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code
AIB TAB 43
COP 1638
2004–09
Hydraulic
Rock drill COP 1638
1250 0021 33
Contents Page
Safety regulations . . . . . . . . . . . . . . . . 2 Filling with lubricating oil and bleeding the syst. 10
Action list . . . . . . . . . . . . . . . . . . . . . 3 Setting of ECL lubricating system . . . . . . . 10
Hose connections . . . . . . . . . . . . . . . . 4 Lubrication of gear . . . . . . . . . . . . . . . 11
Tightening torques . . . . . . . . . . . . . . . . 5 Setting the damper pressure . . . . . . . . . . 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 . . . . . . . . . . . . 14
– Changing the return accumulator . . . . . . . 9 Slinging . . . . . . . . . . . . . . . . . . . . 15
Changing the hydraulic motor . . . . . . . . . . 9 Long-term storage . . . . . . . . . . . . . . . 15
Recommended hydraulic oils and lubricants . 16
2
WARNING Action list
· Before starting any maintenance work, Before starting up a new- or
make sure that the electrical system is
dead. newly overhauled rock drill: Page
There is a risk of injury if these instructions · Connect up the hoses . . . . . . . . . . . . 4
are not observed! · Charge the accumulators . . . . . . . . . . . 6
· Select a suitable hydraulic oil and lubricant . 16
· Fill the lubricating system with oil . . . . . . . 10
· Adjust and set the lubricating system . . . . 10
CAUTION · Set the damper pressure . . . . . . . . . . . 11
· Take care during rod jointing and when
handling the drill bit. Mind your fingers!
· Keep your clothing away from rotating Every shift
machine parts. · Check that air and lubricating oil come out
Carelessness can lead to serious injury. between the shank adapter and front guide
and also out of the hole in the front head . . 13
· Always use ear protectors during drilling. · Check that the damper-pressure gauge on
High noise levels damage hearing.
the drill rig shows the normal value. In case
· Never attempt maintenance or intervene of deviation, adjust the damper pressure . . . 11
in the rock drill, connections or hoses whi- · Check that the shank-adapter threads are
le the hydraulic, lubrication or flushing not damaged . . . . . . . . . . . . . . . . . 13
systems are pressurized.
Air or oil can squirt out at high pressure · Keep an eye on the hydraulic hoses. If they
and high temperature, with the risk of vibrate too much, check the accumulators . . 7
serious injury to the eyes and skin. · 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.
· The following parts may be changed at the · Check the return accumulator . . . . . . . . 7
worksite in accordance with the instruc-
tions given:
– shank adapter
Every 400th percussion-hour:
– driver · Remove the rock drill from the drill rig and
– front head parts send it to a suitable workshop for over-
– accumulators hauling*.
– hydraulic motor
– screws
– connections.
* The rock drill should be overhauled at suitable intervals,
based on local conditions. The characteristics of the rock will
Other repairs must be carried out in a sui- have a great influence on the rate of wear, and thus on the
table workshop in accordance with the required frequency of overhauling.
3
Hose connections
8 7
1
AIR
6
1250 0147 23
5
4
2 3
1. Drainage
2. Rotation to the left
3. Rotation to the right
4. Percussion mechanism, return
5. Percussion mechanism, intake
6. Flushing air/water
7. Lubricating air
8. Damper, intake
4
Tightening torques
6
1
5
4
3
14
13
9
12 6
11
7 10
1250 0147 24
9
8
3 2
5
Accumulators
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
1. Damper accumulator
2. Intake accumulator = Must be charged with nitrogen only
3. Return accumulator
1250 0027 19
6
Checking the accumulators in the event of hose vibration
Damper accumulator (1) and
Intake accumulator (2)
1. Press in the pin on the test valve (7). If the ac-
cumulator is charged, the pin will stick out by
4.5 mm and give a firm resistance when pres-
sed in.
N.B. 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.
1. Damper accumulator
2. Intake accumulator
3. Return accumulator
4. Protective cap
5. Valve nut
6. Gas valve
7. Test valve
8. Plug with O-ring
7
Changing the accumulators
5
1250 0147 25
1 B A
B A
4 2
Removal Mounting
CAUTION CAUTION
· Release all gas before removing the ac- · Mount the accumulators to the rock drill
cumulators from the rock drill. using undamaged original screws.
To do this, remove the protective cap (A), The intake accumulator (2) for COP 1638
loosen the valve nut (B) and open it by must have two screws (4) of length 70 mm.
2–3 turns. The damper accumulator (1) must have
There is a risk of injury if these instruc- two screws (5) of length 70 mm.
tions are not observed! Change both screws at the same time,
even if only one of them is corroded (or
Remove the accumulators (1 and 2) together with damaged in some other way).
the sealings (3) by removing the screws (4 and 5 Defective screws can cause dangerous oil
or 6). leakage, or can cause the accumulator to
be blown off.
Now send the accumulators to a workshop for Squirting oil can seriously injure the eyes
overhauling! and skin.
Parts that come loose can cause serious
injury.
8
Changing the return accumulator Changing the hydraulic
1250 0027 22 motor
8 5
10
1250 0027 23
9
3
2
Removal Removal
Disconnect the hydraulic hoses (1).
CAUTION Remove the return accumulator (3).
· Before intervening in the hydraulic, water Remove the nuts (2) and take off the hydraulic mo-
or air systems, make sure that there is no tor (3).
pressure in the systems.
Pull out the coupling (4).
· Pressure hoses with an internal diameter
of 19 mm (3/4") or more are rated SAE 100
R9R (i.e. high-pressure hose with four lay-
ers of spirally wound steel-wire reinforce-
ment). See spare parts list for drill rig.
For safety reasons, these hoses must not,
under any circumstances, be replaced Mounting
with hoses of a lower rating.
Make sure that the circlip (5) is fitted into the coup-
There is a risk of injury if these instructions ling (4).
are not observed!
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!
Mounting
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
Filling with lubricating oil and bleeding the system
· If the lubricating system has been empty of oil, it
CAUTION must be bled after filling.
This is done as follows:
– Loosen the cap (7) and let the lubricating oil
· Never intervene in the lubricating system escape until all air has been discharged from
while it is pressurized.
Lubricating oil can squirt out, with the the lubricating oil pump. Now tighten the cap.
risk of injury to the eyes and skin. – 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.
IMPORTANT – Disconnect the lubricating-air hose (12) from
the nipple (11) on the rock drill.
· Use the recommended lubricating-air pres- – Start the lubricating pump and let it pump until
sure and the recommended lubri- oil comes out of the plastic hose (10).
cating oil. When re-starting (after standstill), oil must
Certain moving parts of the rock drill are come out of the plastic hose directly when the
lubricated by means of oil-mixed compres- lubricating pump is started.
sed air. It is important that these parts re- – Check that the plastic hose (10) for lubricating
ceive good lubrication. 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.
10
Lubrication of gear
11
Removing the front head
CAUTION
· Never attempt maintenance work while
the drill rig is in operation.
· Before intervening in the hydraulic, water
or air systems, make sure that there is no
pressure in the systems.
There is a risk of injury if these instructions
are not observed!
COP 1638
Remove the flushing hose (5).
Remove the connection plate (1) and nipple (2) by
removing the screws (3) and washers (6).
Remove the cup seal (4).
12
Checking the front head
1250 0071 63
8 7 3 A 3 3 1 5 6 2 9
C
4 B
12
1 1m
m 3 3 4 3 3
5
R38
T38 2 mm
m 2
1m 6 7
39 mm R38
T38
· 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). 2 mm 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 39 mm or 53 mm. than 1 mm, 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 1 mm.
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 1 mm.
When changing the extractor-unit piston, check
the seals and O-rings (11). Change them if they
are worn or damaged.
13
Changing the flushing head and driver
CAUTION
· Take care when removing the flushing
head and driver. Mind your fingers!
14
Slinging
1250 0027 40
CAUTION
· Lifting gear and slings must be approved Rock drill weights, approx.
for a weight of 500 kg (1100 lbs).
COP 1638 . . . . . . 170 kg (375 lbs)
Faulty lifting gear can cause the rock drill
to move unpredictably or drop.
Incorrect handling can result in crush
injuries.
Long-term storage
If the rock drill is not going to be used for a long
time, the following precautions should be taken:
15
Recommended hydraulic oils and lubricants
Lubricant Recommendation
Hydraulic oil · 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.
Grease · 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.
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)
Printed in Sweden
Atlas Copco, 2004
16
Maintenance instructions for
Hydraulic
Rock drill COP 1638
1250 0021 33