained. Check also
3RWHQWLRPHWHU 5<HOORZ/('
that oil comes out of the hole (B) in the front head
and between the shank adapter and front guide. &DSEOHHGLQJ 7$GMXVWPHQWVFUHZ
3UHVVXUHJDXJH OLJKWHPLWWLQJWLPH
5HVWULFWRU 7$GMXVWPHQWVFUHZ
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10
300 of 326
/XEULFDWLRQRIJHDU
1. Remove the bleeder plug (1).

2. Grease the gear through the nipple (2) until gre-
ase comes out of the hole (3). Use heat-
resistant grease (see "Recommended hydraulic
oils and lubricants", page 19).
1250 0027 25
3. Fit back the plug (1).
6HWWLQJWKHGDPSHU
SUHVVXUH
1. Shut completely the constant-flow valve (B) on
the drill rig.
2. Connect a pressure gauge (A) [calibrated from
0 to 60 bar] between the hose and the damper
1250 0027 26
nipple (1).
3. Pressurize the damper circuit.
4. Check that the shank adapter is unloaded, and
that it has been pushed into the forward position.
5. Adjust the constant-flow valve until the pressure
gauge (A) reads 30–35 bar.
6. Read off the pressure on the damper pressure
gauge on the drill rig.
If the pressure gauge later shows a different va-
lue, make a new pressure setting.
7. Disconnect the pressure gauge (A) and re-
connect the hose to the nipple (1).
6HWWLQJWKHH[WUDFWRUXQLW
SUHVVXUH 0(;+(;
1. Close the constant-flow valve (B) on the drill rig
completely.
1250 0027 29
2. Connect a pressure gauge (A) [calibrated from

0 to 60 bar] between the hydraulic hose and the
extractor-unit intake nipple (P).
3. Connect the circuit for the extractor unit by acti-
vating feed reverse and running the cradle to
the stop at the rear end of the feed beam. Hold
the feed lever in the "feed-reverse" position.
4. Adjust the constant-flow valve (B) until the pres-
sure gauge (A) reads 20–25 bar.
5. Disconnect the pressure gauge (A) and re-
connect the hydraulic hose to the extractor-unit
intake nipple (P).
11
301 of 326
5HPRYLQJWKHIURQWKHDG
&$87,21
• Never attempt maintenance work while the
drill rig is in operation.
• %HIRUHLQWHUYHQLQJLQWKHK\GUDXOLFZDWHU
RUDLUV\VWHPVPDNHVXUHWKDWWKHUHLVQR
SUHVVXUHLQWKHV\VWHPV
7KHUHLVDULVNRILQMXU\LIWKHVHLQVWUXFWLRQV
DUHQRWREVHUYHG
N.B. Always clean the outside of the rock drill befo-

re disassembly.
1250 0027 30
&230(+(+)
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).
Remove the front head (1) by tugging the shank
adapter (4).
Now pull out the shank adapter (4) from the front
head (1).
1250 0027 31
Check the internal components of the front head

when changing the shank adapter.
&230(;+(;
Remove the front side-bolt nuts (3) with their
washers (2).
Remove the front head (1) by tugging the shank
adapter (4) or by tapping the front head with a cop-
per hammer.
1250 0027 32
Now pull out the shank adapter (4) from the front
head (1). Check the internal components of the
front head when changing the shank adapter.
12
302 of 326
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11 11 11 3 3 3 3 A 12 9
8 7 3 A 3 3 1 5 6 2 9
1250 0071 63
C
4 B 8 7 C C
12 10 4 B 6 5 2 9
COP 1838ME/HE COP 1838MEX/HEX
1 1m
m 3 3 4 3 3 11 10 11 11
1 mm
R38
T38
ME/HF ME/HE MEX/HEX
1 1m
m 3 3 4 3 3
5
T45 2 mm
T51
ME/HE MEX/HEX
2
m 6
1m 7 7
R38 T38
39 mm 53 mm T45
T38
T51
• Check that air and lubricating oil come out be- • Look inside the gear housing and check the spli-
tween the shank adapter (6) and front guide nes of the driver (5). If the splines are less than
(7), and also out of the hole (B). PP in width, the driver must be changed (see
• Blow clean the lubricating oil ducts (A) using page 14).
compressed air, and check that the restrictors Fit a new driver with the aid of a suitable mand-
(9) are open. rel and a copper hammer.
• Change the guide (7) if its internal diameter is • If the rotation chuck bushing (2) is worn by more
greater than PP or PP. than PP, or if the striking surface of the im-
pact piston (12) is damaged in any way, the rock
• Check the O-rings and flushing seals (3) if drill must be sent to a suitable workshop for over-
air/water is escaping from the hole (C) in the
hauling. See the overhauling instructions.
front head. Change the O-rings and flushing
seals if they are worn or damaged. • Change the shank adapter (6) if the thread is
worn out or the impact surface is upset or chip-
• Change the flushing head (4) if it is seriously cor-
ped, or if the front or rear end surfaces of the
roded, or if it contains cracks.
splines are worn.
• Change the stop ring (1) if it is worn by more
• Check that the drill collar (8), which must be
than PP.
used in upwards-directed drilling, is not dama-
• Change the extractor-unit piston (10) if the surfa- ged and that it rotates with the shank adapter.
ce toward the shank adapter has worn by more
than PP.
When changing the extractor-unit piston, check
the seals and O-rings (11). Change them if they
are worn or damaged.
13
303 of 326
&KDQJLQJWKHIOXVKLQJKHDGDQGGULYHU
'LVDVVHPEO\
&$87,21
• 7DNHFDUHZKHQUHPRYLQJWKHIOXVKLQJ
KHDGDQGGULYHU0LQG\RXUILQJHUV
Remove the flushing hose (1) from the nipple (2).

Remove the nipple (3) and its O-rings.
Press the disassembly tool (A) into the gear hou-
sing (4) until it comes to a stop, i.e. until the spli-
ned part of the tool has passed the splines of the
driver (5).
Turn the disassembly tool clockwise a little.
Tap out the driver (5) and flushing head (6) by stri-
king with the impact hammer (B).
1250 0027 34
14
304 of 326
$VVHPEO\
1250 0027 35
Tap the driver (2) into the rotation chuck in the

gear housing (1) with the aid of a mandrel (A) and
a copper hammer.
Fit the O-rings (3) and seals (4) into the flushing
1250 0027 36
head (2).
IMPORTANT! The seals (4) must be turned as
shown in the figure opposite.
Place the flushing head (2) into the cover (1) and
tap it in using a copper hammer. Check carefully
that the flushing intake in the cover lines up with
the hole in the flushing head.
Fit the O-rings (5 and 6) and back-up ring (7) on to
the nipple (8).
Fit the nipples (8, 9 and 10) and the nut (11).
Tighten the nipple (8) to a torque of 300 Nm
(220 lbf.ft) and the nipple (9) to a torque of 180 Nm
(130 lbf.ft).
15
305 of 326
0RXQWLQJWKHIURQWKHDG
&230(+(+)
Fit the stop ring and shank adapter (4) into the
front head (1).
Check that the pin (6) is fitted into the cover. Fit
the front head (1) on to the side bolts (5).
ase (type NEVER-SEEZ).
1250 0027 37
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) into the flushing head.

Fit the connection plate (1) to the front head using
the washers (6) and screws (3). Tighten the
screws (3) to a torque of 90 Nm (65 lbf.ft).
Change the seal washer (7) if it is damaged.
1250 0027 38
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 coup-
ling nut.
After assembly, check that air and lubricating oil
come out of the hole in the front head and also be-
tween the shank adapter and the front guide.
16
306 of 326
&230(;+(;
1250 0027 39
Fit the shank adapter (4) into the front head of the
extractor unit.
Check the tightening torques of the rear side-bolt
nuts and front side bolt (see 1–2, page 5).
Fit the cylindrical pin (5).
Fit the front head (1) over the stud bolts (6).
ase (type NEVER-SEEZ).
Tighten the nuts (3) alternately to a torque of
300 Nm (220 lbf.ft).
Connect the flushing hose to the nipple (7).
After assembly, check that air and lubricating oil
come out of the hole in the front head and also be-
tween the shank adapter and the front guide.
17
307 of 326
6OLQJLQJ
1250 0027 40
Make sure that the rock drill is safely slung for

lifting. Make sure that the rock drill is securely
anchored for transportation.
5RFNGULOOZHLJKWVDSSUR[
&$87,21 COP 1838ME/HF . 170 kg (375 lbs)
COP 1838HE . . . 176 kg (390 lbs)
• /LIWLQJJHDUDQGVOLQJVPXVWEHDSSURYHG COP 1838MEX . . 230 kg (505 lbs)
IRUDZHLJKWRINJ OEV
COP 1838HEX . . 236 kg (520 lbs)
)DXOW\OLIWLQJJHDUFDQFDXVHWKHURFNGULOO
WRPRYHXQSUHGLFWDEO\RUGURS
,QFRUUHFWKDQGOLQJFDQUHVXOWLQFUXVK
LQMXULHV
/RQJWHUPVWRUDJH
If the rock drill is not going to be used for a long
time, the following precautions should be taken:
• Check that all connections, including the one for

the flushing medium, are properly plugged or
capped. Use clean protective plugs or caps of
the right size.
• Clean the rock drill thoroughly. Use a degre-
asing agent and hose down the rock drill with wa-
ter.
• Thoroughly clean the front head parts that are in
contact with the flushing medium, especially in
the case of high air humidity. After cleaning, oil
the parts with clean hydraulic oil.
• Release the gas from the accumulators (see in-
structions on page 8).
• Store the rock drill in a dry place.
18
308 of 326
5HFRPPHQGHGK\GUDXOLFRLOVDQGOXEULFDQWV
/XEULFDQW 5HFRPPHQGDWLRQ
+\GUDXOLFRLO • Use a mineral-base or synthetic (polyalpha-olefin or diester based) hydraulic oil with good anti-wear, anti-rust,
anti-oxidation and foam inhibiting properties, and with good air and water separation characteristics. Choose an
oil with viscosity grade (VG) and viscosity index (VI), in accordance with the table below. An oil with a high
viscosity index is less sensitive to the effects of temperature.
Hydraulic oil temperature in tank R& R) 9LVFRVLW\ 9LVFRVLW\

Normal operating temp. Min. starting temp. Max. temp. JUDGH9* LQGH[9,
YLVFRVLW\±F6W YLVFRVLW\PLQF6W ,62
+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
$LUWRRORLO • Use a mineral base air tool oil.

Ambient temperature R& R) 9LVFRVLW\JUDGH ,62
–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
*UHDVH • IMPORTANT! Because of the operating temperature in the rock drill gear housing (see "Lubrication of 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.
R R
Grease properties 1/*,QXPEHU %DVHRLOYLVFRVLW\ F6WDW & )
R R R R
'URSSLQJSRLQW & ) 2SHUDWLQJWHPS ±WR & ±WR )
19
309 of 326
Printed in Sweden
Atlas Copco, 2002
310 of 326
Reg. code
Worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIB TAB 43
Drill rig, type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COP 1838ME 05
Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1995–04
Setting the drilling parameters for the COP 1838ME 05 hydraulic rock drill
Drifting and tunnelling – Roof bolting – Reaming
N.B. Base settings should be made only after the hydraulic oil temperature in the tank has
stabilized at normal operating temperature.
Base setting Current setting

1. Intake accumulator (percussion) charge to the
collaring pressure less 30 bar, max. 110 bar * . . . . . . . . . . . . . . . . 100 bar . . . . . . bar
2. Damper accumulator charge to * . . . . . . . . . . . . . . . . . . . . . . . . . . 20–25 bar . . . . . . bar
3. Damping pressure (measured at rock drill) adjust to . . . . . . . . . . . 30–35 bar . . . . . . bar
(by adjusting the oil flow *)
Corresponding pressure at the control panel . . . . . . . . . . . . . . . . . 40–45 bar . . . . . . bar
4. Percussion pressure, at the control panel:
Collaring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130–140 bar . . . . . . bar
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 bar . . . . . . bar
5. Feed pressure (pf) with BMH 6000 feed:
Collaring – horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 bar ...... bar
Collaring – vertically upwards . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 bar ...... bar
Drilling – max. (pf,max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 bar ...... bar
Corresponding damping pressure . . . . . . . . . . . . . . . . . . . . . . . . 80 ± 5 bar ...... bar
6. Rotation speed:
Button bit . . . . . . D = 43–51 mm . . . . . . . . . . . . . . . . . . . . . . . . 230 rpm . . . . . . rpm
Insert bit . . . . . . . D = 43–51 mm . . . . . . . . . . . . . . . . . . . . . . . . 200 rpm . . . . . . rpm
Reaming bit . . . . D = 89–102 mm . . . . . . . . . . . . . . . . . . . . . . . 120 rpm . . . . . . rpm
7. RPCF rotation pressure (pr)
– Read the "free-spin" rotation pressure (pr,i) bar (pr,r)
at normal operating temperature. 60
– Determine the rod-dependent rotation
pressure increase (pr,r) by finding the 50
intersection point for bit-dependent rpm (n)
on the curve for the drill rod in use. 40
– Correct RPCF pressure (pr) at the control
panel is obtained by adding the rod-depen-
30
dent rotation pressure increase (pr,r) to the T38-Hex 35-R32
"free-spin" rotation pressure (pr,i) :
20_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
R32
______
pr = pr,i + pr,r
10 R38-Hex 35-R32
Example (see diagram):
pr,i = 25 bar 0
Button bit, D = 45 mm 50 100 150 200 250 300 rpm (n)
n = 230 rpm
Drill rod = T38-Hex 35-R32
pr = 25 + 19 = 44 bar
Button bit . . . . . . . . . . pr = . . . . +. . . . = . . . . . . bar

Insert bit . . . . . . . . . . . pr = . . . . +. . . . = . . . . . . bar
Reaming bit . . . . . . . . pr = . . . . +. . . . = . . . . . . bar
8. Other settings on the drill rig:

– Flushing water pressure (at 70 l/min water flow) . . . . . . . . . . . . 20–25 bar . . . . . . bar
Printed in Sweden, Atlas Copco, Nacka • 1995
© Atlas Copco Rock Drills AB. All rights reserved.
– Positioning pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 bar . . . . . . bar

– Anti-jamming pressure (15 bar above RPCF pressure) . . . . . . . . . . . . . bar
– Lubricating air pressure at rock drill should be 2–3 bar *
Corresponding pressure on lubricating air pressure gauge . . . . . . . . . . bar
– Lubrication dosage * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–40 pulses/min . . . . . . pulses/min
* see printed matter No. 9852 0809 01

Settings performed by
. ........................... ..........
Authorized service engineer Date
ATLAS COPCO ROCK DRILLS AB • STOCKHOLM 311

• SWEDEN
of 326 No. 9852 0915 01a
,QVWUXFWLRQV :RUNVLWH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reg. code
+2:7286(7+(&23+)52&.'5,// 'ULOOULJW\SH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIB TAB 43
&23+)
6HULDOQXPEHU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
'ULIWLQJDQGWXQQHOOLQJ5RRIEROWLQJ5HDPLQJ 2002-02
,QWURGXFWLRQ At a certain percussion pressure, the penetration rate has a

6HWWLQJWKHGULOOLQJSDUDPHWHUVIRUWKH&23+)K\GUDXOLFURFNGULOO
rather flat maximum as a function of the rotation speed.
The COP 1838HF 05 control system is different to (and
more advanced than) conventional control systems for
The values given at point 6 in the table correspond to the Drifting and tunnelling – Roof bolting – Reaming
lowest rotation speed needed to achieve this maximum in
hydraulic rock drills. For this reason, it is very important Swedish "Bohus" granite. In other rock types, it is often pos-
to follow these instructions carefully. It may also be ne- sible to achieve the maximum penetration rate at lower rota- 1%%DVHVHWWLQJVVKRXOGEHPDGHRQO\DIWHUWKHK\GUDXOLFRLOWHPSHUDWXUHLQWKHWDQNKDV
cessary to revise some of the preconceptions you might tion speeds, but higher speeds than the one needed for Bo- VWDELOL]HGDWQRUPDORSHUDWLQJWHPSHUDWXUH
have had about the relationships that exist between URWD hus granite are seldom necessary.
WLRQ, IHHG and SHUFXVVLRQ in a drilling system. %DVHVHWWLQJ &XUUHQWVHWWLQJ
6HWWLQJWKHSUHOLPLQDU\SHUFXVVLRQSUHVV 1. Intake accumulator (percussion) charge to the
*HQHUDOLQVWUXFWLRQV XUHDQG53&)FRQWUROOHGIHHGSUHVVXUH collaring pressure less 40 bar, max. 110 bar * . . . . . . . . . . . 100 bar ........ bar
The COP 1838HF 05 hydraulic rock drill and its control 2. Damper accumulator charge to * . . . . . . . . . . . . . . . . . . . . . 20–25 bar ........ bar
system can be adjusted to give optimum drilling perfor- Adjust the percussion pressure to the base setting for dril-
ling, shown at point 4 in the table. 3. Damping pressure (measured at rock drill) adjust to . . . . . . 30–35 bar ........ bar
mance and economy at any worksite. Adjustments (by adjusting the oil flow *)
should be made before the drill rig is put to work, accor- Adjust the RPCF valve to the end position which always gi- Corresponding pressure at the control panel . . . . . . . . . . . . 40–45 bar ........ bar
ding to the worksite-specific conditions. Once the opti- ves the maximum feed pressure (pf,max).
mum settings have been established, further adjustment 4. Percussion pressure, at the control panel:
Perform a test drilling, using all base settings described Collaring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 bar ........ bar
is not necessary unless there is a major change in rock above. Observe the different functions of the drilling cycle,
conditions, or the dimensions of the drill steel equipment Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 bar ........ bar
and check that they work correctly. 5. Feed pressure (pf) with %0+ feed:
are changed.
Now set the rotation pressure for drilling on the RPCF-val- Collaring – horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 bar ........ bar
Detailed instructions for adjusting the settings are given ve. The pressure must be set according to the rotation spe- Collaring – vertically upwards . . . . . . . . . . . . . . . . . . . . . . 50 bar ........ bar
in the drill rig manual. Adjustment should be carried out ed for the drill-bit diameter and the type/size of drill rod Drilling – max. (pf,max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 bar ........ bar
only by personnel who have been trained to work on the being used, so that SU SULSUU. (See diagram and in- Corresponding damping pressure . . . . . . . . . . . . . . . . . . . 80 ± 5 bar ........ bar
system. In addition to normal hand tools, the following instructions at point 7 in the table.)The RPCF will now reduce
struments will be needed in order to make the adjustments: 6. Rotation speed:
the feed pressure (pf), so that pf is less than pf,max, unless Button bit . . . . . . . . . . . . . . D = 43–51 mm . . . . . . . . . . . 300 rpm ........ rpm
– Stop watch the rock is extremely hard or the drill bit is blunt. Insert bit . . . . . . . . . . . . . . . D = 43–51 mm . . . . . . . . . . . 320 rpm ........ rpm
– Tachometer When the drill bit is new or freshly reground, the resistance Reaming bit . . . . . . . . . . . . D = 89–102 mm . . . . . . . . . . 120 rpm ........ rpm
– Contact thermometer to rotation is greater, because the sharper drill bit "bites"
1%%DVHVHWWLQJVVKRXOGEHPDGHRQO\DIWHUWKH more deeply into the rock. Under such circumstances, the 7. RPCF rotation pressure (pr)
K\GUDXOLFRLOWHPSHUDWXUHLQWKHWDQNKDVVWDELOL]HG feed pressure is reduced (automatically). As bit wear incre- Read the "free-spin" rotation pressure (pr,i)
DWQRUPDORSHUDWLQJWHPSHUDWXUH ases, however, the RPCF function raises the feed pressure at normal operating temperature.
automatically toward the maximum value (pf,max), which en- bar (pr,r)
Determine the rod-dependent rotation 60
sures that the recommended rotation pressure
6HWWLQJWKHGDPSLQJSUHVVXUHV (SU SULSUU) is maintained. When the feed pressure rea-
pressure increase (pr,r) by finding the
intersection point for bit-dependent rpm (n)
The damper accumulator should be charged with nitro- ches pf,max, the drill bit should be reground, unless the rig 50
on the curve for the drill rod in use. orrect
gen (N2) to a pressure of 20–25 bar. Flow to the is equipped with an RPCI function, which is described be- RPCF pressure (pr) at the control panel is
damper (approx. 8 l/min) can be adjusted by means of a low. 40
obtained by adding the rod-dependent
constant-flow valve in the delivery line to the damping Compared with spherical-button bits, ballistic-button bits bite rotation pressure increase (pr,r) to the
cylinder. If the damping pressure reading is taken at the 30
damper nipple on the rock drill, it should be 30–35 bar.
deeper into certain rock types, which means that they give "free-spin" rotation pressure (pr,i) : T38-Hex 35-
greater resistance to rotation. This means that ballistic-button _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
If it is read off the damping pressure gauge on the control
panel, it should be 40–45 bar. When adjusting the dam-
bits usually require a lower feed pressure. For this reason, SU SULSUU 20 B

B R32
they can sometimes give straighter drill holes, compared with
([DPSOH VHHGLDJUDP
B
ping pressure, it is important that the damping piston rea- spherical-button bits. However, if drill bits with ballistic buttons
R38-Hex 35-
ches its front-end position in the damping cylinder. For 10 B

are used in abrasive rock, bit life will be lower and grinding SUL EDU B

B
this reason, the drill rod must be removed from the shank more difficult. %XWWRQELW' PP
B
adapter before the damping pressure setting is made. 0
Q USP 0 50 100 150 200 250 300 r/min (n)
6HWWLQJRI53&,FRQWUROOHGSHUFXVVLRQ 'ULOOURG 7+H[5
6HWWLQJWKHFROODULQJSUHVVXUHV SU EDU
SUHVVXUH LIILWWHG
Adjust the percussion and feed pressures for collaring to Button bit pr = . . . . +....... = . . . . . . . bar
the respective base values shown at points 4 and 5 in Adjust the RPCI valve so that the percussion pressure is re-
the table. duced when the rotation pressure falls below the recom- Insert bit pr = . . . . +....... = . . . . . . . bar
All rights reserved.
mended level (SU SULSUU). The RPCI function will then Reaming bit pr = . . . . +....... = . . . . . . . bar
reduce the impact power automatically when the rotation
6HWWLQJWKHPD[LPXPIHHGSUHVVXUH pressure becomes too low. This prevents the joints in the
drill string from loosening, e.g. when drilling has been con- 8. Other settings on the drill rig:
Adjust the maximum feed pressure (pf,max) to the base
tinued with a blunt drill bit in hard rock. Without the RPCI Flushing water pressure (at 70 l/min water flow) . . . . . . . . . . . . . . . . . 20–25 bar
value shown at point 5 in the table.
© Atlas Copco Rock Drills AB, 2002.
function, drilling under such circumstances would lead to in- Positioning pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 bar
creased thread wear, with a great risk of pitting (heat dama- Anti-jamming pressure (15 bar above RPCF pressure) . . . . . . . . . . . . bar
6HWWLQJWKHSUHOLPLQDU\URWDWLRQVSHHG ge and chipping). Pitting always causes premature thread Lubricating air pressure at rock drill should be 2–3 bar * . . .
Adjust the rotation speed to suit the drill bit diameter, ac- breakage. Corresponding pressure on lubricating air pressure gauge . ........ bar
cording to the base settings given for the respective drill Lubrication dosage * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–40 pulses/min ........ pulses/min
bit diameters at point 6 in the table. The system will now 6HWWLQJVSHUIRUPHGE\
maintain this speed, regardless of the conditions in the VHHSULQWHGPDWWHU1R
drill hole. The "free-spin" rotation pressure (pr,i) can be FRQW¶G
.
read off the pressure gauge for rotation when the drill bit $XWKRUL]HGVHUYLFHHQJLQHHU 'DWH
is not in contact with the rock.
$7/$6&23&252&.'5,//6$%• g5(%52•6:('(1 1RD 312 of 326

,QVWUXFWLRQV Reg. code
+2:7286(7+(&23+)52&.'5,// FRQW¶G AIB TAB 43
&23+)
'ULIWLQJDQGWXQQHOOLQJ5RRIEROWLQJ5HDPLQJ 2002–02
)XUWKHUDGMXVWPHQW±UHDVRQVDQGSURFHGXUH
The following signs indicate that the drill settings need /RZSHQHWUDWLRQUDWH
1250 0092 61
further adjustment:
1. Hot coupling sleeves
2. "Low" penetration rate
3. Frequent drill steel jamming
1250 0092 59
4. Other problems of a more complex nature, like exces-
sive bit wear (noticable only over longer periods of
time), excessive hole deviation, or other difficulties in 2WKHUSUREOHPV Wherever possible, large-diameter cut-holes should be
obtaining a smooth drilling sequence. given a slight upward inclination, in order to help the pas-
([FHVVLYHGULOOELWZHDU sage of cuttings out of the drill hole. Also, the operator
The rate of drill-bit wear can be reduced by reducing the should get into the habit of stopping the drilling at regular
m/min intervals to flush out the drill hole. This can avoid a lot of
rotation speed and/or the percussion pressure. If drill-bit
wear is excessive, the rotation speed should be reduced trouble, especially in fissured rock formations.
as much as possible, as long as this does not result in The penetration rate is of course lower during reaming,
If the penetration rate is lower than expected, even an unacceptable reduction in the penetration rate. Howe- compared with normal blast-hole drilling. What is more,
+RWFRXSOLQJVOHHYH though the rotation pressure is sufficient (SU SULSUU) ver, if the rotation speed is reduced, then the rotation the drill steel, and especially the shank adapter, is sub-
in relation to the feed pressure (pf is lower than pf,max), pressure increase (pr,r) must also be reduced. To obtain jected to much greater stresses during reaming. This me-
then the percussion pressure may be increased in steps the correct value for pr,r, study the diagram at point 7 in ans that the service life of the shank adapter on the rock-
of 5 bar. The maximum permissible percussion pressure the table, and find the point at which the new rpm-coordi- drill/boom used for cut-holes will be shorter.
(pmax) in respect of drill-steel strength and fatigue charac- nate intersects the curve for the drill steel being used.
40 mm The base setting for the rotation speed (see point 6 in
acteristics is 250 bar. On some drill rigs, however, it is
not possible to exploit the full pmax of 250 bar, owing to When regrinding a drill bit, it is important to restore not the table) will give optimum rock-cutting and minimum bit
1250 0092 58
drill-rig power limitations. only the original shape of the buttons (or inserts), but wear. However, if rotation is "jerky" (which can happen in
also the protrusion of the buttons from the bit face. This certain rock types), a higher rotation speed should be se-
50 C means that the bit-face steel must be ground down over lected, although it should not exceed 180 rpm.
(80 C)
)UHTXHQWGULOOVWHHOMDPPLQJ the entire bit face, and not just around the buttons. If this
is not done, the space for cuttings-flow at the front of the
drill bit will be reduced, causing an increase in cuttings- &KRLFHRIGULOOVWHHO
flow velocity, with increased bit wear as a result. If ne- For drifting with 45 mm drill bits, either R38-Hex 35-R32
cessary, the flushing holes and flushing grooves in the or T38-Hex 35-R32 drifter rods can be used. The R38
drill bit must also be ground back to the correct dimensions. thread has a smaller pitch compared with the T38 thre-
Check the coupling sleeve temperature at a point about
1250 0092 60
40 mm from the end that faces the machine. The tempe- ad, which means that a smaller rotation pressure increa-
rature should not normally exceed 50 °C. However, it se (pr,r) is needed to keep the joint(s) well tightened.
([FHVVLYHKROHGHYLDWLRQ
can be allowed to rise to 80 °C (i.e. too hot to touch with However, if the rock conditions (e.g. very hard rock) are
the bare hand) if the rock is very hard and causing a lar- Hole deviation can be reduced by ensuring that the front such that the recommended rotation pressure increase
ge part of the impact power to be reflected back from the end of the feed is pressed firmly against the rock face (pr,r) for the R38 thread cannot be obtained at the max-
bit. It is not the temperature of the coupling sleeve that is throughout the collaring and drilling cycle. Collaring imum feed pressure (pf,max), then T38 is often a better al-
critical — what is important is that drilling does not cau- should be carried out with the feed pressure as low as ternative. Since the T38 thread has a greater profile
se pitting on the drill-rod threads. A low coupling-sleeve possible to a depth of at least three times the diameter height and a larger wear volume, it is less sensitive to po-
temperature is normally a sure sign that pitting is not oc- of the hole. Hole deviation can be reduced further by re- orer tightening, compared with the R38 thread.
If the drill steel tends to jam frequently during drilling, the gular and accurate regrinding of the drill bit. It is impor-
curring. However, a relatively high coupling-sleeve tem- anti-jamming device must be adjusted. The rotation pres- The above means that the choice of drill steel will always
perature, together with well tightened joints, i.e. where SU tant to remember that a lower bit-regrinding interval yields
sure at which the anti-jamming device is activated (whe- depend on site-specific rock conditions. While certain
SULSUU , should not cause pitting when drilling in not only an increased average penetration rate, but also
reupon it switches the direction of feed) should be set 15 users might consider the penetration rate to be more im-
very hard rock. less work when regrinding the drill bit. What is more, a
bar higher than the recommended rotation pressure (SU portant than the drill-steel costs, others are of the opposi-
well-ground drill bit gives a greater resistance to rotation,
If the coupling-sleeve temperature is too high, you SULSUU) for normal drilling. Do NOT reduce the max- which means that the RPCF function sets a lower feed
te opinion. Close co-operation between the user and
should first consider changing from a regular spherical- imum feed pressure (pf,max)! supplier is therefore of great importance, in order to ob-
pressure. This in turn results in less hole deviation.
button bit to a ballistic-button bit. If the rock is too hard tain the best possible drilling results.
New or freshly reground drill bits are slightly tapered
for ballistic bits, the next step should be to reduce the ro- from the front to the back of the bit head. When drilling
tation speed as far as possible, but without causing too in very abrasive rock (with a high quartz content), heavy 'ULOOLQJFXWKROHV
great a drop in the penetration rate. The last alternative 2WKHU
peripheral wear can eventually turn this taper into an When drilling large-diameter cut-holes in drifting and tun-
is to reduce the percussion pressure, in steps of 5 bar, anti-taper, which causes jamming in the hole. Frequent The COP 1838HF 05 is normally used in drifting and tun-
nelling, the rotation speed must be reduced as shown at
until the coupling-sleeve temperature falls to an accept- signs of jamming in non-fissured rock are therefore a sig- nelling applications, in which it is sometimes necessary
point 6 in the table. However, since reduced rotation spe-
Printed in Sweden • Atlas Copco, • 2002

able level. nal to regrind the drill bit, with emphasis on gauge grin- to drill longer holes for grout injection. Production drilling
ed causes a reduction in flushing efficiency, great care
1% Another reason behind hot coupling-sleeve syndro- ding to restore the taper. On the other hand, decreasing is another possible application. When drilling grout holes
must be taken to avoid jamming during reaming. Rota-
me could be that the rock drill feed rate is too low. For rotation pressure at maximum feed pressure is a sign or longer holes in production drilling, it is particularly im-
tion must not be stopped as the bit is withdrawn from the
this reason, the feed rate should be at least three times that the drill bit needs to be reground, with regard to the portant not to set the rotation pressure higher than is ab-
drill hole. If the bit jams, switch the rotation speed to the
(but ideally five times) higher than the maximum penetra- button shape and protrusion from the bit face. solutely necessary. This will help to keep the holes as
higher value used for drilling blast holes. Then, after
tion rate in the given rock conditions. straight as possible and make it easier to uncouple the
about 10 seconds of high-speed rotation, bit retraction
joints in the drill string. The best way to loosen the shank-
can be resumed, still using the higher rotation speed. It
adapter joint is to "drill" the last centimeter of each exten-
should by then be possible to withdraw the drill bit wit-
sion rod without rotation.
hout difficulty. Naturally, however, the rotation speed
should be reduced back to the lower level before a new
large-diameter cut-hole is started.
$7/$6&23&252&.'5,//6$%•g5(%52•6:('(1
313 of 326 1RD
314 of 326
How to find the CMT Printed Matter Index
CMT PMI database in lotus notes
•Right click on workspace

•Click on ”Open Database…”
1
315 of 326
•Click on:
TMG01/TMG/ATLAS COPCO
•Click on: ”ACRDE”
2
316 of 326
•Click on: ”Service”
•Click on:
”Technical doc”
3
317 of 326
•Click on:
”CMT pmi”
The CMT pmi database will appeare
4
318 of 326
How to find the Rock Drill database
Rock drill database in lotus notes

1
319 of 326
•Click on:
2
320 of 326
•Click on: ”Marketing”
•Click on: ”Rockdrills”
3
321 of 326
•Click on: ”RDE Rockdrills”
The rock drill database will appeare
4
322 of 326
How to find the Service reports/news
Service reports/new database in lotus notes

1
323 of 326
•Click on:
2
324 of 326
•Click on: ”Service”
•Click on:
”CMT Service Reports/News”
3
325 of 326
The Service report/news database will appeare
4
326 of 326

COP Training Student Binder 1838 GB 061114

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OPERATION AND MAINTENANCE

QUESTIONS & MISCELLANEOUS

Hydraulic Rock Drills

Fredrik Öberg / 2006-01-26

Copyright, 1996 © Dale Carnegie & Associates, Inc.

COP 1019 / 1019HF

COP 1022 / 1022HF

COP 1238 ME / 1338 MEX

COP 1338 MEX

COP 1238 LP (low pressure)

COP 1838 ME/MEX

COP 1838 MEX COP 1838 ME

COP 1838 HE/HEX

COP 1838 HEX

Tube adapter COPROD COPROD

Tube Extracting Device TED

COP 1840 HE/HEX

COP 1840 HEX

COP 2160 / 2160 EX

COP 2560 / 2560 EX

COP 4070 ME/MEX

COP 4050 MUX

3 gear house sizes

DHR 48 Family DHR 56 Family

DHR 45 Family DHR 48 Family

Rotation units – Surface

4 ROC F6 with DHR

4 ROC 460 with DHR 45

Rotation units – Underground

El Soldado Mine, Chile

SIMBA M6C with DHR 48H

SIMBA W469 with DHR 48 W LKAB, Kiruna, Sweden

Air powered rotation units DHR(A)

Hydraulic powered rotation units DHR(H)

DHR DHR DHR DHR DHR

Qty of drive motors :1 2 2 2 2

Max speed [4] (rpm) 80 136 107 68 68

DHR 34/45A with floating sub

Floating sub of DHR 34/45

Air motor shuttle valve

Air vane motor to DHR 34/45/56A

Planetary gear to DHR 34/45/56 A

DHR 48H with floating and fix sub

DHR 48H Basic parts

Rotation unit to comply with new

BBX 280 with floating sub

BBX 280 Replaceble spare sleeves

Andreas Nordbrandt / 2004-11-10

ROC D3 ROC D5 ROC D7 ROC F7 ROC F9, F9 CR ROC L7

HPR 45 HPR 45, HPR 45,

HD 606 MkII HD 709 HD 709, HD 712 HD 712, HD 715 HD 715 HD 715

H 410, H420, H 528 H 538 H 751 H 751 H 751

Example on rig Perfora DSI-rigs

HD 1704 HD 125 HD 125 HD 155 HD 165

HPR1H-ATU HPR 45 HPRH-A/AF HPRH-D HPR1-JTW

Example on rig JTH2A-90 JTH2RS-XX JTH3RS-XX MacLean Bolter MacLean Bolter

H 751 H 751 H 528 H 528 H 528

HD 155 HD 155 HD 65 HD 155 HD 155 HD 65 HD 65 HD 65 HD 65

Benefit – There is a 2-3 bar air pressure inside the drill,

Feature and benefit – The Impact piston design

Drillers who have tested the COP 1638 say it is very

8311 1249 53 COP 1638-T38E-07

8311 1249 53 COP 1638 T38E 07

There is a big repowering potential with high profitability

From case to case, AC must help the customer to evaluate the

P/N Part Qty.

Benefit – There is a 2-3 bar air pressure inside the drill,

8311 1280 00 COP 1132 R32-02 Male L=410mm

”COP 1132 technique”, giving following benefits vs COP 1032

There is a big repowering potential with high profitability

P/N Part Qty.