Reg.

code
ASB TAB 43
COP 1432 / 1432ED
1999–10

Overhauling instructions for

Hydraulic COP 1432

Rock drill COP 1432ED
1250 0027 80

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– Cover and gear housing. . . . . . . . . . . . . . . . . . . . . . . . . 19
– Intermediate part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
– Cylinder, piston guides and impact piston . . . . . . . . . . . 35
– Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembling the main parts of the rock drill . . . . . . . . . . . . 45
Charging the accumulators . . . . . . . . . . . . . . . . . . . . . . . . 49
Greasing the gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Recommended hydraulic oils and lubricants. . . . . . . . . . . 50
Testing the rotation and percussion functions. . . . . . . . . . 51
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ATLAS COPCO ROCK DRILLS AB

ÖREBRO • SWEDEN
© Atlas Copco Rock Drills AB, 1999. All rights reserved.
No. 9853 1012 01b
 SAFETY INSTRUCTIONS
• Important safety information is given at various points in these instructions.
• Special attention must be paid to the safety information contained in frames and accompanied by a war-
ning symbol (triangle) and a signal word, as shown below:

indicates hazards or hazardous procedures which COULD

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

indicates hazards or hazardous procedures which COULD

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

The following safety rules must also be observed:

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

General
The following instructions are intended as a guide Workshop standards
for service personnel involved in the overhauling of
the COP 1432 hydraulic rock drill. Workshops for the overhauling of hydraulic
machines must be:
Layout of these instructions • Isolated from all dust- and particle-generating
activities such as grinding, welding etc.
These instructions begin with the safety instructions,
followed by a list of the standard and special tools • Very clean, i.e. free of dust and dirt.
needed to overhaul the rock drill. This is followed • Equipped with
by instructions on how to disassemble the rock drill – all necessary standard and special tools
into its main parts. Then, under respective headings – washing facilities for cleaning and degreasing
for the main parts, detailed instructions are given on components
the further disassembly, checking, inspection of – compressed air for blow cleaning components
parts and re-assembly. – a hydraulic press
The instructions end with a section describing how – hoisting facilities with a minimum capacity of
the main parts of the rock drill are put back toget- 250 kg.
her, followed by the tests and checks that must be
carried out after the machine has been overhauled.
CAUTION
The letters enclosed in brackets in the instructions
refer to the list of special tools on pages 4–7. The • Never intervene in the rock drill, connec-
numbers enclosed in brackets in the instructions re- tions or hoses when the hydraulic system
fer to the exploded views of the machine on pages is pressurized.
43 (hydraulic motor) and 53 (rock drill). Hydraulic oil at high pressure and high
temperature can squirt out with great force.
Risk of injury to eyes and skin.

2
 List of tools / Standard tools

Plastic hammer

Copper hammer

Honing tool ø 20–50 mm

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

Allen keys
Width across flats: 4–10 mm

Screwdrivers

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

Feeler gauge, 0.03–0.10 mm, with 0.01 mm

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

Internal circlip pliers

Torque wrenches, torque range 10–350 Nm

(7–260 lbf. ft)

Socket set with:

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

Awl

T-handle with 3/4" square drive

Impact socket 32 mm
1250 0022 43

Vernier calliper
Micrometer, 0–25 mm

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

A 3115 0329 80 Pivoted mounting Disassembly, assembly and

fixture testing of rock drill (figs. 2, 90).
1250 0024 27

B 3115 1902 80 Press Basic tool for use with other

press tools (figs. 39, 45,
– 3115 1902 00 – Guide plate 46, 48).
– 3115 2734 00 – Nut
– 3115 0317 00 – Screw
1250 0024 28

C 3115 0318 00 Extension sleeve For use with press B (fig. 46).
1250 0024 29

D 3115 1019 00 Mandrel Removal and fitting of guide,

flushing head, guide sleeve
1250 0024 30

and driver (figs. 13, 15, 16,

41, 44).

E 3115 2750 00 Press tool Fitting of seal rings and

damper piston liner (figs. 39,
1250 0028 33

46, 60).
Shimming of roller bearings
(fig. 48).

F 3115 2751 00 Press tool Fitting of tapered roller

1250 0028 34

bearings (fig. 45).

G 3115 2753 00 Mandrel Removal of front seal hou-

1250 0028 37

sing with piston guide (fig.

66).

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

H 3115 0313 00 Mandrel Assembly of gear housing

(fig. 40).
1250 0024 34

I 3115 0314 00 Mandrel Fitting of bushing for damper

1250 0024 35

piston (fig. 59).

J 3115 1877 00 Assembly and Assembly and disassembly of

1250 0024 36

disassembly tool accumulators (figs. 19, 22).

K 3115 0344 00 Wrench adapter Adapter for use with torque

1250 0028 38

(32 mm) wrench when tightening up

the machine (figs. 48, 94).

L 2859 00
3115 2518 80 Assembly and Assembly and disassembly of
tool,
disassembly tool accumulators (figs. 19, 22).
consisting of:
3115 2859 00 Ass. tool
3115 2860 00 Stud ( 2pcs )
3115 2861 00 Ring
0266 2114 00 Nut ( 2pcs )L
1250 0045 44

M 3115 1627 00 Assembly tool Fitting of thread inserts into

(M14) intermediate part and cylinder.
1250 0024 39

3115 1126 00 Assembly tool

(M16)

N 3091 0455 90 Extractor + See figs. 34, 55, 65, 69.

adapters
1250 0024 40

O 3115 2754 00 Mandrel Fitting of needle bearing,

spacer ring and seal ring
1250 0028 39

(fig. 42).

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

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

lators (fig. 100).
1250 0024 42

– 3115 0642 00 – Nipple

– 3115 2075 00 – Adapter
– 3115 0644 00 – Nipple
– 3115 2796 00 – Elbow coupling

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

1250 0024 43

regulator ing of accumulators (fig. 100).

– 3115 0978 00 – Pressure gauge

R 3115 2747 00 Adapter plate Used in conjunction with

pivoted mounting fixture A
1250 0028 40

for disassembly, assembly

and testing of rock drill
(figs. 2, 90).

S 3115 2756 00 Mandrel Removal of washers, needle

1250 0028 41

bearing, guide sleeve and

spacer ring in gear housing
(figs. 29, 30).

T 3115 2163 00 Sleeve Fitting of bushing into inter-

mediate part (fig. 59).
1250 0024 51

U 3115 1594 00 Plates Removal of damper piston

1250 0024 49

liner (fig. 53).

V 3115 2755 00 Spacer ring Removal of needle bearing,

spacer ring and seal ring
1250 0028 42

(fig. 30).

X 3115 1899 00 Sleeve Removal and fitting of

bushing into front head
(figs. 13, 15, 16).
1250 0024 50

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

AA 0335 2141 00 Circlip ø 46 mm Removal of slide bearing

1250 0028 43 (fig. 54).

BB 3115 2749 00 Press tool Removal of guide sleeve

(fig. 30).
1250 0028 44

Fitting of damper piston

(fig. 62).

CC 3115 2846 00 Mandrel Removal of needle bearing,

1250 0028 45

spacer ring and seal ring

(fig. 30).

DD 3115 2752 00 Press tool Fitting of slide bearing into

intermediate part (fig. 63).
1250 0028 46

Fitting of piston guide (fig.

73) and seal housing (fig. 74)
into cylinder.

EE 3115 2844 00 Extension sleeve Fitting of seal ring (fig. 39).

1250 0028 47

FF 3115 2757 00 Press tool Removal of slide bearing

from intermediate part
1250 0028 48

(fig. 54).

GG 3115 2918 80 Bottle regulator Reducing valve with 16-bar

- 3115 0643 00 Nipple pressure gauge for charging
- 3115 2640 00 Tee nipple of return accumulator (92)
located on right-hand side of
rock drill seen from behind
(fig. 100).

7
Main parts of the rock drill

7
5

8
4

3
1250 0027 81

Fig. 1. Hydraulic rock drill COP 1432, main parts

1. Front head, incl. 5. Accumulators

• Shank adapter • Intake accumulator
• Flushing connection • Damper accumulator
• Stop ring • Return accumulator
• Flushing head
• Guide
6. Cylinder, incl.
• Impact piston
2. Cover • Piston guides
• Valve piston
3. Gear housing, incl.
• Rotation chuck 7. Back head
• Driver
• Rotation shaft
8. Hydraulic motor

4. Intermediate part, incl.

• Damper piston
• Damper-piston liner
• Damper-piston seals

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

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 • Hydraulic motor
connections may be changed at the work-
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-
R sassembly begins.

A Bolt the rock drill securely to the pivoted mounting

fixture (A) and adapter plate (R) using two M16
1250 0027 84

screws.

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

1250 0027 86

2 3 4 8

Front head
Remove the flushing connection (5), nipple (6) and
plug (8).
2
Remove the O-rings (2, 3) and back-up rings (4).
3
4
5
6
Fig. 3. Removing the flushing connection

10
1250 0027 88

2
Remove the front side-bolt nuts (2) with washers
1 (3). Remove the front head (1) by tapping it with a
copper hammer.
Take out the cylindrical pin (10).

3
2
Fig. 4. Removing the front head

9
 Accumulators

CAUTION
• All gas must be released from the ac-
cumulators 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 (67, 91, 92) together

with the O-rings (68) by removing the screws
(4).

4 91
A B 4
67

68

68
1250 0027 89

92

Fig. 5. Removing the accumulators

90 Back head and impact piston

89 Loosen and remove the screws (90).
Remove the back head (89) by tapping it with a
copper hammer and carefully prizing it free with
the aid of two screwdrivers.
1250 0027 91

Fig. 6. Removing the back head

10
 87

Tap out the impact piston (87), removing it through

the rear of the rock drill. Put it in a safe place whe-
re it will not be scratched or damaged.
1250 0028 06

Fig. 7. Removing the impact piston

Cover and gear housing

2
3 Remove the rear side-bolt nuts (2) with washers
(3), as well as the two front screws (5).
1250 0028 07

Fig. 8. Removing the side bolts

Tap free the gear housing (18) and cover (6) using
a copper hammer, and pull them off with the aid of
the side bolts (4).
The rotation shaft (27) usually comes out with the
18 gear housing.
6
1250 0028 08

4
27

Fig. 9. Removing the cover and gear housing

11
 75

37 Intermediate part
Tap free the intermediate part (37) using a copper
hammer. If the intermediate part sticks on the cylin-
der, use a screwdriver or similar implement, to pri-
ze it free.
1250 0028 09

Fig. 10. Removing the intermediate part

25

51
Hydraulic motor
Remove the screws (25) using a 16 mm combina-
tion spanner, and remove the hydraulic motor (51).
48
Pull out the coupling (48).
1250 0028 10

Fig. 11. Removing the hydraulic motor

12
 Front head
Disassembly
Inspection, replacement of parts
Assembly

25, 27
15, 20

Disassembly
Pull out the shank adapter (25 or 27) together with
the sleeve (21) and split stop-ring (20) or solid stop-
1250 0028 11

ring (15).

Fig. 12. Removing the shank adapter

Press out the guide (9 or 22) and flushing head

9
(12 or 24).
22
Use the mandrel (D) to remove the guides (9).
Also use the sleeve (X) when removing the guide
(22).
12
1250 0028 12

24

Fig. 13. Removing the guide

13
 Inspection, replacement of parts
Before inspection, all parts must be washed
clean in a degreasing agent.
Change the guide (22 or 9) if its inside diameter ex-
ceeds 56 or 39 mm.
Change the flushing head (24 or 12) and the ring
(28) if it is severely damaged or shows signs of
cracking or fatigue.
1 mm
Change the stop ring (20 or 15) if the surface is
1 mm worn down by more than 1 mm. Use a new stop
ring as a gauge for comparison.

15 Change all O-rings and cup seals.

IMPORTANT! The cup seals must face the direc-
12 tions shown in the figure opposite.

20

39 mm
1250 0055 90

28
24

56 mm
22

Fig. 14. Checking the guide, O-rings, seal rings, flushing

head and stop ring

;;
D
Assembly
Before assembly, the parts must be oiled with
X clean hydraulic oil.
9, 22 Press in the guide (9) with the aid of mandrel (D).

;;;;
Also use the sleeve (X) when fitting the guide (22).
1250 0028 14

Check that the lubricating duct (A) is not blocked.

To do this, blow through it with compressed air.
A

Fig. 15. Fitting the guide

14
 D
Press in the flushing head (12 or 24) with the aid of

;;
;;;;
mandrel (D) and sleeve (X).
X
N.B. Make sure that the flushing holes in the flus-
12, 24 hing head line up with the corresponding holes in
the front head.
1250 0028 15

Fig. 16. Fitting the flushing head

Fit the split stop-ring (20) or one-piece stop-ring

(15) as appropriate.
Fit the O-ring (13) and shank adapter (25 or 27)
1250 0055 91

25
into the front head (1).

15
13
1
13

27

20

28

Fig. 17. Fitting the stop ring and shank adapter

15
 Accumulators
Disassembly
Inspection, replacement of parts
Assembly

67 = Read the instruction book carefully

92
before servicing or changing

91

1250 0020 91
= Must be charged with nitrogen only
D
1250 0028 17

The rock drill is equipped with three accumulators:

– the intake accumulator (67)
– the damper accumulator (91)
Fig. 18. The accumulators on the rock drill – the return accumulator (92)

4
Disassembly
3

CAUTION
• All gas must be released from the ac-
J cumulators before they are removed from
50 the rock drill.
52 To release the gas, remove the protective
67 cap (A) and loosen the valve nut (B) by
2–3 turns.
91 Failure to follow this procedure can result
A B
92 in injury.
L
Clamp the tool (L) in a vice.
1250 0047 45

Place the accumulator (67, 91, 92) 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.
Unscrew the housing from the cover with the aid of
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.
125 0045 46

Fig. 19. Disassembling an accumulator

16
 Inspection, replacement of parts

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 compon-
ents to loosen.
Risk of injury to personnel.
• Always change the screws (4 or 95), hou-
sing (1) or cover (3) if they are corroded,
worn, defective or damaged. Always
change BOTH screws at the same time.

Change the diaphragm (2) if it shows signs of

cracking or other damage.
1 2 3
When changing the diaphragm, make sure that no
bits of rubber have lodged in the valve (9) or in the
10 test valve (5).
9
11 Blow clean the gas ducts in the cover (3) with
compressed air.
4 Change the valves if they are damaged.
1250 0029 98

Always change the O-rings (6, 7, 11) if the valves

8 have been disassembled.
7
6 Change the screws (4) if they are rusted or
5 damaged.
Fig. 20. Checking the diaphragm, valve housing and cover Change the housing (1) and cover (3) if the thre-
(Figure shows intake accumulator) ads are damaged or badly rusted.

Assembly
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-
1 ase the edges of the diaphragm with a thin layer of
2 silicone grease.
3
Smear the threads of the accumulator cover (3)
and housing (1) with grease of type NEVER-SEEZ.
7
8 Fit the cover (3) on to the housing (1) and thread
9
10 the accumulator together by hand.
D

Do not turn the accumulator upside down until it

has been screwed together.
1250 0029 97

6
Fit the valve plunger (10) together with O-rings
4 (8 and 9), and fit the valve body (7). Tighten to a
torque of 45 Nm (32 lbf. ft).
5
Fit the valve (4) and cap (5) together with the
Fig. 21. Fitting back the diaphragm and cover into the O-ring (6), and tighten to a torque of 45 Nm
housing (32 lbf. ft).
(Figure shows damper accumulator)

17
 J

Now place the accumulator on the assembly tool

1 (L).
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. 22. Tightening the housing

10

Inspect the safety labels (10, 11), and change

them if necessary.
N.B. Do not charge the accumulators until they
have been fitted securely to the rock drill.
D

11
10 11
1250 0028 22

Fig. 23. The accumulator safety labels

89

Back head
88
Inspection, replacement of parts
1250 0028 23

Before inspection, the back head must be was-

hed in a degreasing agent.
Change the O-rings (88).

Fig. 24. Fitting the O-rings on to the back head

18
 Cover and gear housing
Disassembly
Inspection, replacement of parts
Assembly

Disassembly
1250 0028 24

Remove the side bolts (4).

4

Fig. 25. Removing the side bolts

1250 0028 25

6
Tap free the cover (6) using a copper hammer. Ca-
refully prize the cover off the gear housing with the
aid of two screwdrivers.

Fig. 26. Removing the cover

27
1250 0028 26

Tap out the rotation shaft (27) using a punch

28 (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 dama-
ging the needle bearing (28).

Fig. 27. Removing the rotation shaft

19
 15
14
13
11 Remove the rotation chuck (14) together with the
shims (11) and outer rings (13 and 15) of the bea-
rings from the gear housing by tapping the rotation
chuck with a copper hammer.
1250 0028 27

Fig. 28. Removing the rotation chuck with shims and be-
aring rings

Take out the gear-wheel (36) and washer (30)

from the gear housing.
Using the mandrel (S), tap out the rotation shaft’s
24 front needle bearing (28) and two washers (24 and
S 29) from the gear housing.

28
36
29

30
1250 0028 28

Fig. 29. Removing the gear-wheel and the rotation

shaft’s front needle bearing with washers

20
 Locate the spacer ring (V) as shown in the figure
S S opposite. Then, with the aid of mandrels (S and
CC), tap out the needle bearing (33), spacer ring
(34), seal ring (35) and O-ring (32).
The guide sleeve (31) should not normally be re-
moved. If, for some reason, it does need to be re-
BB
moved, it can be tapped out with the aid of mand-
rel (S) and the press tool (BB), which should be po-
CC sitioned as shown in the figure opposite.

31
33

34
V
1250 0028 29

35
32

Fig. 30. Removing the spacer ring and needle bearing

Inspection, replacement of parts

Before inspection, all parts must be washed in
1250 0028 30

a degreasing agent.
Change all O-rings.
5
4 Change the side bolts (4) and screws (5) if they
3 are badly rusted or if they show signs of crack for-
mation.
Fig. 31. Checking the side bolts, screws and washers. Change all side bolts after every 400 hours of
operation. Never mix new and old side bolts.

27

25 Change the shank adapter (27or 25) if the thread

1250 0028 31

is worn out, or if the impact surface is upset or chip-

ped.

12 Change the driver (12) when the spline width is

less than 2 mm.

m
2m

Fig. 32. Checking the shank adapter and driver

21
 14 Check the wear between the rotation chuck (14)
and the driver (12) using a feeler gauge. If the clea-
rance exceeds 0.2 mm, the driver or rotation chuck
should be changed.
1250 0028 49

12

Fig. 33. Checking the wear

If the driver (12) needs to be changed, it can be re-

moved with the aid of the extractor (N) and a
37–46 mm expander. See figure.
12
1250 0028 50

Fig. 34. Removing the driver

15
14
13

11
1250 0028 51

Change the rotation chuck (14) if it shows signs of

deformation or cracking, or if the gear ring is badly
worn. Change the roller bearings (13 and 15) in
the event of dissonance or damage.
Change the shims (11) if they show signs of damage.

Fig. 35. Checking the rotation chuck, roller bearings,

seals and shims

22
 If either of the roller bearings (13 or 15) on the rota-
tion chuck needs to be changed, the roller cage
13 must be broken up with a screwdriver. The inner
15 rings of the roller bearing must then be removed
by heating them.
N.B. Avoid heating the gears!
1250 0028 52

Alternatively, cut through the inner rings of the bea-

ring using a grinder.

Fig. 36. Removing the inner rings of the bearings

96 8
22

7
Check the seal rings (7 and 22) in the cover and
gear housing for wear and damage.
If the seals need to be changed, remove the circlip
1250 0028 53

(8) and knock out the seals using a punch.

Change the O-ring (96).

Fig. 37. Removing the seal rings from the gear housing
and cover

Change the needle bearings (28 and 33) of the ro-

35 tation shaft in the event of dissonance or damage.
Change the gear-wheel (36) if it shows signs of de-
33 formation or cracking, or if the gear ring is badly
worn.
36
Change the cup seal (35).

28
1250 0028 54

Fig. 38. Checking the rotation-shaft needle bearings,

gear-wheel and cup seal

23
 EE
Assembly
E Before assembly, all parts must be oiled with
clean hydraulic oil.
18

22
Fit the seal ring (22) into the gear housing (18)
with the aid of the press (B), press tool (E) and
extension sleeve (EE).
B
1250 0028 55

Fig. 39. Fitting the seal ring in the gear housing

Fit the washer (24) and needle bearing (28) with its
inner ring and washer (29). Use mandrel (H).
1250 0028 56

29
28
24

Fig. 40. Fitting the washers and needle bearing

If the guide sleeve (31) has been removed, press it

;;
;; ; 31

18
back into the gear housing (18) with the aid of
mandrel (D).

; ;
;;
;;
1250 0028 57

Fig. 41. Fitting the guide sleeve

24
 Y

35
34

;;;;
;;;
33 With the aid of mandrel (Y), fit the needle bearing
(33), spacer ring (34) and seal ring (35) into the
18 gear housing (18).

;;;;
;;
1250 0028 58

Fig. 42. Fitting the needle bearing, spacer ring and seal
ring

27

;;;; Insert the washer (30) and gear-wheel (36) into the
gear housing.

;; ;;
;; ;;;
15 Fit the outer ring of the roller bearing (15). Use a
copper mandrel.
18
1250 0028 59

Fit the shaft (27) into the gear housing (18). Make

;;;; 30
sure that the shaft splines mesh with the splines in
the gear wheel (36). If necessary, tap the shaft to
the bottom using a plastic hammer.

36

Fig. 43. Fitting the gear-wheel and rotation shaft

;;
;
D

Fit the driver (12) into the rotation chuck (14). Use
the mandrel (D) and a plastic or copper hammer.

;;;
12
1250 0028 60

14

Fig. 44. Fitting the driver

25
 B

13 Fit the roller bearings (13 and 15) on to the rotation

chuck (14).
Use the press (B) and press tool (F).
14
1250 0028 61

15

Fig. 45. Fitting the roller bearing

7 C

E
Fit the seal ring (7) into the cover (6). Use the
6
press (B) with extension sleeve (C) and press tool
(E).
Fit the circlip (8).
1250 0028 62

Fig. 46. Fitting the seal ring into the cover

26
 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
6 cover for the preloading exercise.

Fit the rotation chuck (14) into the gear housing

(18).
11 Fit the outer ring of the front roller bearing (13).

;;; ;;
Tap it into place with the aid of a punch.
Place the shims (11) on the outer ring of the bea-

;;;;;;
14 ring. Choose the thickness and quantity of shims
so that a definite "gap" is created between the
13
gear housing (18) and the cover (6) when the latter
is assembled later.

;;;;
1250 0028 63

18 Fit the cover (6).

Fig. 47. Fitting the rotation chuck, outer ring and shims
into the gear housing for the preloading exercise

Place the gear housing on the press (B).

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).
K Use a feeler gauge to measure the clearance be-
E tween the gear housing and the cover.
6 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
1250 0028 64

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.
B
When this happens, it is important that preloa-
ding of the bearings does not cease, which
could result in damage to the roller bearings
and shims.
Fig. 48. Checking the preloading of the bearings

27
 23
18 Grease all parts, especially the roller bearings.
See grease recommendations on page 50.

10 Fit the O-ring (9) into the cover (6). Place the O-
9 rings (16, 17) in the gear housing (18). First smear
the O-rings with grease, so that they stick in place
6 during assembly.
Fit the guide pin (10) and washer (23) into the gear
housing.
1250 0028 65

Now fit the cover (6). If necessary, tap down the

cover using a plastic hammer.
16
17

Fig. 49. Fitting the O-rings into the cover and gear
housing

28
 Intermediate part
Disassembly
Inspection, replacement of parts
Assembly
17

56

57 Disassembly
58
Remove the check-valve poppet (57), seat (59)
59 and O-rings (17, 56, 58 and 60). Pull out the seat
with the aid of a M6 screw.
60
Pull out the coupling (48), spacer ring (49) and
48 washer (50).
1250 0028 66

49
50

Fig. 50. Removing the check valve

47 Knock out the damper piston (47) using a hammer

and copper mandrel.
1250 0028 67

Fig. 51. Removing the damper piston

39

37

25 Carefully remove the damper-piston seals (25 and

26) with the aid of a pointed tool. Be careful not to
damage the seal grooves in the intermediate part
(37) and liner (39).
1250 0028 68

26

Fig. 52. Removing the damper-piston seals

29
 U

39 Remove the front damper-piston liner (39) by pla-

cing a plate (U) in the seal groove. Then carefully
knock out the liner using a copper mandrel and a
plastic hammer.
1250 0028 69

Fig. 53. Removing the front damper-piston liner

Inspection, replacement of parts

FF
Before inspection, all parts must be washed in
a degreasing agent.

;; ;;
; ;;
;
1250 0028 70

Change all O-rings.

;; ;;
; ;;
The sliding bearing (46) should not be removed un-
less it is damaged. If the sliding bearing is damaged
remove it as follows:
46 Press out the sliding bearing (46) with the aid of the

;; ;;
; ;;
press tool (FF) and circlip (AA).
AA

;;;;;;
Fig. 54. Removing the sliding bearing

42

Check the damper-piston bushing (43). 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
43 be changed.
Remove the lock ring (42) with the aid of a
screwdriver.
Knock out the bushing (43) using a copper mand-
1250 0028 71

rel and a plastic hammer. Alternatively, the bus-

hing can be removed using the extractor (N) and a
70–100 mm expander.

Fig. 55. Removing the bushing

30
 39

Check the damper-piston liner (39). Minor scoring

1250 0028 72

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. 56. Checking the damper-piston liner

Change the damper piston (47) if the seals have

worn into the piston by more than 0.1 mm. Remo-
ve minor scoring using a fine abrasive cloth.
Change the damper piston (47) if the seals have
worn into it by more than 0.1 mm. Polish off any mi-
1250 0055 55

nor damage.
A
FAS / CHAMFER Change the damper piston (47) if the chamfer on
the impact surface (see fig. A) is damaged or worn
down.

Fig. 57. Checking the damper piston When the chamfer shown in fig. A has worn down,
it corresponds to approx. 1.5 mm of wear.

39

Carefully check the nozzle (38) in the rear face of

the intermediate part (37). Also check the holes in
38 the liner (39) and make sure that all holes are free
of dirt. Check that the nozzle is properly screwed
37 in, and locked with LOCTITE 243 or 542.
1250 0028 74

Fig. 58. Checking the intermediate part

31
 Assembly
I
Before assembly, all parts must be oiled with
clean hydraulic oil.

Press in the damper-piston bushing (43) using

mandrel (I) and press tool (T).
N.B. Press the bushing in carefully so that it does
42 not become deformed when it bottoms out!
Fit the lock ring (42) to retain the bushing.
T

;;
;;
;;
;; ;;
;;
43

;;
;; ;;
1250 0028 75

;;
;;;;
Fig. 59. Fitting the damper-piston bushing

39
40 Fit the O-rings (40 and 41) on to the damper-
piston liner (39), and smear them with oil.

;;;; ;;
41
Tap in the liner using press tool (E).

;;
; ;;
;;;;; ;;
1250 0028 76

;;;;;
Fig. 60. Fitting the damper-piston liner

32
 Fit the damper-piston seals (25 and 26) as follows:
Check that the seal grooves are very clean.
Oil the O-rings and fit them into the grooves.
The seal ring may be warmed in hot water to facili-
tate assembly.
Bend the seal ring as shown in the figure. Then pla-
ce the seal on a flat surface and tap down the in-
25 ner upturned edge of the seal using a hammer.
Fit the seal ring into the groove, and press it neatly
26 into the groove using the shaft of a tool.
IMPORTANT! Make sure that the seals are turned
as shown in the figure.
1250 0028 77

Fig. 61. Fitting the damper-piston seals

BB
47

Oil the damper piston (47) and carefully tap it into

the intermediate part using the press tool (BB).
Now press out the damper piston and check that
the seals are located correctly, and that they are
not damaged.
1250 0028 78

N.B. It should be easy to press the damper piston

into the intermediate part.

Fig. 62. Fitting the damper piston

33
 If the sliding bearing (46) has been removed, press
it back into place with the aid of mandrel (DD).
1250 0028 79

46

DD

Fig. 63. Fitting the sliding bearing

Check the sealing surfaces on the check-valve

poppet (57) and seat (59). Minor damage can be
lapped away using fine grinding paste. In the event
37 of more serious damage, change the parts.
Check that the poppet moves easily in the seat.
61
57 Fit the check-valve poppet (57), O-ring (58) and
seat (59) into the intermediate part (37).
1250 0028 80

58 Fit the coupling (48), spacer ring (49) and washer

59 (50) into the intermediate part.

48 Smear the parts with grease so that they stick in

place when the intermediate part is fitted to the
49 cylinder later on.
50 Check that the guide pin (61) is in place in the inter-
mediate part (37).

Fig. 64. Inspecting and fitting the check valve

34
Cylinder, piston guides and impact piston
Disassembly
Inspection, replacement of parts
Assembly

86 75

Disassembly
Pull out the impact piston (87).
Remove the rear piston guide (86). It can usually
87 be pulled out of the cylinder (75) by hand. If this is
not possible, use the extractor (N) with a 37–46 mm
1250 0028 81

expander.

Fig. 65. Removing the rear piston guide and impact pis-
ton

Do not remove the seal housing (63) unless it is

damaged.
If the seal housing is damaged, or if leakage indica-
1250 0028 82

tes that the O-rings (65) need changing, remove

the seal housing. Press or tap out the front piston-
guide (66) and seal housing (63) with the aid of
63 tool (G).

65
66 65

Fig. 66. Removing the seal housing

81
80
1250 0028 83

Loosen the screws (81) and remove the valve co-

vers (80 and 83). Now press out the valve piston
(84).
83
81

84

Fig. 67. Removing the valve piston

35
 Inspection, replacement of parts
Before inspection, all parts must be washed in
a degreasing agent.
66
63
Change all O-rings.
Change the front piston guide (66) and seal
housing (63) if they are worn or damaged.
Change the rear piston guide (86) if it is damaged.
1250 0028 84

Check the clearance between the piston guides

and impact piston with the aid of a feeler gauge.
If the clearance is greater than 0.05 mm, the guide
86 should be replaced.

Fig. 68. Checking the piston guides

;;;;
The front piston-guide (66) is pressed into the seal
N housing (63). Do not separate these parts unless
they are damaged.
If they need to be separated, proceed as
follows:
63
– Press the piston guide out of the seal
housing with the aid of a 28–40 mm
expander (N).

66
1250 0028 85

Fig. 69. Removing the front piston guide

75

If the bore of the cylinder (75), the valve bore

1250 0028 86

or valve piston (84) 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).
84
Wash out all ducts thoroughly to remove any
foreign matter.

Fig. 70. Checking the cylinder and valve piston

36
 87 Inspect the impact piston (87) 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.
R=1
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-
1250 0028 87

site is the minimum permissible dimension. Further,

0.5 mm 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
278 mm the piston thoroughly to remove all traces of grin-
ding residue.
Fig. 71. Checking the impact piston

Assembly
81
76 80 Before assembly, all parts must be oiled with
82 clean hydraulic oil.
Fit the valve piston (84). The end with the hole
1250 0028 88

must face the cover (83) as shown in the figure

opposite. Check that the valve piston moves easily
in the valve bore.

83 Fit the valve covers (80 and 83) with new O-rings
(82). The valve covers should slide in easily and
81 should not be knocked into place.
76 Tighten the screws (81) to a torque of 175 Nm
84 (130 lbf. ft).
82
Check carefully that the four nozzles (76) are not
clogged with dirt and that they are properly tighte-
Fig. 72. Fitting the valve piston and valve covers ned.

DD

If the piston guide (66) has been removed, fit it

back into place as follows:
66
– Press the piston guide into the seal
housing (63) with the aid of mandrel (DD).
N.B. The piston guide must be fitted with the larger
diameter facing upwards, as shown in the figure
63 opposite.
1250 0028 89

Fig. 73. Fitting the piston guide

37
 If the seal housing (63) has been removed, fit it
back as follows:
– Fit the O-rings (65).
– Press in the seal housing with the aid of mandrel
(DD).
63 N.B. Make sure that none of the four recesses (A)
in the seal housing locate directly in front of the
stop screw (B) in the cylinder.
1250 0028 90

B DD
65
A

Fig. 74. Fitting the seal housing

Fit the piston seals (64) into the seal housing.

(A seal kit consists of an O-ring and a Teflon ring).
Fit the O-ring into the groove. Bend the Teflon ring
as shown in the figure, and then press it into the
1250 0028 91

groove.
IMPORTANT! Make sure that the lips of the seal
64 face the direction shown in the figure opposite.

Fig. 75. Fitting the impact-piston seals

86

75

Oil the impact piston (87) and slide it into the cylin-
der (75). When the piston reaches the front piston
64
seals (64), twist the piston gently so as not to
damage the seals.
1250 0028 92

Fit the piston guide (86).

87

Fig. 76. Fitting the impact-piston and piston guide

38
 Hydraulic motor
Disassembly
Inspection, replacement of parts
Assembly
Function and condition test

For exploded view of hydraulic motor, see page 43.

Disassembly
4
Clamp the hydraulic motor (51) firmly in a vice fit-
ted with copper jaw linings.
3
Using a 4 mm Allen key, loosen the screws (4). Re-
7 move the plate (3) and O-rings (2 and 7).

51
1250 0028 93

Fig. 77. Removing the plate

Lift off the cardan shaft (5).

8
Using a 4 mm Allen key, loosen the screws (6)
and remove the cog wheel set (8) from the valve
1250 0028 94

housing (19).

19

Fig. 78. Removing the cardan shaft and cog wheel set

39
 19

Remove the valve drive (10) from the valve hou-

17 sing (19). Turn the valve housing upside down and
knock out the contents (11, 12, 13, 17 and 18)
18 against two blocks of wood. Be careful not to
damage the parts.
13

12

11
1250 0028 95

10

Fig. 79. Emptying the contents of the valve housing

1250 0028 96

23 Clamp the valve housing (19) firmly in the vice.

25
22 Using a 5 mm Allen key, remove the valve plugs
21 (23) and O-rings (25).
Turn the valve housing upside down and remove
the springs (22) and balls (21).
19

Fig. 80. Removing the valve plugs

Inspection, replacement of parts

All parts must be cleaned thoroughly before in-
spection.
mm Check all parts for wear and damage. Change all
0.1
worn or defective parts. Change all O-rings and
seal rings.
1250 0028 97

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. 81. Inspecting the parts

40
 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 2450 90 must always be used.
1250 0028 98

Clamp the valve housing (19) firmly in a vice fitted

23 with copper jaw linings.
25
22 Insert the balls (21) and springs (22) into the two
21 holes in the valve housing (19), and then fit the
plugs (23) and washers (24). Use a 5 mm Allen
key, and tighten the plugs to a torque of 10 Nm
(7 lbf. ft).
19

Fig. 82. Fitting the balls and springs into the valve
housing

17

13 Clamp the valve housing (19) firmly in a vice fitted

with copper jaw linings.
Place the spring ring (18) in the valve housing (19).
14
15 Grease the O-rings (15 and 16) and fit them on to
the balance plate (13).
16 Grease the balance plate and fit it into the valve
housing. The guide pin (14) must locate in the hole
in the bottom of the valve housing. Press the balan-
1250 0028 99

18
ce plate into place using a soft tool shaft.
Grease and fit the spacer pin (17). (The grease will
keep the parts in place during assembly.)
19

Fig. 83. Assembling the internal parts of the valve

housing

41
 5

2
Place the cog wheel set (8) on a flat surface.
1
Grease and fit the seal ring (1) and O-rings (2 and
7) to the plate (3).
4 3
Place the cardan shaft (5) with plate (3) into the
cog wheel set (8).
7
Adjust the plate relative to the screw holes in the
1250 0029 00

cog wheel set, and then fit the screws (4).

Fig. 84. Fitting the plate

Clamp the cog wheel set (8) in a vice fitted with

10 copper jaw linings.
Fit the valve drive (10).
Make a mark on one of the tooth crests on the up-
per side (A) of the valve drive (10). The mark must
B 8 be directly opposite a clearance curve in the outer
cog circle (B) of the rotor, as shown in the figure
1250 0029 01

opposite.

Fig. 85. Fitting the valve drive

11
1250 0029 02

7 Put the channel plate (11) on the cog wheel set (8).
When placing the channel plate on the cog wheel
set, make sure that the guide pin (9) locates in the
bottom hole in the channel plate.
Now fit the O-ring (7).
8
9

Fig. 86. Fitting the O-ring and channel plate

42
 3115 2450 81 (OMSU 80)
Hydraulic motors 3115 2450 83 (OMSU 160)

12 Fit the disc valve (12) so that one of the holes (B) li-
nes up with the marking on the valve drive (10).
B Turn the disc valve anti-clockwise until the splines
10 engage.
N.B. If the disc valve is not fitted in this way, the
motor will rotate anti-clockwise. 1
2
1250 0029 04

4
3

Fig. 87. Fitting the disc valve 5

6
7
8

9
7

Place the valve housing (19) on top of the cog whe-

19 el set (8) and disc valve (12). 10
12 11
Fit the screws (6) and tighten to pull the valve hou- 13
sing and cog wheel set together.
14
1250 0029 05

15
12
16 20
17 18
8

19

1250 0029 06
Fig. 88. Fitting the valve housing

21
22
24
23

25

43
Assembling the main parts of the rock drill

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

75

Cylinder
Using two M16 bolts, bolt the cylinder (75) secure-
ly to the adapter plate (R) and pivoted mounting fix-
ture (A). See figure opposite.
1250 0029 03

Fig. 90. Fitting the cylinder to the pivoted mounting

fixture

25 Hydraulic motor
51 Fit the hydraulic motor to the intermediate part (37).
Tighten the screws (25) to a torque of 60 Nm
(44 lbf. ft).
37
1250 0029 08

Fig. 91. Fitting the hydraulic motor to the intermediate part

45
 17
56 Intermediate part
75 Fit the O-ring (62) into the groove in the middle of
the rear guide of the intermediate part (37).
Fit the O-rings (17, 56 and 60) into the rear face of
the intermediate part (37).
62
60 Fit the O-rings (17 and 32) in place in the front
face of the intermediate plate (37).
37
Fit the intermediate part (37) to the cylinder (75).
1250 0029 09

Lightly tap the intermediate part into position using

a copper hammer.

17
32

Fig. 92. Fitting the intermediate part to the cylinder

37

18
Cover and gear housing
12
Fit the gear housing (18) to the intermediate part
(37) using the side bolts (4) to guide it into place.
If the rotation shaft (27) does not enter the coup-
1250 0029 10

ling (46), insert a shank adapter into the driver (12)

and turn it.

46 4
27

Fig. 93. Fitting the gear housing to the intermediate part

2 Fit the rear washers (3) and nuts (2). Tighten the
3 rear side-bolt nuts (2) alternately to a torque of
300 Nm (220 lbf. ft). Use the wrench adapter (K)
for the torque wrench.
Fit the bolts (5). Tighten the bolts to a torque of
1250 0029 11

220 Nm (160 lbf. ft).

N.B. Before assembly, smear the threads with gre-
ase of type NEVER-SEEZ.
5

Fig. 94. Fitting the bolts

46
 Back head
89 Grease the O-rings (88) and fit them into the groo-
61 ves on the back head (89).
88
Check that the guide pin (61) is fitted into the back
head.

90 Carefully fit the back head to the cylinder. Take

care not to damage the impact piston or the piston
seals.
1250 0029 12

Tighten the six screws (90) for the back head

alternately to a torque of 220 Nm (160 lbf. ft).

Fig. 95. Fitting the back head to the cylinder

2 Front head
1 Fit the front head (1) over the side bolts (4).
Fit the washers (3) and nuts (2).
N.B. Before assembly, smear the threads with gre-
1250 0029 13

ase of type NEVER-SEEZ.

4 Tighten the nuts (2) alternately to a torque of 350 Nm
3 (260 lbf. ft).
2

Fig. 96. Fitting the front head

1250 0027 86

2 3 4 8

Fit the flushing adapter (5) and plug (8) together

with the O-rings (2 and 3) and support rings (4).
Now tighten the flushing adapter and plug to a
torque of 300 Nm (220 lbf. ft).
2
3
4
5
6

Fig. 97. Fitting the plug and flushing adapter to the front
head

47
 Accumulators

CAUTION
• Mount the accumulators to the rock drill
using undamaged original screws.
Each accumulator must have two screws
(4) of length 70 mm.
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
75 leakage, or can cause the accumulator to
4 be blown off.
1250 0029 14

67

68
4
4 91

92 68
37
Place the O-rings (68) on to the accumulators (67,
91, 92).
Fig. 98. Fitting the accumulators Now fit the accumulators (67 and 92) to the cylin-
der (75), and the accumulator (91) to the interme-
diate part (37).
Tighten the screws (4) alternately to a torque of
220 Nm (160 lbf. ft).

= Read the instruction book carefully

before servicing or changing
1250 0020 91

Make sure that the accumulators (67, 91, 92) have

the correct safety labels, and that the labels are
not damaged.
= Must be charged with nitrogen only
Replace any damaged safety labels!

67

92
91
1250 0029 15

Fig. 99. The accumulator safety labels

48
 Charging the accumulators

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

CAUTION
• Do NOT charge the accumulators until
they have been fitted to the rock drill.
There is a risk of injury if these instruc-
tions are not observed!

Throule shooting
To high charged accumulator damage the diap-
hragm and gives heavy marks under neath.
The accumulators must be charged before the drill
rig is started up.
B
The intake accumulator (67) is located on the left-
hand side of the rock drill.
The return accumulator (92) is located on the right-
hand side of the rock drill, and the damper accumu-
67 lator (91) is on the intermediate part.
All stated pressures must be read at the rock drill
92 with the hydraulic oil at operating temperature.

91
1. Unscrew and remove the protective cap (A).
2. Open the valve nut (B) by 2–3 turns.
3. Fit the regulator (Q or GG) and connect the
A charging hose (P)—see figure opposite.
4. Adjust the regulator (Q or GG) to the lowest
P possible pressure.
C 5. Open the gas valve (C).
6. Charge the accumulators to the right pressures,
as given below:
a. Damper accumulator (91): 20 bar
GG for accumulator 92 b. Intake accumulator (67): 30 bar below the
1250 0029 16

Q for accumulators 67 and 91 collaring pressure (max. 110 bar).

N2 c. Return accumulator (92): half the
percussion return pressure.
7. Tighten the valve nut (B) and shut the gas val-
ve (C).
Fig. 100. Charging the accumulators 8. Remove the charging hose (P) and fit back the
protective cap (A).

N.B. In order to avoid the risk of leakage, it is N.B. The reading on the pressure gauge in the
recommended that the charging nipples be re- cab (or on the panel) is approx. 5 bar higher
placed after they have been opened/closed 3 ti- than the reading obtained at the rock drill, de-
mes. pending on the lengths of the hoses and the ty-
pes of valves that may be fitted between the
cab/panel and the rock drill

49
 Greasing the gear
20 19 Remove the plug (19) with washer (20) and fill the
gear housing with a heat-resistant grease via the
nipple (21). Fill until grease comes out through the
hole (A). See the section "Recommended hydraulic
oils and lubricants".

A Fit back the plug (19) with washer (20) and tighten.
1250 0029 20

21

Fig. 161. Greasing the gear

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.

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)

50
Testing the rotation and percussion functions
Testing the rotation function
Connect the hydraulic hoses P (pressure) and R
P
(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.

R
1250 0029 21

R
P

Fig. 102. Testing the function of the hydraulic motor

Testing the percussion function

P Connect the hydraulic hoses P (pressure), and
R (return) as shown in the figure. Apply a hydraulic
pressure (max. pressure 30 bar) to the percussion
circuit for approx. half a minute.
Check that the percussion mechanism functions
properly, and that there is no oil leakage.
1250 0029 22

Fig. 103. Testing the function of the percussion mechanism

51
Tightening torques

5
4
1

5
5

5 3
1250 0027 73

1
10
6
7

3 2
2 9

N.B. Tighten item Nos. 1–3 in the prescribed order.

Ref.No. Qty. Check point Torque Instructions

Nm lbf.ft

1 2 Side bolts 300 220 Tighten the rear nuts

2 2 Front bolts 220 160 Tighten the front bolts
3 2 Side bolts 350 260 Tighten the front nuts
4 6 Back head 220 160 Tighten the screws alternately to full torque
5 6 Accumulators 220 160 Tighten the screws alternately to full torque
6 4 Hydraulic motor 60 44 Tighten the screws alternately to full torque
7 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque
8 4 Valve covers 175 130 Tighten the screws alternately to full torque
9 1 Flushing connection 300 220
10 1 Flushing plug 300 220

52
 17
61
Rock drill 61
88

COP 1432 / 1432ED 56

57
90
89
87
82 63
58 73
59 80 81
Intake accumulator / Return accumulator 37 91 71 75
95
60 38 44 72 83
1 3 A 64
2
66 64
86 75
94 62 72
10 93 74
66
9 65 83 85 72
84
11 26 82 73
43
53 51 42
4 55 54 79
2
1250 0029 95

69 74
3 67 78
8 45 76
7 13 17 70 64 78 77
12
6
49 41 68
55 50 40 66
18 52 65
5 53 39
48 25
52 47 92
46 23 19
20 15
Damper accumulator 8 7 22
9 96
6 27 14
1 10 32 12
2 35 13
3 34 16
11 33 11
31 17
1 30
7 36
29 28 21
8 24
9
10

1250 0050 31
3
1250 0029 96

6 D 5 2
4
4

5 12

Front head 25

15

12
27 11

20 14
13
9
1

10 2 3 4 8
23

Atlas Copco, Nacka 1998

13
28
1250 0055 92

Printed in Sweden
24
2
11 3
23
22 4
7 5 29
6

53