Atlas Copco Cobra mk1 Instructions Manual
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Atlas Copco Cobra mk1 Instructions Manual

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See also: Operator's Instruction Manual
Overhauling instructions
© Copyright 2000, ATLAS COPCO BEREMA AB
STOCKHOLM • SWEDEN
www.CrowderSupply.com • Toll Free: 888-883-5144
Motor breaker
Cobra mk1
Cobra TT
ASB
2000-02
No 9800 0088 01a

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Summary of Contents for Atlas Copco Cobra mk1

  • Page 1 • Toll Free: 888-883-5144 Motor breaker Overhauling instructions Cobra mk1 Cobra TT 2000-02 © Copyright 2000, ATLAS COPCO BEREMA AB No 9800 0088 01a STOCKHOLM • SWEDEN...

  • Page 2: Table Of Contents

    Use only original parts and accessories approved by Atlas Copco. If modifica- The words WARNING and CAUTION have the fol- tions are made that are not approved by lowing significance: Atlas Copco, serious harm to yourself...
  • Page 3 www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling of the electronic unit, carriers and Reassembly ......36 flywheel .

  • Page 4: Technical Data

    Single cylinder, fan-cooled 2-stroke engine Cylinder volume 90 cc Engine speed, machine under load, full speed when tamping in sand 5800–6200 rpm (Cobra mk1) 6500+/-100 rpm (Cobra TT) Engine speed, machine under no load, idling 1800–2200 rpm Max. speed under no-load conditions...

  • Page 5: Hammer Unit

    27 Hz (Cobra TT) Impacts/min 1440 (Cobra mk1) 1620 (Cobra TT) Impact energy 60 J at 24 Hz (Cobra mk1) 40 J at 27 Hz (Cobra TT) Lubrication Hammer mechanism lubricated in its own oil bath Hammer mechanism oil Diesel engine oil...

  • Page 6: Service Schedule

    Point 1, plus: hours. Service time: 5 hours. Measures under 3.1 Replace the spark plug. All Atlas Copco’s spark Points 1, 3, 4 and 5, plus: plugs are preset to 0.6–0.7 mm. 6.1 Dismantle the engine from the hammer cylinder.

  • Page 7: Design And Function

    www.CrowderSupply.com • Toll Free: 888-883-5144 Design and function Carburettor Air Filter Starter mechanism Cooling Fan Throttle Drive piston Decompression valve Electronic unit Engine cylinder Fuel tank Hammer piston Muffler Hammer piston guide Tool holder Tool chuck Tool latch Engine Hammer mechanism The machine is powered by a single-cylinder, Before starting the engine, the hammer piston rests air-cooled two-stroke engine.

  • Page 8: Service Tools

    www.CrowderSupply.com • Toll Free: 888-883-5144 Service tools (Complete set: order number 9234 0003 94) Tool Order No. Designation 9234 0003 58 Puller key 9234 0003 59 Puller handle 9234 0003 57 Puller sleeve 9234 0003 71 Ring 9234 0003 72 Ring 9234 0003 68 Ring...
  • Page 9 www.CrowderSupply.com • Toll Free: 888-883-5144 Tool Order No. Designation 9234 0003 84 Tool 9234 0003 83 Protective bush 9234 0003 85 Ring 9234 0003 70 Ring 9234 0003 81 Tool 9234 0003 74 Ring 9234 0003 73 Ring 9234 0003 93 Puller...
  • Page 10 www.CrowderSupply.com • Toll Free: 888-883-5144 Tool Order No. Designation 9234 0003 86 Ring 9234 0003 80 Puller 9234 0003 52 Tool 9234 0003 49 Tool 9234 0003 75 Tool 9234 0003 82 Point 9234 0003 53 Puller...
  • Page 11 www.CrowderSupply.com • Toll Free: 888-883-5144 Tool Order No. Designation 9234 0003 66 Engine fixture 9234 0003 51 Tool 9234 0004 55 Tool 9234 0004 57 Ring...

  • Page 12: Engine Covers

    (6). Remove the spark plug. Examine the cover for damage or cracks, and re- Spare part numbers are provided in a separate place if necessary. spare parts list. Use only Atlas Copco original spare parts.

  • Page 13: Rear Cover

    www.CrowderSupply.com • Toll Free: 888-883-5144 Rear cover Remove the four nuts (7) and lift off the rear cover (8). Examine the cover for damage or cracks, and replace if necessary. Filter cover Undo the filter cover knob (10) and take off the filter cover (11).

  • Page 14: Starter Mechanism

    www.CrowderSupply.com • Toll Free: 888-883-5144 Pull out the rope and lay it in the notch. Rotate the Starter mechanism starter pulley anticlockwise for five turns. Support the starter pulley securely. Take the rope from the notch, release the starter pul- Replacing starter rope with starter ley and allow the rope to wind up slowly.

  • Page 15: Reassembly Of Starter Mechanism

    www.CrowderSupply.com • Toll Free: 888-883-5144 Wind the rope anticlockwise onto the starter pulley. Leave about 5 cm of rope outside the cover. Engage the spring hook (B) in the notch on the starter cover and press the starter pulley into place. Fit the washer (4).

  • Page 16: Filter Housing And Carburettor

    www.CrowderSupply.com • Toll Free: 888-883-5144 Filter housing and carburettor Dismantling of filter housing Dismantling and reassembly of choke control and lever Fig. 11 Rotate the choke control so that the locking pin en- gages in the groove on the filter housing (2). Pull out the choke control from the housing.

  • Page 17: Engine And Hammer Mechanism

    www.CrowderSupply.com • Toll Free: 888-883-5144 Engine and hammer mechanism Dismantling of muffler, stabilizer Dismantling of the engine from the brace and engine mounting bolts machine Fig. 13 Fig. 14 Remove the screws (1) and the springs (2). Lift up the engine (1) from the hammer cylinder (2), supporting the drive piston at all times to prevent it Pull back the muffler and remove the seals from being damaged.

  • Page 18: Dismantling Of The Muffler, Heat Shield And Fuel Tank

    www.CrowderSupply.com • Toll Free: 888-883-5144 Remove the plastic bushes (7) and replace them Dismantling of the muffler, heat with new ones. shield and fuel tank Remove the six nuts (3) and the two screws (4) from the hammer cylinder. Note: The top left-hand pressure plate has captive nuts and is secured with two screws.

  • Page 19: Dismantling Of The Tool Shank

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling of the tool shank Dismantling and reassembly of the tool latch Fig. 18 Fig. 19 Lift out the return spring (1). Examine the spring; the Dismantling spring must be replaced if the contact surfaces are Use a suitable drift to press out the locking pin (5).

  • Page 20: Dismantling And Reassembly Of The Hammer Piston And Hammer Piston Guide

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling and reassembly of the hammer piston and hammer piston guide Fig. 21 Remove and discard the O-rings (1), (2), (3) and (4), support ring (5) and scraper ring (6) of the hammer piston guide (10). Tap a sharp screwdriver into the locking ring (7) without damaging the groove in the guide.

  • Page 21: Dismantling Of The Drive Piston

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling of the drive piston Dismantling and reassembly of the connecting rod bearings Fig. 23 Fig. 24 Remove and discard the locking rings (1). Dismantle the needle bearing (1) using service tools S1, S2, S3, S10 and S25. Use a suitable drift to press out the gudgeon pin (2), supporting the connecting rod and the piston at all Fit a new bearing using service tools S1, S2, S3 and...

  • Page 22: Dismantling Of Plastic Bushes

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling of plastic bushes Dismantling of the cooling fan Fig. 25 Dismantle and discard the three plastic bushes (1). Mounting the engine on the fixture Fig. 27 Type A Lock the flywheel using service tool S19 and disman- tle the nut (5), the spring washer (4) and the flat washer (3).

  • Page 23: Dismantling Of The Electronic Unit, Carriers And Flywheel

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling of the electronic unit, Dismantling of the engine cylinder carriers and flywheel and piston Fig. 28 Fig. 29 Remove the three screws (1) and the washers (2) Remove the four screws (1) and lift off the cylinder and (3) and remove the electronics unit (4).

  • Page 24: Dismantling Of The Transmission Cover

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling of the transmission Dismantling of the fan side cover crankcase Fig. 30 Fig. 31 Remove the eight nuts (1). Remove the eight nuts (1). Note the position of the supporting bush (3) for the Place a flat-bladed screwdriver in one of the notches that are present on both sides of the crankcase half filter cover.

  • Page 25: Dismantling Of The Hammer Crankshaft Gear Wheel

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling of the hammer Dismantling of the hammer crankshaft gear wheel crankshaft Fig. 32 Fig. 34 Dismantle the engine from fixture S23. Fix service Fix the engine half in fixture S23. tool S24 in the swivel vice. Dismantle the locking ring (1).

  • Page 26: Dismantling Of The Hammer Crankshaft Bearing

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling of the hammer Dismantling and reassembly of the crankshaft bearing engine crankshaft bearing and seal Fig. 36 Fig. 38 Use service tools S1, S2, S3, S6, S7 and S8 to dis- Dismantling mantle the bearing (1). Use service tools S1, S2, S3, S8 and S11.

  • Page 27: Reassembly Of Engine Crankshaft

    www.CrowderSupply.com • Toll Free: 888-883-5144 Reassembly of engine crankshaft Reassembly of hammer crankshaft bearing Fig. 40 Fig. 42 Fit the crankshaft (1) in the crankcase (2) using ser- Fit a new bearing (1) in the crankcase using service vice tools S1, S2, S3 and S10. tools S1, S2, S3, S4, S8 and S11.

  • Page 28: Reassembly Of Hammer Crankshaft

    www.CrowderSupply.com • Toll Free: 888-883-5144 Reassembly of hammer crankshaft Reassembly of hammer crankshaft gear wheel Fig. 44 Fig. 46 Fit the hammer crankshaft (1) in the crankcase using Dismantle the engine crankcase from the fixture S23. service tools S1, S2, S3, S12 and S13. Fix service tool S24 in the swivel vice.

  • Page 29: Dismantling Of Transmission Cover Needle Bearing And Seal

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling of transmission cover Dismantling of the engine needle bearing and seal crankshaft bearing and seal on the fan side crankcase Fig. 50 Fit the crankcase in fixture S23. Use service tools S1, S2, S3, S8 and S11 to dismantle the bearing (1) and the seal (2).

  • Page 30: Reassembly Of The Drive Piston Connecting Rod And Engine Crankcase

    www.CrowderSupply.com • Toll Free: 888-883-5144 Reassembly of the drive piston Assembly of fan side crankcase connecting rod and engine seal crankcase Fig. 52 Fig. 53 Fit the transmission side (7) of the crankcase to fix- Fit a new seal (1) using service tools S1, S2, S3 and ture S23.

  • Page 31: Reassembly Of Transmission Cover

    www.CrowderSupply.com • Toll Free: 888-883-5144 Reassembly of transmission cover Reassembly of the engine piston and cylinder Fig. 54 Fit the Woodruff key (1). Fit a new gasket (2) and reassemble the transmis- sion cover (3). Fit the support bush (4) and tighten the eight nuts (5) to the stipulated torque load.

  • Page 32: Reassembly Of The Carrier, Flywheel And Electronics Unit

    www.CrowderSupply.com • Toll Free: 888-883-5144 Reassembly of the carrier, flywheel and electronics unit Fig. 59 Tighten the three screws (8) slightly and adjust the gap between the flywheel magneto and the electron- ics unit to 0.25 – 0.3 mm. Tighten the screws (8) to the stipulated torque load. Fig.

  • Page 33: Reassembly Of Plastic Bushes

    www.CrowderSupply.com • Toll Free: 888-883-5144 Reassembly of plastic bushes Reassembly of tool shank Fig. 61 Fig. 63 Fit the bushes (1). The short screw does not require Fit the seal (4) in the tool shank. a bush. Fit the feed stop (2) on the tool shank (3). Locate the tool shank and the feed stop in the tool holder (5).

  • Page 34: Reassembly Of Anti-Vibration Springs

    www.CrowderSupply.com • Toll Free: 888-883-5144 Reassembly of anti-vibration Dismantling and reassembly of springs right handle Fig. 65 Fig. 66 Fit the leaf spring (7), marked R, on the hammer cyl- Dismantling inder (1) with the pressure plates (2) and (3). Remove the handle locking nut (1) and washer (4) Note: The upper pressure plate (2) has captive nuts.

  • Page 35: Dismantling And Reassembly Of Fuel Filter

    www.CrowderSupply.com • Toll Free: 888-883-5144 Dismantling and reassembly of Dismantling and reassembly of fuel filter throttle handle Fig. 67 Remove the rubber grommet (1) from the tank and pull out the fuel pipe (2) and the filter (3) from the tank.

  • Page 36: Reassembly

    www.CrowderSupply.com • Toll Free: 888-883-5144 Reassembly Reassembly of engine Fit the throttle cable(9) and the electrical wires (5) and (6) in the protective sheath (11). Push the wires down through the hole for the bush (10) and then up through the hole for the stop button. Connect the wires to the stop button and then fit the stop button in the handle.

  • Page 37: Fitting The Muffler And Stabilizer Brace

    www.CrowderSupply.com • Toll Free: 888-883-5144 Fitting the muffler and stabilizer Reassembly of filter housing brace Fig. 72 Fig. 71 Fit the diaphragm valve (7) on the crankcase using Fit new gaskets (1) and (3) to the insert (2) and the four screws (8). Tighten the screws to the stipu- tighten the two screws (4) together with the springs lated torque load.

  • Page 38: Reassembly Of Machine Covers

    www.CrowderSupply.com • Toll Free: 888-883-5144 Reassembly of machine covers Throttle cable adjustment Fig. 74 Slacken the lock nut (1). Use the adjuster screw (2) to set the tension of the cable so that the idling speed is not affected by any movement caused by the anti-vibration springs.

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