Epiroc Secoroc COP 44 Specifications

Secoroc COP 44
down-the-hole hammer
Operator’s instructions
Spare parts lists

2
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thereof is prohibited.This applies in particular to trademarks,
model denominations, part numbers and drawings.
© Copyright 2018
Epiroc DrillingTools AB, Fagersta, Sweden
Contents
Safety regulations �������������������������������������������������������3
Technical data..................................................................................... 3
General �������������������������������������������������������������������������4
Application (drill rigs) ....................................................................... 4
Technical description......................................................................... 4
Preparing to drill ����������������������������������������������������������5
Hose connection ................................................................................ 5
Setting-up the rig............................................................................... 5
Drilling ��������������������������������������������������������������������������6
Rotation to the right .......................................................................... 6
Collaring ............................................................................................. 6
Feed and rotation............................................................................... 6
Feed force........................................................................................... 6
Rotation speed ................................................................................... 7
Flushing — air blowing ..................................................................... 7
Drilling in wet holes........................................................................... 7
Water injection................................................................................... 7
Foam injection ................................................................................... 8
Tools������������������������������������������������������������������������������8
Tools for removing the drill bit and top sub from the DTH hammer........... 8
Removing the drill bit��������������������������������������������������9
Breaking the driver-chuck joint using percussion only ........... 9
Breaking the driver-chuck joint using the bit removal tool ............ 9
Dirt in the hammer������������������������������������������������������9
Other instructions������������������������������������������������������ 10
Wear of driver chuck and hammer cylinder .................................. 10
Checking the wear of the driver chuck and cylinder ..................... 10
Shimming......................................................................................... 10
Assembly of the drill bit and driver chuck ......................................11
Instruction for disassembling of disc spring unit ..........................11
Plastic footvalve in the bit shank �����������������������������12
Replacing the foot valve.................................................................. 12
Protrusion of the foot valve ............................................................ 12
Removing the foot valve ................................................................. 12
Fitting a new foot valve................................................................... 12
Regrinding the drill bit ����������������������������������������������12
Grinding equipment ��������������������������������������������������13
Lubrication �����������������������������������������������������������������14
Lubricators ....................................................................................... 14
Choice of lubricating oil .................................................................. 14
Recommended lubricants ............................................................... 14
Wear limits �����������������������������������������������������������������15
Trouble shooting��������������������������������������������������������15
Overhauling...................................................................................... 15
Spare parts list�����������������������������������������������������������16

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Safety regulations
• Before starting, read these instructions carefully.
• Important safety information is given at various points in these
instructions.
• Special attention must be paid to the safety information con-
tained in frames and accompanied by a warning symbol (triangle)
and a signal word, as shown below.
Indicates immediate hazards which WILL result in serious or
fatal injury if the warning is not observed.
DANGER
Indicates hazards or hazardous procedures which COULD result
in injury or damage to equipment if the warning is not observed.
WARNING
Indicates hazards or hazardous procedures which COULD result
in injury or damage to equipment if the warning is not observed.
CAUTION
• Read through the operator’s instructions for both the drill rig
and the DTH hammer thoroughly before putting the DTH hammer
into service. Always follow the advice given in the instructions.
• Use only authorized parts. Any damage or malfunction caused
by the use of unauthorized parts is not covered by Warranty or
Product Liability.
The following general safety rules must also be observed:
• Make sure that all warning signs on the rig remain in place and
are free from dirt and easily legible.
• Make sure there are no personnel inside the working area of the
drill rig during drilling, or when moving the rig.
• Always wear a helmet, goggles and ear protectors during drill-
ing. Also observe any local regulations.
•The exhaust air from air driven hammers and grinding machines
contains oil. It can be dangerous to inhale oil mist. Adjust the
lubricator so that the correct rate of lubrication is obtained.
• Make sure that the place of work is well ventilated.
• Always check that hoses, hose nipples and hose clamps are
properly tightened and secured, and that they are not damaged.
Hoses that come loose can cause serious injury.
• Local regulations concerning air hoses and connections
must always be strictly observed.This is especially the case if
the DTH-hammer is to be operated at pressures above 10 bar
(145psi).
• The machine must not be used for purposes other than those
prescribed by Secoroc. See “Application” on page 4.
Technical data
Dimensions and weights COP 44
Length without drill bit, mm (in) 1034 (40.7)
Length with optional thread, mm (in)
Length excl. thread, mm (in) 958 (37.7)
Outside diameter,mm (in) 98 (4.0)
QHD design, mm (in)
Piston diameter, mm (in) 78 (3.1)
Piston weight,
kg (lbs) 7,1 (16)
Stroke, mm (in) 115 (4.5)
Top sub thread (standard) API Reg 2 3/8
(Optional) API Reg
Wrench flat on top sub, mm (in) 65 (2.6)
Weight without drill bit, kg (lbs) 38 (84)
QHD design, kg (lbs)
Drilling parameters
Working pressure, bar (psi)
Rotation speed, r/min 25–80
Feed force, kN (lbs) 5–15
(1100-3300)
Feed force at 16 bar, kN (lbs) 10 (2000)
Recommended bit size, mm (in) 110-125
(4.3–4.9)
QHD design, mm (in)
Bit shank IR 340A
Air consumption, different working pressures, l/s
Bit shank IR 340A
10.5 bar (150 psi) 105
16 bar (230 psi) 165
20 bar (290psi) 205
25 bar (360 psi) (estimated consump.) 255
Blowing capacity, l/s
6 bar (87 psi) 317 (670)
10.5 bar (150 psi) 495 (1050)
Impact rate, strokes/min
10,5 bar (150 psi) 1420
16 bar (230 psi) 1680
20 bar (290 psi) 1860
25 bar (360 psi) 2100
Penetration rate in Swedish granite, 2200 bar, 30% SiO,
mm/min (Standardized laboratory test)
Bit size, mm (in) 115 (4.5)
10,5 bar (150 psi) 310 (61)
16 bar (230 psi) 510 (101)
20 bar (290 psi) 640 (125)
25 bar (360 psi) 800 (157)
Performance figures are average values for new hammers at sea
level. Specifikations and other data subject to alteration without
prior notice.

4
General
The down-the-hole hammer is a percussion hammer drill. As the
name implies, the hammer works down the hole at the end of the
drill string, where the impact piston strikes the drill bit directly.
Compressed air is led to the hammer via the rotation spindle and
drill pipes. Exhaust air from the hammer is discharged through
holes in the drill bit and used to flush clean the drill hole. Rotation
is provided by a rotation unit on the feed beam and transmitted to
the hammer via the drill pipes.The drill pipes are threaded so that
the drill string can be extended as drilling progresses and the hole
becomes deeper. Feed force is also transmitted to the hammer via
the rotation unit and drill pipes. One of the main advantages of
DTH hammers is that the drilling rate is not affected very much by
the length or depth of the drill hole.
DTH hammers are very productive and have many applications
in the mining, quarrying, civil-engineering and water-well drilling
industries.
Application (drill rigs)
A= Drill pipe
B= Down-the-hole hammer
C= Drill bit
D= Rotation unit
E= Feed
F= Drill rig
Secoroc COP down-the-hole
hammers are designed for use
on DTH or ITH drill rigs.They
can also be used on rotary and
auger type drill rigs, provided
that such rigs meet the
specifications for DTH applica-
tions.The main demands on the
drill rig are as follows:
• It should be equipped with
a rotation unit that has a vari-
able rotation speed of 0–90 r/
min and a rotation torque of
750–3000 Nm (75–300 kpm).
Naturally, the torque demand
for a recommended rotation
speed will depend on the ham-
mer size and bit diameter.
• A variable feed force of 3–43
kN (300–4300 kp) for shallow
holes (less for deeper holes, bearing in mind the weight of the
drill string). Obviously, the feed must be strong enough to pull the
hammer and drill string out of the drill hole.This is an especially
important consideration when drilling deep holes.The weight of
the drill string varies between 9 and 34 kg/m, depending on the
pipe- and bit diameters.
Technical description
The Secoroc COP down-the-hole hammer and drill bit operate at
the bottom of the hole as a unit.
COP hammers have a long cylinder D, which houses a check valve
B, compression ring C, impact piston F, control tube E, stop ring
Hand drill-bit shank J� The back end of the cylinder is closed by a
threaded top sub A� The top sub has a male thread for connection
to the drill pipes, and is provided with wrench flats.
A driver chuck Kthreads into the front end of the cylinder.
A
B
C
D
E
F
L
H
J
K
The splined union between the driver chuck K
and bit shank Jtransmits rotation to the drill
bit.The front end of the driver chuck transmits
feed force to the drill bit.The split stop ring H
limits axial movement of the drill bit.The
check valve Bprevents water from entering
the hammer through the driver chuck when
the compressed air supply is shut off.
When feed force is applied, the drill bit is
pushed into the hammer and pressed against
the front of the driver chuck.The impact
piston strikes the shank of the drill bit directly.
The passage of compressed air through the
hammer is directed by the piston and control
tube, both of which have regulating ducts.
A built-in damping chamber cushions the
piston return stroke and increases the impact
frequency.
After the compressed air has imparted most
of its pressure energy to the piston, it is led as
exhaust air through the foot valve L into the
central gallery in the drill bit.The exhaust air
then emerges as flushing air through holes in
the drill bit head.This gives efficient transpor-
tation of cuttings out of the drill hole.
When the hammer is lifted off the bottom of
the hole, the piston drops into the air blowing
position.This disengages percussion and
gives air blowing only, i.e. a large volume of
air flows straight through the hammer and
drill bit. During drilling, air blowing starts if
the drill bit loses contact with the bottom of
the hole.
The hammer starts operating again as soon
as the bit is pressed back against the driver chuck. Air blowing is
used when powerful flushing of the drill hole is required, and in
certain difficult drilling conditions.
Friction between the drill pipes and the hole wall can sometimes
reduce the penetration rate.This can often be counteracted by
increasing the air pressure to give more impact power and faster
penetration.
Together with Epiroc ODEX equipment, COP hammers are used
for simultaneous drilling-and-casing through overburden. When
used with Secoroc precision drilling equipment, COP hammers
are capable of drilling long, straight holes.
Preparing to drill
Hose connection
Connecting and securing the air hoses
For a compressed air system to be
efficient, reliable and economic,
there must be:
• sufficient compressed-air capaci-
ty (volume and pressure);
• minimal pressure loss between
the compressor and the hammer;
• minimal air leakage between
couplings.
This can be realized by ensuring
that:
• the correct size of compressor is
selected;

5
• the correct hose size is used between the compressor and the
hammer;
• there is no leakage in hose connections between the compressor
and hammer.
• Compressed-air hoses between the compressor and the
drill rig must be secured by means of an external or internal
safety wire, which must be fastened safely to the drill rig. If
the DTH hammer is to work at pressures above 10 bar (145
psi), any local regulations regarding air hoses and couplings
must be strictly observed.
• Always check that hoses, hose nipples and hose clamps
are not damaged, and that they are properly tightened and
secured.
DANGER
• Always check the condition of drill string components. Bent
or worn pipes can cause damage and excessive wear to the
hammer and rig.
CAUTION
Setting-up the rig
AB
Before drilling with
the DTH hammer,
the rig must be
set-up correctly in
order to give
stability and safety.
If this is not done,
the effects of feed
force and rotation
torque can cause
the rig to move.This will have a negative effect on drilling,
especially when drilling deep, straight holes.
When setting up a drill wagon or crawler drill rig, a stable three-
point set-up must be obtained, with the weight of the rig distribut-
ed between the base of the feed beam and the two rear corners of
the rig. It is of the utmost importance that the rear loading points
are as far to the rear of the rig as possible, with most of the rig
weight being loaded on to the base of the feed.
When drilling in soil or other non-consolidated formations, the
weight of the rig must not be loaded on to the feed near the
mouth of the hole, since this could easily cause the hole to cave-
in. Instead, the load should be distributed some distance to either
side of the hole. Suitable support can be obtained by placing a
sturdy U-beam under the base of the feed beam, and support-
ing the beam on planks at both ends. A two inch (50 mm) plank
should then be placed inside the U-beam to prevent mechanical
chatter and damage to the base of the feed beam.
If the rig is wheel-bound, it should be raised off the ground com-
pletely using the jacks, so that all wheels are clear of the ground.
•The rig must be set-up correctly in order to give stability
and safety. If this is not done, the effects of feed force and
rotation torque can cause the rig to move or even to over-
turn.This can incur the risk of serious or fatal injury as well
as damage to the drill rig and equipment.
DANGER
• Heavy lift.Take care when
handling the hammer.The
hammer and its internal
components are heavy and
difficult to handle, especially
in the case of the larger
hammers.
When lifting using mechanical lifting equipment, sling the
hammer as shown in the fig. Alternatively, a lifting-eye cou-
pling can be screwed on to the top sub.
•Transportation. Do not let the hammer lie unsecured on a vehi-
cle or drill rig. Always secure the hammer for transportation.
WARNING
• Always wear goggles during drilling!
•The exhaust air from the hammer (and also from the top
sub if a unit for extra flushing is fitted) has a very high
velocity. Objects such as small stones, drill cuttings, sand,
earth and oil residue that are entrained in the flushing air
can cause serious injury to unprotected eyes. Pay special
attention to this danger during collaring, when a top sub with
extra flushing is in use, an when the hammer is fed through
the drill steel support or down into the hole.
WARNING
Drilling
Rotation to the right
DTH hammers must be rotated to the RIGHT
(clock wise) during drilling, since the driver
chuck and top sub are threaded into the
cylinder with RIGHT-HANDTHREADS.
Rotation must always be to the right when
the hammer is operating. Left-hand rotation
(or no rotation) will cause the driver chuck to
loosen, which could mean losing the drill bit
(or even the entire hammer) down the hole.
The drill string should be rotated to the right
even when the hammer is not operating.
For example, this should be done when
cleaning the drill hole and when lifting up the drill string. It can
be said that rotation to the right should be switched on as long
as other operations are in progress with the hammer in the hole.
The risk of the drill bit working loose should also be considered
when breaking the joints between drill pipes. When adjusting the
breaking wrenches, bear in mind that the drill string must not be
rotated anti-clockwise any more than is absolutely necessary.
• Always switch on rotation to the right before starting the
feed or hammer.
• Let the hammer rotate to the right (clockwise) even during
lifting or lowering of the hammer.
• Do not switch off rotation to the right until all other func-
tions have been switched off.
IMPORTANT

6
•Take great care when jointing drill pipes. Make sure there
is no danger of your fingers being pinched or clothing being
entangled when the drill string is rotated.
• When a pipe wrench is used during jointing, there is a risk
of the wrench flying off and causing injury when rotation is
applied.
WARNING
• When drilling on soft or unstable ground, great care must
be taken because the flushing air from the hammer can
erode the material around the drill hole, and so undermine
the ground beneath the drill rig.This can pose a great danger
to personnel and risk damaging the equipment.
DANGER
• Always wear ear protectors during drilling.
CAUTION
Collaring
• Feed the hammer downward until the drill bit is about 5 cm from
the collaring point.
• Start rotation to the right at low speed (creeping).
• Feed the hammer on to the rock using minimal feed force, so that
the bit is pressed into the hammer, and into the impact position.
• Start collaring the hole with reduced impact and feed, until the
bit has entered the rock.
• Open the impact mechanism control fully and adjust the rotation
and feed so that the hammer drills smoothly and steadily.
5 cm
Feed and rotation
With holes of relatively shallow depth, the setting of feed and
rotation is usually a simple matter in DTH drilling, since the
hammers are comparatively insensitive to small variations in the
“normal” flow and pressure settings.The settings can be regarded
as correct when the drill string turns evenly without jerks or jam-
ming, and a steady penetration rate is obtained.
Feed force
When drilling with COP DTH-hammers, the feed force should be
high enough to keep the shank of the drill bit pressed into the
hammer during drilling.
•Too low a feed force will give easy rotation, excessive vibration
and reduced penetration.The resultant reflex shock waves can
damage the rotation unit and feed beam.
•Too high a feed force causes the rotation to jam (either erratically
or completely) and can subject the drill string to severe bending
stresses. It can also damage the rotation unit and feed beam.
The feed force often needs to be corrected during drilling, de-
pending on the rock formation and the weight of the drill string,
which obviously varies with the hole depth.
A rough guide to drill pipe weights for different sizes of DTH-ham-
mer are given in the table below:
Feed force – recommendations COP 44
Feed force 5–15 kN
Feed force at 16 bar 10 kN
Pipe dimension, mm Approx� weight, kg/m
76 9
89 15
102 18
114 20
127 23
140 34
Bit diameter, rock formation, hole depth and available rotation
torque will have a considerable influence on the setting of the
feed force. What is important is that the feed force is adjusted to
give steady penetration and a constant, even rotation speed with
no jamming (see table).
N�B.It is important that the feed force be adapted to suit the
weight of the drill string. When drilling deep holes, this requires
control facilities for “negative feeding”, a so-called “holdback”
function.
Rotation speed
In hard rock the rotation speed for COP hammers should be set
between 20-90 r/min, depending on the hammer size and bit
diameter (the larger the bit diameter, the slower the speed).The
upper limit generally produces the best penetration rate. In very
abrasive rock formations, however, the rotation speed should be
reduced to avoid excessive wear of the drill bit. When drilling in
softer rock or with high air pressure (above 18 bar) in non-abra-
sive formations, higher rotation speed may be used.The following
should be noted:
Too high a rotation speed will cause increased wear to the drill bit,
hammer and drill pipes. Stresses to the feed and rotation unit will
also increase.
Too low a rotation speed results in a poor drilling output and
uneven operation.

7
Rotation speed, r/min COP 44
Ø 115 mm
Recommendations 40 – 80
Flushing — air-blowing
To avoid wasteful re-crushing and the risk of jamming, drill cut-
tings must be flushed out of the drill hole at the same rate as new
cuttings are produced. It is good drilling practice to clean out the
hole at regular intervals by means of air-blowing.This is especially
important in non-consolidated formations and when there is a
danger of the hole wall collapsing. Air-blowing is done by lifting
the hammer off the bottom of the hole (fig. a) and running the
feed back and forth.
N�B� Rotation must always be to the right.The impact mechanism
stops as soon as the hammer is lifted and the bit drops down-
wards, which causes a considerable volume of air to flow through
the hammer and flush-out the hole. When the hammer is lowered
back on to the bottom of the hole, the bit is pressed back into the
impact position, which re-starts the impact mechanism (fig. b).
N�B� The hammer can flush more air than the compressor can
deliver.This means that the air supply from the compressor
should be restricted (by means of the impact-control valve) if the
air-blowing sequence is activated longer than 3–5 seconds.
ab
• Always wear goggles during drilling.The backward-di-
rected flushing air from the top sub contains drill cuttings
and oil residue which can injure the eyes.
WARNING
Drilling in wet holes
The inflow of water into the drill hole is expected when drilling
water wells, but can also occur when drilling deep holes for other
purposes. Water inflow does not normally create problems for
drilling, although both “too little” and “too much” can be trouble-
some.
Too little water tends to bind the drill cuttings into a paste, which
sticks to the drill pipes or the hole wall and can easily form collars
or plugs.The problem can be lessened by adding water to the
flushing air, thus increasing the fluidity of the cuttings. Fluidity
can be further improved by adding washing detergent to the
water.
N�B� Remember to increase the lubrication dosage when injecting
water into the flushing air!
Water injection
Water injection is normally used to suppress dust when drilling
dry holes. COP down-the-hole hammers are designed to function
with a certain amount of water injection. As an example, only 2—6
litres of water per minute (at 18 bar air pressure), injected into the
main air line. Too much water injection will have a very negative
influence on the penetration rate of the hammer.
Rule of thumb: 0,25 l water per m3compressed air consumed by
the hammer during the drilling sequence�
Flow chart for water flushing
A = Main inlet valve on drill rig K = Water tank
B = Container for air tool oil N = Compressor
C = Filter O = DTH-hammer
D = Lubricator valve
E = Pressure gauge Optional
F = Check valve L = Separate foam pump
G = Valves M = Separate foam tank
The injection point for water and foaming concentrate should
always be located after the main shut-off valve on the rig.
If not, there is a danger of the mixture being pumped back
through the main air line and into the compressor.This could
seriously damage the compressor.
CAUTION
Foam injection
Foam can be used in DTH drilling to improve the flushing perfor-
mance (especially in non-consolidated formations). It does this by
“lifting up” the cuttings out of the hole, and also has the desirable
effect of sealing the hole walls. Foaming concentrate is pumped
into the compressed-air line in the form of a concentrate/water
mixture. Epiroc foaming concentrate has lubricating properties
and contains corrosion inhibitors, which prevent seizing in the
hammer.
N�B� Before using foaming concentrates not supplied by Epiroc,
please consult your Epiroc representative for advice.
With Epiroc foaming concentrate, a mixture of 0,5–2 percent
concentrate/water is normally recommended. When drilling in
water-bearing rock and other difficult formations, it might be nec-
essary to increase the percentage of concentrate, and also to add
polymers to the operating air.This will help to stabilize the hole
walls and increase the lifting capacity of the foam.The concen-
trate/water mixture is injected into the main air line by means of a
high-pressure pump.
Minimum requirements for the water-injection pump are as
follows:
• min. pressure = 30 bar
• min. flow = 20 l/min.
After drilling with foam, it is recommended that residual foam
should be flushed out of the hammer to prevent corrosion.This is
done by injecting water only into the air, and so flushing the foam

8
out the hammer. Oil should then be poured into the drillstring and
the hammer operated for a few minutes before the drill string is
withdrawn from the hole. If the hammer is then to be stored for a
long time, it should be dismantled and all parts cleaned and oiled
thoroughly.
Tools
Tools for removing the drill bit and top sub
from the DTH hammer
The threaded connections of the driver-chuck and top sub can be-
come very tightly tensioned during drilling.There are special tools
for removing the bit and top sub from the cylinder of the DTH
hammer, and these should be used whenever possible.
Wrench for pipe-jointing and top sub
Wrench flat, mm Ordering No�
55 8484-0211-43
65 8484-0211-00
95 8484-0211-02
102 8484-0214-13
120 8484-0211-36
140 8484-0211-44
Bit removal tool
Loosening the threads of the hammer
If special tools like chain wrenches or other types of wrench are
used to break the hammer joints, then the tool must be attached
around the hammer cylinder as shown in the figure. Do not attach
at other points!
A
B
C
D
A
mm (in)
B
mm (in)
C
mm (in)
D
mm (in)
COP 44 90 (3.5) 70 (2.8) 70 (2.8) 55 (2.2)
•Take great care when breaking the driver-chuck joint using
the bit removal tool in combination with reverse rotation. If
the shaft of the tool is not locked or touching the edge of the
feed beam, the shaft can turn with great force when breaking
the driver chuck joint.
• Keep your hands and clothing well clear of the hammer/drill
string when it is rotated. Entanglement can result in serious
injury.
• Blows against hammer or bit can cause fragments of metal
to fly. Always wear goggles when breaking joints.
DANGER
Breakout bench
It is always most convenient to
break the hammer threads on
the rig. For circumstances, when
the threads cannot be broken or
tend to get stuck, there is a
breakout bench available.
N�B.Failure to attach the wrench
as illustrated (B, C) may result
in damage to the cylinder. Any
such damage will not qualify for
compensation.
Removing the drill bit
The drill bit can be removed in a number of different ways,
depending on the tools available.The following two methods are
commonly used:
A� Breaking the driver-chuck joint using percussion only
Run the hammer into the rock or a thick plank.
• Apply light feed force.
• Carefully start the impact mechanism of the
hammer.
• Stop the impact mechanism as soon as the driv-
er-chuck joint “cracks”.
• Run the hammer up the feed beam to a suitable
working height, and unthread the driver chuck and
drill bit.
N.B. Beware of the weight of the drill bit. It could
be too heavy to hold.

9
B� Breaking the driver-chuck joint using the bit
removal tool
If the driver-chuck joint is very tight, the special
bit-removal tool should be used to break the joint.
Important: Never use a sledge-hammer on down-
the-hole hammers.
• Place the bit-removal tool in the drill steel support.
N�B� Looking from behind the feed beam, make sure
that the shaft of the bit-removal tool is touching the
left-hand edge of the feed beam.
• Carefully run the bit down into the bit removal tool.
• Slowly start up the impact mechanism of the
hammer.
• Stop the impact mechanism as soon as the
driver-chuck joint “cracks”.
• Unscrew the driver chuck by rotating the COP ham-
mer to the LEFT (anti-clockwise).
Dirt in the hammer
Stoppages and breakdowns caused by dirt in the percussion
mechanism are practically inevitable with all rock drills, and DTH
hammers are no exception. However, it should be remembered
that, while DTH hammers are no more sensitive to dirt than
tophammers, there is obviously a greater risk of dirt ingress in
down-the-hole drilling, especially during pipe jointing. Any dirt
that enters the drill pipes goes straight into the percussion mech-
anism.To ensure reliable operation of the hammer, every effort
should therefore be made to prevent dirt from entering the drill
pipes.The following rules should be observed:
• Always keep drill pipes clean. Always store or stack drill pipes
in such a way that the risk of dirt ingress is minimized. Do not let
the thread ends rest on grit or mud. Use thread covers wherever
practicable.
• Always keep the open thread end of the drill pipe covered during
jointing, and remove the cover just before the pipe is coupled up.
• Before coupling up, check that the drill pipe is clean around the
threads and on the inside. If in doubt, blow clean the pipe.
Remember to cover the pipe end that is already in the hole.
• If threads are dirty, they should be cleaned using a strong bristle
brush or a cloth.
N.B. Always clean away from the hole in the pipe. Do NOT let
grit fall into the hole in the pipe. After cleaning, always coat the
threads with Epiroc thread grease before jointing.
•Take extra care during jointing operations when drilling in abra-
sive rock formations, since the ingress of quartz particles into the
hammer will cause heavy wear.
• When drilling holes in water-bearing rock, never leave the ham-
mer at the hole bottom with the air supply switched off. If drilling
is to be suspended temporarily, always pull up the hammer by at
least two pipe lengths.
• Clean around the driver chuck before changing the drill bit. Make
sure the shank of the new drill bit is clean.
• Keep the hammer clean and plug both ends when not in use.
Change worn or damaged parts in good time.
A
B
All Secoroc COP down-the-hole hammers
contain a check valve that is designed to trap
a quantity of air inside the hammer when the
air supply is switched off. In most conditions,
this prevents the ingress of water and dirt into
the hammer during jointing operations.The
check valve A and O-ring B must be fault-free
when drilling in water-bearing formations.
When drilling deep holes in rock with a high water inflow,
however, it is possible that some seepage of water into the front
of the hammer will take place during jointing. Since only very
small particles of dirt would be able to penetrate the hammer in
this way, the threat to the hammer is not serious.
The sealing efficiency of the check valve
can be checked by pouring a small
quantity of lubricant through the top
sub of the hammer, with the hammer
held vertical. If the lubricant passes
through the checkvalve, then the valve
spring and/or valve seal is worn or
damaged and should be replaced
immediately.
•Take great care when jointing the drill pipes and handling
the drill bit.
• Mind your fingers!
• Keep your clothing, hair etc. well clear of rotating compo-
nents! Carelessness can result in serious injury.
WARNING
Other instructions
Wear to the driver chuck and hammer
cylinder
Since the driver chuck and hammer
cylinder are “sand-blasted” continuously
by large volumes of abrasive cuttings
during drilling, they eventually become
worn out.The areas adjacent to the
cuttings grooves in the drill bit will be
subjected to the most wear.To prevent
uneven wear of the hammer cylinder,
therefore, the driver chuck and bit should
be marked as shown in figure, before the
chuck is lifted off the bit.
When fitting the driver chuck back on to
the drill bit after grinding or replacing a
drill bit, its radial location on the bit
shank should be advanced by one spline
section.This will give a more even
distribution of wear on the driver chuck
and hammer cylinder.
If the driver chuck is exposed to exceptionnally heavy wear, e.g.
when drilling in rock formations with a high quartz content (gran-
ite, quartzite etc.), it may be necessary to turn the driver chuck by
more than one spline section in order to prevent the driver chuck
and hammer cylinder from wearing out too quickly. As a rule, the
cuttings grooves in the bit should always be pointing towards the
part of the driver chuck that is least worn.
Since the hammer cylinder has three thread inlets, the part of the
driver chuck that is worn the most can be located against the part
of the hammer that is worn the least.

10
Checking the wear of the driver chuck and
hammer cylinder
Wear to the driver chuck and hammer cylinder should be checked
regularly, e.g. every time the bit is reground or changed. Meas-
ure the diameter of the hammer cylinder using a sliding calliper.
Measure along the full length of the cylinder, with the exception
of the outermost 100 mm at each end. At any point between these
points, the diameter of the hammer cylinder must not be less than
the minimum permissible diameter given for the respective DTH
hammer sizes in the table below.
Minimum permissible diameter
COP 44 89 mm
The outside diameter of the driver chuck must not be less than
that of the hammer cylinder.
N�B� When the hammer cylinder has to be changed, the driver
chuck must be replaced at the same time (see the section “Wear
limits”).
The hammer should be overhauled at suitable intervals, depend-
ing on the operating conditions.The abrasiveness of the rock will
affect the overhauling intervals, since it has a strong bearing on
the rate of wear.
Shimming
Checking the clearance
between the top sub and the
cylinder
When fitting the top sub to the
hammer, the clearance between the
top sub and the cylinder must be
checked with a feeler gauge.This is done as follows:
• Remove the valve body D and compression ring B from the
cylinder.
• Remove the control tube G and buffer housing H from the cylin-
der, using a rod.
• Remove the outer buffer K from the control tube, (the inner
buffer J should not be removed).
• Smear the O-ring on buffer housing H and the inner buffer J with
silicone grease. Oil all other surfaces of the control tube G with oil.
• Fit the buffer housing H and control tube G back into cylinder.
Clearance before/after shimming
Ordering No�
shims (1–4)
Min�
clearance
Clearance after
shimning
COP 44 3161-1422-00 1,5 mm 1,9–2,5 mm
• Fit the buffer housing H and control tube G back into cylinder.
• Fit the compression ring B and valve body D back into the cylinder.
• Remove the O-ring E from the top sub F.
•Thread the top sub into the cylinder and tighten it by hand.
• Measure the clearance between the top sub and cylinder.
If the clearance is less than the minimum value given in the table,
shimming must be carried out.
GJ
H K
Fit the necessary number of shims C (1 – 4 pcs) between the
compression ring B and valve body D.
If, after the maximum number of shims (4 pcs) has been inserted,
the minimum clearance is still less than the value shown in the
table, then the compression ring or circlip is worn out and must
be replaced.
• After inspection and eventual shimming, smear the outer rubber
buffer K with silicone grease and fit it back into the cylinder to-
gether with the control tube G and buffer housing H.
•Then fit all other parts back into cylinder.
N�B� Do not forget O-ring E — first smear it with silicone grease
and then fit it back on to the top sub.
• Finally, smear the threads of the top sub with Epiroc thread
grease, and thread it into the cylinder.Tighten hard with the aid of
a wrench.There should now be hardly any clearance between the
top sub and cylinder.
Assembly of the drill bit and driver chuck
• Smear the splines of the bit shank with Epiroc thread
grease.
• Smear the O-ring of the stop ring with silicone grease.
• Assemble the bit 1, driver chuck 2 and stop ring 3 as shown in
figure.
3
2
1
Make sure the stop ring is located
correctly, and that it faces the
right direction. Incorrect fitting
will result in severe damage to
the hammer.
IMPORTANT
• Smear the thread on the driver chuck with Epiroc thread grease.
• Screw in the bit assembly by hand. Note that there should be a
clearance of 0,1–0,4 mm between the driver chuck and the cylin-
der casing. If there is no clearance, the end surface of the cylinder
casing should be ground down as necessary.Tighten the driver
chuck with the aid of the bit spanner.
Instruction for disassembling of disc spring
unit
N�B�There is normally NO NEED for disassembling of the disc
spring unit. If you have to – follow this instruction carefully.
• Never disassemble the spring unit if the friction springs
may be preloaded.
DANGER

11
• Remove topsub from hammer.
•Take out disc spring unit (picture 1).
• At this time act very carefully, and do NOT touch the friction
springs, since they may be preloaded.
• Hit the springs with a hammer to separate the rings (picture 2).
1 2
• Hold the check valve body in an upright position and unscrew
the spring stop 2-3 turns (picture 3).
• Use a screwdriver to ensure the rings are separated (picture 4).
• At this time it is very important to check that all rings are sepa-
rated from each other.
• Unscrew the spring stop.
43
Plastic foot valve in
the bit shank
Replacing the foot valve
When the footvalve becomes worn or damaged, it must be
replaced. If this is not done, the performance of the hammer will
be seriously affected.The signs of wear or damage to the foot
valve include excessive air consumption, uneven percussion and
difficulty in starting the hammer.
Wear limits and protrusion – foot valves
Diam�
new
Diam�
worn out
Foot valve
ordering No�
Effective
protrusion A
COP 44 27 mm 26,8 mm 9227 45 ± 1 mm
Protrusion of the foot valve
After fitting the foot valve into the bit shank,
its protrusion from the end of the shank
must be checked.Too much or too little
protrusion will seriously affect the perfor-
mance of the hammer.
After the foot valve has been pressed into
its seat and protrusion is within the speci-
fied limits (see table), do not put more pressure on the foot valve,
since this could result in damage.
Removing the foot valve
The worn or damaged foot valve is removed by cutting it with a
hacksaw blade or knife, and then prising it out of the bit shank
with the aid of a screwdriver. Heating the foot valve to 50—70° C
can make removal easier.
• When removing and fitting foot valves, always wear protec-
tive goggles, gloves and appropriate protective clothing. Care-
lessness can result in injury to the eyes or other body parts.
• Foot valves are brittle. Heavy blows can deform or dislocate
the foot valve, with the risk that it would then obstruct the
movement of the impact piston.
WARNING
Fitting a new foot valve
The new foot valve should be pressed into the seat in the flushing
hole in the bit shank using a special assembly tool that guaran-
tees guidance of the foot valve into the seat, and ensures that
the amount of protrusion is correct. For easier installation, the
temperature of the plastic foot valve should be 20 — 60° C (it can
be heated in water, or on the compressor). Before fitting the foot
valve into the bit shank, coat the part of the valve that is pressed
into the drill bit with rubber glue (or a similar substance).The
rubber glue will act as a lubricant during fitting, and as a fixative
thereafter. If rubber glue is not available, use silicone grease or
some other similar lubricant.
N�B� Do NOT use a hammer to seat the foot valve. Heavy blows can
damage the foot valve or cause it to locate incorrectly so that it is
struck by the impact piston during drilling. Use some kind of hydrau-
lic press to press it gently but firmly on to its seat in the bit shank.
Assembly tool Ordering No�
COP 44 9226
• Before grinding, always check the flushing holes of the drill
bit for traces of explosive. Contact with the grinding wheel
can cause the explosive to explode causing serious or fatal
injury as well as damage to the equipment.
To clean the flushing hole, use only a wooden rod, copper
wire or flushing water.
DANGER
• Always wear ear protectors, protective clothing, gloves and
goggles when grinding.
• Use a dust extraction system or an approved dust mask.
This is of special importance when dry grinding indoors.
CAUTION

12
Regrinding the drill bit
The rate of bit wear depends on the rock formation, and is highest
in rocks with a high quartz content. A suitable grinding interval
should be determined according to the rate of bit wear. It is more
economical to regrind too early rather than to suffer poor pene-
tration rates and risk damaging the drill bit through overdrilling. A
few hints about the care of drill bits:
When to regrind
Button bits should be reground
when the penetration rate
drops, or if any of the cement-
ed carbide buttons are
damaged (fractured buttons
should be ground flat). It is
both practical and economical
to redress the buttons when
the wear flat reaches about ½ of the diameter of the button.
Note: This is a general recommendation.
Look out for “snake skin”
If microscopic fatigue cracks –
so-called “snake skin” – begin to
appear on the cemented carbide
buttons, they must be ground away. In
any event, bits should be reground
after 300 metres of drilling at the most.
This should be done even if there are
no visible signs of wear and the penetration rate continues to be
good. If snakeskin is not removed, the cracks will deepen and
ultimately result in button fracture.
Do not grind away too much cemented carbide
Do not grind too much on the top of the
buttons. Let a few millimetres of the wear flat
remain on top of the button.
Always grind broken buttons flat
A drill bit can remain in service as long as
the gauge buttons maintain the diameter of
the bit. Fractured buttons must always be
ground flat to prevent chips of cemented
carbide from damaging the other buttons.
Avoid grinding the perimeter
Gauge-button anti-taper has to be removed by grinding, although
excessive reduction of the bit diameter should be avoided. Leave
about 2 mm of the wear flat.
If necessary, remove some of the bit-body steel below the gauge
buttons, so that a clearance (taper) of 0,5 mm is maintained.
If the flushing holes start to deform, open them up with the aid of
a rotary burr or steel file.
2 mm
Min
0,5
Grinding equipment
The Grind Matic HG is a portable,
hand-held, air-powered grinding
machine for button bits, ideal for use at
the worksite. It is used with dia-
mond-impregnated grinding cups,
which can be used with or without
water flushing.
The Grind Matic Manual B-DTH is a
mechanized air-powered grinding
machine for button bits. It is mounted
in a steel box-barrow, which can be
wheeled easily around the worksite.
The Grind Matic Manual B-DTH uses
diamond-impregnated grinding wheels.
For “permanent” grinding stations, a
mechanized stationary grinding
machine is available, the Grind Matic
BQ3-DTH. It is equipped with automat-
ic feeding devices and grinds both the
cemented-carbide buttons and the
bit-body steel in one operation.The
machine uses diamond-impregnated
grinding wheels.
Further information about grinding equipment can be found in the
respective product leaflets.
Always use water flushing with grinding wheels.
• Use water if possible also with grinding cups and
hand-held grinders.
IMPORTANT
Care & maintenance
The service life and performance of DTH hammers depends to a
large extent on good operating practice and regular maintenance.
The following recommendations should be observed:
• Make sure that the compressed air is always clean and dry.
• Always blow clean the air hoses before connecting them to the rig.
• Make sure that the drill pipes are stored properly in the pipe
rack, or stacked on trestles in such a way that dirt cannot enter the
pipes.
• Fit thread guards to the ends of the drill pipes whenever practi-
cable. Keep the threads and the insides of the pipes clean.
• Always cover the “open” thread end of the drill pipe during
pipe-jointing operations.The ingress of dirt into the drill string will
cause blockages and/or seizure in the hammer, which can result in
breakdown.
• Check regularly that the dosage of lubricating oil into the oper-
ating air is sufficient. Check that the lubricating-oil tank on the rig
is filled with oil of the correct type and quality. See “Recommend-
ed lubricants”, page 15.
• Check the wear on the driver chuck and hammer cylinder regu-
larly.The diameter of the driver chuck must never be less than that

13
of the hammer cylinder.The service life of the hammer cylinder
can be prolonged by always fitting a driver chuck with a greater
outside diameter than that of the hammer cylinder. When the
components are approaching their minimum permissible diam-
eters, frequent inspection is necessary. Alternatively, change the
components in good time – it makes good economic sense.
N�B� When the hammer cylinder is replaced, the driver chuck
should be replaced at the same time (see “Wear limits”, page 10).
A general overhaul of the hammer should be carried out at suita-
ble intervals, depending on the operating conditions and empiri-
cal statistics.The abrasiveness of the rock will have a considerable
effect on the rate of wear, and will affect the overhauling intervals
accordingly.
Lubrication
Lubricating oil is vital for the satisfactory
operation of DTH hammers. Apart from
regular checking of the oil level in the
lubricating-oil tank, always make sure that
there is oil in the compressed air.This can
be checked whenever the rotation unit is
free, i.e. disconnected from the drill string.
Simply place a plank over the drill-steel
support and blow operating air on to the
plank. After a few moments, the surface of
the plank should become oily, which con-
firms that lubricant is being carried to the
hammer in the operating air.
The importance of adequate lubrication of the hammer cannot
be over-emphasized. Poor lubrication will accelerate wear and
ultimately result in breakdown.The effective lubrication of the
DTH hammer is not always a straight-forward matter, owing to
wide variations in operating conditions, e.g. extreme temperature
differentials between the hammer and the lub-ricator, water or
foaming concentrate added to the operating air, etc.
Different lubricants have different properties. Mineral oils have
the best lubricating properties and are preferable in most cases.
Mineral-base oils have good adhesion properties and are pro-
duced in different viscosity and temperature- range grades.
Since mineral oils have good resistance to water, they are suitable
for use even when comparatively large volumes of water are
injected into the operating air. In this case, however, the dosage
must be increased.
Glycol-based lubricants, such as Epiroc Air Oil, are water soluble,
and must not be mixed with mineral oils.They are used primarily
to prevent freezing, and should be used only when there is a min-
imal water content in the operating air. Glycol-based lubricants
are used extensively in water-well drilling for reasons of water
hygiene. If there is a lot of condensation in the drill string, which
is often the case in long drill strings, then lubrication may become
unsatisfactory because dilution seriously affects the function of
glycol-base lubricants.
Other lubricants worth mentioning are the so-called “edible”
oils, which consist of vegetable oils, synthetic lubricants of the
ester type, or a mixture between these two. Edible oils can be
mixed with mineral oils, have good lubricating properties and are
non-toxic.
Lubricators
Both plunger-pump and nozzle-type lubrication systems are
available.
The plunger pump is relatively insensitive to the viscosity of the
lubricant and gives a more reliable dosage compared with the
nozzle-type lubricator.This is of major importance when the ambi-
ent temperature is low.
About 1 ml of oil per m3of operating air consumed should be the
minimum dosage for bench drilling. As a rule, higher dosages are
needed in water-well drilling.
Normal lubrication dosage
COP 44 0,3–0,5 l/hr
In case of water injection, increase dosage by 0,1–0,2 l/hr.
N�B�The distribution of lubricating oil through the compressed air
system generally takes place in the form of so-called “wall flow”.
If the air system has been shut off for a long period of time, it can
take quite some time for the lubricant to reach the hammer. In
such cases, a small amount of oil must be poured directly into the
hammer or air hose before drilling.
Choice of lubricating oil
For COP down-the-hole hammers it is recommended to use Epi-
roc COP oil. When choosing between other types of lubricants, the
oil should have:
• Suitable viscosity
Ambient temp�°C(°F) Viscosity grade
–20 to +15 (-4 to +59 ISO VG 46-100
+15 to 35 (59 to 95) ISO VG 100-150
> +35 (95) ISO VG 150-220
• Good adhesion properties
• High film strength
• Corrosion inhibitors
• EP additives
For reasons of water hygiene, lubricating oils used in water-well
drilling should be non-toxic.
The temperature limits given above refer to the temperature
of the oil in the tank, i.e. the ambient temperature. In cases
where the hammer is powered by warm compressed air at high
operating pressures, e.g. when connected to a nearby portable
compressor, the temperature of the operating air must be taken
into consideration. In such cases it may be necessary to choose a
thicker oil than what is recommended in the table.
Recommended lubricants
Lubricating oil tank Epiroc COP oil
Threads and splines Epiroc thread grease
O-rings and rubber parts Silicone grease (temperature limits
-20 to +120°C)
Ordering No� Epiroc COP oil:
Can 10 litres 3115 3125 00
Can pallet 48 x 10 litres 3115 3126 00
Drum 208 litres 3115 3127 00

14
Wear limits
Component Wear limit Action Comments
Drill bit (diameter). Min. 6–10 mm (COP 34 4–7
mm) greater than the max.
diam. of the cylinder.
Fit new bit. Min. measurement at lower working pressures.
Max. measurement at higher working pressure.
Driver chuck (diameter). Never less than the diameter
of the cylinder.
Replace. Failure to replace in good time will cause severe
wear to hammer cylinder.
Cylinder (diameter). COP 44 – min. 89 mm Replace. Measure the diameter along the full length of the
cylinder, with the exception of the outermost 100
mm at each end. Risk of fracture.
Bit bushing (inside diameter). Replace. Measure the bit bushing at its waist.
Piston / Cylinder. Diametric clearance:
max. 0,20 mm
Replace worn
parts.
Outside diameter of piston should be measured at
the sealing surface of the piston.
Piston / Control tube. Diametric clearance:
max. 0,20 mm
Replace worn
parts.
Inside diam. of the piston against outside diam. of
the control tube.
Check valve. Valve seat worn or damaged. Replace worn or
damaged parts.
Tightness of check valve can be tested by pouring a
small amount of oil into the valve with the hammer
in vertical position.
Sleeve (flushing valve). Worn or damaged. Replace.
Buffer. Worn or damaged. Replace.
Trouble shooting
Fault Cause Remedy
Impact mechanism does
not operate, or works with
reduced effect.
Air supply throttled or blocked. Check the air pressure. Check that all air passages leading to
the hammer are open.
Oil is not reaching the impact mechanism
of the hammer. Poor or no lubrication,
causing increased wear, scoring or seizure.
Let operating air blow through rotation spindle on dry
plank or similar. After a few moments, plank surface should
become oily. Inspect lubricator. Top-up with oil if necessary
or increase lube oil dosage.
Too large clearance (wear) between the
piston and cylinder, or between piston and
control tube.
Disassemble the hammer and inspect the wear (see ”Wear
limits”). Replace worn parts.
Hammer clogged with dirt. Disassemble the hammer and wash all components.
Compression ring worn or damaged. Check clearance between top sub and cylinder. (See
”Checking the clearance between the top sub and cylinder”,
page 10) Replace worn or damaged compression ring.
Worn buffer rings in the cover. Disassemble the hammer and replace the buffer rings.
Dirt enters the hammer when drilling in
water-bearing formation.
Make sure the check valve seals against the seat in the top
sub (see ”Dirt in hammer”, page 9). Remove the top sub and
replace check valve.
Lost drill bit and chuck Impact mechanism has been operated
without rotation to the right.
Fish out the lost equipment using a fishing tool. Remember
to always use right-hand rotation, both when drilling and
when lifting the drill string.
Excessive air
consumption
Flushing valve parts damaged.
Foot valve worn or damaged.
Disassemble and replace damaged parts, see page 7.
Replace foot valve, see page 12.
Overhauling
DTH hammers should be overhauled at suitable intervals depending on the drilling conditions and empirical service records. Since the
abrasiveness of the rock has a considerable bearing on the rate of wear, it will affect the overhauling intervals accordingly. Before the DTH
hammer is sent to an authorized Epiroc service workshop for overhauling, the joints at the top sub and driver chuck should be ”cracked” on
the rig.

15
Hammers and kits Prod. No. Product code
COP 44 complete, 2 3/8” API Reg Pin 89000482 9704-CO-00-10P-34-000
COP 44 complete, 2 7/8” API Reg Pin 89001236 9704-CO-00-12P-34-000
O-ring kit incl. item 5x3, 1x11, 1x18 89000708 9704-CO-00-000-00-000-K47
Economy kit, 2 3/8” API Reg Pin (incl.
item 2, 5x3, 5, 7, 2x9, 12, 13, 18, 19 )
89000736 9704-CO-00-10P-34-000-K40
Economy kit, 2 7/8” API Reg Pin (incl.
item 2, 5x3, 5, 7, 2x9, 12, 13, 18, 19 )
89001317 9704-CO-00-12P-34-000-K40
Ref. Part Prod. No. Product code
1 Exhaust tube 86002883 9227
2 Chuck 89000053 9704-CO-00-000-34-000-001
3 O-ring* for Bit retaining ring
4 Bit retaining ring assembly incl.
O-ring
89000010 9704-CO-00-000-34-000-A02
5 Casing 89000051 9704-CO-00-000-00-000-004
6 Piston 89000085 9704-CO-00-000-34-000-005
7 Lock ring 89000052 9704-CO-00-000-00-000-006
8 Control tube 89000045 9704-CO-00-000-00-000-007
9 Buer ring, 2 pcs required 89000047 9704-CO-00-000-00-000-009
10 Cover assembly incl. O-ring 89000046 9704-CO-00-000-00-000-021
11 O-ring* for Cover
12 Compression ring 89000025 9704-CO-00-000-00-000-014
Shim for Compression ring 89000087 3161-1422-00
13 Valve body 89000026 9704-CO-00-000-00-000-015
14 Spring for Check valve 89001019 9704-CO-00-000-00-000-016
15 Check valve 89001020 9704-CO-00-000-00-000-017
16 Seal for Check valve 89001021 9704-CO-00-000-00-000-018
17 O-ring* for Backhead
18 Backhead assembly, 2 3/8” API
Reg Pin, incl. O-ring
89000451 9704-CO-00-10P-00-000-A20
18 Backhead assembly, 2 7/8” API
Reg Pin, incl. O-ring
89001237 9704-CG-00-12P-00-000-A20
2 3
*O-rings not sold separately. Included in dierent kits - see table.
Wear limits
Casing Min. OD 89 mm
Piston / Casing clearance Max. 0,2 mm
Piston / Control tube clearance Max. 0,2 mm
Exhaust tube Min. OD 26,8 mm
Exhaust tube protrusion 45 +/– 1 mm
Secoroc COP 44
Down-the-hole hammer
1 4 5
678910 11
12 13 14 15 16 17 18

9866 0328 01 Subjected to alterations without prior notice. © Epiroc Drilling Tools AB. All rights reserved. 2019.07.
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