Atlas Copco

Hydraulic Rock Drill

COP 1638+, 1838+, 2238+
Version F
Reconditioning of of parting surfaces

PM no. 9853 1321 01

2015-03
 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 Reconditioning.............................................................................................................. 3
1.2 Flame Spraying ............................................................................................................ 4

2. FRONT HEAD .................................................................................................... 5

2.1 COP 1638+, 1838+/HE+, 2238+ .................................................................................. 5
2.2 COP 1638HD+, 1838HD+, 2238HD+........................................................................... 6
2.3 COP 1838MUX+ .......................................................................................................... 7

3. COVER ............................................................................................................... 9
3.1 COP 1638+, 1838+/HE+, 2238+ .................................................................................. 9
3.2 COP 1838MUX+ ........................................................................................................ 10

4. INTERMEDIATE PART .................................................................................... 11

5. ACCUMULATOR SURFACE ON THE INTERMEDIATE PART ...................... 13
6. CYLINDER........................................................................................................ 15
7. VALVE END SURFACES ON THE CYLINDER ............................................... 17
8. GEAR HOUSING .............................................................................................. 19
9. BACK HEAD .................................................................................................... 21
10. ROTATION CHUCK ......................................................................................... 23
11. INSTRUCTIONS FOR REGRINDING THE PISTON AND ANVIL’S IMPACT 
SURFACE......................................................................................................... 25
11.1 Mounting the Piston in the Grinding Machine........................................................... 25
11.2 Recommended Grinding Disc Type ......................................................................... 25
11.3 Coolants ................................................................................................................... 25
11.4 Grinding Implementations ........................................................................................ 25
11.5 Piston ....................................................................................................................... 26
11.6 Anvil.......................................................................................................................... 28
11.7 HD Anvils.................................................................................................................. 29

1
Table of Contents

2
 1. General

1. General
1250 0304 67

Hydraulic Rock drill COP 1638+, 1838+, 2238+

1.1 Reconditioning

Important!
Perform the reconditioning work with care, otherwise future consumption of other rock drill-parts will
rise unnecessarily.

DelningsThe parting surfaces in the rock drill can become damaged after a long period of use. 
Such damage will occur earlier if the rock drill is used in a corrosive environment.
Damaged parting surfaces can usually be reconditioned by grinding, 
as described in the following instructions.
The greatest possible care must be taken when mounting the parts in the grinding machine since they
require precise centering and balancing.
This work should therefore always be carried out by qualified workshop personnel.

3
1. General

1.2 Flame Spraying

2
1250 0304 66

1. Add material by flame spraying.

2. Remove material by grinding.

Important!
After correcting by flame spraying, be sure to check the other dimensions so that they are still
correct.

Sometimes the parting surfaces can become badly damaged so that grinding alone is not enough to obtain
satisfactory surfaces. 
In this case, the parts should either be replaced or the surfaces flame sprayed with METCO 447 metallic
powder (or a corresponding brand) prior to final grinding.
Before flame spraying, the parting surfaces should be grounded (by max. 0,4 mm) and all holes plugged.
You are advised to entrust the job to a workshop with good knowledge in flame spraying.
When reconditioning parting surfaces, several depth dimensions has to be corrected. 
This can be done either by grinding or by flame spraying. 
When correcting the depth X by grinding, material is removed at the bottom to increase the depth.
When correcting by flame spraying material is instead added to the parting surface and then ground down
to final dimension. 
Always entrust this job to a workshop with good knowledge in flame spraying.

4
 2. Front Head

2. Front Head
2.1 COP 1638+, 1838+/HE+, 2238+
1250 0304 68

Since the front head is hardened to 62 HRC, the only way to remove material from parting surface is by
grinding.

1. Clamp the front head firmly in the grinding machine.

2. Align the front head so that the diameters 80 H7 and 100 H9 mm are out of by no more than 0,02 mm.
3. Grind the end surface (A) until it is clean, but by no more than 0.2 mm.
4. Check that the dimensions 50 +0.2/0, 120 +0,2/0 and 41±0.1 mm are obtained. 
If not, correct the depth by grinding.

5
2. Front Head

2.2 COP 1638HD+, 1838HD+, 2238HD+

Since the front head is hardened to 62 HRC, the only way to remove material from parting surface is by
grinding.

1. Clamp the front head firmly in the grinding machine.

2. Align the front head so that the diameter d2 and D2 are out of by no more than 0,02 mm.
3. If necessary, grind the diameter d1, d2, D1 and D2 to the next oversize.
4. Grind the end surface (A) until it is clean, but by no more than 0.2 mm.
5. Check that the dimensions 52 +0.2/0, 120 +0,2/0 and 41±0.1 mm are obtained. 
If not, correct the depth by grinding.

6
 2. Front Head

2.3 COP 1838MUX+

1250 0404 99

Since the front head is hardened to 62 HRC, the only way to remove material from parting surface is by
grinding.

1. Clamp the front head firmly in the grinding machine.

2. Align the front head so that the diameters 90 H6 and 142 H6 mm are out of by no more than 0,02 mm.
3. Grind the end surface (C) until it is clean, but by no more than 0.2 mm.
4. Check that the dimension 17 0/-0,2 mm is obtained. 
If not, correct the depth by grinding.
5. Check that the dimension 36 +0.2/0 mm is obtained. 
If not, correct the depth by grinding.

7
2. Front Head

8
 3. Cover

3. Cover
3.1 COP 1638+, 1838+/HE+, 2238+
1250 0304 70

Since the cover is hardened to 62 HRC, the only way to remove material from parting surface is by grinding.

1. Clamp the cover firmly in the grinding machine, with surface (A) against the grinding machine.
2. Align it so that the diameter 140,5 g6 mm and surface (B) are out of true by no more than 0,02 mm.
3. Grind the surface (B) until it is clean, but by no more than 0.2 mm.
4. Check that the dimension 19 0/-0,05 mm is obtained. 
Correct by grinding and/ or by flame spraying (B) if necessary.
5. Turn the cover around.
6. Align it so that the diameter 116 H7 mm and surface (A) are out of true by no more than 0.02 mm.
[Link] the surface (A) by no more than 0,2 mm, so that it is parallel with surface (B).
Notice! The dimension 53.5 mm is the minimum permissible value.

9
3. Cover

3.2 COP 1838MUX+

1250 0304 82

Since the cover is hardened to 62 HRC, the only way to remove material from parting surface is by grinding.

1. Clamp the cover firmly in the grinding machine, with surface (D) against the grinding machine.
2. Align it so that the diameter 140,5 g6 mm and surface (B) are out of true by no more than 0,02 mm.
3. Grind the surface (B) until it is clean, but by no more than 0.2 mm.
4. Check that the dimension 19 0/-0,05 mm is [Link] by grinding.
5. Turn the cover around.
6. Align it so that the diameter 160 H8 mm and surface (D) are out of true by no more than 0.02 mm.
7. Grind the surface (D) by no more than 0,2 mm, so that it is parallel with surface (B).
8. If dimension 17 min mm is not obtained, grinding will be needed.
Notice! The dimension 53.9 mm is the minimum permissible value.

10
 4. Intermediate Part

4. Intermediate Part
min 214.5
B A
151+- 0.1 47 +0.1
0

1250 0380 60
P
113 H8

92 H7

25 H8
57 H7

7+-0.1

15 +0.1
0

P 80+0.2
-0.1

Since the intermediate part is hardened to 62 HRC, the only way to remove material from parting surface
is by grinding.

1. Clamp the intermediate part in the grinding machine.

2. Align it so that the diameter 113 H8 and 92 H7 mm are out of true by no more than 0.02 mm.
3. Grind the surface (A) until it is clean, but no more than 0.2 mm.
4. Check that the deep dimensions 7 ±0.1, 47+0.1/0 and 80 +0.2/-0.1 mm are obtained.
If not, correct by grinding and/ or by flame spraying the appropriate surface.
5. Turn the intermediate part around.
6. Align it so that the diameter 113 H8 mm is out of true by no more than 0.02 mm.
7. Grind the surface (B) by no more than 0,2 mm.
8. Check that the dimensions 15 +0.1/0 and 151 +0.1/0 mm are obtained.
If not, correct the depth by grinding and/ or by flame spraying the surface (B).
Notice! The dimension 214.5 mm is the minimum permissible value

11
4. Intermediate Part

12
 5. Accumulator Surface on the Intermediate Part

5. Accumulator Surface on the Intermediate Part

1250 0304 73

Since the intermediate part is hardened to 62 HRC, the only way to remove material from parting surface
is by grinding.

1. Clamp the intermediate part firmly in the grinding machine.

2. Align it so that the surface (C) is out of true by no more than 0,02 mm.
3. Grind the surface (C) until it is clean, but by no more than 0.2 mm.
4. Turn the intermediate part around and align it so that the surface (D) is parallel with the surface (C). 
Max. run out 0.02 mm.
5. Grind the surface (D) until it is clean, but by no more than 0.2 mm.
6. Check that the two seal ring locations in surfaces (C) and (D) are 2.2 ± 0.1 [Link] depth.
If not, correct by grinding and/ or by flame spraying the surfaces (C) and (D).
7. Check that there is enough space (S) for the accumulator (min. Ø14x36 mm).
Notice! The dimension 63 mm is the minimum permissible value.

13
5. Accumulator Surface on the Intermediate Part

14
 6. Cylinder

6. Cylinder
1250 0304 64

Since the cylinder is hardened to 62 HRC, the only way to remove material from parting surface is by
grinding.
1. Clamp the cylinder firmly in the grinding machine, with the surface (B) against the grinding machine.
2. Align the cylinder so that the diameters 50 H6 and 92 g6 mm are out of true by no more than 0.02 mm.
3. Grind the end surface (A) until it is clean, but by no more than 0.2 mm.
4. Check the dimensions 2 +0.1/0 and 7 0/-0.1 mm. If the dimensions are smaller, further grinding will be
required.
Notice! Keep the same setup of the work piece.
5. Turn the cylinder around.
6. Align it so that Ø67 g6 mm is out of true by no more than 0.02 mm.
7. Grind the end surface (B) until it is clean, but by no more than 0.2 mm.
8. Check that the dimensions 15 0/-0.05 and 1.9 +0.1/0 mm are obtained. 
If not, correct by grinding and/ or by flame spraying the surface (B). 
Notice! The dimension 228.5 mm is the minimum permissible value.
9. Grind the surface (F) and the diameter 70 H11 mm before flame spraying, but no more than 0,4 mm.
[Link] spray the surface and the hole with METCO 447 metallic powder (or a corresponding brand).
11. Clamp the cylinder firmly in the grinding/milling machine with a chuck with a diameter of 92 g6 mm.
[Link] the cylinder so that the surface (E) is perpendicular to the rotational axis.
[Link]/mill the surface (F) until it is clean, but by no more than 0.2 mm.
[Link] the dimension7 +0,5/0 mm, see "Valve end Surfaces on the Cylinder" on page 17. 
Grind if necessary.
[Link]/ mill the end surface of the hole and diameter 70 H11 mm.

15
6. Cylinder

[Link] the deep gauge 20 and diameter 70 H11. Grind if necessary.

Notice! During milling, use a carbide milling tool only.

16
 7. Valve End Surfaces on the Cylinder

7. Valve End Surfaces on the Cylinder

1250 0304 65

If the cylinder surfaces against the valve ends have been attacked by corrosion, they must be flame
sprayed before grinding.
Always entrust his job to a workshop with good knowledge in flame spraying.

1. Grind down the surfaces that are to be flame sprayed by max. 0.4mm.
2. Plug all holes.
3. Flame spray the surfaces (C) and (D) with METCO 447 metallic powder (or a corresponding brand).
Ideally, the METCO 5P powder gun should be used.
4. Clamp the cylinder firmly in the grinding machine.
5. Indicate the entire valve bore Ø30 H6 mm and align the cylinder so that the valve bore is out of true by
no more than 0.02 mm.

Important!
Use a silicon carbide grinding wheel only (grain size 60).

6. Grind the surfaces (C) and (D) so that they are parallel and the dimensions 78 ±0.05 and 176 ±0.1 mm
are obtained.
7. Grind the chamfers 32.5 mm x 30°.

17
7. Valve End Surfaces on the Cylinder

18
 8. Gear Housing

8. Gear Housing
1250 0304 74

Since the gear housing is hardened to 62 HRC, the only way to remove material from parting surface is by
grinding.

1. Clamp the gear housing firmly in the grinding machine, with the surface (B) against the grinding
machine.
2. Align the gear housing so that the diameters 100 H8 and 140.5 H7 mm are out of true by no more than
0.02 mm.
3. Grind the surface (A) until it is clean, but by no more than 0.2 mm.
4. Check that the depth dimension 124 +0.1/0 mm is obtained. 
If not, correct the depth by grinding and/ or flame spraying the surface (B).
5. If the dimension 1.7 ±0.1 mm is not obtained, adjust the depth by grinding or flame spraying.
6. Turn the gear housing around.
7. Align it so that the diameters 100 H8 and 140.5 H7 mm are out of true by no more than 0.02 mm.
8. Grind the surface (B) until it is clean, but by no more than 0.2 mm.
Grind the flange to dimension 16 0/-0,15 mm.
9. Check that the dimensions 95 +0.3/0 and 121 +0.2/-0.1 mm are obtained.
If not, correct by grinding and/ or by flame spraying the surface (B).
Notice! The dimension 139.5 mm is the minimum permissible value.

19
8. Gear Housing

20
 9. Back Head

9. Back Head
1250 0304 75

Since the back head is hardened to 62 HRC, the only way to remove material from parting surface is by
grinding.

1. Clamp the back head firmly in the grinding machine.

2. Align the back head so that the diameters 67 H7 and 60 H7 mm are out of true by no more than 0.02 mm.
3. Grind the surface (A) until it is clean, but by no more than 0.2mm.
4. Check that the depth dimensions 42 +0.05/0 and 25 +0.2/0 mm are obtained.
If not, correct by grinding and/ or by flame spraying the surface (A).

21
9. Back Head

22
 10. Rotation Chuck

10. Rotation Chuck

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JURXQGWRUHTXLUHGGLDPHWHUDQG JURXQGWRUHTXLUHGGLDPHWHUDQG
VXUIDFHILQLQVK VXUIDFHILQLQVK

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Machine grooves according to fig. at the location for the wear grooves from the rotation chuck seals.
The location and width of the machine should be adapted to remove the wear grooves entirely.
The depth of the machined grooves should not exceed 1 mm.
Metal spray the grooves to a diameter larger than the adjacent surfaces by one of the following methods:
• Plasma spraying with bonding layer Praxair AL 1037 + top layer TAFA CrO 192 (chrome oxide).
Hardness 69-75 HRC.
• Powder flame spraying with bonding layer Castolin 51000 + top layer Castolin 28010 (chrome oxide).
Hardness 2250 HV10.

1. Clamp the rotation chuck in a circular grinding machine.

2. Align the reference surfaces A and B so they are out of true by not more than 0,02 mm.
3. Grind the metal sprayed surfaces to required diameter and surface roughness. Please note the different
tolerances of the adjacent surfaces.
4. Check if necessary adjust the lead in chamfers at each end and verify that the transition between the
chamfers and the ground surfaces are smooth.

23
10. Rotation Chuck

24
 11. Instructions for Regrinding the Piston and Anvil’s Impact Surface

11. Instructions for Regrinding the Piston and Anvil’s Impact

Surface
11.1 Mounting the Piston in the Grinding Machine

1. Affix the piston in the chuck with soft jaws.

2. Align support bearings/grinding supports.
3. Check the running on the piston guide surface
within 0.02 mm.

11.2 Recommended Grinding Disc Type

A grinding disc with ceramic binding agent with grain size 60-80.

Example:
Norton-3SG60KVX
Tyrolit-454A60K5V3

11.3 Coolants
A water-based cooling emulsion with min. 4% mixture.

11.4 Grinding Implementations

Check the impact piston for scoring and

scratches as well as the impact surface with
regard to wear and chipping.
1. Rotate the chuck at 350-400 rpm anticlock-
wise.
2. Rotate the grinding disc 30-45 m/s (metres
per second).
3. Align the grinding disc carefully against the
piston’s impact surface.
4. Apply plenty of cooling water between the
impact surface and the grinding disc.
5. Grind down 0.1-0.2 mm on the plane.
6. Check the impact surface so that it is smooth
and free of cracks.
7. Max. grinding of impact surface 1.2 mm.

25
11. Instructions for Regrinding the Piston and Anvil’s Impact Surface

11.5 Piston
Notice! The stated length dimension (see table) must be taken as a minimum. Exterior and interior radii
must be reset (see table), so a smooth transition is obtained (no sharp edges).
Wash the piston so that all grinding residue is removed, and examine to make sure that the impact surface
is free from cracks.

Machine type Part nr. Length A Radius B Radius C

COP 1838ME 3115 2129 00 427 1 1
COP 1838HD 3115 3635 01 427 1 1
COP 1838HE 3115 2126 00 424,5 1 1
COP 1238ME 3115 0288 00 374 1 1
COP 1238LE 3115 1173 00 374 1 1
COP 1238LP 3115 1651 00 374 1 1
COP 1238HF 3115 1490 00 378 1 1
COP 1240EX 3115 3498 00 428,5 1 1
COP 1640EX 3115 3544 00 426 1 1
COP 1638 3115 3096 00 422,5 1 1
COP 2238 3115 3244 00 425,7 1 1
COP 2540 3115 3600 00 428 1 1
COP 2550 3115 2981 01 424,5 - 2
COP 2560 3115 3426 00 424,5 - 2
COP 2150 31153091 01 420,5 - 2
COP 2160 3115 3427 00 420,5 - 2
COP 3038 3115 3301 01 525 Diagram 1 Diagram 1
COP 4050ME 3115 2823 00 424,5 Diagram 2 Diagram 2
COP 4050HE 3115 2935 01 407,5 Diagram 2 Diagram 2
COP 5060CR 3115 5266 02 415 Diagram 2 Diagram 2
COP 1132 3115 3276 00 - Diagram 3 Diagram 3
COP 3060ME/MEX/MUX 3115 5000 57 330,9 Diagram 4 Diagram 4
COP 3060ME/MEX/MUX Version B 3115 5732 00 342,1 Diagram 4 Diagram 4
COP 3060CR Version B 3115 5733 00 381,5 Diagram 4 Diagram 4

1. COP 1238 - COP 2560

R=B
1250 0229 98

R=C 0,5 mm
77

26
 11. Instructions for Regrinding the Piston and Anvil’s Impact Surface

2. Diagram 1, COP 3038

1250 0229 99
R=1 mm 0,5 mm

77

3. Diagram 2, COP 4050, COP 5060CR

R=3
Ø7±0,5

R=2
402 0,6-1,2 mm
1250 0322 94

4. Diagram 3, COP 1132

Max. 0.8 mm or until the indentation (A) disap-
pears on the impact surface, and reset the radius 77
R=1.
1250 0230 29

5. Diagram 4, COP 3060ME/MEX/MUX

COP 3060ME/MEX/MUX Version B A
COP 3060CR Version B
15

R1
1250 0240 26

R8
48

27
11. Instructions for Regrinding the Piston and Anvil’s Impact Surface

11.6 Anvil
Notice! The stated length dimension (see table) must be taken as a minimum. Exterior and interior radii
must be reset (see table), so a smooth transition is obtained (no sharp edges).
Wash the anvil so that all grinding residue is removed, and examine to make sure that the impact surface
is free from cracks.

Machine type Part nr. D L

COP 4050ME CR 3115 2015 02 48 795
COP 4050ME CRL 3115 2378 02 38 1256
COP 4050ME CRL 3115 2390 02 48 1356
COP 4050ME CR 3115 2515 02 38 795
COP 4050HE CR 3115 2939 02 48 795
COP 4050HE CRL 3115 2940 02 48 1256
COP 5060CR 3115 2939 02 48 795
COP 5060CRL 3115 2940 02 48 1256
COP 2150/2550 CR 3115 3637 00 38 803
COP 2150/2550 CRL 3115 3638 00 38 1260
COP 3060ME CR89 3115 5613 00 38 963,5
COP 3060ME CR102 3115 5614 00 48 963,5

COP 4050CR, COP 5060CR,

COP 2150/2550CR, COP 3060CR

L=
Minimum Length

1250 0244 62

28
 11. Instructions for Regrinding the Piston and Anvil’s Impact Surface

11.7 HD Anvils
Notice! The stated length dimension (see table) must be taken as a minimum. Exterior and interior radii
must be reset (see table), so a smooth transition is obtained (no sharp edges).
Wash the anvil so that all grinding residue is removed, and examine to make sure that the impact surface
is free from cracks.

Machine type Part nr. D Min. L Figure pos.

COP 4050ME CR 3115 2015 02 48 795 1
COP 4050ME CRL 3115 2378 02 38 1256 2
COP 4050ME CRL 3115 2390 02 48 1256 3
COP 4050ME CR 3115 2515 02 38 795 4
COP 4050HE CR 3115 2939 02 48 795 5
COP 4050HE CRL 3115 2940 02 48 1256 6
COP 5060CR 3115 2939 02 48 795 5
COP 5060CRL 3115 2940 02 48 1256 6
COP 1838/1850 CRL 3115 2581 02 38 1260 7
COP 2150/2550 CR 3115 3637 00 38 803 8
COP 2150/2550 CRL 3115 3638 00 38 1260 9

Check these points before starting to grind the

HD anvil:
1. Measurement C is greater than 12 mm.
2. Measurement C is between 10-12 mm, must
not be less than measurement L after grin-
1250 0318 80

ding.
Measure the total length of the anvil to take the C=Check measure
correct decision about grinding or not.

3. Anvil’s with dimensions less than Min L must

not be used because it accelerates the wear 1
of the pipe and drill bit.
2
4. When grinding the anvil’s impact surface it is
recommended that one grinds off approx 1 3
mm to remove any microcracks, and to
ensure that the anvil can make another
4
service interval. 5
5. The anvil’s surface to the impact piston must
6
be checked for wear and it is recommended
that the surface is not ground because it 7
accelerates wear of the impact piston and 8
guide.
9

L=Anvil Length
D

30
1250 0318 81

29
11. Instructions for Regrinding the Piston and Anvil’s Impact Surface

30
[Link]