Atlas Copco

Hydraulic Rock Drill

COP 3060ME
Version B
Maintenance Instructions

PM no. 9852 3346 01d

2015-05
 SAFETY INSTRUCTIONS
Before starting, read all instructions carefully.

Special attention must be paid

to information alongside
this symbol.

Only use genuine Atlas Copco parts.

1250 0071 04

© Copyright 2015, Atlas Copco Rock Drills AB, Sweden

All product names in this publication are trademarks of Atlas Copco. Any unauthorised use or copying of the
contents or any part thereof is prohibited. Illustrations and photos may show equipment with optional extras.
No warranty is made regarding specifications or otherwise. Specifications and equipment are subject to
change without notice. Consult your Atlas Copco Customer Centre for specific information.

Translation of original instructions

Atlas Copco Rock Drills AB

SE-70191 Örebro, Sweden
 Table of Contents

Table of Contents
1. GENERAL .......................................................................................................... 3
1.1 Description of Manufacturing Number.......................................................................... 3
1.2 Leakage Problems ....................................................................................................... 3
1.3 Dismantling................................................................................................................... 3
1.4 Assembly...................................................................................................................... 3
1.5 Environment ................................................................................................................. 3
1.6 Safety Regulations ....................................................................................................... 4
1.6.1 Warning Boxes ....................................................................................................4
1.6.2 Required Safety Rules ........................................................................................4

2. TOOL LIST.......................................................................................................... 7
3. SERVICE INTERVAL ......................................................................................... 9
3.1 Overhaul Kits................................................................................................................ 9
3.2 Before Starting-up a New or Newly-overhauled Rock Drill........................................... 9
3.3 After the First Shift with a New or Newly-overhauled Rock Drill................................... 9
3.4 Before Each Shift ......................................................................................................... 9
3.5 After Every 40 Percussion Hours ................................................................................. 9
3.6 After Every 600 Percussion Hours ............................................................................... 9

4. HOSE CONNECTIONS .................................................................................... 11

4.1 General....................................................................................................................... 11
4.2 Connecting the Hoses ................................................................................................ 12

5. TIGHTENING TORQUES ................................................................................. 13

5.1 Threaded Unions........................................................................................................ 13
5.2 Nipples ....................................................................................................................... 14

6. ACCUMULATORS ........................................................................................... 15
6.1 Safety Label Location................................................................................................. 15
6.2 Safety Label Instructions ............................................................................................ 15
6.3 Charging the Accumulators ........................................................................................ 16
6.4 Check Accumulator Pressure..................................................................................... 18
6.4.1 Intake Accumulator (440a) and Return Accumulator (440b) .............................18
6.5 Replacing the Accumulators....................................................................................... 18
6.5.1 General .............................................................................................................18
6.5.2 Dismantling .......................................................................................................19
6.5.3 Assembly ...........................................................................................................20

7. REPLACEMENT OF HYDRAULIC MOTOR .................................................... 21

7.1 Dismantling................................................................................................................. 21
7.2 Assembly.................................................................................................................... 22
7.3 Function and Condition Test of the Hydraulic Motor .................................................. 22
7.3.1 Function Test ....................................................................................................22
7.3.2 Belle Test ..........................................................................................................23
7.3.3 Half Belle Test ...................................................................................................23

8. FILLING WITH LUBRICATING OIL AND BLEEDING THE SYSTEM............. 25

9. SETTINGS ........................................................................................................ 27
9.1 Setting of Electric-controlled Lubrication (ECL) System............................................. 27
9.2 Setting Damper Pressure ........................................................................................... 27

10. FRONT HEAD .................................................................................................. 29

10.1 Dismantling............................................................................................................... 29

1
Table of Contents

10.2 Inspect Front Parts................................................................................................... 31

10.3 Assembly ................................................................................................................. 34

11. LUBRICATION.................................................................................................. 37
11.1 Gear Lubrication ...................................................................................................... 37

12. DISMANTLING FROM CRADLE...................................................................... 39

12.1 Slinging .................................................................................................................... 39
12.2 Rock Drill Weights.................................................................................................... 39
12.3 Action before Service and Tong-term Storage......................................................... 39

13. HYDRAULIC FLUID AND LUBRICANT RECOMMENDATIONS .................... 41

13.1 Hydraulic Fluid ......................................................................................................... 41
13.1.1 Causes of Low Viscosity .................................................................................41
13.1.2 Causes of High Viscosity ................................................................................41
13.1.3 Change of Hydraulic Fluid ...............................................................................41
13.2 Pneumatic Tool Oil................................................................................................... 42
13.3 Grease ..................................................................................................................... 42

2
 1. General

1. General
This Maintenance Instructions manual is intended as a guide to be used during maintenance on your rock
drill.

1.1 Description of Manufacturing Number

All rock drills are given a manufacturing number depending on the manufacturing location, the year, the
product family and the version.

The manufacturing number is stamped-on and the location on the rock drill varies, depending on the model.

1. Factory code for manufactured unit:

AVO = Atlas Copco Rock Drills AB 2 4
2. Year the product was produced
3. Product family letter that identifies the number
series:
D = Hydraulic rock drills
P = Pneumatic rock drills
AVO 15 D 333B
1250 0404 84
T = Rotation units
1 3 5
4. Serial number in the "Product Family Group"
5. Version letter for the product - shows the rele-
vant manual/spare parts list

1.2 Leakage Problems

Check the source of the leakage before removing the rock drill from the rig.

1.3 Dismantling
Before dismantling, always wash the rock drill externally using grease solvent.
An assembly fixture must be used when dismantling the rock drill.

1.4 Assembly
During all fitting assemblies, all component parts must be coated with grease, unless otherwise specified.

1.5 Environment

Environmental Regulations
Think of the environment!
Leaking hydraulic couplings and grease are hazardous to the environment.
Changing oils, hydraulic hoses, and various types of filters can be hazardous to the environment.
Always collect oil and grease residue and waste. Follow local environmental regulations.
Use biodegradable hydraulic fluid and lubrication oil wherever possible.

3
1. General

1.6 Safety Regulations

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

1.6.1 Warning Boxes

The manual contains warnings.
Warnings are preceded by a heading (Danger, Warning or Caution).

Warning Boxes
Danger
Indicates an imminent risk of serious or fatal injury if the warning is not heeded.
Warning
Indicates hazards or hazardous procedures which could result in serious or fatal injury if the warning
is not heeded.
Caution
Indicates hazards or hazardous procedures which could result in personal injury or damage to prop-
erty if the warning is not heeded.

1.6.2 Required Safety Rules

The following general safety rules must be observed:
r

Important!
Read through the maintenance instructions thoroughly before starting maintenance work. Follow
the instructions given and follow local regulations.
Do not use or intervene in the rock drill unless you have been trained to do so.
Never attempt to carry out maintenance work while the rock drill is in operation.
Ensure that the hydraulic, water, and air systems are depressurized, and that the electrical system
is de-energized, prior to removing the rock drill or prior to starting work on the system.
Use approved lifting devices when handling the rock drill. Avoid lifting heavy weights yourself.
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.
Check that the hoses used are of the right quality, and that all hose connections are in good condi-
tion 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.

Important!
Make sure that the rock drill has been maintained in accordance with the applicable instructions.
Before tramming the rig and rock drill or starting to drill, make sure that no personnel is in the imme-
diate vicinity of the drill rig.
Checks and adjustments that are necessary when the rock drill is in operation must be carried out
by at least two people. One person must be present at the operating station and have a good view
of the work.
Always wear a helmet and earmuffs when drilling. Follow local regulations.
Make sure that the work place is well ventilated.
Make sure that the safety labels are fitted, clean, and fully legible.
Particular attention must be paid to all warnings in the manual.
Exercise caution when jointing drill rods and when handling drill bits. Watch your fingers!
Make sure that clothes do not come too close to rotating machine parts.
Negligence could cause serious injury.

4
 1. General

Important!
A mining machine has many components and functions that are directly or indirectly controlled by
a hydraulic system. Before working on or inspecting any part of the machine, it is important to know
how the machine moves and how its functions are controlled by the hydraulic system.
Prior to starting work and prior to inspecting any part of the machine, it must be physically locked/
stopped from being able to move and cause bodily injury. The mechanic must be careful to not place
any body part where a movement of the machine could cause injury if the hydraulic system fails or
is disconnected.
There may be occasions where components and/or vehicles may start moving when trapped energy
is released. Where applicable, there must be confirmation that all measures to safeguard against
involuntary movement have been taken by releasing the energy and/or physically locking/stopping
the machine.
Individuals involved in operating the rigs are obliged to ensure that all local, national, and federal
safety regulations are followed, before and during work on, or inspection of, the rig.

5
1. General

6
 2. Tool List

2. Tool List
Letter Tools Part no.
A1 Plastic mallet

A4 U-ring spanners 10-32 mm

A5 Allen keys 4-10 mm

A10 Torque wrenches 10-350 Nm

A11 Socket wrench set with sockets 10-32 mm for external

hexagon
Socket wrench set with sockets 4-10 mm for internal
hexagon
A14 Vernier calliper

B2 Mandrel 3115 5001 13

C2 Tool for mounting bushing in backhammer 3115 5001 16

L1 Sleeve for front guide 3115 5767 00

V Charging equipment for accumulators 3115 3425 80

W Pressure gauge incl. adapter 3115 3799 80

7
2. Tool List

Letter Tools Part no.

Puller

8
 3. Service Interval

3. Service Interval
3.1 Overhaul Kits
Overhaul kits are available for every type of Atlas Copco rock drill and rotation unit. The overhaul kits are
designed to coordinate with designed intervals during the overhaul schedule. Overhaul kits are listed in the
respective Spare Parts catalog and contain a list of all the parts necessary to overhaul the rock drill, or rota-
tion unit, at a particular interval.

3.2 Before Starting-up a New or Newly-overhauled Rock Drill

Chapter
• Connect up the hoses ..........................................................................................................................4
• Charge the accumulators .....................................................................................................................6
• Fill the lubricating system with oil .........................................................................................................8
• Adjust and set the lubricating system ...................................................................................................9
• Set the damper pressure ......................................................................................................................9
• Select a suitable hydraulic oil and lubricant........................................................................................13

3.3 After the First Shift with a New or Newly-overhauled Rock Drill
• Tighten all threaded unions ..................................................................................................................5

3.4 Before Each Shift

• Keep an eye on the hydraulic hoses. If they vibrate too much, check the accumulators .....................6
• Check that the drill rig’s damper pressure gauge is showing normal speed values.
In the event of deviation, adjust the damper pressure. ........................................................................9
• Check that the shank adapter threads are not damaged ...................................................................10
• Check that air and lubricating oil comes out at the outlet for the ECL oil ...........................................10
• Check that the machine does not leak. If the flushing medium leaks out from the overflow holes,
replace the seals and O-rings ............................................................................................................10
• When replacing the shank adapter or removing the front head, check the internal components 
including piston nose, driver and the visible parts of the starter bushing ...........................................10

3.5 After Every 40 Percussion Hours

• Tighten all threaded unions ..................................................................................................................5
• Check the safety labels on the accumulators. Replace them if they are damaged or illegible.............6
• Grease the gear .................................................................................................................................11

3.6 After Every 600 Percussion Hours

• Remove the rock drill from the drill rig.
Transport the rock drill to a suitable workshop for inspection ............................................................12

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.

Important!
Always function test the rock drill after service.

9
3. Service Interval

10
 4. Hose Connections

4. Hose Connections
4.1 General

Caution!
Never attempt any maintenance or work on the rock drill, connections or hoses while the hydraulic,
lubrication or flushing pressure 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.
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). See the rock drill’s spare parts list. 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!

1 2

4
6

5
7

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9
1. Flushing air (F) 6. Percussion return (HT)
2. ECL oil outlet* (ALR) 7. Lubricating air intake (AL)
3. Rotation, intake (RRL) 8. Damper intake (HDP)
4. Rotation, return (RRR) 9. Stroke length regulation (HS)
5. Percussion pressure intake (HP) *Always open or connected to ECL return

11
4. Hose Connections

4.2 Connecting the Hoses

• 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.

12
 5. Tightening Torques

5. Tightening Torques
5.1 Threaded Unions

6
8 7 8
6

11 2
7 8 9
6 1
6
8
1250 0383 07

4 1 3
2 9
5 10
Lubricate the nuts’ threads and the washers’ contact surfaces with Never-Seez Regular Grade.

Ref. Qty. Check point Torque Torque Instructions

No. Nm
Ibf*ft
1 2 Cradle 500 370 M24x80
2 3 Cradle 300 221 M20, grade 8.8
3 4 Side bolts 500 370 M24x1.5
4 8 Valve covers 220 162 M16, grade 10.9
5 6 Back head 220 162 M16, grade 10.9
6 8 Intake and return accumulators 220 162 M16
7 22 Intake and return accumulators 220 162 M16
8 4 Filling valve 30 23
9 8 Hydraulic motor 90 66 M12
10 4 Percussion mode 40 31 M10
11 2 Intake, flushing medium 155 114 M16

13
5. Tightening Torques

5.2 Nipples

1 2

4
6

5
7

1250 0378 67
3

Ref. Def. Check point Torque Torque Instructions

No. Nm Ibf*ft
1 F Flushing air/water 330 244 G1
2 ALR ECL oil outlet 85 63 G 1/2
3 RRL Rotation, intake 85 63 G 1/2
4 RRR Rotation, return 85 63 G 1/2
5 HP Percussion, pressure intake 430 318 G 1 1/4
6 HT Percussion, return 430 318 G 1 1/4
7 AL Lubricating air, intake 85 63 G 1/2
8 HDP Damper, intake 85 63 G 1/2
9 HS Stroke length reduction 70 52 G 3/8

14
 6. Accumulators

6. Accumulators
Check and replace any damaged or illegible safety labels on the accumulators.

6.1 Safety Label Location

440a. Intake accumulator

440b. Return accumulator

440b
440a

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6.2 Safety Label Instructions

1. Read the operator’s instructions carefully

before service or replacement of the accumu-
lator.
2. Must only be charged with nitrogen gas (N2).
N2
1250 0187 04

1 2

15
6. Accumulators

6.3 Charging the Accumulators

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

Warning!
A gas other than N2 could cause an explosion.

1. Remove the protective cap (2) from the filler

valve.

1250 0333 07

2. Fit the gas hose with connection adapter (3)

on the new filler valve (1).
Tighten the connection adapter (3) using
manual force.

1
3

N2
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16
 6. Accumulators

3. Close the bleed valve (8) by turning the

control knob clockwise. 440b
4. Close the pressure regulator (7) by turning the 440a
control knob anticlockwise (-).
5. Open the bottle valve (9) slowly and check
that the high pressure gauge (4) gives
readings to full bottle pressure.
Notice! Charge at the bottom if possible rather
than too high.
6. Slowly turn the pressure regulator knob (7)
clockwise (+) and set the desired filling pres-
sure on the low pressure gauge (6) or high
pressure gauge (5).
Return accumulator (440b) - 2-3 bar. 9
Intake accumulator (440a) - 80-100 bar* 5 3
*Intake accumulator 30-40 bar under collaring 1
pressure. Normal 80-100 bar. Max. 100 bar. 6
N2
7. In the event of the pressure being too high, 8
adjust the pressure regulator control knob (7)
anticlockwise (-). Evacuate the overpressure 4 7
carefully by turning the control knob for the
1250 0333 09

bleed valve (8) anticlockwise and then close

the bleed valve. Adjust the pressure regulator
(7) slowly to the correct accumulator pres-
sure.
8. Close the pressure regulator (7) by turning the
control knob anticlockwise (-).
9. Close the bottle valve (9).

10.Loosen the connection adapter (3) from the

filler valve (1).
Notice! The gas in the hose will hiss out. The
accumulator is switched off and will not
release gas when the adapter is removed.
11. Fit the protective cap on the filler valve (1).

1
3

N2
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17
6. Accumulators

6.4 Check Accumulator Pressure

Warning!
The hydraulic system must be depressurised before checking the accumulators.

6.4.1 Intake Accumulator (440a) and Return Accumulator (440b)

1. Remove the protective cap from the filler

valve (1).
2. Fit the pressure gauge (10) on the filler valve 1
(1). Tighten using manual force.
3. Read the pressure gauge (10) and check that
the correct accumulator pressure is obtained.
Return accumulator (440b) - 2-3 bar.
Intake accumulator (440a) - 80-100 bar*
*Intake accumulator 30-40 bar under collaring
pressure. Normal 80-100 bar. Max. 100 bar.
4. Remove the pressure gauge (10) with
connection adapter.

1250 0383 09
5. If required, charge the accumulators with
nitrogen gas (N2). See section: Charging the
accumulators.
6. Refit the charge valve's protective cover, 10
tighten using manual force.

6.5 Replacing the Accumulators

6.5.1 General

Warning!
All gas must be released before removal, by means of removing the protective cap and fitting the
connection adapter (3).
There is a risk of injury if these instructions are not observed!

Caution!
Defective bolts may lead to dangerous oil leakage or the accumulator working loose.
Oil spray can injure the eyes and skin.
Parts that come loose can cause serious injury.

18
 6. Accumulators

6.5.2 Dismantling

1. Remove the protective cap (2) from the filler

valve.
2. Fit the connection adapter (3) and the
nitrogen gas (N2) in the accumulator is rele-
ased.
Notice! Align the connection adapter so that
there is no risk of personal injury.
3. Reassemble the protective cap (2) on the filler
valve.

2 3

1250 0346 45
4. Remove the accumulators (440a and 440b)
by undoing the screws (6). 6
5. Remove the seal ring (7) and O-ring (8).
6. Send the accumulators to a workshop for 5
overhauling!
440b
440a 7
8
1250 0333 10

19
6. Accumulators

6.5.3 Assembly

1. Position the greased seal ring (7) and the

greased O-ring in their respective grooves on 6
the accumulator and then fit the accumula-
tors. 5
2. Make sure that the seal ring (7) and O-ring (8)
do not become damaged during assembly. 440b
3. Tighten the bolts (6) alternately to the correct 7
tightening torque in accordance with the 440a
chapter Tightening torques. 8
4. Charge the accumulators with nitrogen gas
(N2). See chapter Charging the Accumulators.

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20
 7. Replacement of Hydraulic Motor

7. Replacement of Hydraulic Motor

Caution!
Ensure that the hydraulic, water and air systems are depressurised before starting any work on the
systems.
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). See the rock drill’s spare parts list. 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 Dismantling
Removal of the rock drill from the carriage, is depending on the size of the hydraulic motor.

1. Remove the hydraulic hoses.

2. Undo the nuts (309) and remove the hydraulic 309 2 307
motor (2).
3. Remove the O-ring (307) from the hydraulic
motor (2).

308

307
1250 0333 15

2
309

21
7. Replacement of Hydraulic Motor

7.2 Assembly

1. Fit the O-ring (307) on the hydraulic motor (2).

2. Lubricate the coupling’s splines with grease. 309 2 307
Use the same grease as for the gear.
3. Fit the hydraulic motor (2) to the gear housing.
4. Tighten the nuts (309) to the correct tightening
torque in accordance with the chapter Tight-
ening torques.
5. Connect the hydraulic hoses.
6. Check that the correct rotation direction is
obtained for both motors.

308

307
1250 0333 15

2
309

7.3 Function and Condition Test of the Hydraulic Motor

The following tests give an approximation of the present state of the motor.
The following items are required to conduct the tests:
• Apparatus for hydraulic flow and pressure.
• A pressure gauge.
• A flow meter in the range 0-15 l/min, preferably with an accuracy of at least 0.5 l/min
• Couplings and hoses to assemble the components.
• A fixture to lock the rotation of the rear axle.
Oil grade HLP46 at 50 degrees and viscosity approx. 35 CST

7.3.1 Function Test

1. Connect the hydraulic hoses P (Pressure) and

R (return) to the hydraulic motor.
2. Allow the motor to rotate for about 30 seconds
with a maximum flow of 10 l/min.
3. Make sure rotation is smooth and without
noise.
P

R
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22
 7. Replacement of Hydraulic Motor

7.3.2 Belle Test

For motors with external drainage line only.
The test indicates the general state of the motor, including axial wear, condition of seals, valves, etc.
Replace the motor if the size of the leak exceeds table value.

Test procedure:
1. Plug port "B" with a suitable plug. B A
2. Connect a flow meter to the motor’s drainage
line. T (drain)
3. Make sure the rear axle can rotate freely.
4. Pressurise port "A" in accordance with the
following table. Make sure to use the correct
pressure for the current motor type! P
5. Measure the flow from the drainage line.
Replace the motor if it exceeds the specified

1250 0403 67
value. R

Motor type Pressure port Permitted flow

A in drainage line

MS 210 bar 3,5 l/min

7.3.3 Half Belle Test

The following test indicates the condition of the gear wheel in the motor. It can be used for all motors.

Test procedure:
B
1. If the motor has a drainage line, couple it to A
port "B" with a T-coupling.
T (drain)
2. Couple the flow meter to port "B" on the motor.
3. Secure the rear axle with suitable equipment.
It must not rotate.
4. This unit can be ordered for type MS motors. S
5. Pressurise port "A" in accordance with the P
following table. Make sure to use the correct
1250 0403 68

pressure for the current motor type! R

6. Measure the flow from port "B" (if necessary in
combination with the drainage line). Replace
the motor if it exceeds the specified value.

Motor type Pressure port Permitted flow

A in drainage line

MS 80-160cc 140 bar 10 l/min

MS 200-315 110 bar 10 l/min

MS 400-475 70 bar 10 l/min

23
7. Replacement of Hydraulic Motor

24
 8. Filling with Lubricating Oil and Bleeding the System

8. 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.
Notice! If the lubricating system has been empty of oil, it must be bled after filling.

25
8. Filling with Lubricating Oil and Bleeding the System

26
 9. Settings

9. Settings
9.1 Setting of Electric-controlled Lubrication (ECL) System
Rock drill lubrication must be set with regard to local conditions.

1. Start the lubricating system.

2. Check the rock drill lubricating air pressure
using a pressure gauge. The pressure should
be 2,5-3 bar. If the pressure is too low, clean
the restrictor or increase the diameter of the
restrictor.
3. Set the correct lubricating oil dose.
Pump (3217 8667 52) - 15 pulses/min
4. After setting, check that the correct pulse
frequency has been obtained and that air and
lubricating oil emerge from the ECL return
(ALR nipple).

1250 0333 16

9.2 Setting Damper Pressure

Notice! Setting damper pressure should take

place when the hydraulic oil is at normal opera-
ting temperature (40º- 60ºC).
1. Make sure that the machine has the correct
operating temperature.
2. Fully close the constant flow valve (B) on the
drill rig.
3. Connect a pressure gauge (A), calibrated for
0-60 bar, between the hose and the damper
union C (HDP). C
4. Pressurise the damper circuit. B
1250 0378 68

5. Check that the shank adapter is unloaded and

in the forward position. A
6. Adjust the constant flow valve until the pres-
sure gauge (A) shows 25 bar (8 l/min) at the
rock drill (operator panel shows 30 bar).
7. Disconnect the pressure gauge (A) and
connect the hose to the union C (HDP).

27
9. Settings

28
 10. Front Head

10. Front Head

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

Important!
Always clean the outside of the rock drill before disassembly.

10.1 Dismantling

1. Remove the flushing hose.

2. Remove the nipple (A) for the flushing/air (F).
3. Remove the connecting plate (132) with the
screws (134) from the front head (110).
4. Remove the O-ring (133).
A
110 133
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132
134

5. Remove the front side-bolt nuts (10) with their

washers (11). 110
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6. Remove the front head (110) by pulling the 10 11

shank adapter (1) or by tapping with a plastic
mallet.

7. Pull out the shank adapter (1) from the front

head (110) backwards.
370 1
110
8. Remove the stop ring (370).
9. Check the internal components when repla-
1250 0339 06

cing the shank adapter(1).

29
10. Front Head

10.Remove the wiper (135) from the front head

(110). 110

135

1250 0339 07
11. Use sleeve (L1) to press out the flushing head
(150) and the guide (131) from the front head
(110).

L1

131

150
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110

30
 10. Front Head

10.2 Inspect Front Parts

Overview illustration of the front section of the rock drill:

1 135 131 110 150 371 320 325 350 330 429 438
1250 0339 09

151 152 B 151 152 B 372 332

Many of the position numbers in the instruc-
tions below are included in the figure above.

1. Check that air and lubricating oil comes out

from the connection for the ECL oil’s outlet (2).
See also chapter Hose connections.
1250 0383 11

2. Blow clean the lubricating air duct and the

connection for the ECL oil’s outlet using
compressed air.

3. Check and replace the wiper (135) if it is worn

or damaged. 135
1250 0339 13

31
10. Front Head

4. Replace the guide (131) if the inner diameter

D exceeds 61 mm. Notice! Max. dimension.
5. Check the lubricating ducts on the front guide
(131).

ØD
1250 0339 11
6. Check the O-rings (152) and the cup seals
(151) if there is leakage in front of or behind 332
the flushing head (150). Replace the O-rings
(152) and cup seals (151) if they are worn or
damaged. 152
Notice! The cup seals must be turned in
accordance with the figure.
151
7. Replace the flushing head (150) if it is serio- 150
usly corroded, or if it contains cracks.
8. Check and replace the seal (332) if it is worn 151
or damaged.
152
1250 0339 12

9. Replace the stop ring (371) if:

• any point within the wear surface (S) is worn 1,0
more than 1 mm, compare with a new stop
372
ring
• any cracks (signs of breakage) are found S
• the wear surface (S) is uneven
M - Measuring point
S - Wear surface
371
10.Replace the stop ring’s O-rings (372) if they
are worn or damaged.
1250 0339 14

370

32
 10. Front Head

11. Look inside the gear housing and check the

splines on the driver (325). If the thickness of 325
the splines is less than 2 mm then the driver
must be replaced.

1250 0342 52
12.Send the rock drill to a workshop for inspec-
tion if: 1,0
• the rotation chuck bushing (330) is worn 330
more than 1 mm on the wear surface (S)
• after 600 percussion hours
• if the impact piston’s (438) impact surface is
damaged in any way
13.Also replace the rotation chuck bushing (330)
if marks (wave type) from splines are visible M
on the wear surface (S).
M - Measuring point
S - Wear surface

S
1250 0339 15

14.Replace the shank adapter (1) if:

• the thread is worn out 1
• the impact surface is crushed or chipped
• the front or rear end surfaces of the splines
are worn
15.Check for rust on the surface of the flushing
1250 0312 00

seal, if there is any rust then polish it away.

33
10. Front Head

10.3 Assembly

Important!
Before fitting the parts must be lubricated with clean hydraulic oil.

1. Press the guide (131) into the front head (110)

with tools L1 and B2.

B2

110

L1
1250 0339 19

131

2. Lubricate O-rings and parts with grease/oil in

order for them to press in easily. 332
3. Fit the cup seals (151) in the flushing head
(150). Notice! The cup seals must be turned
in accordance with the figure. 152
4. Fit the O-rings (152) on the flushing head
(150). 151
150

151
152
1250 0339 12

34
 10. Front Head

5. Press down the flushing head (150) with press

tool (C2). Check that the flushing hole in the
flushing head (150) coincides with the flushing
hole in the front head (110).

C2

110

150

131

1250 0339 20
6. Fit the wiper (135) in the front head (110).
Notice! The wiper must be turned in accor- 110
dance with the figure.

135
1250 0339 07

7. Fit the stop ring (370) and the shank adapter

(1) in the front head (110).
370 1
110
1250 0339 06

8. Check and fit the seal (332) in the groove on

the cover plate (320). Replace the seal (332) 332 331
if it is worn or damaged. 110
10 11
9. Make sure that the pin (331) is fitted in the
cover plate (320).
10.Apply the intended grease to the threads, type
1250 0339 18

Never Seez, before assembly.

1 320
11. Fit the front head (110) on the side bolts (12). 12
12.Fit the washers (11) and nuts (10).
13.Tighten the nuts (10) alternately to the correct
tightening torque in accordance with the
chapter Tightening torques.

35
10. Front Head

14.Fit the O-ring (133) on the connection plate

(132).
15.Assemble the connecting plate (132) on the
front head (110) with the bolts (134).
16.Tighten the bolts (134) alternately to the
correct tightening torque in accordance with A
the chapter Tightening torques.
110 133
17.Fit the nipple (A) for the flushing/air (F)and

1250 0339 04
tighten to the correct tightening torque in
132
134
accordance with the chapter Tightening
torques.
18.Install all hoses.

36
 11. Lubrication

11. Lubrication
11.1 Gear Lubrication

1. Unscrew the bleed plug (317) with gasket

(318).
2. Lubricate with heat-resistant grease through 319
the grease nipple (319) until new grease
escapes through the hole for for the plug or
the check valve (314) on the underside. (The
hydraulic motor is removed in order to visua-
lise the position of the check valve).
3. Tighten the bleed plug (317) with gasket
(318).
Grease nipple (319) and plug (317) can change
sides to facilitate lubrication.

317
314
1250 0333 18

37
11. Lubrication

38
 12. Dismantling From Cradle

12. Dismantling From Cradle

12.1 Slinging

Caution!
Lifting devices and straps must be approved for lifting at least 500 kg.
Incorrect lifting devices could cause the rock drill to start moving or fall down.
Incorrect operation could cause crushing damage.

Make sure that the rock drill is safely slung for

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

1250 0333 19

12.2 Rock Drill Weights

COP 3060ME 370 kg

12.3 Action before Service and Tong-term Storage

1. Check that all connections, including the one

for the flushing medium, are properly capped
with protective caps of the right size
2. Clean the rock drill carefully. Use degreasing
agent and rinse with water.
3. Clean thoroughly and oil in the front head
components in contact with flushing medium
(especially in high humidity).
4. Release gas from the accumulators.
5. Store the rock drill in a dry place.
1250 0333 16

39
12. Dismantling From Cradle

40
 13. Hydraulic Fluid and Lubricant Recommendations

13. Hydraulic Fluid and Lubricant Recommendations

13.1 Hydraulic Fluid
Atlas Copco offers a range of hydraulic oils based on operational requirements and varying temperature
ranges.These oils offer superior protection against wear, rust, and oxidation as well as air and water sepa-
ration properties and good anti-foaming. All Atlas Copco hydraulic oils conform to standard ISO 11158 HM,
DIN 51524 HLP/HVLP and ISO 15380 (for biodegradable options).
The variety of Atlas Copco Hydraulic oil helps to meet all the ranges of viscosity required for different
working conditions and ambient temperatures. It is important to have the viscosity grade suited for your
operating environment (please review the table below). There are different types of oils across these
ranges, varying from mineral to synthetic-based. With superior cleanliness and excellent filtering, these oils
ensure high performance operation.

Hydraulic Oil Climate 20 Liters 209 Liters 1000 Liters

100 ISO VG 46 Normal 9106 2303 21 9106 2303 20 9106 2303 26
120 ISO VG 46 Normal Biodegradable 9106 2303 22 9106 2303 33
9106 2303 23
200 ISO VG 32 Arctic 9106 2303 27 9106 2303 28 9106 2303 29
300 ISO VG 68 Tropical 9106 2303 30 9106 2303 31 9106 2303 32

13.1.1 Causes of Low Viscosity

• 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 causing increasing fluid losses and
increasing energy requirements.

13.1.2 Causes of High Viscosity

• Increased flow-loss in the hydraulic lines along with increasing energy consumption and higher pressure
levels, increase the strain on the seals.
• Increased risk of cavitation resulting in damage to the rock drill and hydraulic pumps. The hydraulic fluid
must be filtered to a purity of 20/18/15, in accordance with 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 Centistroke (cSt), of suitable hydraulic fluids, will drop a maximum of 25% when tested for shear stability
in accordance with DIN 51350-6 at 100ºC.

13.1.3 Change of Hydraulic Fluid

The hydraulic fluid must be changed at regular intervals. Factors influencing the length of intervals are:
• 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 of the water. If the hydraulic fluid becomes cloudy and light gray, the water content has
reached such a level that the hydraulic fluid must be changed.
• Deterioration of properties such as oxidation, foam inhibition, and so forth.

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

41
13. Hydraulic Fluid and Lubricant Recommendations

13.2 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 -25ºC and +50ºC.
COP OIL can be ordered with the following part numbers:

Quantity Part Number

1 can of 4 liters 3115 3125 02
1 can of 20 liters 3115 3125 01
24 cans of 20 liters 3115 3126 01
1 barrel of 208 liters 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)

-30 to 0 VG 32-68
-10 till +20 VG 68-100
+10 till +50 VG 100-150

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

ASTM D 2783 Minimum 250 kg

ASTM D 4172 (40 kg) Maximum 0.5 mm

13.3 Grease
Notice! 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 Operating Temperature

2 260ºC 220 cSt at 40ºC -15 to +150ºC

Atlas Copco recommends the use of Atlas Copco COP Grease (gear housing grease) which has been
specially-developed for our hydraulic rock drills. Atlas Copco COP Grease withstands temperatures
between -40ºC to +150ºC, and temperatures of up to 220ºC during shorter periods.
Atlas Copco COP Grease can be ordered with the following part numbers:

Quantity Part Number

Tube 0.4 kg 3115 3422 00
Can 18 kg 3115 3423 00

42
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