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Original Instructions
2017-12-01 | No: 9852 3895 01a. 4124851851.1.4125163019 en-US
Hydraulic Rock Drill COP RR14 / SC14 Ver. C Table of Contents
Table of Contents
1 Introduction ........................................................................................................... 5
1.1 Safety first................................................................................................................................... 5
1.2 The Purpose of This Publication .............................................................................................. 5
1.3 Target Group .............................................................................................................................. 6
1.4 Feedback and Contact Information .......................................................................................... 6
6 Tools..................................................................................................................... 17
6.1 Standard Tools ......................................................................................................................... 17
6.2 Special Tools ............................................................................................................................ 19
11 Lubrication........................................................................................................... 49
11.1 Fill Air Lubricant Oil................................................................................................................. 49
11.2 Lubricate Front Head ............................................................................................................... 49
11.3 Lubricate Gears........................................................................................................................ 50
11.4 Check ECL Lubricant Oil Return ............................................................................................ 50
1 Introduction
WARNING
Serious injury
Risk of personal injury!
u Never operate the Rock Drill in any explosive environment.
u Always read the machine Safety Manual before start maintenance work on the Rock
Drill.
u Always observe local regulations.
u Always carry out a documented risk analysis and take the necessary precautions be-
fore maintenance work.
u Only use clean, calibrated tools in good condition.
u Only use approved handling and working equipment in good condition.
u Always use personal protective equipment.
u During maintenance work, the equipment should be shut down, in service mode, and
the main switch turned off and locked.
u Attach WORK IN PROGRESS signs according to local regulations, or at least at the
main switch and operator's station.
WARNING
Serious injury or death
Serious danger when working on the hydraulic system!
u Ensure that the air, water and hydraulic system is depressurised before starting work.
u Adjacent moving units should always be anchored before working on a system part.
u Always stop work if there is an unforeseen or suspected risk.
The maintenance instructions are intended for use by maintenance and service personnel.
Persons working to these instructions must have completed relevant Atlas Copco training
for the Rock Drill.
2 General Information
2.3 Cleaning
WARNING
Serious Injury
Risk of personal injury
u Always read general safety regulations before starting maintenance work. Refer to
Safety manual.
u Always turn off the equipment and the main switch before cleaning and maintenance
work is carried out. Set up WORK IN PROGRESS warning signs at the main switch
and control positions.
u Be aware of the units kinetic energy due to accumulated hydraulic pressure. Relieve
pressure in hydraulic, water, and compressed air systems and always secure moving
units.
2.3.2 Cleaning
1. Clean the Rock Drill frequently from rock fragments, drill cuttings and accumulations
of dust.
2. Clear away fragments of rock and other objects from air, water and hydraulic hoses
and cables frequently to avoid the risk of chafing on sharp edges.
3. Rinse the Rock Drill with water after every work shift. Use only rinsing pressure and
avoid spraying directly at seals. Wipe away any accumulations of water.
WARNING
Serious Injury
Risk of abrasions and crushing injuries.
u Always change damaged hoses and couplings.
n Wet areas around hoses and connections is a sign for leaks that can cause spurting oil
or burst hoses if the leak worsens.
n The hose casing must be intact without any swelling (sign of inner hose or cord break-
age).
n Couplings must not have indentations or cracks and must make a secure connection.
Retighten or feel the coupling connection manually if a leak is suspected.
n Check that all hose attachments and clamps are intact. Loose attachments means that
hoses are damaged or get jammed during angle adjustment or when lowering the ma-
chine.
n Replace or rectify in the event of any faults.
2.4.1 General
The hydraulic system is sensitive to contamination. The environment where the machine is
normally used is generally an unsuitable place for repairing hydraulic components. Inter-
vention in hydraulic systems in workplaces must be limited. Components must be repaired
in an adapted environment, refer to Hydraulic Workshops.
Observe the following points to avoid breakdowns and interruptions in operation due to
fouled hydraulic oil:
n Keep the machine clean. Hose it down at regular intervals using a degreasing additive.
n Before opening any connection, clean the area around it.
n Use clean tools and work with clean hands.
n Always plug hydraulic connections immediately after they have been detached. Use
clean protective plugs.
n Hydraulic components like hoses, valves, engines must always be stored with suitable
protective plugs fitted in place.
2.5 Welding
n All welding on the Rock Drill is forbidden.
3 Maintenance Tables
Atlas Copco Rock Drills Overhaul Kits are designed to optimize the performance and ser-
vice life of the rock drill. Information about the overhaul kits and part numbers are available
in the spare parts catalog for each rock drill.
WARNING
Risk of Lifting the Rock Drill
Incorrect handling can cause serious crushing injury or death.
u Use extreme caution when strapping and lifting heavy objects.
u Lifting must be done through the center of gravity.
u Only use straps that are intact and designed for the load they will carry.
u Do not approach a suspended load.
2. Lift the Rock Drill carefully through the center of gravity. Make sure the Rock Drill is
balanced and the two straps do not slip.
5 Hose Connections
WARNING
Pressurized Systems
Can cause serious injury to eyes and skin.
u Always de-pressurize hydraulic, lubrication, and flushing system before any mainte-
nance work.
u Never replace new hoses with hoses of lower grade and quality.
u Always use gloves and eye protection.
1 Flushing, air/water
n Always clean the rock drills hose connections before removing the protective caps.
6 Tools
A Plastic mallet
B Sledge hammer
F Screwdriver
K Awl
M Vernier caliper
N Micrometer 0-25 mm
R Bearing puller
S Magnet
T Puller
A4
7 Tightening Torques
n Check all tightening torques on the rock drill according to the torque table below.
Always use a calibrated torque wrench.
Recommended Oil
8 Accumulators
1. Check that signs are in the correct location, clean, and fully legible on the machine,
replace damage signs.
Symbol Description
Warning sign
n Read the instruction manual thor-
oughly before performing service or
replacement
Warning sign
n Charge only with nitrogen gas
WARNING
Explosion Risk
There is a risk of personal injury or death when using wrong gas.
u Only use dry nitrogen (N2).
2. Install the pressure gauge (A15) with nipple (B) to the charging valve (604) hand tight.
3. Read the pressure gauge and check the values for correct accumulator pressure.
a. Intake accumulator (P) Recommended base settings: 80 bar. Max setting 100
bar.
5. Charge the accumulators with nitrogen gas (N2) if necessary. See Chapter Charging
Accumulators.
! NOTE: Aim the connection adapter (B) so there is no risk for per-
sonal injury when the gas is released.
4. Remove the connection adapter (B) and install the charging valve protective cap (A).
1. Undo and remove screws (608) together with damper accumulator (600) and seal ring
(233) from the damper side (D).
2. Undo and remove screws (608) together with intake accumulator (600) and seal ring
(320) from the intake side (P).
All parts must be clean, dry, and free of oil before installing.
1. Position the seal ring (233) in the groove on the rock drill damper side (D).
! NOTE: Always replace all bolts, even if only one bolt is corroded or
otherwise damaged.
3. Install the damper accumulator (600) with two accumulator screws (608) on the rock
drill damper side (D).
5. Position the seal ring (320) in the groove on the rock drill intake side (P).
7. Install the intake accumulator (600) with two accumulator screws (608) on the rock
drill intake side (P).
Recommended Oil
WARNING
Explosion Risk
There is a risk of personal injury or death when using wrong gas.
u Only use dry nitrogen (N2).
WARNING
Explosion Risk
There is a risk of personal injury or death when using wrong gas.
u Only use dry nitrogen (N2).
1. Check that the gas cylinder (20) contains Nitrogen (N2) gas.
2. Secure the gas cylinder (20) so that it cannot fall over and cause damage.
4. Remove protective nut (18) from the gas cylinder valve and check that the gas cylin-
der valve threads are undamaged and clean.
5. Check that the bottle connection (110) and the o-ring (1) are undamaged and clean.
6. Connect the hose connection (110) to the gas cylinder valve (19) hand tight. Check
that the hose (60) is not twisted or stretched.
9. Open the gas cylinder valve (19) slowly by turning it counterclockwise and check that
the high-pressure gauge (50) shows full pressure reading.
1. Remove the protective nut (17) from the accumulator valve (16).
2. Check that the threads of the accumulator valve (16) are undamaged and clean.
4. Connect the hose connection (130) to the accumulator valve (16) hand tight. Check
that the hose (70) is not twisted or stretched. Connection (90) is used instead of con-
nection (130) with the earlier version of accumulator valve.
4. Open the pressure regulator (140) slowly by turning the knob clockwise while monitor-
ing the manometer (100) until correct filling pressure is achieved.
a. Slowly open the needle valve (40) by turning the knob counterclockwise until cor-
rect pressure is achieved.
7. Close the hose valve (3) by turning it clockwise. When using connection (90) with the
earlier version of accumulator valve, the accumulator valve (16) must be closed.
3. Open needle valve (40) to evacuate the gas, check that the manometers (50) and
(100) drops to 0.
6. Disconnect hose connection (110) from the gas cylinder valve (19).
8. Transport the gas cylinder (20) to the designated location and secure it.
9 Hydraulic Motor
1. Lubricate the gear housing (200) and the hydraulic motor splines (500) with grease.
Recommended Oil
WARNING
Pressurized Systems
Can cause serious injury.
u Never stand behind the hydraulic motor during the test.
u Only the operator is to be around the hydraulic motor during the test.
3. Install the hydraulic motor fixture in position 1a (the motor shaft rotates freely) with the
bolts (4) and washer (3) on the hydraulic motor.
5. Connect hydraulic hose R (Return) to the return port (B) on the hydraulic motor.
6. Connect the pressure hose (P) to the inlet port (A) on the hydraulic motor.
10. Press down the lever (1) to pressurize the hydraulic motor.
11. Turn the flow restrictor (4) slowly clockwise until the flow meter reaches 10 l/min maxi-
mum.
b. Make sure that rotation is constant and without any abnormal noise.
14. Move the lever (1) up and down a couple of times to release the pressure in the
hoses.
15. Carefully loosen and remove the hoses, a small pressure can remain in the system.
Plug all connections to secure them from dirt.
WARNING
Pressurized Systems
Can cause serious injury.
u Never stand in front of the rock drill during the test.
u Only the operator is to be around the rock drill during the test.
3. Install the hydraulic motor fixture in position 1c (the motor shaft is locked) with bolts
(4) and washer (3) on the hydraulic motor.
10. Turn the flow restrictor (3) slowly counterclockwise until pressure manometer (2)
reaches the correct value according to the table. Make sure to use the correct pres-
sure for the current motor type.
13. Move the lever (1) up and down a couple of times to release the pressure in the
hoses.
14. Carefully loosen and remove the hoses, a small pressure can remain in the system.
Plug all connections to secure them from dirt.
10 Front Head
2. Remove the nipple (15), flushing adapter (104), and o-ring (105).
4. Remove the front part (101) together with o-rings (107) by pulling the shank adapter
and tapping the front part with a plastic mallet.
5. Remove the shank adapter (16), stop ring (131), washer (103), and drill collar (18)
from front part (101).
6. Use tool (A5) to press out the guide (102) and flushing head (121) from the front head
(101).
1. Use a pointed tool to remove the wiper (108) carefully, do not damage sealing
grooves in the front guide (102).
2. Use a pointed tool to remove the wipers (125), cup seals (123), and O-rings (124)
carefully, do not damage sealing grooves in the flushing head (121).
3. Use a pointed tool to remove the O-ring (106) carefully, do not damage sealing
groove in the washer(103).
1. Inspect guide (102) and the lubrication ducts (A). Replace the guide if the inside diam-
eter exceeds 36 mm.
2. If air and water leaks out through the front head tell tale holes or around the shank
adapter (16):
6. Lock inside the gear housing and inspect the splines on the driver (212), rotation
chuck bushing (206), and impact piston (305). If parts look damage or worn, remove
them with a puller for further inspection.
a. Measure the width of the driver (212) splines. If less than 2 mm the driver must
be replaced.
b. Measure the wear of the rotation chuck bushing (206). If worn more than 1 mm
the Rock Drill must be sent for overhaul. See chapter Rock Drill Overhaul.
c. Inspect the impact pistons (305) impact surface. If damages in any way, the
Rock Drill must be sent for overhaul. See chapter Rock Drill Overhaul.
1. Lubricate and install the wiper (108) according to the figure in the front guide (102)
sealing groove.
2. Lubricate and install the wipers (125), the cup seals (123), and O-rings (124) accord-
ing to the figure in the flushing head (121).
2. Lubricate and press flushing head (121) into the front part (101) using tool A5. Make
sure the flushing holes in the flushing head and the front part aligns.
3. Lubricate and install o-ring (105), flushing adapter (104), and nipple (15) in the front
part (101).
4. Lubricate and install the washer (103) with O-ring in the front part (101).
5. Install stop ring (131) and o-ring (132) on the shank adapter (16).
10. Install the front part (101) onto gear housing (201).
12. Install and tighten screws (9) alternately to 220 Nm (162 lbf-ft).
2. When replacing the shank adapter, inspect internal components. See Instruction In-
specting and Replacing Front Head Parts.
n If oil leaks from the front head, shut of the percussion and activate the damper only to
determine if it is percussion or damper leakage. See chapter Rock Drill Overhaul.
11 Lubrication
WARNING
Serious injury
Risk of serious injury to the eyes and skin.
u Never work on the lubrication system when it is pressurised. Lubrication air and oil may
spray out.
NOTE: Certain moving parts on the Rock Drill are lubricated with compressed air con-
! taining oil. Is important that these parts receive good lubrication. Use the recom-
mended lubrication air pressure and lubricant.
1. Check the level in the lubrication tank on every shift. Exercise cleanliness and fill with
the right grade oil. See chapter: Lubricating.
2. If the lubrication system is drained of oil, bleeding must take place after filling. See the
appropriate Rig manuals for instructions.
1. Lubricate both grease nipples (109) until grease exits through the tell tale hole for
flushing water.
2. Move the shank adapter (16) to distribute the grease inside the front.
1. Loosen and remove the bleed plug (239) that is in the highest position.
The plug (239) to remove can vary depending on how the Rock Drill is positioned.
2. If the Rock Drill is positioned vertically (A), the grease nipple (237) and one of the
bleeding plugs (239) must change places.
3. Lubricate with recommended grease through the grease nipple until grease emerges
out through the upper bleeding hole.
n After a few minutes of drilling and regularly during the shift, check that air and lubri-
cant oil come out of the ECL return outlet.
12 Settings
2. Recommended lubricating air pressure is 2–3 bar at the Rock Drill, use a pressure
gauge to check the pressure.
3. If the pressure is too low, clean the restriction or increase the diameter of the restric-
tion.
6. Check that air and lubricating oil is emerging from the ECL return outlet.
! NOTE: Configure Rock Drill settings at normal operating temperature for the hydraulic
oil.
2. Connect a pressure gauge (A), calibrated for 0-60 bar, between the hose and the
damper nipple (1).
4. Check that the shank adapter is unloaded and in the forward position.
5. Adjust the constant flow valve (B) until the pressure gauge (A) shows 30 bar (Opera-
tor panel shows 35 bar).
6. Disconnect the pressure gauge (A) and connect the hose to the damper nipple (1).
WARNING
Pressurized Systems
Can cause serious injury to eyes and skin.
u Always de-pressurize hydraulic, lubrication, and flushing system before any mainte-
nance work.
u Never replace new hoses with hoses of lower grade and quality.
u Always use gloves and eye protection.
1. Sling and lift the Rock Drill according to chapter Lifting Rock Drill.
2. Lubricate the four screws (A) with oil and install them.
WARNING
Pressurized Systems
Can cause serious injury to eyes and skin.
u Always de-pressurize hydraulic, lubrication, and flushing system before any mainte-
nance work.
u Never replace new hoses with hoses of lower grade and quality.
u Always use gloves and eye protection.
NOTE: Overhaul period may vary based on local condition. 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 need of servicing the Rock Drill.
4. Sling and lift the Rock Drill according to chapter Lift Rock Drill.
5. Send Rock Drill to the workshop for overhaul. Make sure that it is securely anchored
for transportation.
Normal Operat- Min. Start Temp Max. Operating Viscosity Grade Viscosity Index
ing Temp °C °C Temp °C VG VI
Viscosity 25-50 ISO 3448
cSt
! NOTE: In compliance with ISO 4406, the hydraulic fluid must be filtered to the purity
class of 20/18/15.
n The risk of cavitation increases, which leads to the risk of damage to the rock drill and
hydraulic pumps.
The hydraulic fluid must be changed at regular intervals
Oil viscosity changes 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 suffi-
cient stability must be used. In compliance with DIN 51350-6, viscosity of suitable hydraulic
fluids shall drop a maximum of 25% when tested at 100 ºC for shear stability.
Factors influencing the interval between changes are:
n Viscous stability of the hydraulic fluid as specified above. The hydraulic fluid must be
changed before the viscosity drops to a critical level.
n Contamination with water. If the hydraulic fluid becomes cloudy and light grey, the wa-
ter content has become such that the hydraulic fluid must be changed.
n Deterioration of properties such as oxidation inhibition and anti-foaming.
-30 to ±0 VG 32-68
The tool oil must have an EP additive which covers the following load-bearing properties:
14.3 Grease
Considering the high operating temperature in the rock drill gear housing, always use a
high-temperature grease with lithium complex soap based on a synthetic base fluid (polyal-
phaolefin/synthetic ester) with EP additive, and additives that protect against oxidation, cor-
rosion and wear at high loads. The grease should meet the specifications, specified in the
table below:
! NOTE: Molybden (Molybden disulfide) grease is harmful for seals. Molybden grease
shall be avoided.
Atlas Copco recommends the use of Atlas Copco COP GREASE, which has been specially
developed for our hydraulic rock drills, and is suitable to be used in both gear housing and
flushing seals. COP Grease withstands temperatures between -40ºC to +150ºC, and tem-
peratures of up to 220ºC during shorter periods. COP Grease is developed to be imple-
mented in both arctic and tropical conditions, and can be ordered with the following part
numbers:
www.atlascopco.com