Reg.

code
ASB TAB 43
COP 2160/2160EX
COP 2560/2560EX
2007-03

Overhauling instructions for

Hydraulic COP 2160/2160EX
Rock drills COP 2560/2560EX

List of contents Page

Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main parts of the rock drill . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembling the rock drill into its main parts . . . . . . . . . 10
Disassembly, inspection, replacement of parts
and assembly of:
– Front head of extractor unit COP2160/2560 . . . . . . . . . 14
– Front head of extractor unit COP2160EX/2560EX . . . . 16
– Cover COP 2160/2560 . . . . . . . . . . . . . . . . . . . . . . . . . 20
– Cover of extractor unit COP 2160EX/2560EX . . . . . . . . 20
– Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
– Back head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
– Cover, extension piece and gear housing . . . . . . . . . . . 32
– Intermediate part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
– Cylinder, piston guides and impact piston . . . . . . . . . . . 52
– Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Function- and condition test of hydraulic motor. . . . . . . . . 58
Assembling the main parts of the rock drill . . . . . . . . . . . . 59
Charging the accumulators . . . . . . . . . . . . . . . . . . . . . . . . 65
Recommended hydraulic oils and lubricants . . . . . . . . . . . 66
Testing the rotation and percussion functions . . . . . . . . . . 67
Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

ATLAS COPCO ROCK DRILLS AB

ÖREBRO · SWEDEN
© Atlas Copco Rock Drills AB, 2007. All rights reserved.

No. 9853 1124 01

 SAFETY REGULATIONS
· Important safety information is given at various points in these instructions.
· Special attention must be paid to the safety information contained in frames and accompanied by a
warning symbol (triangle) and a signal word, as shown below:

indicates hazards or hazardous procedures which COULD

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

indicates hazards or hazardous procedures which COULD

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

The following safety rules must also be observed:

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

General
The following instructions are intended as a guide
for service personnel involved in the overhauling of
COP 2160/2160EX/2560/2560EX hydraulic rock
drill.
Layout of these instructions
The instructions begin with a list of the standard
and special tools needed to overhaul the COP
2160/2160EX/2560/2560EX rock drill. This is fol-
lowed by instructions on how to disassemble the
rock drill into its main parts. Then, under respecti-
ve headings for the main parts, detailed instructions
are given on
further disassembly, checking, inspection of parts
and re-assembly.
The instructions end with a section describing how
the main parts of the rock drill are put back toget-
her, followed by the tests and checks that must be
carried out after the machine has been overhauled.
The letters enclosed in brackets in the instructions
refer to the list of special tools on pages 3–8. The
numbers enclosed in brackets in the instructions re-
fer to the exploded views of the machine on pages
55 (hydraulic motor) and 69 (rock drill).
Workshop standards
Workshops for the overhauling of hydraulic
machines must be:
· Isolated from all dust- and particle-generating
activities such as grinding, welding etc.
· Very clean, i.e. free of dust and dirt.
· Equipped with
– all necessary standard and special tools
– washing facilities for cleaning and degreasing
components
– compressed air for blow cleaning components
– a hydraulic press
– hoisting facilities with a minimum capacity of
500 kg.
CAUTION
· Never intervene in the rock drill, connec-
tions or hoses when the hydraulic system
is pressurized.
Hydraulic oil at high pressure and high
temperature can squirt out with great force.
Risk of injury to eyes and skin.

2
 List of tools / Standard tools

Plastic hammer

Copper hammer

Honing tool ø 19–70 mm

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

Allen keys
Width across flats: 4–10 mm
Width across flats: 3/16"

Screwdrivers

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

Feeler gauge, 0.03–0.10 mm, with 0.01 mm

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

Internal circlip pliers

Torque wrenches, torque range 10–350 Nm

(7–260 lbf. ft)

Socket set with:

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

Awl

Sliding offset handle, with 3/4" square drive

Impact socket 32 mm
1250 0022 43

Vernier calliper
Micrometer, 0–25 mm

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

A 3115 0329 80 Pivoted mounting Disassembly, assembly and

fixture testing of rock drill (figs. 2, 115)
1250 0024 27

B Press, Basic tool for use with other

consisting of: press tools (figs. 15, 16, 17,
– 3115 1902 00 – Guide plate 19, 20, 21, 29, 71, 78, 80, 81,
– 3115 2734 00 – Nut 83)
– 3115 0317 00 – Screw
– 3115 2420 00 – Screw
1250 0024 28

C 3115 0318 00 Extension sleeve For use with press B

1250 0024 29

(2 pcs) (figs. 16, 17, 19, 20, 78, 81)

D 3115 1019 00 Mandrel Removal and fitting of guide

1250 0024 30

(figs. 15, 79)

E 3115 3494 00 Press tool Fitting of seal rings and

1250 0024 31

damper liner (figs. 29, 71,

81, 100)

F 3115 3490 00 Press tool Fitting of tapered bearings

1250 0024 32

(fig. 80)

G 3115 3003 00 Mandrel Fitting of piston guides

(figs. 110)
1250 0024 33

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

H 3115 0313 00 Mandrel Assembly and disassembly of

gear housing (figs. 58, 72–77)
1250 0024 34

I 3115 3004 00 Mandrel Fitting of piston seal housing

(figs. 51, 97)
1250 0024 35

Fitting of bushing for damper

piston (fig. 99)

J 3115 1877 00 Assembly and Assembly and disassembly of

disassembly tool accumulators (figs. 33–45)
1250 0024 36

K 3115 0343 00 Wrench adapter Adapters for use with torque

(24 mm) wrench when tightening up
1250 0024 37

3115 0344 00 Wrench adapter the machine (fig. 83)

(32 mm)

L 3115 2859 80 Assembly and Assembly and disassembly of

disassembly tool, accumulators (figs. 33–45)
consisting of: (COP 1032 - 2550)

– 3115 2859 00 Ass. tool

– 3115 2860 00 Stud (2 pcs)
– 3115 2861 00 Ring
1250 0045 44

– 0266 2114 00 Nut (2 pcs)

M 0462 7010 34 Assembly tool Fitting of thread inserts into

(M12) intermediate part and cylinder
3115 1627 00 Assembly tool
1250 0024 39

(M14)
3115 1126 00 Assembly tool
(M16)
3115 1628 00 Assembly tool
(M20)

N 3091 0455 90 Extractor + See figs. 50, 62, 70, 92

1250 0024 40

adapters
1250 0024 41

O 3115 0284 00 Washer Locking of valve plunger

when condition testing per-
cussion mechanism (fig. 130).

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

P 3115 3425 80 Charging Equipment for charging of ac-

LA
TO
R
equipment cumulators
MU ER
CU RG
AC HA
     C
200
150

250
100

E
BAR

UR
SS
0

RE
200

G P
GIN
150

250
1250 0177 32

AR
CH
100

BAR

E
UR
0

SS
RE
G P
GIN
AR
CH
200
150

250
100

BAR

E
UR
SS
0

RE
R P
DE
LIN
CY

R
TO
LA
MU
CU ER
ACARG
CH

Q 3115 3495 00 Mandrel Removal and fitting of guide

and flushing head

R 3115 2263 00 Ring spanner Nuts for hydraulic motor

(figs. 15, 111)
1250 0024 44

S 3115 1897 00 Fixture Assembly and testing of hyd-

raulic motor (fig. 111)
1250 0024 45

T 3115 3492 00 Plate Fitting of bushing into rota-

tion chuck (fig. 78)
1250 0024 46

U 3115 1594 00 Plates Removal of damper piston

1250 0024 49

liner (fig. 89)

X 3115 2163 00 Sleeve Fitting of bushing into inter-

mediate part (fig. 99)
1250 0024 51

Y 3115 2519 00 Tensioning tool Disassembly and gripping of

diaphragm support
1250 0024 52

(figs. 34, 37, 38)

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

AA 0335 2169 00 Circlip ø 100 mm Removal of bushings

0335 2176 00 Circlip ø 120 mm (figs. 16, 17).

BB 3115 2265 00 Nut (M20x2) Removal and fitting of stud

bolts and side bolts
(figs. 23, 31).

CC 3115 2409 00 Press tool Removal of bushing (fig. 17).

DD 3115 2410 00 Press tool Removal of bushing (fig. 16)

and fitting of bushing (fig. 20).

EE 3115 2412 00 Press tool Removal and fitting of guide

(figs. 15, 19).

FF 3115 2422 00 Press tool Removal of guide (fig. 15) and

fitting of bushing (fig. 21).
Shimming of roller bearings
(fig. 83)

GG 3115 2411 00 Press tool Removal of bushing (fig. 16).

HH 3115 2423 00 Guide ring Fitting of guide (fig. 19) and

bushings (fig. 20, 21).

JJ 3115 3493 00 Support ring Shimming of roller bearings

(fig. 85).

7
List of tools / Special tools and test
equipment
Tool Part number Name Use

LL 3115 2739 00 Spacer pipe Shimming of roller bearings

(fig. 83)
1250 0045 66

NN 3115 3489 00 Mandrel Fitting of driver into rot.

chuck bushing (fig 79)

PP 3115 3491 00 Mandrel Removal and fitting of needle

bearing and sleeve in gear
housing (fig. 57,58,75)

RR 3115 3496 00 Mandrel Removal of seal retainer

8
Main parts of the rock drill

8 7 5 4 3 2a 1a

COP 2160
COP 2560
1250 0178 18

9 6

Fig. 1a. Hydraulic rock drill COP 2160/2560, main parts

5 4 3 2b 1b
8 7

COP 2160EX
1250 0100 45

COP 2560EX

9 6

Fig. 1b. Hydraulic rock drill COP 2160EX/2560EX, main parts

1a. Front head incl. (COP 2160/2560) 5. Intermediate part, incl.

· Shank adapter · Damper piston
· Flushing head · Damper-piston liner
· Guide · Front piston seals
· Stop ring

2a. Cover (COP 2160/2560) 6. Accumulators

· Intake accumulator
1b. Front head of extractor unit (COP · Damper accumulator
2160EX/2560EX · Return accumulator
incl.
· Shank adapter
· Piston 7. Cylinder, incl.
· Guide · Impact piston
· Piston guides
2b. Cover of extractor unit, incl. (COP · Valve piston
2160EX/2560EX) · Regulator plug
· Flushing head
· Flushing connection
8. Back head, incl.
3. Extension piece · Rear piston seals
4. Gear housing, incl.
· Rotation chuck bushing 9. Hydraulic motor
· Rotation chuck
· Driver
· Rotation shaft

9
Disassembling the rock drill into its main
parts
The pivoted mounting fixture (A) must be used when disassembling the rock drill.

Disassembly sequence:
IMPORTANT
· Front head/ Front head of extractor unit
· Always observe a high standard of cleanli- · Accumulators
ness when opening up the rock drill or its · Back head and impact piston
connections. · Cover
· Only the front-head parts, shank adapter, · Gear housing
accumulators, hydraulic motor, bolts and · Intermediate part
connections may be changed at the work- · Cylinder
site. All other repairs must be carried out · Hydraulic motor
in a suitable workshop.

N.B. Always wash down the outsides of the

rock drill using a degreasing agent before di-
sassembly begins.
Bolt the rock drill securely to the pivoted mounting
fixture (A).

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

Front head
Take off the connection plate (2) with its nipple (6)
by removing the screws (5) together with the was-
hers (4).
3 Remove the cup seal (3).
1250 0084 50

4
5
6 2
Fig. 3a. Removing the nipple, connection plate,
screws and cup seal
9
1B
Remove the front side-bolt nuts (2) and washers
(3). Remove the front head (1B) by tugging the
shank adapter (20 or 21).
Take out the cylindrical pin (9).
1250 0084 51

21

3 2

Fig. 3b. Removing the front head

10
 Front head of extractor unit
Remove the front side-bolt nuts (11) with washers
(12). Remove the front head (1) by prizing it free
with the aid of a parting tool and tapping it with a
copper hammer.
Take out the cylindrical pin (22).
1250 0177 33

Fig. 4. Removing the front head of the extractor unit

CAUTION
· All gas must be released from the accumu-
lators before they are removed from the
rock drill.
To release the gas, remove the protective
cap (A) and loosen the valve nut (B) by
2–3 turns.
There is a risk of injury from incorrect hand-
93 ling.
B A
103
92

Accumulators

Take off the accumulators (52 and 92) together

with the seals (103) by removing the screws
12500084 54

103 (7 and 93).

52 B A

7
Fig. 5a. Removing the accumulators

Remove the return accumulator (94) by removing

the nuts (15), screws (14), screw (16) and retainer
(12). Pull off the clamp (13) and unscrew the ac-
cumulator from the nipple (17).

Fig. 5b. Removing the return accumulator

11
 Back head and impact piston
Remove the back head (83) by loosening and re-
moving the screws (84).
If necessary, tap the back head with a copper
hammer and carefully prize it free with the aid of a
parting tool or similar tool.

Fig. 6. Removing the back head

79
77
1250 0031 33

Pull out the impact piston (77) together with the

rear piston guide (79). Put the impact piston in a
safe place where it will not be scratched or dama-
ged.

Fig. 7. Removing the impact piston and rear piston guid

2 3

Cover, extension piece and gear

housing (COP 2160/2560)
Remove the rear side-bolt nuts (2) and washers
(3). Removi the side bolt (4).
1250 0079 18

Fig. 8a. Removing the side bolts

Cover of extractor unit

(COP 2160EX/2560EX)
Remove the rear side-bolt nuts (2) with washers
(3). Remove the side bolt (4).
Tap loose the cover (23) using a copper hammer.
Remove the O-ring (10).

Fig. 8b. Removing the cover of the extractor unit

12
 Gear housing
Using a copper hammer, tap loose and pull out the
gear housing (17) together with the extension pie-
ce (101).
Normally the rotation shaft (26) comes out with the
gear housing. If it does not, pull out the rotation
shaft afterwards.

Fig. 9. Removing the gear housing

Intermediate part
Tap free the intermediate part (36) using a copper
hammer. If the intermediate part sticks on the
lower guide, use a parting tool or something simi-
lar, to prize it free.

Fig. 10. Removing the intermediate part

Hydraulic motor
1250 0043 47

74 102 72 Remove the nuts (75) using the ring spanner (R),
and remove the hydraulic motor (74).
Remove the gasket (102).
Pull out the coupling (72).

R 75

Fig. 11. Removing the hydraulic motor

13
 Front head
(COP 2160/2560)
Disassembly
Inspection, replacement of parts
Assembly
20, 21

Diassembly
1250 0079 21

Pull out the shank adapter (20,21).

Fig. Removing the shank adapter

7
14 Press out the guide (7,14), flushing head (10,16)
10
and stop ring (12,18). Use the mandrel (D) to remo-
16 ve the 38 mm guide. Use the mandrel (D) plus the
sleeve (V) to remove the 52 mm guide.
1250 0079 22

12 18

Fig. Removing the guide

Inspection, replacement of parts

Before inspection, all parts must be washed clean
in a degreasing agent.
Change the guide (14) if its inside diameter is grea-
13
ter than 61 mm.
16 17 19 18 1 mm
14 15 9 9 15
Change the flushing head (16) in the event of se-
rious damage, cracks etc.
1250 0084 60

61 mm Change the stop ring (18) if the surface is worn

down by more than 1 mm. Use a new stop ring as
a guage for comparison.
Fig. Checking the guide, O-rings, seal rings, flushing Change all O-rings and cup seals. IMPORTANT!
head and stop ring
The cup seals must face the directions shown in
the figure opposite.

14
 Assembly
D Before assembly, the parts must be oiled with cle-
an hydraulic oil.
Press in the guide (7) with the aid of mandrel (D).
V
Press in the guide (14) with the aid of mandrel (D)
plus sleeve (V).
A
Check that the lubricating duct (A) is not blocked.
7 To do this, blow through it with compressed air.
14
1250 0024 61

Fig. Fitting the guide

Press in the flushing head (10) with the aid of

V mandrel (D). Alternatively, press in the slushing
head (16) with the aid of mandrel (D) and sleeve
(V).

10
Make sure that the flushing hole in the flushing
16 head lines up with the corresponding hole (A) in
the front head.

A
1250 0079 24

Fig. Fitting the flushing head

Fit the stop ring (18) with O-ring (19), O-ring (13)
1 and shank adapter (21) into the front head (1).
1250 0177 34

19 18 13 21

Fig. Fitting the stop ring and shank adapter

15
Front head of extractor unit
(COP 2160EX/2560EX)
Disassembly
Inspection, replacement of parts

1250 0178 15
Assembly

Disassembly
Pull out the shank adapter (31).
31 Tip out any hydraulic oil that might be in the front
head.

Fig. 12. Removing the shank adapter

Press out the piston (10) with the aid of a copper

mandrel, or by carefully blowing compressed air
in through the nipple (14).

Fig. 13. Removing the extractor piston

Remove the piston seals (4 and 8) carefully, using

a narrow pointed tool.
Be careful not to damage the seal grooves!

N.B. Leave the O-ring in the groove as support for

the circlip when the bushings (5 and 9) are pres-
sed out later.

Fig. 14. Removing the seals

16
 Press out the guide (2) using press (B) and press
tools (EE and FF).
The guide (2) can also be pressed out using a
hydraulic press together with mandrel (D) and slee-
ve (V).

Fig. 15. Removing the guide

Press the bushing (9) out of the front head (1). To

do this, fit the ø 120 mm circlip (AA) into the seal
groove in bushing (9), and press out the bushing
using the press (B) and press tools (C, DD and
GG).
Remove the O-ring from the bushing (9).

Fig. 16. Removing the bushing

AA

CC Remove the lock ring (6) using an internal clip plier.

Now remove bushing (5). To do this, fit the ø 100
5 mm circlip (AA) into the seal groove in bushing (5),
and press out the bushing using the press (B) and
press tools (C and CC).
Remove the O-ring from the bushing (5).
1250 0100 47

6
B

Fig. 17. Removing the lock ring and bushing

17
 Inspection, replacement of parts
3 4 5 6 10 7 9 8 7 Before inspection, all parts must be washed in
1mm a degreasing agent.
Change the guide (2) if its inside diameter is grea-
ter than 61 mm.
Change the O-rings (3 and 7) and seal rings
(4 and 8).

31 2 Change the piston (10) if it is badly worn

(max. 1 mm).
61 mm T51 Change the bushings (5 and 9) if they are badly
1250 0178 16

scored. Minor scoring can be polished using a fine

abrasive cloth.
Change the shank adapter (31) if the thread is
Fig. 18. Checking the guide, O-rings, seal rings, piston worn out, or if the impact surface is upset or chip-
and bushings ped.

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

Press the guide (2) into the front head (1) using
the press (B) and press tools (C, EE and HH).

Fig. 19. Fitting the guide

6
C
Fit the lower O-ring (3) on the bushing (5), as

;
4 shown in the figure opposite.
DD
Fit the seal ring (4) with O-ring into the bushing (5),

;
1 5 as shown in the figure opposite.
5 Now press the bushing (5) into the front head,
using the press (B), press tools (C and DD) and
guide ring (HH).
1250 0100 48

3
HH Fit the lock ring (6).

Fig. 20. Fitting the front bushing

18
 B

8 Fit the lower O-ring (7) on the bushing (9), as

FF shown in the figure opposite.

;
Fit the other two O-rings (7) to the bushing (9).

;
9 Fit the seal ring (8) with O-ring into the bushing (9),
as shown in the figure opposite.
Now press the bushing (9) into the front head,
1
using the press (B) and press tools (FF and HH).
1250 0100 49

HH 7
B

Fig. 21. Fitting the rear bushing

Oil the piston (10) and press it into the front head
(1).
N.B. This must be done with the greatest of care.
Then press out the piston and check that the seals
are correctly located and not damaged.
N.B. It should be easy to press the piston into the
front head!

Fig. 22. Fitting the piston

19
 Cover (COP 2160/2560)

Disassembly
Check the seal (21) in the cover for wear and
damage.
If the seals need to be changed, remove the circlip

1250 0177 35
(22) and knock out the seal using a punch.
21
22
Fig. Removing the seal rings from the cover

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

Cover of the extractor

unit (COP
2150EX/2550EX)
Fig. 23. Fitting the seal ring into the cover Disassembly
Inspection, replacement of parts
Assembly
23 13 BB 11
29

Disassembly
1250 0084 75

Remove the stud bolts (13) from the cover (23). To

do this, first fit a nut (BB) to the stud bolt. Then fit
dome nut (11) and tighten against nut (BB). Now
13
remove the stud bolt by turning nut (BB) as shown
in the figure opposite. Remove all stud bolts in this
way.
Fig. 24.Removing the stud bolts and side bolts
Now remove the side bolts (29) in the same way.
19

32

33

34

35 Remove the nipples (19 and 32), and the nut (21).
Remove the O-rings (34, 35) and back-up ring (33).
1250 0131 54

Fig. 25. Removing the flushing intake nipple

20
 25

Remove the circlip (25) using a strong pair of cir-

clip pliers. Now pry the seal (24) out of the cover
(23) using a strong screwdriver.

24
1250 0084 77

23

Fig. 25. Removing the seal

Press the flushing head (28) out of the cover (23).

Fig. 26. Removing the flushing head

Inspection, replacement of parts

Before inspection, all parts must be washed in a
degreasing agent.
Change all O-rings (26) and seals (27).
Change the flushing head (28) if it is seriously cor-
roded, cracked or worn.
Fig. 27. Checking the flushing head

Change the side bolts (4 and 29), washers (12)

and stud bolts (13) if they are badly rusted, or if
there is evidence of crack formation.
Also check the threads in the dome nuts (11).
Change all side bolts after every 400 hours of
operation. Never mix new and old side bolts.

Fig. 28. Checking the side bolts

21
 Assembly
Before assembly, all parts must be oiled with clean
hydraulic oil.

Fit the seal ring (24) into the cover (23) using the
press (B) and press tool (E).
Fit the circlip (25) into the groove in the cover,
using a strong pair of circlip pliers.

Fig. 29. Fitting the seal ring

26 Fit the O-rings (26) and seals (27) into the flushing
head (28).
IMPORTANT! The seals (27) must face the direc-
27 tions shown in the figure opposite.

28
Fit the flushing head (28) into the cover (23),
27 tapping it down with a copper hammer. Make sure
that the flushing intake in the cover lines up with
26 the hole in the flushing head.
23 Fit the O-rings (34, 35) and back-up ring (33) to
the nipple (32).
35 34
1250 0131 55

33 Tighten nipple (32) to a torque of 300 Nm (220 lbf.

32 ft).
19
Fit the nipples to the cover (23).
Tighten nipple (19) to a torque of 180 Nm (130 lbf.
ft).

Fig. 30. Fitting the flushing head

COP 2160EX/2560EX
Fit the side bolts (29) and stud bolts (13) using the
nut (BB) and a dome nut (11) on each respective
bolt, as shown in the figure opposite.

Fig. 31. Fitting the stud bolts and side bolts

22
 Accumulators
Disassembly
Inspection, replacement of parts
Assembly

= Read the instruction book carefully

before servicing or changing

1250 0020 91
= Must be charged with nitrogen only

The rock drill is equipped with three accumulators:

1250 0027 19

– the intake accumulator (52)

– the damper accumulator (92)
– the return accumulator (94)

Fig. 32. The accumulators on the rock drill

4 Intake accumulator (52)

3
Disassembly
J CAUTION
· All gas must be released from the accumu-
52 lator before it is removed from the rock
drill.
To release the gas, remove the protective
cap (A) and loosen the valve nut (B) by
A B 2–3 turns.
1250 0045 45

Incorrect handling will incur the risk of

L
injury.

Clamp the tool (L) firmly in a vice.

Place the accumulator (52) on tool (L).
Place tool (J) on the accumulator. Fit ring (3) and
tighten the nuts (4) by hand. Ring (3) serves to
keep tool (J) in place when high torque is applied.
Now, with the aid of a 32 mm impact socket and
long T-handle with 3/4" square drive, unscrew the
housing from the accumulator cover.
125 0045 46

If necessary, strike the top of the drive with a cop-

per hammer to help loosen the thread.

Fig. 33. Disassembling the housing

23
 J Place the tensioning tool (Y) in the cover (6).
Place a used diaphragm (5) over the tool.
2 Tighten the housing (1) with the tool (J) so that the
4 nut (2) is pressed upward.
1 Try to unscrew the nut (2). If it does not loosen,
saw off the shaft of the diaphragm support (4) just
6 below the nut.
5
Disassemble the housing (1) and other compo-
nents.
Y
1250 0045 47

Fig. 34. Disassembling the diaphragm support

Inspection, replacement of parts

Fig. 35. Intake accumulator Change the diaphragm (5) if it shows signs of
cracking or other damage.
When changing the diaphragm, make sure that no
bits of rubber have lodged in the valve (12) or in
CAUTION the test valve (8).

· Screws of incorrect length, as well as rus-
ted or damaged threads on the screws,
housing or cover can lead to dangerous
oil leakage and can cause the compo-
nents to loosen.
Risk of injury to personnel.
· Always change the screws (7), housing
(1) or cover (6) if they are corroded, worn,
defective or damaged. Always change
BOTH screws at the same time.
Blow clean the gas ducts in the cover (6) with
compressed air.
Change the valves (8 and 12) if they are damaged.
Always change the O-rings (9, 10 and 14) if the val-
ves have been disassembled.
Always change the diaphragm support (4) and the
nut (2) if they have been disassembled.
Change the screws (7) if they are rusted or dama-
ged.
Change the housing (1) and cover (6) if the thre-
ads are damaged or badly rusted.
Change the spring (3) if it is shorter than 31.5 mm.

24
 Assembly
Before assembly, it is important that all parts are
clean, dry and free of oil.
Fit the compression spring (3) on to the diaphragm
support (4). Press the end of the diaphragm sup-
port through the housing (1), and thread on the nut
(2) by hand.

Fig. 36. Fitting the diaphragm support

J
Clamp the tool (L) firmly in a vice.
On to the tool (L) put:
2 4 – the cover (6)
– the tool (Y)
5 1 – a used diaphragm (5)
6
– the housing (1)
– the tool (J).
Tighten the housing hard enough to prevent the
125 0045 48

Y diaphragm support (4) from rotating when the nut

(2) is tightened later.

Fig. 37. Holding the diaphragm support

Remove the nut (2) and clean the threads.

Put a drop of "Loctite 270" locking compound on
2 the thread and tighten the nut using a 10 mm fixed
1 spanner. Make sure that none of the locking com-
pound runs down and locks the diaphragm support
5
(4) in the housing (1).
Y 4
Now lock the nut further by means of four punch
marks.
Remove the housing (1), the old diaphragm (5)
and tool (Y).
Check that the diaphragm support (4) is still mov-
1250 0102 39

able after the locking compound has hardened.

Fig. 38. Locking the nut

25
 Place a perfect diaphragm (5) in the cover (6).
J Smear the edges of the diaphragm with a thin lay-
er of silicone grease.
1 Smear the threads of the accumulator cover (6)
and housing (1) with grease of type NEVER-SEEZ.
5
Tighten the housing to a torque of 300 Nm
(220 lbf. ft) using the tool (J) and a torque wrench.
125 0045 50

Fig. 39. Fitting the diaphragm and housing

Fit the valve plunger (11) together with O-rings (9

and 10), and fit the valve body (8). Tighten to a
torque of 45 Nm (33 lbf. ft).
Fit the valve (12) together with O-ring (14). Tighten
to a torque of 30 Nm (22 lbf. ft).

Fig. 40. Fitting the valves

Inspect the safety labels (15, 16), and change

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

Fig. 41. The accumulator safety labels

26
 Damper accumulator (92)

4 Disassembly

3 CAUTION
· All gas must be released from the accumu-
lator before it is removed from the rock
drill.
To release the gas, remove the protective
J
cap (A) and loosen the valve nut (B) by
2–3 turns.
67 / 92 Incorrect handling will incur the risk of
injury.

Clamp the tool (L) in a vice.

L Place the accumulator (92) on tool (L).
Place tool (J) on the accumulator. Fit ring (3) and
1250 0045 51

tighten the nuts (4) by hand. Ring (3) serves to

keep tool (J) in place when high torque is applied.
Unscrew the housing from the cover with the aid of
tool (J). Use a 32 mm impact socket and extended
T-handle with a 3/4" square drive.
If necessary, strike the top of the drive with a cop-
per hammer to help loosen the thread.
125 0045 46

Inspection, replacement of parts

Change the diaphragm (2) if it shows signs of
Fig. 42. Disassembling the accumulator cracking or other damage.
When changing the diaphragm, make sure that no
bits of rubber have lodged in the valve (4) or in the
test valve (7).
Blow clean the gas ducts in the cover (3) with
compressed air.
Change the valves if they are damaged.
1 Always change the O-rings (6, 8, 9) if the valves
2
3 have been disassembled.
Check the condition of the screws (93). If they are
rusted or damaged, they must be replaced.
7 Change the housing (1) and cover (3) if the thre-
8 ads are damaged or badly rusted.
9
10
93
CAUTION
1250 0045 63

6
4 · Screws of the wrong length and rusted or
damaged threads on the screws, housing
5 or cover can lead to dangerus oil leakage,
and can cause the components to loosen.
Risk of injury to personnel.
· Always change the screws (93), housing
Fig. 43. Checking the diaphragm, valve housing and co- (1) or cover (3) if they are corroded, worn,
ver defective or damaged. Always change
BOTH screws at the same time.

27
 Assembly
1 2
3 Before assembly, it is important that all parts are
clean, dry and free of oil.

7 Place the diaphragm (2) in the housing (1) and gre-

9
8 ase the edges of the diaphragm with a thin layer of
10 silicone grease.
93
Smear the threads of the accumulator cover (3)
and housing (1) with grease of type NEVER-SEEZ.
1250 0045 63

6
4
Fit the cover (3) on to the housing (1) and thread
5 the accumulator together by hand.
Do not turn the accumulator upside down until it
has been screwed together.
Fit the valve plunger (10) together with O-rings (8
and 9), and fit the valve body (7). Tighten to a
torque of 45 Nm (33 lbf. ft).
Fit the valve (4) together with the O-ring (6), and
tighten to a torque of 30 Nm (22 lbf. ft).
Fig. 44. Fitting the diaphragm into the housing and the
cover on to the housing

Now place the accumulator on the assembly tool

L (L).
Tighten the housing (1) to a torque of 300 Nm
(220 lbf. ft) using the assembly tool (J) and a
torque wrench.
1250 0045 53

Fig. 45. Tightening the housing

28
 Inspect the safety labels (11, 12), and change
them when necessary.
N.B. Do not charge the accumulator until it havs
been fitted securely to the rock drill.

Fig. 46. The accumulator safety labels

19
11
1 2
8 18
16
20
1250 0041 46

14

12

15
17 10 9 7 6 5 4 3 13

Fig. 47. Return accumulator

Return accumulator (94)
Disassemble the return accumulator and check all
parts. If the diaphragm (1) shows signs of cracking
or other damage, it must be changed.
Change all O-rings.
When assembling the accumulator, smear the ed-
ges of the diaphragm with a thin layer of silicone
grease or similar lubricant.
Fit the plug (11) together with the O-ring (8).
Tighten to a torque of 45 Nm (33 lbf. ft).
Fit the tube (2) in such way that the plug (11) is
accessible for checking the accumulator dia-
phragm (see fig. 124).

29
 Back head
Inspection, replacement of parts
Assembly

77

Inspection, replacement of parts

Before inspection, all parts must be washed in a
degreasing agent.
Check the piston seals (81) for damage or wear.
To check the wear of the piston seals, slide the im-
81 pact piston (77) into the back head (83). Then pull
the piston upwards, whereupon the back head
83 should stick to the piston.
Make sure that the breather (95) is not clogged. If
it is, blow it clean with compressed air.
1250 0100 50

95

Fig. 48. Checking the piston seals

If the piston seals (81) need to be changed, they

can be removed carefully with the aid of a pointed
instrument. Take care not to damage the grooves
in the seal housing (80).

Fig. 49. Removing the piston seals

30
 It is not necessary to remove the seal housing (80)
unless it is damaged, or if leakage indicates that
the O-ring (82) must be changed.
If it is necessary to remove the seal housing, this is
done as shown in the figure. Use the extractor (N)
with a 37–46 mm expander.

Fig. 50. Removing the seal housing

Assembly
Before assembly, all parts must be oiled with clean
hydraulic oil.
If the seal housing (80) has been removed, it must
be fitted back into the back head as follows:
First fit a new O-ring (82). Then press the seal hou-
sing into place with the aid of mandrel (I).

Fig. 51. Fitting the seal housing into the back head

Fit the piston seals (81) as shown in the figure.

(A seal kit consists of an O-ring and a Teflon ring).
Bend the Teflon ring as shown in the figure, and
then press it into the groove.
N.B. The lips of the seals must face the direction
shown in the figure!

Fig. 52. Fitting the piston seals

31
Cover, extension piece and gear housing
Disassembly
Inspection, replacement of parts
Assembly

Disassembly
Remove the rotation chuck bushing (25).
Tap loose the extension piece (101) using a cop-
per hammer. Use two parting tools, or similar tool,
to carefully prize it free.

Fig. 53. Removing the rotation chuck bushing

A B

Tap the rotation shaft (26).

Use a punch (ø approx. 7 mm) inserted through
the hole in the front end of the gear housing. If a
26 27 thicker punch is used, there is a risk of damaging
the needle bearing (27). The rear bearing sleeve
(1) and the two thrust needle bearings (2) will
come out with the rotation shaft.
1250 0177 39

Fig. 54. Removing the rotation shaft

16 14 12 11

Remove the rotation chuck (14) together with the

shims (11) and outer rings (12 and 16) of the bea-
rings from the gear housing by tapping the rotation
chuck with a copper hammer.
Now take out the gear-wheel (34) from the gear
1250 0079 42

housing.

34

Fig. 55. Removing the rotation chuck and shims, bearing

rings and gear-wheel from the gear housing

32
 Using a punch (ø 10 mm), knock out of the gear
housing the front needle bearing (27) and two
washers (23 and 28) for the rotation shaft.

Fig. 56. Removing the front needle bearing and washers

for the rotation shaft

17

Remove the bearing sleeve (32) and the needle be-

aring(33) as follows:
1250 0178 01

– Place the mandrel (PP) on the needle bearing.

– Place the gear housing (17) on two blocks of
wood as shown in the figure opposite.
– Knock out the guide sleeve with the aid of a drift
(12x150 mm).

PP
33
32

Fig. 57. Removing the guide sleeve

33
 Inspection, replacement of parts
Before inspection, all parts must be washed in a
4 degreasing agent.
Change all O-rings.
1250 0100 52

Change the side bolts (4 ) if it is badly rusted or if it

show signs of crack formation.
Change all side bolts after every 400 hours of
operation. Never mix new and old side bolts.
Fig. 59. Checking the side bolts

31

Change the shank adapter (31) if the thread is

13 worn out, or if the impact surface is upset or chip-
ped.
2 mm
Change the driver (13) when the spline width is
less than 2 mm.
1250 0178 02

Fig. 60. Checking the driver and shank adapter

Check the wear between the rotation chuck (14)

and the driver (13) using a feeler gauge. If the clea-
rance exceeds 0.2 mm, the driver or rotation chuck
should be changed.
Check the bushing (15). If the internal diameter is
greater than 64.0 mm the bushing should be
changed.

Fig. 61. Checking the wear

34
 If the driver (13) needs to be changed, this is done
with the aid of the extractor (N) and a 37–46 mm
expander. See figure.

Fig. 62. Removing the driver

If the bushing (15) needs to be changed, split it

with the aid of a screwdriver. Be careful not to
damage the rotation chuck.

Fig. 63. Removing the bushing

A 16 14 12 11 Change the rotation chuck (14) if it shows signs of

deformation or cracking, or if the gear ring is badly
worn, or if the depth of the lubrication grooves (A)
is less than 1.0 mm.
The rotation chuck also has to be changed if the
rear seal has worn a deep groove in the rotation
chuck. A wear groove from the front seal can be
1250 0088 04

avoided by placing the front seal in another groove

Fig. 64. Checking the rotation chuck, roller bearings,
seals and shims
in the extension piece.
Change the roller bearings (12 and 16) in the
event of dissonance or damage.
Change the shims (11) if they show signs of dama-
ge.

35
 If either of the roller bearings (12 or 16) on the rota-
tion chuck needs to be changed, the roller cage
must be broken up with a screwdriver.
1250 0176 96

Place the rotation chuck vertically on a dolly that

has a smaller diameter than the inside diameter of
the bearing (so that the inner rings can drop down)
12 and then remove the inner rings of the roller bea-
16 ring by an extractor.
Alternatively, cut through the inner rings of the bea-
ring using a grinder.

Fig. 65. Removing the inner rings of the bearings

If the rotation chuck seals need to be changed,

they can be removed carefully with the aid of a po-
inted instrument.

;;;
Before removing the seal from the extension piece,
make a notation in which groove the seal is placed.
Take care not to damage the groove in the seal re-
tainer and extension piece
1250 0178 03

Fig. 66. Removing the rotation chuck seals

It is not necessary to remove the seal retainer un-
less:
A B - The seal retainer is damaged.
- Leakage indicates that the O-ring must be repla-
ced.
D
- The rotation chuck has a deep wear groove from
the rear seal. A new position for the seal can be
obtained by removing the seal retainer and as-
U
RR semble it in the other direction.
To remove the seal retainer, remove the circlip.
- If the seal retainer is assembled as shown in fig
A, place the plate (U) in the seal groove and care-
fully tap the seal reatainer out using a copper
mandrel and plastic hammer. Move the plate from
1250 0178 04

side to side of the seal retainer to prevent it from

sticking in the gear housing.
- If the seal retainer is assembled as shown in fig
B, press it out using the mandrel (D) and (RR).
Fig. 67. Removing the seal retainer

36
 Change the rotation chuck bushing (25) if its surfa-
m 25 ce against the shank adapter is worn by more than
1m
1 mm. Use a new rotation chuck bushing as a gau-
ge.
1250 0088 07
Polish or change the rotation chuck bushing if the
surface that faces the damping piston is scored.
N.B. The minimum permissible length of the rota-
tion chuck bushing is 66 mm.

66 mm Always change the rotation-chuck bushing every

15,000 drillmetres (max.).

Fig. 68. Checking the rotation chuck bushing

Change the needle bearings (27 and 29) of the ro-

tation shaft in the event of dissonance or damage.
Change the gear-wheel (33) if it shows signs of de-
formation or cracking, or if the gear ring is badly
1250 0178 05

worn.
Inspect the bearing race surfaces of the bearing
sleeves and shaft. Replace if worn or damaged.
Change the shaft seal (31).
27 31 29 31

Fig. 69. Checking the rotation-shaft needle bearings,

gear-wheel and cup seal

37
 Assembly
B
Before assembly, all parts must be oiled with clean
C hydraulic oil.

E Inspect the sealing surface of the rotation chuck. If

there is a deep wear groove in the surface, the
seal retainer can be assembled in the other direc-
tion to move the seal to a new position.
1250 0178 06

Fit the O-ring on the seal retainer and smear it with

oil. Tap the seal retainer in using press tool (B,C
and E)

Fig. 71. Fitting the O-ring and seal retainer

Fit the circlip in its groove.

Fit the rear rotation chuck seal (A consist of an O-

ring and a Teflon ring). The seal is fitted as follows:
Check that the seal groove is very clean. Oil the O-
ring and fit it into the groove.
Insert the seal ring into the seal retainer, and then
press it neatly into the groove using a e.g. a tool
shaft.
1250 0178 07

Fig. 72. Fitting the rear rotation chuck seal.

Fit the washer (23) and needle bearing (27) with its
inner ring and washer (28). Use mandrel (H).

Fig. 73 Fitting the washers and needle bearing

38
 Fit the outer ring of the roller bearing (16). Use a
copper mandrel.

16
1250 0079 60

Fig. 76. Fitting the needle bearing into the sleeve

PP
30

31 Insert the gear-wheel (33) into the gear housing to

act as a spacer.
Fit the needle bearing (30) and the bearing sleeve
(31) into the gear housing, with the needle bearing
turned toward the gear-wheel. Use mandrel (PP).
33
1250 0178 08

Fig. 75. Fitting the sleeve

39
 C

Fit the bushing (15) into the rotation chuck (14).

T Use the press (B) with extension sleeve (C) and
plate (T).
15
N.B. Press the bushing in carefully so that it does
not become deformed when it bottoms out!
1250 0088 05

14

Fig. 78. Fitting the bushing into the rotation chuck

40
 D

NN

Fit the driver (13) into the rotation chuck (14). Use
the mandrel (D+NN) and a plastic hammer.
13

14
1250 0178 09

Fig. 79. Fitting the driver

Fit the roller bearings (12 and 16) on to the rotation

chuck (14).
C Use the press (B) and press tools (C and F).

F
12 16
14
1250 0178 10

If the rotation chuck has a deep wear groove from

Fig. 80. Fitting the roller bearing
the front seal, recall in which groove the old seal
was placed and choose the groove next to it for
the new seal.

;;;;
Do not put a seal in more than one of the three
grooves in the extension piece.
Fit the front rotation chuck seal in the extension
piece (A seal consist of an O-ring and a teflon

;;
ring). The seal is fitted as follows:
1250 0100 58

Check that the seal groove is very clean. Oil the O-

ring and fit it into the groove.
Insert a seal ring into the extension piece and then
press it neatly into the groove using e.g. a tool shaft

Fig. 81. Fitting the seal ring into the cover

41
 Preloading the bearings in the
gear housing by means of shims
On assembly, preloading of the roller bearings
(12 and 16) in the gear housing must always be
checked.
N.B. During the preloading exercise, all parts must
be free of grease and oil.
Do not fit any O-rings into the gear housing or co-
ver for the preloading exercise.

Fit the rotation chuck (14) into the gear housing

(17).
Fit the outer ring of the front roller bearing (12).
Tap it into place with the aid of a punch.
Place the shims (11) on the outer ring of the bea-
ring. Choose the thickness and quantity of shims
so that a definite "gap" is created between the
gear housing (17) and the extension piece (101).
Fit the extension piece (101).

Fig. 82. Fitting the rotation chuck, outer ring and shims
into the gear housing for the preloading exercise

Place the gear housing on the press (B) and guide

ring (JJ).
Place the press tool (FF) and spacer pipe (LL) on
the extension piece (101).
Rotate the chuck 2 - 3 turns
Tighten to a torque of 200 Nm (150 lbf. ft) using
the adapter wrench (K) or a 32 mm socket.
Release the tension and tighten again, this time to
a torque of 20 Nm (15 lbf. ft).
Use a feeler gauge to measure the clearance be-
tween the gear housing and the extension piece.
Measure to an accuracy of 0.05 mm.
Remove the extension piece (101) and reduce the
number of shims (11) until a measured clearance
of 0.15–0.20 mm is obtained. This will give the
roller bearings a preloading of 0.15–0.20 mm when
the rock drill is finally pulled together by the side
bolts.
N.B. It is important that the bearings are preloa-
ded correctly, and also that the tightening
torque is correct. After a period of drilling, the
seats of the bearings can become bedded in.
When this happens, it is important that preloa-
ding of the bearings does not cease, which
could result in damage to the roller bearings
and shims.
Fig. 83. Checking the preloading of the bearings

42
 101

10

24
9 Grease all parts, especially the roller bearings.
See grease recommendations on page 76.
Fit the O-ring (10) into the extension piece (101).
17
Place the O-ring (24) in the gear housing (17).
First smear the O-rings with grease, so that they
stick in place during assembly.
1250 0100 59

Fit the guide pin (9) into the gear housing, and
then fit the extension piece (101).
If necessary, tap down the extension piece using a
plastic hammer.
Fig. 84. Fitting the O-rings into the extension piece and
gear housing

17
1250 0178 11

Fit the o-ring (11) in its groove in the gear housing

(17). Place the inner thrust needle bearing (12) on
the rotation shaft (26) and fit the rotation shaft into
26 12 11 the gear housing (17). Use a plastic hammer to ca-
refully tap the shaft down to the bottom.
Fig. 85. Fitting the rotation shaft into the gear housing,
and the chuck bushing into the rotation chuck
Make sure the thrust needle bearing enters its seat
on the shaft.
PP
Press the shaft seal (13) into the bearing sleeve
13 (15). Use the mandrel (PP).
1250 0178 12

15
Place the outer thrust needle bearing (16) on the
seat on the rotation shaft. Tap the bearing sleeve
(15) into the gear housing.

25 14 17
Fit the rotation chuck bushing (25) into the rotation
chuck (14) with the lubrication grooves facing
backward.
1250 0178 13

26 15 16

43
 Intermediate part
Disassembly
Inspection, replacement of parts
Assembly

Disassembly
Remove the check-valve poppet (89), seat (91)
and O-ring (90). Pull out the seat with the aid of a
M6 screw.

Fig. 86. Removing the check valve

Knock out the damper piston (35) using a hammer

and copper mandrel.

Fig. 87. Removing the damper piston

Carefully remove the damper-piston seals (46 and

47) with the aid of a sharp instrument. Be careful
not to damage the seal grooves in the intermediate
part (36) and liner (41).

Fig.
88. Removing the damper-piston seals

44
 Remove the front damper-piston liner (41) by pla-
cing a plate (U) in the seal groove. Then carefully
knock out the liner using a copper mandrel and a
plastic hammer.

Fig. 89. Removing the front damper-piston liner

Inspection, replacement of parts

Before inspection, all parts must be washed in a
degreasing agent.
Change all O-rings.
Check the impact-piston seals (54) for wear and
damage.
To measure the wear, carefully slide the impact pis-
ton (77) through the seals. If the seals give a firm
resistance to the passage of the piston, they do
not normally need to be changed. Compare with
the procedure for checking the impact-piston seals
in the back head.
Fig. 90. Checking the impact-piston seals

If the impact-piston seals (54) need to be changed,

carefully remove them with the aid of a sharp in-
strument. Be careful not to damage the grooves in
the seal housing (53).

Fig. 91. Removing the impact-piston seals

45
 The seal housing (53) should not be removed un-
less it is damaged. If the seal housing is damaged or
if leakage indicates that the O-ring (55) needs to be
replaced, the seal housing should be removed as
shown in the figure opposite. Use the extractor (N)
and a 37–46 mm expander.

Fig. 92. Removing the seal housing

Check the damper-piston bushing (45). Minor sco-

ring can be removed by polishing with a fine abrasi-
ve cloth, after which the bushing must be washed.
If the bushing is worn or badly damaged, it must
be changed.
Remove the lock ring (44) with the aid of a
screwdriver.
Knock out the bushing (45) using a copper mand-
rel and a plastic hammer. Alternatively, the bus-
hing can be removed using the extractor (N) and a
70–100 mm expander.

Fig. 93. Removing the bushing

46
 Check the damper-piston liner (41). Minor scoring
can be removed using a fine abrasive cloth, after
which the liner must be washed. If the liner is worn
or badly damaged, it must be changed.

Fig. 94. Checking the damper-piston liner

Change the damper piston (35) if the seals have

worn into the piston by more than 0.1 mm. Remo-
ve minor scoring using a fine abrasive cloth.

Fig. 95. Checking the damper piston

;;;;
37A ( ø 1,7 mm )

;;;;
;;;;;
37 ( ø 1,7 mm )

37 ( ø 1,7 mm )

Carefully check the nozzles (37, 37A) in the rear

and front faces of the intermediate part. Also check
the holes in the liner (41) and make sure that all ho-
les are free of dirt. Check that the nozzles are pro-
41 perly screwed in, and locked with LOCTITE 243 or
1250 0100 60

542.
( ø 2,0 mm )
In surface drilling, the oil flow to the parting surfa-
ces of the rock drill can be shut-off (if necessary)
by replacing the nozzle (37A) with a plug.
N.B. In underground drilling, all nozzles must
Fig. 96. Checking the intermediate part always be open (1.7 mm).

47
 Assembly
Before assembly, all parts must be oiled with clean
hydraulic oil.

If the seal housing (53) has been removed, it

should be re-fitted as follows:
Fit the O-ring (55).
Press the seal housing into place with the aid of
mandrel (I).

Fig. 97. Fitting the seal housing

Fit the impact-piston seals (54). (A seal kit consists

of an O-ring and a Teflon ring.) The seals are fitted
as follows:
Check that the seal grooves are very clean. Oil the
O-ring and fit it into the groove.
Insert the seal ring into the seal housing, and then
press it neatly into the groove using, e.g. a tool
shaft.
IMPORTANT! Make sure that the lips of the seal
face the direction shown in the figure opposite.

Fig. 98. Fitting the impact-piston seals

48
 Press in the damper-piston bushing (45) using
mandrel (I) and sleeve (X).
N.B. Press the bushing in carefully so that it does
not become deformed when it bottoms out!
Fit the lock ring (44) to retain the bushing.

Fig. 99. Fitting the damper-piston bushing

Fit the O-rings (42 and 43) on to the damper-

piston liner (41), and smear them with oil.
Tap in the liner using press tool (E).

Fig. 100. Fitting the damper liner

49
 Fit the damper-piston seals (46 and 47) as follows:
Check that the seal grooves are very clean.
Oil the O-ring and fit it into the groove.
Bend the seal ring as shown in the figure. Then pla-
ce the seal on a flat surface and tap down the in-
ner upturned edge of the seal using a hammer.
Fit the seal ring into the groove, and press it neatly
into the groove using a tool shaft.
IMPORTANT! Make sure that the seals are turned
as shown in the figure.

Fig. 101. Fitting the damper-piston seals

Oil the damper piston (35) and press it into the in-
termediate part.
N.B. This must be done with the greatest of care!
Now press out the damper piston and check that
the seals are located correctly, and that they are
not damaged.
N.B. It should be easy to press the damper piston
into the intermediate part.

Fig. 102. Fitting the damper piston

50
 Check the sealing surfaces on the check-valve
poppet (89) and seat (91). Minor damage can be
lapped away using fine grinding paste. In the event
of more serious damage, change the parts.
Check that the poppet moves easily in the seat.

Fit the check-valve poppet (89), O-ring (90) and

seat (91) into the intermediate part.
Smear the parts with grease so that they stick in
place when the intermediate part is assembled.

Fig. 103. Inspecting and fitting the check valve

51
Cylinder, piston guides and impact piston
Disassembly
Inspection, replacement of parts
Assembly

Disassembly
Remove the front piston guide (57) by inserting the
impact piston (77) and knocking out the guide care-
fully.

Fig. 104. Removing the front piston guide Check that the contact surfaces (A) of the piston
guides in the cylinder (66). Burnish the surfaces if
necessary.
62
61 63 64 65
34
59
1250 0079 86

66

Remove the screws (62) that hold the valve covers

(60 and 61), and press out the valve piston (59).
Remove the regulating plug (63) and washers (64)
by unscrewing the nut (65).

104
60
62

Fig. 105. Removing the valve piston and regulating plug

Inspection, replacement of parts

Before inspection, all parts must be washed in
a degreasing agent.
Change all O-rings.
Change the piston guides (57 and 79) if they show
signs of serious cavitation damage.
If the clearance is greater than 0.06 mm, the gui-
des should be replaced.
Insert the impact piston and measure the clearan-
ce using a feeler gauge.

Fig. 106. Checking the piston guides

52
 If the cylinder (66) (the cylinder bore or the valve
bore) and valve piston (59) show signs of scoring
or scratches, the parts must be changed. Minor
scoring can be removed using a fine abrasive
cloth, a whetstone or a honing tool (see List of
standard tools, page 3).
Wash out all ducts thoroughly to remove any
foreign matter.

Fig. 107. Checking the cylinder and valve piston

Inspect the impact piston (77) for scoring and

scratches. Also inspect the impact surface for
77 wear and chipping.
Minor scoring and scratching on the piston can be
removed using a fine whetstone.

Grinding the piston

Minor scoring or pitting on the impact surface of
the piston can be removed by face grinding. Grind
by 0.1–0.2 mm at a time, until the surface is even.
The accumulative maximum is 0.5 mm.
N.B. The length dimension given in the figure oppo-
R=2 0.5 mm site is the minimum permissible dimension. Further,
the outside radii must be restored precisely so that
1250 0132 11

an even transition is obtained. There must be no

sharp edges.
424,5 mm (COP 2560)
420,5 mm (COP 2160)
After grinding, check carefully that there is no
cracking on the impact surface of the piston. Wash
the piston thoroughly to remove all traces of grin-
ding residue.

Fig. 108. Checking the impact piston

53
 Assembly
Before assembly, all parts must be oiled with
clean hydraulic oil.
62 Fit the valve piston (59) into the valve bore.
61 63 64 65 The valve piston is symmetrical, so it can be inser-
34 ted either way. Check that the valve piston moves
59 easily in the valve bore.
Fit the valve covers (60 and 61) with new O-rings
1250 0079 86

(104).
66
The valve covers should slide in easily and should
not be knocked into place.
Tighten the screws (62) to a torque of 145 Nm
(105 lbf. ft).
Fit the regulating plug (63) and seal rings (64).
Tighten the nut (65) to a torque of 80 Nm (60 lbf. ft).

104
60
62
Fig. 109. Fitting the valve piston and valve covers

Slide the impact piston (77) into the cylinder. Fit

the O-ring (58) on to the front piston guide (57).
Now fit the piston guide using the impact piston as
a guide. Tap the piston guide into place using the
mandrel (G). Then remove the impact piston from
the cylinder.

77 58 57 G
1250 0032 26

Fig. 110. Fitting the piston guide

54
Hydraulic motor 3115 1010 83 (10 - OMS 315)
3115 1010 84 (09 - OMS 250)
Dismantling
25 1
2

3
4
5
7
8
6
9

10

11

10 14
17
12 23

10
15
16 24
18
19
20

1250 0086 33
21

Fig. 111. Hydraulic motor 22

Item Parts to remove

7, 8 Drain plug and washer 12 Gear wheel set
Hold fingers under the gearwheel set
23 Seal plugs (2 off)
Place the motor in holding tool. to prevent the parts from dropping out.
10 O-ring
24 Screw (4 off)
Use 17 mm socket spanner. 9 Cardan shaft
22 Valve housing 6 Intermediate part
Lift carefully as a unit, holding your
fingers under the channel plate (item 11). 4 Conical seal ring
12 Channel plate 5 O-ring
10 O-ring 3 Shaft incl. Bearings
Turn the bearing housing. Press out the
13 Ball (2 off) shaft/bearing assembly using a hydraulic
press. pressing force max. 250 daN).
15 Disc valve
Note: Shaft/bearing assembly should not
20 Spacer be dismantled!

16 Balance plate 25 Dust seal ring

Fill in oil into the spacer hole and use Item 25 and 2 to be knocked out by
the 14.25 mm mandrel as a piston to means of the special mandrel.
press up the balance plate.
2 Shaft seal
17 Guide pin Item 25 and 2 to be knocked out by
means of the special mandrel.
18 O-ring After dismantling, clean all parts in low
aromatic kerosene.
19 O-ring Examine the parts and exchange them
21 Spring washer if necessary.
Immidiately before assembly, lubricate
14 Valve drive each part with hydraulic oil and grease
rubber parts with vaseline.

55
Hydraulic motor 3115 1010 83 (10 - OMS 315)
3115 1010 84 (09 - OMS 250)
Assembly
25 1
2

3
4
5
7
8
6
9

10

11

10 14
17
12 23

10
15
16 24
18
19
20

1250 0086 33
21

Fig. 112. Hydraulic motor 22

Item Parts to mount

2 Shaft seal.
Knock into position in the bearing
housing, using the assembly mandrel.
Grease lip with vaseline.
25 Dust seal
Use assembly mandrel and plastic
hammer. Grease lip with vaseline.
3 Shaft incl. Bearings
Use the hydraulic press. (max. 250 daN).
Note: Always press on the bearing outer
ring.
11 Gearwheel set
Hold fingers under the gearwheel set to
prevent parts falling out. Carefully lay the
gearwheel set on the intermediate plate
so that the O-ring groove is upwards.
The through-hole (6 mm) must line up
with the hole in the intermediate plate.
Mark the wheel of the gearwheel set at
the point where the bottom of an internal
tooth is opposite the bottom of an internal
tooth is opposite the bottom of an external
tooth (see drawing).

6, 5, 4 Intermediate plate 14 Valve drive

O-ring, conical seal ring
Screw the guide into the bearing housing.
Screw the guide bolts into the bearing
housing. Fit the O-ring into the bearing
housing. Fit the conical ring (biggest
diameter facing the intermediate plate)
into the recess in the intermediate plate.
Place the intermediate plate in position
on the bearing housing with the conical
seal ring downwards.
9 Cardan shaft
Guide the cardan shaft down into the
output shaft so that the splines engage.
10 O-ring
Grease with vaseline.
Mark the tip of a spline tooth on the end
of the valve rive with the widest splines.
Line up mark on rotor and valve drive.
The end with the widest splines must
point upwards.
12 O-ring
Grease with vaseline. Mount in the
gearwheel and channel plate groove.
11 Channel plate
Fit the channel plate so that the O-ring
groove is upwards and the check valve
holes line up with the through-hole in the
gearwheel set.
13 Ball (2 off)

56
Item Parts to mount
15 Disc valve
Align mark on valve with a hole in the
outer rim. (A on drawing). Turn disc valve
counter clockwise until splines in the two
parts engage.
21 Spring washer
Place into valve housing
18, 19 O-ring
Fit the O-rings (greased with vaseline)
in the balance plate grooves.
17 Guide pin
Mount in valve housing
16 Balance plate
Mount in valve housing
20 Spacer
Grease with vaseline to prevent the
spacer from dropping out.
22 Valve housing
Mount unit on the rest of the motor.
Ports should face in the same direction
as the drain port.
24 Screw (4 off)
Lubricate threads and cross tighten
screws to 7.5 - 8.0 daNm.
7, 8 Drain plug
Fill motor with oli before plugging.
Tighten to 3.0 - 6.0 daNm.
4 Conical seal ring
Grease with vaseline to keep in place
23 Seal plug (2off)

57
Function and condition test of hydraulic
motor

Connect up the motor as shown in the figure oppo-

site (P = Pressure; R = Return), and let it rotate for
about 30 seconds with a maximum flow of 10 l/min
(2.6 US gal/min). Check that the motor runs smoot-
hly and that there is no dissonance.

Fig. 113. Testing the hydraulic motor

Clamp the fixture (S) firmly in a vice and fit the hyd-
raulic motor so that the splined output shaft is
locked. See figure opposite. Connect the hydraulic
hoses (P = Pressure; R = Return) and adjust the
hydraulic pressure to 40 bar (580 psi). Measure
the leakage flow from the motor. It must not exceed
2–3 l/min (0.53–0.79 US gal/min).

Fig. 114. Checking the flow of leakage oil

58
 Assembling the main parts of the rock drill

General Assembly sequence:

All parts must be cleaned thoroughly before fi- · Cylinder
nal assembly. Just before assembly, the parts · Hydraulic motor
must be oiled with clean hydraulic oil. · Intermediate part
All O-rings must be changed. Grease the new · Gear housing, compl.
O-rings with silicone grease before fitting. · Cover
· Extractor-unit front head.
· Back head and impact piston
· Accumulators

Cylinder
Put the pivoted mounting fixture (A) in the horizon-
tal position.
Using two M16 bolts, bolt the cylinder (66) securely
to the mounting fixture, with the front part of the
cylinder facing into the workbench.

Fig. 115. Fitting the cylinder to the pivoted mounting

fixture

Hydraulic motor
Make sure that the circlip (73) is fitted in the coup-
ling (72).
1250 0043 52

74 102 72 Smear the splines of the coupling with grease, and

slide the coupling on to the output shaft of the hyd-
raulic motor (74).
Fit a new gasket (102) to the end face of the cylin-
der (66).

R 75 Fit the hydraulic motor to the cylinder (66).

Tighten the nuts (75) to a torque of 65 Nm
(50 lbf. ft) using the ring spanner (R).
Fig. 116. Fitting the hydraulic motor to the cylinder

59
 Intermediate part
Put the pivoted mounting fixture into the vertical
position.
Fit the O-ring (56) into the groove in the middle of
the rear guide of the intermediate part (36).
Fit the O-ring (50) into the rear face of the interme-
diate part (36). (First smear some grease into the
groove, so that the O-ring sticks in place during as-
sembly.)
Fit the intermediate part (36) to the cylinder (66).
Lightly tap the intermediate part into position using
a copper hammer. Make sure that the check valve
(91) stays in place.

Fig. 117. Fitting the intermediate part to the cylinder

36
72
COP 2160/2560

13

34
1250 0178 14

26 17

13

COP 2160EX/2560EX
Fig. 118. Fitting the gear housing to the intermediate part Gear housing, compl.
Put the pivoted mounting fixture into the horizontal
position.
Grease and fit the O-ring (34).
Fit the gear housing (17) to the intermediate part
(36). If the rotation shaft (26) does not enter the
coupling (72), insert a shank adapter into the driver
(13) and twist it.

60
 COP 2160/2560
Fit the side bolts (5). Fit the rear washers (3) and
5 nuts (2). Tighten the rear side-bolt nuts (2) alter-
naely to a torque of 300 Nm (220 ibf.ft). Use the
wrench adapter (K) for the torque wrench.

4
Fit the bolt (4). Tighten the bolt to a torque of 300
Nm (220 ibf.ft).
1250 0080 18

N.B. Before assembly, smear the threads with gre-

ase of type NEVER -SEEZ.
2 3

2 3
10
23 Cover (COP 2160EX/2560EX)
Fit the O-ring (10).
Fit the cover (23) and the side bolt (4). Fit the rear
washers (3) and the nuts (2).
1250 0085 06

N.B. Before assembly, smear the threads with gre-

ase of type NEVER-SEEZ.
4 Tighten the rear side-bolt nuts (2) alternately to a
torque of 300 Nm (220 lbf. ft). Use the wrench
adapter (K) for the torque wrench.
Then tighten the side bolt (4) to a torque of 300 Nm
Fig. 119. Fitting the cover (220 lbf. ft).

61
 Back head and impact piston
Oil the impact piston (77) with clean hydraulic oil.
Slide the impact piston into the cylinder bore.
When the piston reaches the front piston seals,
twist the piston gently through the seals. If the pis-
ton is knocked through the seals, there is a risk of
damaging the seals.

Fig. 120. Fitting the impact piston

Fit the rear piston guide (79) with a new O-ring (58).
Tap in the piston guide with the aid of mandrel (G).

79 58
1250 0024 62

Fig. 121. Fitting the rear piston guide

Fit the O-rings (76) and (78) to the cylinder block

Fig. 122 Fitting the back head to the cylinder
as illustrated opposite. (First grease the O-rings so
they stick in place.)
Before fitting the back head, check that it is possib-
le to move the piston (77) back and forth in the
cylinder with a twisting motion.
Carefully fit the back head to the cylinder. Take
care not to damage the impact piston or the piston
seals.
Tighten the three screws (84) for the back head
alternately to a torque of 220 Nm (160 lbf. ft). The
two lower screws should be tightened to the final
torque before the upper screw.
Use the wrench adapter (K) for the torque wrench.

62
 9 Front head (COP 2160/2560)
1B FIt the pin (9) into the cover. Fit the front head (1B)
over the side bolts (5).
Fit the washers (3) and nuts (2).
N.B Before aassembly, smear the threads with
greae of type NEEVER-SEEZ.
Tighten the nuts (2) alternately to a torque of 350
Nm (260 Ibf. ft).
1250 008021

5 3 2

Fig. Fitting the front head

Fit the cup seal (3) into the flushing head.

Fit the connection plate (2) to the front head using
the washers (4) and screws (5). Tighten the
screws (5) to a torque of 90 Nm (65 Ibf. ft). Fit the
nipple (6) to the connection plate, and tighten the
nipple to a torque of 300 Nm (2220 Ibf. ft).
3
1250 0085 07

4
5
6 2

Fig. Fitting the connection plate to the front head

Extractor-unit front head

(COP 2160EX/2560EX)
13
1
Fit the cylindrical pin (22).
Fit the front head (1) over the stud bolts (13).
Fit the washers (12) and nuts (11).
1250 0178 17

22 N.B. Before assembly, smear the threads with gre-

12 11
ase of type NEVER-SEEZ.
Tighten the nuts (11) alternately to a torque of 300
Nm (220 Ibf. ft.).

63
 Accumulators

CAUTION
· Fit the accumulators to the rock drill using
undamaged original screws.

The intake accumulator (52) must have

two screws (7), 100 mm in length.
The damper accumulator (92) must have
two screws (93), 70 mm in length.
Change both screws at the same time,
even if only one of them is corroded or
damaged in some other way.
Defective screws can cause dangerous oil
1250 0148 27

leakage, or can cause the accumulator to

be blown off.

Fit the seals (34) on to the intermediate part (36)

and then fit the accumulators to the intermediate
part (36).
Fit the damper accumulator (92) to the left-hand
side of the rock drill, and the intake accumulator
(52) to the right-hand side of the rock drill, i.e. the
hose side. Tighten the screws (93 or 7) alternately
to a torque of 220 Nm (160 lbf. ft).
Fig. 124. Fitting the accumulators

= Read the instruction book carefully

before servicing or changing

Make sure that the accumulators (52, 92) have the

correct safety labels, and that they are undamaged.
Replace damaged safety labels!
N.B Do not charge the accumulators until they
been fitted securely to the rock drill.
= Must be charged with nitrogen

Fig. 125. The accumulator safety labels

Fit the return accumulator (94) to the nipple (17)

and tighten in such a way that the plug (11) is ac-
cessible for checking the accumulator diaphragm.
Thread on the clamp (13) and fit the retainer (12)
using the screws (14, 16) and nuts (15).

Fig. 126. Fitting the return accumulator

64
 Charging the
accumulators
WARNING
· The accumulators must be charged with
nitrogen (N2) only!
Other gases can cause an explosion!

CAUTION
· Charge the accumulators AFTER they have
been fitted to the rock drill.
There is a risk of injury from incorrect
handling.

The intake accumulator (52) and damper accumu-

92
lator (92) must be charged before the drill rig is
P started up.
The intake accumulator (52) is located on the right-
hand side of the rock drill, by the oil intake nipple.
A
The damper accumulator (92) is located on the left-
94 Q hand side of the rock drill.
52
0
20
0

0
15

25
0
10

R
A
B
0
0
20
0

0
15

25
0
10

R
A
B
0
0
20

1250 0175 98
0

0
15

25
0
10

Take off the protective cap (A) from the

R
A
B
0

accumulator valve.
Open the valve nut by 2–3 turns.
Fit the regulator (Q) into the gas cylinder, and con-
Fig. 127. Charging the accumulators
nect the charging hose (P) between the regulator
and the accumulator valve.
Adjust the regulator to the lowest possible pressu-
re, and then open the valve on the gas cylinder.
Charge the intake accumulator (52) to a pressure
of 30 - 40 bar below the collaring pressure.

N.B It’s better to undercharge rather than over-

charge the accumulators.
Close and tighten the valve nut, close the valve on
the gas cylinder, and disconnect the charging hose
(P) from the accumulator. Fit the protective cap (A)
back on to the accumulator valve.
Now charge the damper accumulator (92) to a
pressure of 20–25 bar (290–360 psi) by following
the same procedure as outlined above.
The return accumulator (94) must not be charged.

65
Recommended hydraulic oils and lubricants
Lubricant Recommendation

Hydraulic oil · Use a mineral-base or synthetic (polyalpha-olefin or diester based) hydraulic oil with good anti-wear, anti-rust, anti-
oxidation and foam inhibiting properties, and with good air and water separation characteristics. Choose an oil with
viscosity grade (VG) and viscosity index (VI), in accordance with the table below. An oil with a high viscosity index
is less sensitive to the effects of temperature.
Hydraulic oil temperature in tank oC ( oF) Viscosity Viscosity
Normal operating temp. Min. starting temp. Max. temp. grade VG index VI
(viscosity 25–50 cSt) (viscosity min. 1000 cSt) (ISO 3448)
+50 to +70 (122 to 158) +5 (41) 80 (176) ISO VG 100 Min. 100
+45 to +60 (113 to 140) –5 (23) 75 (167) ISO VG 68 Min. 100
+35 to +50 (95 to 122) –10 (14) 65 (149) ISO VG 46 Min. 100
+25 to +40 (77 to 104) –15 (5) 55 (131) ISO VG 32 Min. 100
+10 to +25 (50 to 77) –25 (–13) 35 (95) ISO VG 15 Min. 100

Air tool oil · Use a mineral based air tool oil.

Ambient temperature oC ( oF) Viscosity grade (ISO 3448)
–30 to 0 (–22 to +32) ISO VG 32–68
–10 to +20 (14 to 68) ISO VG 68–100
+10 to +50 (50 to 122) ISO VG 100–150

66
 Testing the rotation and percussion functions

R
Testing the rotation function
Connect the hydraulic hoses P (pressure) and R
(return) to the hydraulic motor. Switch on the hyd-
raulic pressure (max. 40 bar/580 psi) to the motor
for about half a minute.
1250 0100 63

Check that the rotation motor operates smoothly,

without dissonance or leakage, and in the correct
direction.

Fig. 128. Testing the function of the hydraulic motor

P
Testing the condition of the
R percussion mechanism
For the condition test, the hydraulic hoses
must be connected as shown in the figure op-
posite.
1250 0100 64

Remove the valve cover (61) from the right-hand

Fig. 129. Testing the condition of the percussion
mechanism
side of the machine.
Insert the washer (O), which must be very clean,
and fit back the valve cover.
Switch on the hydraulic pressure to the percussion
function and adjust the pressure regulator in the
test equipment until the pressure gauge reads
100 bar (1450 psi).
Depress the "low" scale button on the flow meter,
and take the reading.
Leakage flow of more than 5 l/min (1.32 US gal/
min) is not acceptable and indicates some kind of
deflect in the impact-piston bore, valve-piston
bore, piston guides or reflex damper.
N.B. Do not forget to remove the washer (O) after
the test.
Fit back the valve cover (61). Now run the rock drill
at low pressure (5-15 bar) and check that the pis-
ton moves back and forth.

Fig. 130. Checking the flow of leakage oil in the

percussion mechanism

67
Tightening torques

6
5 1
4

15
16
9 13
1250 0100 65

6
12
7 11 3
9 10
8

Ref.No. Qty. Check point Torque Instructions

Nm lbf.ft

1 2 Side bolts 300 220 Tighten the rear nuts

2 1 Front bolt 300 220 Tighten the front bolt
3 3 Side bolts 300 220 Tighten the front nuts
4 3 Back head 220 160 Tighten the screws alternately to full torque
(uppermost screw last)
5 1 Regulating plug 80 60
6 4 Accumulators 220 160 Tighten the screws alternately to full torque
7 4 Hydraulic motor 65 48 Tighten the nuts alternately
8 2 Clamping attachment,
return accumulator 30 22
9 4 Rock drill mounting 250 185 Tighten the screws alternately to full torque
10 1 Plug 45 33
11 4 Valve covers 145 105 Tighten the screws alternately to full torque
12 2 Connection plate 120 90 Tighten the screws alternately to full torque
13 1 Flushing connection 300 220
14 4 Inlet, flushing medium 90 65 Tighten the screws alternately to full torque
15 1 Intake, extractor unit 120 90
16 1 Return, extractor unit 120 90

68