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INSTRUCCIONES PARA ELEVAR MARTILLOS HIDRULICOS

D 20100 - 2 es 0101 / TMK

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HE 122 / HE 119 39 kg

HE 300 HL 300 HL 300 S 89 kg 94 kg 92 kg HL 500/ HL 500S/ HL500G/ HL550super/ HL 500F : 130 kg

HL 600 / HL 600 S 180 kg HL 700 245 kg

HL 1000/ HL 1000 S 290 kg rod, 300 kg versin de tubo HL 1500/ HL 1500 S 450 kg

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

B 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

CONTENTS
1. 2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAKING A NEW ROCK DRILL IN USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOSE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING FRONT END WITH ROCK DRILL ON FEED RAIL . . . . . . . . . . . . 5.1. Replacing the flushing housing seals . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. Changing the bearings of the flushing housing . . . . . . . . . . . . . . . . . . 5.3. Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4. Rotation sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5. Chuck bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6. Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7. Rotation bushing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8. Wear limits of the shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND TIGHTENING BOLTS AND TIE RODS . . . . . . . . . . . . . . . . . . 6.1. Tie rod tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2. Pressure accumulator and stabilator bolts . . . . . . . . . . . . . . . . . . . . . . 6.3. Flushing house bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2. Maintenance tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3. Every day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4. Every week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5. Basic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6. After rock drill service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7. Service card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8. Service followup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

2 2 2 2 3 4 6 7 8 8 8 8 9 9 9 10 11 11 12 13 13 13 14 14 14 14 15 15

3. 4. 5.

6.

7.

E 2002 SANDVIK TAMROCK CORP., Tampere Plant

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B 23700 2 en 0602 / JS

HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

1.

GENERAL

These instructions describe in brief the main maintenance procedures for HLX5 series hydraulic rock drills. Service is always ready to help and give advice in all maintenance problems. The qualified TAMROCK maintenance personnel of your TAMROCK dealer and original TAMROCK spare parts ensure reliable operation of your drilling equipment.

2.

TAKING A NEW ROCK DRILL IN USE


New rock drills are delivered with the pressure accumulators not pressurized and the hose connections plugged.
CAUTION

2.1. Preparations

Pressurize the accumulators according to the instructions. See Pressure accumulator, Repair instructions. Before a new rock drill is installed the drilling equipment hydraulic system must be checked and flushed thoroughly.

2.2. Test run


Test run the rock drill and make sure that it operates properly before starting production drilling. During test run observe: shank lubrication flushing pressures and temperatures possible oil leakages Avoid use of full percussion power if the steel is not against the rock. This will reduce the breakage of the accumulator s diaphragm, the wear of flushing housing, drilling tools and the CAUTION cavitation of the percussion mechanism. This type of idling drilling is the most critical while drilling upwards or cleaning the holes with pumping motion.

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

B 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

3.

HOSE CONNECTIONS

3 4 7 5 6

Fig 1.

Hose connections 5. Rotation, pressure (H.P.) 6. Rotation, return (L.P.) 7. Flushing

1. Stabilator 2. Shank lubrication 3. Percussion mechanism pressure side (H.P.) 4. Percussion mechanism return side (L.P.)

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

4.

LUBRICATION SYSTEM

The rock drill percussion mechanism and the rotation motor are lubricated by the hydraulic oil flowing through them.

Fig 2.

Lubrication scheme

The rotation mechanism and the shank have oil mist lubrication. The lubrication line from the central oiler is connected to end of the rock drill. From there the oil mist is ducted through piston rear end to the front end of the rock drill where the flow will lubricate the rotation mechanism, coupling and the bushing of the flushing housing. Leakage oil from the rear seals of piston is also ducted to the front end of the rock drill through hole. The oil that has circulated through the rock drill lubrication system is removed through the shank lubrication collector or can be led via return channels and spacer to the feed rail. Never connect the used oil mist to the hydraulic system return line.
CAUTION

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

B 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance


1

4 2

Air Fig 3. Shank lubrication 3. Drain valve 4. Filler cap

1. Rock drill 2. SLU 1/2/3

1. The shank lubrication oil consumption can be adjusted. ** 2. If the oil level in the oiler does not lower during drilling. ** 3. Drain regularly the water that has collected in the oiler. The draining interval depends on the local conditions. 4. Only the oils mentioned in the oil recommendation are allowed. 5. Refill the oiler regularly.

** See the instruction manual for SLU 1/2/3

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

5.

REMOVING FRONT END WITH ROCK DRILL ON FEED RAIL


When you remove the flushing housing and shank, turn the rock drill to a horizontal position. The rotation bushing and the coupling can fall out and cause injury.

WARNING

WARNING

If the shank lubrication is clogged (no air comes from the shank lubrication return hose), stop the compressor. Before opening the flushing housing bolts, carefully open the locking screw and let the air pressure out. Otherwise the air pressure can blow / burst out the flushing housing and cause injury.

The flushing housing can be removed when the rock drill is in the feed rail. Through opening the bolts (4), the flushing housing (1), shank (2), and coupling (3) can be removed without removing the rock drill from the feed rail. The rotation sleeve (6) can be pulled out by opening the screw (5). The screw (5) prevents the rotation sleeve from dropping, for example, when the shank is changed. Check the condition of the stabilizer pins.

6 3

2 1 5 4

Fig 4.

Removing the flushing housing

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

B 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

5.1. Replacing the flushing housing seals


Flushing housing seals must be replaced when the flushing air or water escapes from the sides of the seal housing, and they should be checked whenever the shank is changed. Seals are easier to install when they are lubricated. Install the new flushing housing seals making sure they face the right direction (shown in the figure). The use of a spare flushing housing is recommended, as it speeds up onsite maintenance of the rock drill.

AIR FLUSHING


WATER FLUSHING

Fig 5. The flushing housing seals must be installed facing the right direction, determined by the flushing mode In addition, a damaged seal plate (1) must be replaced due to risk of corrosion.
CAUTION

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance


5.2. Changing the bearings of the flushing housing


5.3. Coupling

The bearings must be changed if the wear indicationgroove has worn out from any area (as shown in the picture).

Pull the coupling out from the rotation bushing. Check and replace, if the edges of the inner teeth are worn sharp.

5.4. Rotation sleeve


The rotation sleeve must be replaced when the collar A is worn down to the level of the surface or the surface is damaged. Check also that the sliding surfaces of the rotation sleeves outer ring are in appropriate condition.

5.5. Chuck bearing

Check the chuck bearing inside the rotation sleeve. The bearing must be replaced when the bearing surface is worn to the level of the wear indicator groove at any point.

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

B 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

5.6. Chuck
1 mm C The chuck inside the rotation sleeve must be replaced every 500 percussion hours; it has worn over 1 mm from its original level, the surface against the stabilizer is worn to the level of the wear indicator groove C; or the chuck has cracks in it.

5.7. Rotation bushing bearings

The bearings must be changed if the lubrication groove has worn out from any area (as shown in the picture).

5.8. Wear limits of the shank


The shank must be changed if the 1 mm bevel of the striking max.1 mm max.1 mm head or 1 mm of the splines is worn out or any other wear limit is exceeded.

Manufacturing 2 mm Reject 1mm

CAUTION

When installing a new shank, take care that no dirt enters inside the rock drill with the shank. Insert the shank carefully through the flushing housing, so that the flushing device seals are not damaged.

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

6.

CHECKING AND TIGHTENING BOLTS AND TIE RODS

Perhaps the most important maintenance task is to check the tightness of the bolts, particularly the tie rods and mounting bolts. Loose tie rods cause rapid wear of the body section faces, shortening the service life of the rock drill. If the threads are not clean the bolts cannot be tightened correctly. In such cases the bolt must be removed, and the threads checked, cleaned, and lubricated with Vaseline. Following procedure is recommended for checking the bolt tightness during normal maintenance: 1. Check the tightness each bolt by using 10 % higher torque than specified. 2. The joint being tested is loose if the wrench turns. In this case loosen all the bolts being tested and retighten in the correct order. 3. If the threads are dirty, clean the threads, check them, and lubricate with grease. Use only an inspected, highquality torque wrench.
CAUTION

1 Fig 6. Rock drill bolts

1. Tie rod bolts 2. Pressure accumulator bolts 3. Flushing housing bolts

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

B 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance


6.1. Tie rod tightening
The tools required: torque wrench 24 mm socket 1. Lubricate the threads and the nut faces with Vaseline. 2. Pretighten to 200 Nm (20 kpm). Correct tightening order is 12345678. 3. Final tightening torque is 400 Nm (40 kpm). Same tightening order (12345678) should be used.

1 5 3 7

4 6 2 8

Fig 7.

Tie rods; tightening order

6.2. Pressure accumulators


The tools required: torque wrench 24 mm socket 1. Lubricate the bolt threads with Vaseline. 2. Pretighten all four bolts to 100 Nm (10 kpm). Correct tightening order is 1234. 3. Final tightening torque is 200 Nm (20 kpm). Same tightening order (1234) should be used. 4. Pretighten the bolts 5,6 and 7 to 100 Nm (10 kpm) and finally tighten to 200 Nm (20 kpm). No tightening order required. 2 4

6 5 7

3 Fig 8.

Pressure accumulator bolts tightening order


E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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B 23700 2 en 0602 / JS

HYDRAULIC ROCK DRILL HLX5T Operation and maintenance


6.3. Flushing housing bolts
The tools required: torque wrench 24 mm socket 1. Lubricate the bolt (1, 2, 3, 4) threads with Vaseline. 2. Pretighten all four bolts to 200 Nm (20 kpm). Correct tightening order is 1234. 3. Final tightening torque is 400 Nm (40 kpm). Same tightening order (1234) should be used.

Fig 9.

Flushing housing bolts

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

B 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

7.

PERIODIC MAINTENANCE

7.1. General
The idea of periodic maintenance is that the rock drill is serviced before any breakdown occurs. This way expensive additional damages and unwanted stops can be avoided. The maintenance interval is 500 percussion hours, but depends on the local conditions, and it must therefore be determined according to this experience. Searching for the correct maintenance interval, it is advisable to start the periodic maintenance as specified, and then lengthen the intervals until a period that suits the local conditions has been found. In addition the rock drill should always be taken in for service when the operator reports of a fault that can cause major damage or a production stop.

7.2. Maintenance tools and parts


Tools 1. 2. 3. 4. 5. 6. 7. required for maintenance: Torque wrench Socket, 24 mm Ring spanner head, 24 mm Spanner, 19 mm Extension Check gauge for lowpressure accumulator Check gauge for highpressure accumulator

4 7 3 Fig 10. Maintenance tools Other rock drill parts which are to be available at the rig for maintenance are flushing housing gasket, flushing seals and shank adapter.
E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance


7.3. Every day
1. Check flushing housing bolt tightness. 2. Check for possible oil leaks. 3. Check hoses and connections.

7.4. Every week


1. Check hour meter reading. 2. Check accumulator filling valves and their protective caps and the accumulator bolt tightness. 3. Check accumulator pressures. Low pressure accumulator 50 bar High pressure accumulator 8 bar Stabilator accumular 4 bar 4. Check condition of shank, chuck, flushing housing, coupling, shank bushing and rotation bushing. 5. Check tie rod tightness. If loose, tighten them.

7.5. Basic maintenance


Rock drill basic maintenance is recommended every 500 operating hours, Cf. Repair Instructions. This maintenance interval can be adjusted according to local conditions and experiences which are accumulated to the rock drill maintenance history. Do planned and preventive maintenance rather than repairs after damages. Monitor percussion hour meter reading and / or drilled meters / shifts between each maintenance. Fill in the service card of the rock drill.

7.6. After rock drill service


After rock drill service the reassembled parts will settle down to their proper position during drilling under normal drilling loads. Especially when parts have worn surfaces it may result that the tie rods and the mounting bolts do not keep their tightness. Therefore a retightening of these bolts is required after each rock drill service or if the rock drill has been off the feed rail. After rock drill service and 1 round / 100300 meters drilling: 1. Retighten the rock drill mounting bolts on the feed rail. 2. Retighten the rock drill tie rods and flushing device bolts.

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

B 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Operation and maintenance

7.7. Service card


Each rock drill has its own service cards. When a rock drill is taken up for maintenance, all the earlier cards should be at hand. All relevant information about the maintenance must be written down on the card. When the rock drill is again taken into use, the next maintenance date should be written down on the card. Benefits of the card: Wear of every specific component of each rock drill is clearly displayed, and by comparing the cards the effect of different circumstances and measures can be determined. The cards help in determining maintenance required to prevent major damage. Properly filled cards show the complete maintenance history of the rock drill. The cards help to determine the point when the rock drill should be scrapped. Use service card presented on the next page.

7.8. Service followup


In order to follow the maintenance of a rock drill, a maintenance card presented next page can be used.

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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B 23700 2 en 0602 / JS

HYDRAULIC ROCK DRILL HLX5T Operation and maintenance


ROCK DRILL SERVICE CARD No
Equipment Rock drill S/n S/n drill. shifts/rounds drilled meters
Serviceman Prev.service Prev.service card No Prev.perc.hours Working hours Rep. Dism. Ass. Insp. Total

Since previous service percusion hours

SERVICE INFORMATION
Purpose of the service Arr.date Dep.date

REPLACED PARTS/ PART INSPECTION Qty Part No Description Piston Front cylinder Fron bushing Rear cylinder Rear bushing Distributor LP accumulator HP accumulator Spacer Gear housing Rotation bushing Rot.bush.bearing Chuck Connecting piece Rotation motor Rotation shaft Rot. shaft bearings Front cover/ body Flus. seal housing Shank bearings Idle gear Idle gear bearing Idle gear pin Percussion mechanism tested Repaired / Batch Replaced / Batch OK Remarks

Remarks

Rotation mechanism tested

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

D 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

CONTENTS
1. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. Flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. Replacing seals of flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3. Replacing bearings on flushing housing . . . . . . . . . . . . . . . . . . . . . . . . 1.4. Replacing bearing inside rotation bushing . . . . . . . . . . . . . . . . . . . . . . 1.5. Pressure accumulators and rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6. Gear housing, primary gear and stabilizer accumulator . . . . . . . . . . 1.7. Removing spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8. Percussion cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9. Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10. Stabilizer spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1. Percussion cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2. Rotation motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3. Assembling and centralizing the stabilizer piston seal . . . . . . . . . . . 3.4. Stabilizer spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5. Installing bearings of gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6. Installing chuck, rotation bushing and stabilizer accumulator . . . . 3.7. Installing of flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8. Pressure accumulators, hose connector flanges, rear cover . . . . . . TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 4 5 7 8 9 13 15 17 18 20 24 24 26 28 29 31 34 35 36 38 40

2. 3.

4. 5.

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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D 23700 2 en 0602 / JS

HYDRAULIC ROCK DRILL HLX5T Repair instructions

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

D 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

1.

DISASSEMBLY

1.1. Flushing housing


The flushing housing (1), the shank (2), and the coupling (3) can be pulled out without removing the rock drill from the feed rail, just open the bolts (4). When the Allen screw (5) is opened, the rotation bushing (6) and the chuck (7) can also be pulled out. The Allen screw (5) prevents the rotation bushing from accidentally falling out when, for instance, the shank is being replaced.

7 6 3

2 1 4 5

Fig 1.

Flushing housing disassembly

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


1.2. Replacing seals of flushing housing
The flushing housing seals must be replaced if flushing air or water is leaking out past the seal housing, and checked whenever the shank is being replaced. Lubricate the seals with grease before installation. Install the new seals in the right direction, as illustrated. We recommend that a preassembled spare flushing housing is used, it saves time in rock drill maintenance at the drilling site.

AIR FLUSHING

WATER FLUSHING

Fig 2. The flushing housing seals must be installed the correct way according the type of flushing Due to risk of corrosion, also replace the gasket (1) if it is damaged.
CAUTION!

E 2002 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

D 23700 2 en 0602 / JS

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


1.3. Replacing bearings on flushing housing

The bearings must be replaced if the indicator groove is worn away from any place. (Fig. 3)

Fig 3.

Flushing housing bearings Make sure that the lubrication channels are flushed clean with pressured air.

CAUTION!

Detach the front cover (Fig. 4) and press the bearings out (Fig. 5, 6, 7) using a hydraulic press and the punches in the tool kit in the direction indicated by the arrows in the illustration.

Fig 4.

Detaching the front cover

Fig 5. Pressing the shank bushing out by using the special tools no. 5 and 7 (See Special tools)
E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

9 2

Fig 6. Pressing the front bearing out of front cover by using the special tool no. 2 and 9(See Special tools) 9 2

Fig 7. Pressing the rear bearing out of the shank bushing by using the special tool no. 2 and 9 (See Special tools)

Pull the coupling out from the rotation bushing. Check and replace, if the edges of the inner teeth are worn sharp or visible cracks are seen. Fig 8. Coupling

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

1.4. Replacing bearing inside rotation bushing


The rotation bushing must be replaced if the shoulder A (Fig. 9) is worn down to end face level or damages are observed. Check chuck bearing inside rotation bushing. Bearing B has to be replaced if the indicator groove is worn away from any place as illustrated. Use special tool no. 4 and 9 for this purpose. (See Special tools)


Fig 9. Rotation bushing, chuck bearing

The chuck inside the rotation bushing must be replaced after 500 percussion hours or if shank end has worn more than 1 mm from original surface, shoulder on stabilizer end has worn down to end face level C (Fig. 10) or it has hair cracks.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


1 mm

Fig 10. Wearing surfaces

1.5. Pressure accumulators and rear cover


Release the accumulator pressure by opening the filling valve before removing the pressure accumulators (1) from the rock drill. Never remove a pressured accumulator.

WARNING!

Open the accumulator fastening bolts (2). Remove the accumulators. Remove the Oring and the gasket. Put protective plugs into the openings on the rock drill body. Open the rear cover s fastening bolts (4). Detach the rear cover (3) from the rock drill. On disassembly, inspection, reassembly, and filling of pressure accumulator, see Pressure accumulators, repair instructions. 3 4

2 1

Fig 11. Disassembly of pressure accumulators and rear cover

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

1.6. Gear housing, primary gear and stabilizer accumulator


Mount the rock drill (1) to the repair stand (2, See Special tools, item 16). Repair stand and lifting eye bolts (3, See Special tools, item 17) are included in special tool set. Fasten bolts (4) on both side of rock drill firmly. Disassemble the stabilizer accumulator (5). Remove the front (6) and rear (7) brackets of the feed wires.

3 6

1 2

Fig 12. Mounting rock drill to repair stand and disassembling stabilizer accumulator

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Open the cap nuts (1) of the tie rods (6 pcs). Remove the gear housing (2). If gear housing has stuck together with spacer, they can be detached by unfastening the lower most tie rods with a 19 mm spanner. Remove simultaneously primary gear (3) and slide washers (4). Check gear and washers. Replace if they are worn down, seized up or have hair cracks.

Fig 13. Disassembling of gear housing and primary gear Remove the gear housing side bolts (4 pcs). Clean the bores carefully through the side bolt holes.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Check the gear housing front bearing and rear bearing for wear. Bearings must be replaced if the bearing surface is worn down at any point of the indicator grooves (1). If the gear housing bearings are worn or damaged, remove them using a hydraulic press and punches (Fig. 14, 15 and 16).

Fig 14. Disassembly of gear housing bushings

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

13

Fig 15. Pressing the front bearing out by using the special tools no. 7 and 13 (See Special tools)

12

Fig 16. Disassembly of rear bearing with steel frame with special tools no. 7 and 12 (See Special tools)

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Remove rotation shaft front bearing assembly from gear housing. Replace the needle bearing every 500 operating hours. Use grease (3) and the special tool no. 10 (See Special tools) as illustrated. Blows with the hammer make the grease drive the bearing out. (Fig. 17).

3 1

10

2 Fig 17. Removal of front bearing

1.7. Removing spacer


Mark the front ends of the stabilizer pins with a permanent marker and pull loosen pins (1) apart from pin housing. Turn rock drill to horizontal position. Secure the spacer with lifting eye bolts (6, See Special tools, item 18). Release nuts (2) of middlemost tie rods (3). Detach spacer (4) from body cylinder (5). (Fig. 18) 6

5 4 3 1 Fig 18. Removal of spacer

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


If body cylinder (1) is stucked together with the spacer (2), they can be detached by unfastening middlemost tie rods (3) using a 19 mm spanner (Fig. 19). 2 3 1

Fig 19. Detaching the body cylinder from the spacer Detach hose jointing flanges (1) from body cylinder. 1

Fig 20. Disassemble hose jointing flanges

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


1.8. Percussion cartridge
Pull front bearing (1) and piston (2) out from body cylinder (3). Check the piston, and replace it if: The chamfer (A) has worn off. The piston has cracks or seizure marks. The piston may be polished with a cloth pad disc. No grinding is allowed! Check the bearing bushing (4) of the front bearing. If it is damaged (=has scratches, seizure marks or hot spots), replace the front bearing. Front bearing is recommended to be replaced latest after 2000 percussion hours usage. (Fig. 21) 3

4 1 Fig 21. Removing the piston Place special tool (8) inside rear bearing (2), and push rear bearing out together with pilot cylinder (3) and distributor (4). (Fig. 22) 3 4 2 8

Fig 22. Disassembling the rear bearing, pilot cylinder and distributor
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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Detach rear bearing (1) and distributor (2) from pilot cylinder (3). Check parts for cracks, seizure marks and other damages. Minor scratches can be polished with cloth pad disc, grinding is not allowed. Rear bearing is recommended to be replaced latest after 2000 percussion hours usage. (Fig. 23)

3 2 1

Fig 23. Dismantling of rear bearing and distributor Check the piston seal grooves (A) at the rear bearing. Maximum groove width is 4.35 mm. The width of the groove can be checked with gauge no. 14 (see page 40). Also check the grooves visually; if the groove is too wide or damaged, replace the rear bearing.

14

Fig 24. Checking the piston seal grooves (A)


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HYDRAULIC ROCK DRILL HLX5T Repair instructions

1.9. Hydraulic motor


After every 500 operating hours, the condition of the hydraulic motor shall be checked, and the Orings replaced. Open the rotation motor mounting screws (2), and pull the motor out. Check all parts carefully and replace damaged (scratched, seized, cracked) parts.

Fig 25. Disassembly of the hydraulic motor If the Orings are holding the balance plate (5) and the channel plate (6) tight, they can be released by using grease (2) (Fig. 26), spacer pin (3) (Fig. 26) and a punch (10) (Fig. 26). 10 6 3 5 2


Fig 26. Disassembly of the balance and the channel plates

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


1.10. Stabilizer spacer
Detach rotation shaft (1) and bearing housing (2) from stabilizer spacer (3). Inside rotation shaft is a spacer pin (4) which drops down when shaft is turned to vertical position. Check shaft for wear, particularly seal and bearing areas. Bearings and rotation shaft seal have to be changed after every 500 operating hours. 6 7

2 4 1

Fig 27. Disassembling the stabilizer spacer Extract pin housing (1). Rotate housing so that lower spigot (2) of pin housing does not fit in its hole. Put pin housing partly back on to stabilizer spacer spigot and carefully puff stabilizer pistons (3) out of their cylinders by compressed air through stabilizer oil channels (Fig. 27, 6 and 7). If the pistons do not come loose, fit the threaded holes (6 and 7) with grease nipples. Secure the pin housing (1) axially to the spacer (3). Apply grease inside the unit with a grease gun until the stabilizer pistons come loose. Clean the grease from the channels. 3 1

2 Fig 28. Extracting the pin housing


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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Inspect grooves for percussion piston seals. Maximum width of the groove is 4.35 mm. If groove is worn too wide, or damaged, seal bushing has to be replaced, recommended change period is 500 percussion hours. Use special tool no. 14 (See Special tools) for inspecting the groove. Check also the groove visually. A

14

Fig 29. Special tool for checking the groove The seal bushing can be removed by special tool (no. 3 and 7, See Special tools) and press.

Fig 30. Removal of seal bushing


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HYDRAULIC ROCK DRILL HLX5T Repair instructions

2.

WEAR LIMITS

Make sure that the percussion cartridge goes into the body cylinder together with the spacer. Take measurements C, D, E. Measurement C > (D+E) (Fig. 31), otherwise the body cylinder must be discarded.

Fig 31. Wear limits


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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Take measurements C, E, L, M. Measurement L < (CE+M) (Fig. 32), otherwise the body cylinder must be discarded.

Fig 32. Wear limits

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Part A B F G Shank bearings Rotation bushing bearings Piston Chuck Replace if chamfer has worn off. The chuck inside the rotation bushing must be replaced after 500 percussion hours or if shank end has worn more than 1 mm from original surface, shoulder on stabilizer end has worn down to end face level or it has hair cracks. Replace if worn > 1mm or if wearing surface is cracked. Replace rotation bushing if wear shoulder has worn down. Replace if teeth have worn pointed. Replace stabilizer piston if wear indicator groove has worn away or if there are seizures or hair cracks. Replace gear housing if N < 0,5mm. Wear limits Replace bearings if wear indicator has worn off at any point.

H I J K

Shank bushing Rotation bushing Coupling piece Stabilizer piston

Rotation bushing end float

See Figure 33.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

A/B

1 mm

H H 1 mm H I J B N F I A B G J K

Fig 33. Wear limits


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HYDRAULIC ROCK DRILL HLX5T Repair instructions


3. ASSEMBLY

Before assembly: Remove all old Orings and seals. Clean all parts thoroughly. Lubricate parts liberally ! Mount body cylinder to repair stand.

3.1. Percussion cartridge


Liberally lubricate the piston rear seals and cautiously rub them softer with your fingers. An alternative is to soften the seals in warm oil or water (max. +50C). Install the seals into their grooves in the rear bearing. Place the distributor into the pilot cylinder. Check that the distributor is the right way round. Using a plastic mallet, tap the rear cylinder into the pilot cylinder.

Fig 34. Assembling the distributor, the piston rear seals and rear bearings
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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Push the pilot cylinder assembly into the body cylinder (1). Mount piston into pilot cylinder and push front bearing to its position inside pilot cylinder (2). (Fig. 35)

1.

2.

Fig 35. Assembling the pilot cylinder

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


3.2. Rotation motor
Make sure, that all parts and motor housing in body cylinder are clean and studs are mounted fully home. Lubricate all parts and housing properly, install new Orings. Place spring washer to the bottom of the housing. Push balance plate to its place, locate according guide pin in housing. Place spacer pin inside balance plate. 11, 12 1

3 6 4 5 7 8 9 10

Fig 36. Assembly of rotation motor 1. 2. 3. 4. 5. 6. Stud Cardan shaft Flange Gear wheel set Channel plate Valve drive 7. 8. 9. 11. Disc valve Space pin Balance plate Hex. nut

10. Spring washer 12. Lock washer

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Place disc valve (1) on top of the balance plate, mark (with chalk or ink) drive spline tip, which lines up with the hole (A) on outer rim of the valve. Mark drive spline bottom of valve drive shaft which counteracts with the marked spline in disc valve. Place valve drive (2) inside disc valve, the end with widest splines (5mm) is mounted into the disc valve. Push channel plate to its place. Mount gear wheel set and align rotor (3) so that bottom of the external teeth is aligned with the marked spline of valve drive. Turn rotor counterclockwise until splines engage with the splines on the valve drive.

A 1

Fig 37. Gearwheel set, OMS motor Install the shaft and the hydraulic motor cover. Ensure that the studs are fully tightened. Tighten the nuts in a crosswise pattern first to 40 Nm. The final tightening torque is 80 Nm.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


3.3. Assembling and centralizing the stabilizer piston seal
Fit the punch (2, See Special tools, item 19) to the piston (1). First mount the Oring on the punch and push the seal carefully in place by punch (4, See Special tools, item 20). Take off the punches. Centralizing the piston seal, lightly push oiled punch (5, See Special tools, item 21) over the seal. The seal will settle into the correct position and form. 3

Lubricate stabilizer all parts. Mount stabilizer pistons into their cylinders thru seal centralizing punch (5) in order to avoid seal damages during assembly. Make sure, that coated (marked with VC on bottom face) stabilizer pistons are aligned with the 3 recesses in pin housing. Mount Orings (1) on the spigots of stabilizer spacer and pin housing. Push (or tap gently with rubber mallet) pin housing to its position. 1

VC

Fig 38. Assembling of stabilizer spacer and pin housing

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


3.4. Stabilizer spacer
Hit the bearing through the holes in the bearing housing so that it collapses, and remove the bearing.

Fig 39. Removing the bearing Press a new needle bearing (2) into its position with a special tool (no. 1, page 40). Replace the rotation shaft seal (3) and Orings (4).


Fig 40. Replacing the shaft seal and bearing
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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Install the piston seals in their grooves. Lubricate the seals thoroughly and soften them carefully with your fingers. Alternatively, the seals can be softened in warm oil or water (max. +50C).

Fig 41. Installing the seals Insert the bearing housing (1) and the spherical roller bearing (3) into the spacer (4).

4 1 3 Fig 42. Installing the seal housing and roller bearing Turn the rock drills installation base to horizontal position.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Install the Orings at the end of the body cylinder and on the spacer hub with grease. Install the rotation motor shaft (1) in the rotation motor. Install the spacer (2), and lubricate the cap nut (3) (2 pcs) threads with grease. Pretighten (tightening torque 200 Nm) the centermost side bolts to secure the spacer.

Fig 43. Installing the spacer

3.5. Installing bearings of gear housing


1. Press the gear housing bearings 1 and 2 (Fig. 44, 45) into position using a hydraulic press and punches (6, 7 and 11, See Special tools). In order to make installing easier, the gear housing can be cautiously warmed up (max. 150C).


11

Fig 44. Gear housing rear bearing


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HYDRAULIC ROCK DRILL HLX5T Repair instructions

6 11

2 Fig 45. Gear housing front bearing Install the needle bearing into the bearing housing of the rotation shaft using a punch 26 (See Special tools).

26

Fig 46. Installation of needle bearing Install the Oring into its groove and install the bearing housing into its position in the gear housing. Make sure that the bearing housing is pushed fully home.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


Turn the drifter to vertical position. Locate stabilizer pins into their holes in pin housing (3). Make sure the pins are assembled in the exact same way they were removed (marked ends towards chuck). Place lower side washer (2) of gear on rotation shaft. Install the gear housing into position. Install primary gear (1) and its upper side washer simultaneously. Lubricate the threads of the cap nuts (4) (4 +2 pcs) with graphite grease. Tighten the nuts crosswise in two stages, first to 200 Nm and final tightening for all 8 nuts to 400 Nm. 5 2 1 2 3

Fig 47. Assembling of gear housing and primary gear

1 5 3 7

4 6 2 8

Fig 48. Tightening order

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


3.6. Installing chuck, rotation bushing and stabilizer accumulator
1. Push chuck (1) into the rotation bushing (2) install the assembly into the gear housing. Place coupling piece (3) into position. 2. Install the Allen screw (4) and the seal (5). Install stabilizer accumulator (6) with new gasket (7). Tighten bolts in 2 phases, pretighten 100 Nm and final torque 200 Nm. Place front (8) and rear (9) feed rope mounting clamps to spacer claws, fasten with bolts torque 240 Nm (Fig. 49).

9 8 6 7 5 4

2 3

Fig 49. Assembling of chuck, rotation bushing and stabilizer accumulator

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

3.7. Installing of flushing housing


1. Check that the mating surfaces of the flushing housing and the gear housing are clean. Install the gasket (1) to the mating surface of the flushing housing. Locate shank and seal housing inside the flushing head body. Install the flushing housing assembly into position. 2. Lubricate the threads of the fastening bolts (2), and install the locking washer pairs into position. Tighten the bolts in two stages: first to 200 Nm, and final tightening to 400 Nm.

2 1

Fig 50. Assembling of the flushing housing Detach rock drill from assembly stand.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions


3.8. Pressure accumulators, hose connector flanges, rear cover
1. Remove the protective plugs from the pressure accumulator connection, and clean the mating surfaces of the accumulator and the rock drill body. 2. Install the Oring and the gasket. 3. Check that the accumulator fastening bolts turn freely in the threads on the rock drill body. Install locking washer pairs and lubricate the fastening bolt threads. Cross tighten the bolts in two stages: first to 100 Nm, and final tightening to 200 Nm. 4. Place rear cover with gasket to into position and cross tighten bolt in 2 phases (50 Nm and 100 Nm).

Fig 51. Assembling of accumulators, connector flanges and the rear cover

5. Attach hose connector flanges, use lubricating grease to hold the Orings in their grooves during assembly. Check, that shank lubrication can flow through rock drill from connector flange to lubrication outlet.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

Surface model

UG model

Fig 52. Oil outlet in rock drill Filling of pressure accumulator, see Pressure accumulators, repair instructions.

Accumulator pressures Accumulator type High pressure Low pressure Stabilizer accumulator Pressure [bar] 50 4 8

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

4.

TEST RUN

General After completed maintenance, the rock drill can be tested in the TAMROCK Service Container using the hydraulic powerpack. Test run can be carried out on the floor of the service container with the rock drill lying on a piece of cushion rubber, for instance. The rock drill may not be test run on the assembly stand! The shank must be removed before test run.
CAUTION!

The purpose of test run is to check the operation of the percussion and rotation mechanism of the rock drill, and to see if any major leaks are observed. When testing the rotation mechanism, the hoses to the percussion mechanism must be connected to the rock drill to enable the internal lubrication of the rotation motor to operate. Wear hearing protectors when the powerpack is running!

WARNING!

Before test run 1. Using a double nipple, connect the hoses of the powerpack to make a loop so that the lines of both pumps form their own closed circuits. 2. Start the powerpack. 3. Pull the levers of both control valves into operating position, whereby oil starts flowing through the systems in free circulation. 4. Allow the powerpack to run for about 3 minutes, after which it is ready for test run.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

6
120 bar

6
175 bar

10

10...210 bar

2 M

9 1

1. 2. 3. 4. 5.

Tank Electric motor Double pump Control valve (percussion) Control valve (rotation)

6. 7. 8. 9. 10.

Pressure relief valve Pressure gauge (percussion) Pressure gauge (rotation) Return filter Differential pressure valve

Test run 1. Connect the rock drill according to the hydraulic flowchart. 2. Make sure that: There is enough oil in the tank (1). The control valve (4) and (5) levers are in neutral position. 3. Start the powerpack. 4. Start percussion by pulling the control valve (4) lever towards yourself. 5. Start rotation by pulling the control valve (5) lever towards yourself. You can change the direction of rotation by pushing the lever to the other extreme position. 6. Continue the test run for about 5 minutes, and observe possible leaks.
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HYDRAULIC ROCK DRILL HLX5T Repair instructions


5.
1.

SPECIAL TOOLS
550 056 57 10. 150 551 68

2.

152 248 88 11.

550 055 57

3.

550 055 88 12.

550 054 94

4.

550 057 30 13.

550 054 80

5.

150 545 68 14.

150 746 48

6.

550 055 68 15.

152 249 08

7.

151 866 08 16.

550 057 16

8.

550 056 20 17.

449 701 50

9.

150 546 98 18.

449 697 70

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

19.

150 679 28 23.

20.

150 680 98 24.

21.

150 678 08 25.

22

26.

Fig 53. Tool kit id. number: 550 065 07 The table shows some special tools in the tool kit 550 065 07. A complete listing of the contents of the tool kit is provided in the spare part manual.

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HYDRAULIC ROCK DRILL HLX5T Repair instructions

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions

CONTENTS
1. 2. 3. 4. 5. 6. 7. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FILLING GAS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE PRESSURE ACCUMULATOR FROM THE ROCK DRILL . DISMANTLING THE PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1. Filling device of pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . 7.2. Filling instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3. Filling pressures of accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1. Low pressure accumulator (LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2. High pressure accumulator (HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.3. Pressure of stabilizer accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOUNTING THE PRESSURE ACCUMULATOR ON THE ROCK DRILL . . . . 2 3 3 4 4 5 7 7 8 9 9 9 10 11

8.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions


1. GENERAL

As in all hydraulic machinery so also in hydraulic drill rigs cleanness is the most important consideration if trouble--free operation is to be ensured. We therefore recommend that all maintenance work of the accumulators is done in a clean and dustless room. The condition of pressure accumulator should be checked always when the accumulator is dismantled and when the rock drill is overhauled. The rock drill special tool set includes all the tools needed in maintenance and checking the accumulators. Experiences have shown that the first (originally fitted) accumulator diaphragm does not reach the normal service life, particularly if the time interval between the pressurization and taking into use is long. For this reason the accumulators supplied as spares are unpressurized. There is a note of this on the accumulator. The accumulator bottom and cover should always be kept as a pair. Tamrock supplies covers and bottoms only as a pair; other parts such as diaphragms and filling valves can be obtained separately.

Only qualified service personnel may service the pressure accumulators. The following instructions must be strictly observed; failure to do so may cause a danger of accident.
WARNING

Before removing the accumulator from the rock drill, discharge the accumulator pressure by opening the filling valve.
WARNING

Repair of a pressure accumulator by welding or by other means is strictly forbidden.


WARNING

While using the gauge, the pressure relief hole must always be pointed to the opposite direction from any persons close by to avoid personal injures in case the sudden pressure discharge.
WARNING

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

D 28160 - 6 en 1201 / PIR

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions


2. CHECKING THE FILLING GAS PRESSURE

Check the accumulator filling gas pressure once a week. The rock drill special tool set includes two pressure gauges for this purpose: one gauge with the scale 0...100 bar for the high pressure accumulator, and the other with the scale 0...10 bar for the low pressure accumulator.

a 1. 2. 3. 4. 5. 6.

Remove the cap (a). Screw the pressure gauge to the filling valve. Undo the lock nut (b). Wait until the needle of the gauge stops and then read the gauge indication. Close the lock nut (b). Unscrew the gauge from the filling valve and fit the cap (a) in place.

3.

REMOVING THE PRESSURE ACCUMULATOR FROM THE ROCK DRILL

Pressure accumulator can be changed without demounting the rock drill from the feed. If you for some reason cannot immediately install a new accumulator, must the open oil channels be covered thoroughly with eg. plastic plugs. 1. Discharge the accumulator pressure by opening the filling valve! 2. Undo the accumulator bolts (wrench size 24 mm). Do not start the hydraulic powerpack if an accumulator is not in place in the rock drill.
WARNING

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions


4. DISMANTLING THE PRESSURE ACCUMULATOR
Before dismantling the accumulator, be sure it has no pressure.

WARNING

1. Fasten the assembly stand (1) in the vice, and place the accumulator in the stand with the bottom upwards. 2. The same number appears both on the accumulators cover as well as on the bottom. The cover and the bottom must remain paired. 3. Make sure that the filling valve is open! 4. Open the accumulator bottom with the opener (2).

5.

CHECKING THE PRESSURE ACCUMULATOR


1. Check the accumulator visually for wear, damage, corrosion, etc. 2. Clean and check the threads carefully.

If the threads are badly corroded or worn, the accumulator must be scrapped!
WARNING

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

D 28160 - 6 en 1201 / PIR

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions


6. ASSEMBLY

a b b
40 Nm secure with glue

10 Nm

20 Nm

1. Fit a new or inspected diaphragm in the cover. Make sure that the diaphragm is in the groove and fitted the right way down. 2. Lubricate the surface (a) with vaseline or lanolin.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

6 (12)

D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions


Check that the number on the cover and the bottom is the same.

WARNING

The high pressure accumulator is marked with uneven numbers and the low pressure accumulator with even numbers. HP LP

3. Lubricate the threads of the bottom with vaseline or lanolin. 4. Screw the bottom all the way in and tighten it with the special tool to a torque of 150 Nm. D When the pressure accumulator diaphragm is changed, the O--rings (b) should also be changed.

Check the wear limit marks of the threads always after tightening (150 Nm) of the bottom. If the mark (I) in the bottom remains after the tightening between the dot (S) and the mark (R) in the cover, the thread is in order. If the mark (I) in the bottom goes beyond the mark (R), are the threads of the accumulator cover and bottom too much worn. Replace the accumulator and discard the old one. A worn-out or damaged pressure accumulator must be discarded immediately.
WARNING

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

D 28160 - 6 en 1201 / PIR

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions


7. FILLING
The only allowable filling gas is nitrogen (N2).
WARNING

Do not fill an unchecked or a too worn accumulator.

WARNING

You can refill the accumulator while mounted to the rock drill.

7.1. Pressure accumulator filling device


12 9 8 7 6 5 3 2

N2
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

11

10

13,14 15

Accumulator body Filling valve Locking nut Cap Quick coupling stem Quick coupling sleeve Hose Accumulator pressure gauge Gas bottle pressure gauge Pressure reducing valve Pressure regulating valve Shut--off valve Adapter Seal Elbow adapter
E 2001 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions

7.2. Filling instruction


1. Remove the cap (4). 2. Screw the elbow adapter (15) to the filling valve (2). 3. Push the quick coupling sleeve (6) onto the stem (5). 4. Undo the locking nut (3). 5. Turn the pressure regulating valve (11) open. 6. Open the nitrogen bottle valve (12). The gauge (9) indicates the pressure in the bottle. 7. Adjust the pressure in the low pressure accumulator to 5 -- 10 bar by turning the regulating valve (11). Gauge (8) indicates the pressure in the accumulator. 8. Adjust the pressure in the H.P. accumulator with the pressure control valve (11), according to the instructions. Gauge (8) indicates the pressure in the accumulator. Max. pressure is marked on the accumulator. 9. Adjust the pressure of the stabilizer accumulator with the pressure control valve, according to the instructions. Gauge (8) indicates the pressure in the accumulator. 10. Close the filling valve (2) by turning the locking nut (3). 11. Close the nitrogen bottle valve (12). 12. Turn the pressure regulating valve (11) open. 13. Disconnect the quick couplings (5) and (6). 14. Release the elbow adapter (15) from the filling valve (2). 15. Mount the checking gauge (0--10 bar) in to the low pressure accumulator filling valve (2) and by opening the locking nut (3) let the pressure flow out until the gauge shows 3 - 5 bar. 16. Tighten the locking nut (3) to 20 Nm. 17. Refit the cap (4). 18. Assure the tightness of the accumulator by immersing it in water. Dry the accumulator carefully for example with compressed air. 19. If the accumulator is not taken into use directly, release the pressure and store it in a dry place protected from dirt.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

D 28160 - 6 en 1201 / PIR

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions


7.3. Filling pressures of accumulators
7.3.1. Low pressure accumulator (LP)

Low pressure accumulator damps hydraulic vibrations in the return line. It also prevents cavitation in return lines and channels. To get the optimum result of LP--accumulator, gas pressure should be half of the return line pressure. Normally its from 3 to 5 bars. 7.3.2. High pressure accumulator (HP)

The main function of high pressure accumulator is to store pressurised oil during the return stroke of the piston. This stored pressure can be utilized during the next piston stroke. Another vital function is to dampen vibrations. HP--accumulator gas pressure should be related to the set max. percussion pressure according to graph below.

Stem- type diaphragm


100 90 80

Filling pressure

70 60 50 40 30 20 10 0 100 120 140 160 180 200 220

Upper limit Lower limit

Percussion pressure

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions

Normal (stemless) diaphragm


100 90 80

Filling pressure

70 60 50 40 30 20 10 0

100

120

140

160

180

200

220

Upper limit Lower limit

Percussion pressure

7.3.3.

Pressure of stabilizer accumulator HLX 5 T . . . . . . . . . HL 700 T . . . . . . . . . HL 700 ST . . . . . . . HL 1500 . . . . . . . . . 8 bar 30 bar 30 bar 50 bar

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

D 28160 - 6 en 1201 / PIR

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions


8.
D

MOUNTING THE PRESSURE ACCUMULATOR ON THE ROCK DRILL


See Hydraulic rock drill, repair instructions.

1. Before mounting the accumulator on the rock drill, remove the cover plugs from the accumulator connection port, and clean the joint surfaces both in the accumulator and in the rock drill. 2. Check that the bolts move easily in their threads in the drill body. Lubricate the threads of the bolts. 3. Fit the O--ring and the gasket. 4. Tighten the pressure accumulator bolts in two phases: pretightening 100 Nm, final tightening 200 Nm.

Tightening of the four-bolt accumulator The four---bolt accumulator must be tighten by using a cross---tightening method 1-3-2-4.
CAUTION

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120

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D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions

Notes:

E 2001 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120