9852 1007 01k Maintenance Instructions Cop 1840

Atlas Copco Maintenance instructions Hydraulic Rock drills COP 1840, 1840EX

Atlas Copco Rock Drills AB Örebro, Sweden ©Atlas Copco Rock Drills AB, 2009, All rights reserved

No. 9852 1007 01k

©Copyright 2009, Atlas Copco Rock Drills AB, Sweden Any unauthorised use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. Atlas Copco Rock Drills AB SE-70191 Örebro, Sweden

CONTENTS

CONTENTS 1.

GENERAL .......................................................................................................... 5 1.1 1.2

2.

SERVICE INTERVAL.......................................................................................... 7 2.1 2.2 2.3 2.4 2.5

3.

TIGHTENING THE SIDE BOLTS...................................................................................... 12 RETIGHTENING THE SIDE BOLTS................................................................................. 12

ACCUMULATORS............................................................................................ 13 5.1 5.2 5.3 5.4 5.5

5.6

6.

CONNECTING THE HOSES ............................................................................................ 10

TIGHTENING TORQUES ................................................................................. 11 4.1 4.2

5.

BEFORE STARTING A NEW OR NEWLY OVERHAULED ROCK DRILL ......................... 8 AFTER EACH SHIFT WHEN USING A NEW OR NEWLY OVERHAULED ROCK DRILL 8 FOR EACH SHIFT .............................................................................................................. 8 AFTER EVERY 40TH PERCUSSION-HOUR ..................................................................... 9 EVERY 400TH PERCUSSION-HOUR:............................................................................... 9

HOSE CONNECTIONS .................................................................................... 10 3.1

4.

ENVIRONMENT.................................................................................................................. 5 SAFETY REGULATIONS.................................................................................................... 5 WARNING BOXES.............................................................................................................. 5 THE FOLLOWING GENERAL SAFETY RULES MUST BE OBSERVED .......................... 6

SAFETY LABEL LOCATION............................................................................................. 13 SAFETY LABEL INSTRUCTIONS .................................................................................... 13 CHARGING THE ACCUMULATORS................................................................................ 13 CHECKING THE ACCUMULATORS IN THE EVENT OF HOSE VIBRATION................. 14 INTAKE AND DAMPER ACCUMULATORS ..................................................................... 14 REPLACING INTAKE AND DAMPER ACCUMULATOR.................................................. 14 DISMANTLING.................................................................................................................. 15 ASSEMBLY ....................................................................................................................... 15 REPLACING THE RETURN ACCUMULATOR................................................................. 15 DISMANTLING.................................................................................................................. 15 ASSEMBLY ....................................................................................................................... 15

CHANGING THE HYDRAULIC MOTOR.......................................................... 16 DISMANTLING.................................................................................................................. 16 ASSEMBLY ....................................................................................................................... 16

7.

FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM ............. 17

8.

SETTINGS ........................................................................................................ 18 8.1 8.2 8.3

9.

SETTING OF ECL LUBRICATING SYSTEM.................................................................... 18 SETTING DAMPER PRESSURE...................................................................................... 18 SETTING EXTRACTOR PRESSURE............................................................................... 19

REMOVING THE FRONT HEAD...................................................................... 20 9.1

EXTRACTOR FRONT HEAD............................................................................................ 20

10. CHECKING THE FRONT HEAD ...................................................................... 21 10.1 EXTRACTOR FRONT HEAD............................................................................................ 22

11. REPLACING THE FLUSHING HEAD AND DRIVER....................................... 23 DISMANTLING.................................................................................................................. 23 ASSEMBLY ....................................................................................................................... 23 11.1 EXTRACTOR FRONT HEAD............................................................................................ 24 DISMANTLING.................................................................................................................. 24 ASSEMBLY ....................................................................................................................... 24

3

CONTENTS

12. MOUNTING THE FRONT HEAD ..................................................................... 25 12.1 EXTRACTOR FRONT HEAD ........................................................................................... 25

13. SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING ............ 26 13.1 13.2 13.3 13.4

SLINGING ........................................................................................................................ ROCK DRILL WEIGHTS .................................................................................................. LONG-TERM STORAGE ................................................................................................. STROKE LENGTH SETTING........................................................................................... BASIC SETTING ..............................................................................................................

26 26 26 26 26

14. LUBRICATION ................................................................................................. 29 14.1 LUBRICATION OF GEAR ................................................................................................ 29

15. HYDRAULIC AND LUBRICANT RECOMMENDATIONS................................ 31 15.1 HYDRAULIC FLUID ......................................................................................................... 31 15.2 PNEUMATIC TOOL OIL ................................................................................................... 32 15.3 GREASE........................................................................................................................... 32

4

GENERAL 1

1. GENERAL

1.2 SAFETY REGULATIONS The Safety chapter contains important information for the prevention of accidents.

This instruction is intended as a guide when performing maintenance on your rock drill.

WARNING BOXES The instructions include warnings.

1.1 ENVIRONMENT

Warnings are preceded by a heading (Danger, Warning and Caution).

ENVIRONMENTAL REGULATIONS Care for the environment!

WARNING BOXES

Leaking hydraulic couplings and grease are hazardous to the environment.

Danger Indicates an imminent risk of serious or fatal injury if the warning is not heeded.

Changing oils, hydraulic hoses and various types of filter can be hazardous to the environment. Always collect oil residues, oil spillage, oily waste and residues and spilt grease. Deal with according to local provisions.

Warning Indicates hazards or hazardous procedures which could result in serious or fatal injury if the warning is not heeded.

Use biodegradable hydraulic and lubricating oils where possible.

Caution Indicates hazards or hazardous procedures which could result in personal injury or damage to property if the warning is not heeded.

5

GENERAL 1

THE FOLLOWING GENERAL SAFETY RULES MUST BE OBSERVED

IMPORTANT!

IMPORTANT!

Make sure that the rock drill has been maintained in accordance with the applicable instructions.

Read through the maintenance instructions carefully before starting maintenance work. Follow the instructions given and local regulations.

Before moving the rig and rock drill or starting to drill, make sure that there are no personnel in the immediate vicinity of the drill rig.

Do not use or intervene in the rock drill unless you have been trained to do so.

Checks and adjustments that are necessary when the rock drill is in operation must be carried out by at least two persons. One person must then be present at the operating station and have a good view of the work.

Never attempt to carry out maintenance while the rock drill is in operation. Ensure that the hydraulic, water and air systems are depressurised and that the electrical system is de-energised prior to removing the rock drill or starting work on the system.

Always wear a helmet and earmuffs when drilling. Follow local regulations

Use approved lifting devices when handling the rock drill. Avoid lifting heavy weights yourself.

Make sure that the place of work is well ventilated.

To prevent injury during service and maintenance, all components that could possibly move or drop must be supported safely on blocks or trestles, or secured by means of adequately dimensioned slings.

Make sure that the safety labels are fitted, clean and fully legible. Particular attention must be paid to all warnings in the instructions.

Check that the hoses used are of the right quality, and that all hose connections are in good condition and properly tightened. Hoses that loosen could cause serious injury. Use only Atlas Copco original parts. Any damage or malfunction caused by the use of non-original Atlas Copco parts is not covered by warranty or product liability.

6

SERVICE INTERVAL 2

2. SERVICE INTERVAL IMPORTANT!

Read all safety regulations before starting to work on the machine.

Observe great cleanliness when intervening in the rock drill or its hydraulic circuit.

Order numbers for the repair kits are in the rock drill’s spare parts catalogue.

The following parts may be changed at the work site in accordance with the instructions given:

WARNING!

•shank adapter •driver •front head parts •accumulators •hydraulic motor •screws •connections

Before starting any maintenance work, make sure that the electrical system is dead. There is a risk of injury if these instructions are not observed!

CAUTION!

Other repairs must be carried out in a suitable workshop in accordance with the repair instructions for the rock drill.

Exercise caution when jointing drill rods and with drill bit handling. Watch your fingers! Make sure that clothes do not come too close to rotating machine parts.

IMPORTANT!

Negligence could cause serious injury.

Ensure bolted joints are tightened to the correct tightening torques after every 40 percussion hours and when reconditioning the rock drill.

Always use hearing protection when drilling. High noise levels damage the hearing. Never attempt maintenance or intervene in the rock drill, connections or hoses while the hydraulic, lubrication or flushing systems are pressurised. Air or oil can spray out at high pressure and high temperature. There is a risk of serious injury to the eyes and skin.

IMPORTANT! Servicing should be carried out at appropriate time intervals based on local conditions. The condition of the rock has a major affect on the amount wear and with that the need of servicing.

7

SERVICE INTERVAL 2

IMPORTANT! Any defect must be rectified in the designated workshop

2.1 BEFORE STARTING A NEW OR NEWLY OVERHAULED ROCK DRILL Action

Chapter

Connect up the hoses Charge the accumulators Select a suitable hydraulic oil and lubricant Fill the lubricating system with oil Adjust and set the lubricating system Set the damper pressure Set the extractor unit pressure

3 5 15 7 8 8 8

2.2 AFTER EACH SHIFT WHEN USING A NEW OR NEWLY OVERHAULED ROCK DRILL Action

Chapter

Tighten all threaded unions

4

2.3 FOR EACH SHIFT Action

Chapter

Check that air and lubricating oil escape from the hole in the front head Check that the drill rig’s damper pressure gauge is showing normal values. Check that the drill rig’s damper pressure gauge is showing normal values. In the event of deviation, adjust the damper pressure. Check that the shank adapter threads are not damaged Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulators Check that the machine does not leak. If the flushing medium leaks from the flushing head, replace the seals and O-rings When replacing the shank adapter or removing the front head, check the internal components including piston, driver and the visible parts of the rotation chuck bushing In the event of oil leakage from the front head: close percussion and only activate the damper in order to determine if the leakage is coming from the percussion or damper.

10 8

8

10 5 10 10

10

SERVICE INTERVAL 2

2.4 AFTER EVERY 40TH PERCUSSION-HOUR Action

Chapter

Grease the gear Tighten all threaded unions Check the safety labels on the accumulators. Replace them if they are damaged or illegible Check the accumulators

14 4 5 5

2.5 EVERY 400TH PERCUSSIONHOUR: Action

Chapter

Dismantle the rock drill from the drill rig. Transport the rock drill to an appropriate workshop for servicing

13

IMPORTANT! Always function test the rock drill after service.

9

HOSE CONNECTIONS 3

3. HOSE CONNECTIONS CAUTION!

3.1 CONNECTING THE HOSES

Never attempt maintenance or any work in the rock drill, connections or hoses while the hydraulic, lubrication or flushing systems are pressurised. Air or oil can spray out at high pressure and high temperature. There is a risk of serious injury to the eyes and skin.

• Clean the rock drill’s hose connections before undoing the protective caps. • Never remove a protective cap until the hose is ready to be connected. • Always store the rock drill with all hose connections plugged. Use suitable protective caps, and make sure that they are clean.

8

Pressure hoses with an internal diameter of 19 mm (3/4") or greater are of the quality SAE 100 R9R (high-pressure hose with four layers of steel reinforcement). For reasons of safety, under no circumstance may these hoses be replaced with hoses of a lower quality. There is a risk of injury if these instructions are not observed!

7

1

1250 0210 53

6

5 2

3

4

6 1. 2. 3. 4. 5.

Drainage Rotation left Rotation right Percussion return Inlet impact mechanism

6. Flushing air/water 7. Lubricating air 8. Damper, intake 9. Extractor unit, return 10.Extractor unit, intake

10

9

10

TIGHTENING TORQUES 4

4. TIGHTENING TORQUES

4

5 1

6

3A 14

3A 2

9 13 12 11 8 9 10

3B 15 16

1250 0210 54

7

6

13

2

Lubricate the nuts’ threads and the washers’ contact surfaces with Never-Seez Regular Grade. Ref. No.

Qty.

Check point

Torque Nm

1 2 3A 3B 4

2 1 2 3 3

Side bolts Front bolt Side bolt Side bolts EX Back head

300 300 350 300 220

5 6

1 4

Regulating plug Accumulator

80 220

7 8

4 2

65 30

9

4

Hydraulic motor Clamping attachment, return accumulator Rock drill mounting

250

10 11

1 4

Plug Valve end plates

45 145

12

2

Connecting plate

120

13 14

1 4

Flushing connector Intake, flushing medium

300 90

15 16

1 1

Intake, extractor unit Return, extractor unit

120 120

11

Instructions

Tighten the rear nuts Tighten the front bolt Tighten the front nuts Tighten the front nuts Tighten the screws alternately to full torque, top bolt last Tighten the screws alternately to full torque Tighten the nuts alternately

Tighten the screws alternately to full torque Tighten the screws alternately to full torque Tighten the screws alternately to full torque Tighten the screws alternately to full torque

TIGHTENING TORQUES 4

4.1 TIGHTENING THE SIDE BOLTS

4.2 RETIGHTENING THE SIDE BOLTS Not extractor unit version

• Undo the front nuts (3A) so that the tension releases.

1250 0219 79

1

2

If the threads are seized, remove the nuts and clean and lubricate them with Never-Seez Regular Grade.

3B

Tighten the front nuts (3A) manually. Both versions

• Tighten the rear nuts (1) to the tightening torque. • Tighten the side bolt (2) to the tightening torque.

2

• Tighten the front bolts (3A or 3B) to the tightening torque.

3A

• Check whether the side bolts, nuts or washers have cracks, scratches or rust. Replace damaged side bolts, nuts and washers. • Lubricate the threads and contact surfaces of the side bolt (2), nuts and washers with NeverSeez Regular Grade. • Tighten the rear nuts (1) to the tightening torque. • Tighten the side bolt (2) to the tightening torque. • Tighten the front bolts (3A or 3B) to the tightening torque.

12

ACCUMULATORS 5

5. ACCUMULATORS

5.3 CHARGING THE ACCUMULATORS

Check the safety labels on the accumulators. Replace them if they are damaged or illegible.

1250 0210 55

5.1 SAFETY LABEL LOCATION

221

CAUTION!

231

211

Charge the accumulators when assembled on the rock drill. There is a risk of injury if these instructions are not observed!

221.Damper accumulator 211.Intake accumulator 231.Return accumulator

WARNING! A gas other than N 2 could cause an explosion.

5.2 SAFETY LABEL INSTRUCTIONS

• Remove the protective cap (A).

1250 0210 56

• Open the valve nut (B) by 2-3 turns, and connect the gas hose. • Open the gas valve (C).

1

• Charge the accumulators with nitrogen gas (N 2) to the correct pressure in accordance with the following: NB! Charge at the bottom if possible rather than too high.

2

1. Read the operator’s instructions carefully before service or replacement of the accumulator. 2. Must be charged with nitrogen only

Damper accumulator (221)

20-25 bar

Intake accumulator (211)

30-40 bar (80-100 bar)*

Return accumulator (231)

Must not be charged with N2

*Intake accumulator 30-40 bar under collaring pressure. Normal 80-100 bar. Max. 100 bar.

• Tighten the valve nut (B) and close the gas valve (C). • Remove the gas hose and screw in the protective cap (A) to the accumulator valve.

13

ACCUMULATORS 5

5.4 CHECKING THE ACCUMULATORS IN THE EVENT OF HOSE VIBRATION

RETURN ACCUMULATOR

C

INTAKE AND DAMPER ACCUMULATORS

1250 0210 58

1250 0210 59

A

A B

231 C

• Position the rock drill in horizontal position.

211 221

• Remove the stopper with O-ring (C). If oil escapes then the diaphragm is damaged.

• Push in the control valve’s pin (A). If the accumulator is charged, the pin protrudes 4.5 mm and is hard to push in. If the pin is easy to press in then the gas pressure has disappeared (broken diaphragm or defective filler valve). NB! The damper accumulator’s pin is slightly easier to press in. • Replace the accumulator, diaphragm and/or filler valve if they are damaged.

• Replace the accumulator and/or diaphragm if they are damaged. • If the diaphragm is in contact against the outer tube, press diaphragm with a cylindrical (blunt) mandrel (7-9 mm). See Figure A. The correct position for the diaphragm is, see Figure B. • Refit the stopper and O-ring (C). • Charge by means of admitting air at atmospheric pressure into the accumulator.

• Charge the new accumulator after replacement. .......... NB! The seat of the filler valve is easily deformed by repeated opening/closing. The filler valve must be replaced frequently.

5.5 REPLACING INTAKE AND DAMPER ACCUMULATOR

D

221 82

BA

1250 0210 60

53

211 C

82 BA

WARNING! All gas must be released prior to fitting by means of removing the protective cap (A), undoing the valve nut (B) and opening it 2-3 turns. There is a risk of injury if these instructions are not observed

14

ACCUMULATORS 5

5.6 REPLACING THE RETURN ACCUMULATOR

CAUTION! Defective bolts may lead to dangerous oil leakage or the accumulator working loose. Oil spray can injure the eyes and skin.

CAUTION! Ensure that the hydraulic, water and air systems are depressurised before starting work on the system.

Parts that come loose can cause serious injury. DISMANTLING • Remove the accumulators (221, and 211) with the sealing rings (82) by undoing the bolts (C and D). Send the accumulators to a workshop for reconditioning!

For reasons of safety, under no circumstance may the pressure hoses be replaced with hoses of a lower quality. The hoses must be high-pressure hoses with four layers of steel reinforcement, quality SAE 100R9R. There is a risk of injury if these instructions are not observed!

ASSEMBLY • Locate the sealing rings (82) in the grooves on the intermediate section (53).

1250 0210 61

• Make sure that the sealing rings (82) do not get damaged during the assembly. • Fit the damper accumulator (221) on the rock drill’s left-hand side and the intake accumulator (211) on the rock drill’s right-hand side (hose side). Fit with undamaged original bolts (D) length of 70 mm and (C) length 100 mm. Replace the bolts in pairs even if only one bolt is corroded or damaged in some other way.

23 A

21

11 B

24

25 231

• Tighten the bolts (C and D) alternately to tightening torque 220 Nm. DISMANTLING • Remove the hydraulic hose (A) from the return accumulator (231).

• Charge the accumulators with nitrogen gas (N 2).

• Remove the return accumulator (231) by removing the nuts (24) and the bolts (23). • Pull away the clamp (21) and unscrew the accumulator from the nipple (B). • Send the return accumulator to a workshop for overhauling. ASSEMBLY • Screw in the return accumulator (231) onto the nipple (B) in such a way that the stopper (11) is accessible for checking the accumulator’s diaphragm. • Fit the clamp (21) onto the return accumulator. Fit the rock drills with the bolts (23) and the nuts (24). • Connect the hydraulic hose (A) to the return accumulator (231).

15

CHANGING THE HYDRAULIC MOTOR 6

6. CHANGING THE

ASSEMBLY • Make sure that the groove ring (130) is fitted in the coupling (249).

HYDRAULIC MOTOR

• Lubricate the coupling’s splines with grease and fit the coupling (249) on the hydraulic motor (241).

3

1250 0210 62

A

241

248

• Replace the gasket (248) if it is damaged. • Fit the gasket (248) and the hydraulic motor (241) on the cylinder (3). Tighten the nuts (246) to tightening torque 65 Nm.

246

• Connect the hydraulic hoses (A). Check that the correct direction of rotation is obtained.

249 130

DISMANTLING • Detach the hydraulic hoses (A). • Undo the nuts (246) and remove the hydraulic motor (241). • Pull out the coupling (249).

16

FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM 7

7. FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM CAUTION! Never work on the lubrication system when it is pressurised. Lubricating oil could spray out. There is a risk of serious injury to the eyes and skin.

IMPORTANT! Use the recommended lubrication air pressure and recommended lubrication oil. Some moving parts on the rock drill are lubricated with oil mixed with compressed air. Is important that these parts receive good lubrication. Check the level in the lubricating oil tank for every shift. Exercise cleanliness and fill with the right grade oil. NB! If the lubricating system has been empty of oil, it must be bled after filling.

17

SETTINGS 8

8. SETTINGS

8.2 SETTING DAMPER PRESSURE

A

8.1 SETTING OF ECL LUBRICATING SYSTEM

1

ECL=Electric Controlled Lubrication Rock drill lubrication must be set with regard to the local conditions. • Start the lubricating system. 1250 0210 72

• Check the lubricating air pressure at the rock drill using a pressure gauge. The pressure should be 2-3 bar. If the pressure is too low, clean the restriction or increase the diameter of the restriction.

NB! The setting should take place at normal operating temperature for the hydraulic oil.

• Set the correct lubricating oil dose. Pump (3217 8667 50)

35-40 pulses/minute

Pump (3217 8667 52)

20-25 pulses/minute

B

• Fully close the constant flow valve (B) on the drill rig. • Connect a pressure gauge (A), calibrated for 060 bar, between the hose and the damper union (1).

• After setting, check that the correct pulse frequency has been obtained and that oil is emerging from the front head’s hole and between the shank adapter and front guide.

• Pressurise the damper circuit. • Check that the shank adapter is unloaded and in the forward position. • Adjust the constant flow valve until the pressure gauge (A) shows 30-35 bar at the rock drill (operator panel shows 10-15 bar higher value). • Read off the drill rig’s damper pressure gauge. If this pressure gauge later shows another value, make a new pressure setting. • Disconnect the pressure gauge (A) and connect the hose to the union (1).

18

SETTINGS 8

8.3 SETTING EXTRACTOR PRESSURE

A

1250 0210 73

P B

• Fully close the constant flow valve (B) on the drill rig. • Connect a pressure gauge (A), calibrated for 060 bar, between the hose and the extractor unit’s intake union (P). • Connect the extractor unit circuit by activating the return feed and running the cradle against the stop. Let the lever remain in this position. • Adjust the constant flow valve (B) until the pressure gauge (A) shows 20-25 bar. • Disconnect the pressure gauge (A) and connect the hose to the union (P).

19

REMOVING THE FRONT HEAD 9

9. REMOVING THE FRONT HEAD 172

CAUTION! Never attempt to carry out maintenance while the drill rig is in operation.

1250 0210 76

Ensure that the hydraulic and air systems are depressurised before starting any work. There is a risk of injury if these instructions are not observed!

300 252 251

NB! Always clean the outside of the rock drill before disassembly. • Remove the front side-bolt nuts (251) with their washers (252). • Remove the front head (172) by pulling the shank adapter (300). • Then pull the shank adapter from the front head.

1250 0210 75

180

A

• Always check the internal components, also when replacing the shank adapter.

179 178

9.1 EXTRACTOR FRONT HEAD

173 177

• Remove the flushing hose (A).

162

• Remove the connecting plate (177) and nipple (173) by removing the bolts (178) and washers (179). 1250 0210 77

• Remove the cup seal (180).

300 252 251

• Remove the front side-bolt nuts (251) with their washers (252). • Remove the front head (162) by pulling the shank adapter (300) or by tapping with a copper hammer. • Then pull the shank adapter from the front head. • Always check the internal components, also when replacing the shank adapter.

20

CHECKING THE FRONT HEAD 10

10. CHECKING THE FRONT HEAD 192 300 172 190 174 191 176

A 131 132

E

1250 0210 74

F 173

175 131

B

C

185

185

1m m

2 mm

173

21

m 132 1m

86

175 190 174

192 191

176 175

300

53 mm

D • Check that air and lubricating oil escape between the shank adapter (300) and front guide (173), and also out of the hole (B)

• If the rotation chuck bushing (132) is worn more than 1 mm or the piston (21) impact surface is damaged in any way then the rock drill must be sent to a workshop for inspection. NB! Fit the rotation chuck bushing so that the lubricating grooves (D) are aligned towards the damper piston (86).

• Blow clean the lubricating air ducts (A) in the front head (172) with compressed air and check that the restrictions (E) are open. • Replace the guide (173) if the inside diameter exceeds 53 mm.

• Replace the shank adapter (300) if the thread is worn out or the impact surface is warped or chipped, or if the front or rear end surfaces of the splines are worn.

• Check the O-rings (190-192) and flushing seals (175,176) if air is escaping from the hole (C) in the front head. Replace the O-rings and flushing seals if they are worn or damaged. • Replace the flushing head (174) if it is seriously corroded, or if it contains cracks. • Replace the stop ring (185) if it is worn by more than 1 mm. • Look inside the gear housing and check the splines on the driver (131). If the splines are less than 2 mm in width, the driver must be changed. Fit a new driver with the aid of a suitable mandrel and a copper hammer.

21

CHECKING THE FRONT HEAD 10

E

A

131

162 170 172 168 171 193 185 194 185 195 185 196 185 182

167 169

300

10.1 EXTRACTOR FRONT HEAD

21

F 1250 0210 88

163 181 131 2 mm

B

C

132 194 193 185

m 132 1m

182

196 185 195

D 169 167

163 53 mm

300

181

170 168 171,172

1 mm

grooves (D) are aligned towards the damper piston (86).

• Check that air and lubricating oil escape between the shank adapter (300) and front guide (163), and also out of the hole (B)

• Replace the shank adapter (300) if the thread is worn out or the impact surface is warped or chipped, or if the front or rear end surfaces of the splines are worn.

• Blow clean the lubricating air ducts (A) in the front head (162) with compressed air and check that the restrictions (E) are open. • Replace the guide (163) if the inside diameter exceeds 53 mm.

• Check that the drill sleeve (F), to be used with upwards directed drilling, is not damaged and rotates with the shank adapter.

• Check the O-rings (193-195) and flushing seals (185) if air is escaping from the hole (C) in the front head. Replace the O-rings and flushing seals if they are worn or damaged.

• Replace the extractor unit’s piston (181) if the surface against the shank adapter has worn more than 1 mm. When replacing the extractor unit’s piston check the seals (167,168) and Orings (169-172). Replace the seals and O-rings if they are worn or damaged.

• Replace the flushing head (182) if it is seriously corroded, or if it contains cracks. • Look inside the gear housing and check the splines on the driver (131). If the splines are less than 2 mm in width, the driver must be changed. Fit a new driver with the aid of a suitable mandrel and a copper hammer.

•

• If the rotation chuck bushing (132) is worn more than 1 mm or the piston (21) impact surface is damaged in any way then the rock drill must be sent to a workshop for inspection. NB! Fit the rotation chuck bushing so that the lubricating

22

REPLACING THE FLUSHING HEAD AND DRIVER 11

11. REPLACING THE

ASSEMBLY

FLUSHING HEAD AND DRIVER

D V

CAUTION! Exercise care when dismantling flushing head and the driver. Watch your fingers!

174

D

• Press the flushing head (174) into the front head using a mandrel and sleeve. NB! The flushing head must be reversed so that the lubricating grooves are turned upwards.

V 173 174 1250 0210 89

A

1250 0210 50

DISMANTLING

• Make sure that the flushing hole in the flushing head (174) aligns with the hole in the front head.

185

• Use a mandrel and suitable sleeve to push out the guide (185), the flushing head (174) and the stop ring (173) from the front head.

D

131

1250 0210 49

1250 0210 51

C

131 B

A

117

• Use a mandrel and plastic hammer to fit the driver (131) in the drill sleeve (117).

• The driver (131) is pulled out manually or with an extractor (C) and an expander 37-46 mm, alternatively with dismantling tool (A)(3115 2724 80).

23

REPLACING THE FLUSHING HEAD AND DRIVER 11

11.1 EXTRACTOR FRONT HEAD

• Tap in the rotation chuck bushing (132) with a suitable copper mandrel.

131 A 182

198 197 184 183 263

183 103 263

AB • Fit the O-rings (193-196) and the seals (185) in the flushing head (182). Important! The seals (185) must be turned in accordance with the illustration.

C

• Remove the flushing hose (C) from the nipple (263). • Remove the nipple (183) and its O-rings and support ring.

• Fit the flushing head (182) in the cover plate (153) and tap it in with a copper hammer. Check carefully that the flushing intake in the cover is aligned with the hole in the flushing head.

• Press the removal tool (A) (3115 2724 80) into the gear housing (103) until the tool moves to the stop, i.e. the tool’s splines-equipped section has then passed the driver’s (131) splines.

• Fit the O-rings (197,198) and the support ring (184) on the nipple (183).

• Turn the removal tool clockwise slightly.

• Fit the nipples (183,263 and B) and the nut (A).

• Tap out the driver (131) and flushing head (182) using the sliding hammer (B).

• Torque tighten the nipple (183) to 300 Nm and the nipple (263) to 180 Nm.

• Normally the rotation chuck bushing (132) follows as well when removing the driver. If this is not the case, then remove the rotation chuck bushing using a puller and an expander.

1250 0210 8

ASSEMBLY

103

185 195 196

132 1250 0210 83

1250 0210 81

B

153

DISMANTLING

182

Exercise care when dismantling flushing head and the driver. Watch your fingers!

193 194 185

• Tap the driver (131) into the drill sleeve in the gear housing (103) using a mandrel (A) and a copper hammer.

CAUTION!

131 A

132

• Fit the rotation chuck bushing (132) so that the lubricating grooves are aligned towards the damper piston.

24

MOUNTING THE FRONT HEAD 12

12. MOUNTING THE FRONT

After assembly Check that air and lubricating oil escapes out of the hole in the front head and between the shank adapter and front guide.

HEAD

12.1 EXTRACTOR FRONT HEAD

172

1250 0210 78

1250 0210 8

162

300 162

263 188

300 161

186

252 251

• Fit the shank adapter (300) in the extractor unit’s front head (162).

252 251

• Fit the stop ring and shank adapter (300) in the front head (172).

• Fit the cylindrical pin (188). • Fit the front head (162) on the side bolts (186).

• Make sure that the pin (162) is fitted in the cover plate. Position the front head (172) on the side bolts (161).

• Apply grease, type Never Seez, onto the threads of the side bolts (186).

• Apply grease, type Never Seez, onto the threads of the side bolts (161).

• Fit the washers (252) and nuts (251).

• Fit the washers (252) and nuts (251).

• Check the tightening torques on the rear sidebolt nuts and the front side bolt.

• Check the tightening torques on the rear sidebolt nuts and the front side bolt.

• Following which, tighten the nuts (251) alternately to a torque of 300 Nm.

• Following which, tighten the nuts (251) alternately to a torque of 350 Nm.

• Connect the flushing hose to the nipple (263). After assembly Check that air and lubricating oil escapes out of the hole in the front head and between the shank adapter and front guide.

1250 0210 79

180

A

173 177

179 178

• Fit the cup seal (180) into the flushing head. • Fit the connecting plate (177) to the front head using the washers (179) and bolts (178). Tighten the bolts to a torque of 90 Nm. • Fit the nipple (173) on the connecting plate. Tighten the nipple to tightening torque 300 Nm. • Fit the flushing hose (A) and tighten the nut.

25

SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING 13

13. SLINGING, WEIGHT,

13.2 ROCK DRILL WEIGHTS

STORAGE AND STROKE LENGTH SETTING 13.1 SLINGING

COP 1840

184 kg

COP 1840EX

247 kg

1250 0184 84

1250 0184 87

13.3 LONG-TERM STORAGE

If the rock drill is not going to be used for a long time, the following precautions should be taken.

Make sure that the rock drill is safely slung for lifting. Make sure that the rock drill is securely anchored for transportation.

• Check that all connections, including the one for the flushing medium, are properly capped with protective caps of the right size.

caution!

• Clean the rock drill carefully. Use degreasing agent and rinse with water.

Lifting devices and straps must be approved for lifting 500 kg. Incorrect lifting devices could cause the rock drill to start moving or fall down.

• Clean thoroughly and oil in the front head components in contact with flushing medium (especially in high air humidity).

Incorrect operation could cause crushing damage.

• Release gas from the accumulators. • Store the rock drill in a dry place.

13.4 STROKE LENGTH SETTING

63

1250 0210 52

66

BASIC SETTING • On cylinder (66) there is a plug (63). Turning the plug changes the stroke length of the piston. There are two different positions. They are shown on the plug (63) by punched dots. For

26

SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING 13

example, when two dots are shown upward the setting is 2

27

SLINGING, WEIGHT, STORAGE AND STROKE LENGTH SETTING 13

28

LUBRICATION 14

14. LUBRICATION 1

1250 0210 87

3

2

14.1 LUBRICATION OF GEAR • Unscrew the bleed plug (1). • Lubricate with heat-resistant grease through the nipple (2) until new grease escapes through the hole (3). • Tighten the plug (1).

29

LUBRICATION 14

30

HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15

15. HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15.1 HYDRAULIC FLUID A good hydraulic fluid provides superior protection against wear, rust and oxidisation as well as good antifoaming and air and water separation properties. In order to ensure a lowest level on these properties the mineral oil based and synthetic (polyalphaolefin) hydraulic fluids must conform to the standard ISO 11158 HM/HV or DIN 51524 HLP/HVLP. Environmentally friendly hydraulic fluids must fulfil ISO 15380 It is essential to chose a hydraulic fluid of a suitable viscosity for the operating temperature of the drill rig. Select a viscosity grade (VG) and viscosity index (VI) as specified in the following table. A high viscosity index reduces the effect of temperature on the hydraulic fluid. Normal operating temp. ºC Viscosity 25-50 cSt

Min start temp. ºC (Viscosity min. 1000 cSt)

Max temp. ºC

Viscosity grade VG (ISO 3448)

Viscosity index VI

+50 to +70 +45 to +60 +35 to +50 +25 to +40 +10 to +25

+5 -5 -10 -15 -25

80 75 65 55 35

ISO VG 100 ISO VG 68 ISO VG 46 ISO VG 32 ISO VG 15

Min. 100 Min. 100 Min. 100 Min. 100 Min. 100

IF THE VISCOSITY IS TOO LOW: • The hydraulic fluid may not form a lubricating layer between surfaces, thus increasing the risk of wear. • The hydraulic fluid can leak past seals more easily in the rock drill thus increasing fluid losses and increasing energy requirements. IF THE VISCOSITY IS TOO HIGH: • Flow losses in the hydraulic lines will be high increasing energy consumption and pressure levels, putting increased strain on seals. • The risk of cavitation will increase, thus also the risk of damage to the rock drill and hydraulic pumps.

The hydraulic fluid must be filtered to a purity of 20/18/15 in accordance to ISO 4406. The viscosity will change during the period that the hydraulic fluid is used. In general viscosity will drop with increased operating hours. To ensure that the viscosity of the fluid does not drop to a critical level before the recommended service interval, a hydraulic fluid of sufficient stability must be used. The viscosity in cSt of suitable hydraulic fluids shall drop a maximum of 25% when tested for shear stability in accordance with DIN 51350-6 at 100 ºC. THE HYDRAULIC FLUID MUST BE CHANGED AT REGULAR INTERVALS. FACTORS INFLUENCING THE INTERVAL BETWEEN CHANGES: • The viscous stability of the hydraulic fluid as specified above. The hydraulic fluid must be changed before the viscosity drops to a critical level. • Contamination with water. If the hydraulic fluid becomes cloudy and light grey, the water content has become such that the hydraulic fluid must be changed. • Deterioration of properties such as oxidation inhibition and anti-foaming.

ENVIRONMENT! Excess and/or waste hydraulic fluid must be disposed of in an environmentally suitable manner and in accordance with regulatory requirements.

31

HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15

15.2 PNEUMATIC TOOL OIL Atlas Copco recommends the use of Atlas Copco COP OIL which has been specially developed for our hydraulic rock drills. COP OIL is an environmentally friendly, degradable oil which can be used in ambient temperatures between -25 ºC and +50 ºC. COP OIL can be ordered with the following part numbers: Quantity

Part number

1 can of 10 litres 48 cans of 10 litres 1 barrel of 208 litres

3115 3125 00 3115 3126 00 3115 3127 00

If COP OIL is not available then the oil should have the following properties: • • • •

Use an oil with good lubricating properties intended for compressed air tools. The oil must have good adhesion capacity. The oil must have additives that prevent foam formation. Depending on ambient temperature, the oil should have the following viscosity grades if the viscosity index (VI) is about 100: Ambient temperature ºC

Viscosity grade (ISO 3448)

-25 to 0 -10 to +20 +10 to +50

VG 15-32 VG 32-46 VG 46-68

• The oil must have an EP additive which covers the following load-bearing properties: ASTM D 2783

Min. 250 kg

ASTM D 4172 (40 kg)

Max. 0.5 mm

15.3 GREASE NB! Because of the operating temperature in the rock drill gear housing, always use a high-temperature grease with lithium complex soap based on a synthetic base fluid (polyalphaolefin/synthetic ester) with additives that protect against oxidation, corrosion and wear at high loads and with EP additive. NLGI number

Drop point

Base oil viscosity

1.5

250 ºC

400-600 mm2/s at 40 ºC

32

Operating Temperature

-40 to +150 ºC

HYDRAULIC AND LUBRICANT RECOMMENDATIONS 15

33