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C 00640-1 en 0198

ROCK DRILL SERVICE CARD N:o


Equipment S/n
Rock drill S/n
Percussion hours since last
service
drill. shifts/rounds
drilled meters

SERVICE INFORMATION
Purpose of the service Service man

Arrival date Previous service Edell. iskutunnit Work. hours Dism. Insp.

Departure date Previous service card n:r Rep. Ass. Total

REPLACED PARTS / PART INSPECTION


Qty Part no. Description Repaired Replaced OK Remarks
Piston
Front cylinder
Front bearing
Rear cylinder
Rear bearing
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
Flushing seal housing
Shank bearings

Perc.mechanism Rot.mechanism
Remarks tested tested

Cont.

© 2000 SANDVIK TAMROCK CORP., Tampere Plant


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

EXIT
D 20111 - 2 en 1104 / JT 1 (1)

HYDRAULIC ROCK DRILL HLX5T


LIFTING INSTRUCTIONS

CORRECT INCORRECT

Max.
55_

HLX5T . . . . . . . . . . . . . . . . . . . . . . 218 kg

E 2004 SANDVIK TAMROCK CORP., Tampere Plant


P:O. Box 100
FIN--33311 TAMPERE,Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
B 23700 - 5 en 0106 / TL 1 (16)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Operation and maintenance

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. TAKING A NEW ROCK DRILL IN USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2. Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. HOSE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. REMOVING FRONT END WITH ROCK DRILL ON FEED RAIL . . . . . . . . . . . . 6
5.1. Replacing the flushing housing seals and the seal housing
guide rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2. Changing the bearings of the flushing housing . . . . . . . . . . . . . . . . . . 8
5.3. Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.4. Rotation sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.5. Chuck bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.6. Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.7. Rotation bushing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.8. Wear limits of the shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. CHECKING AND TIGHTENING BOLTS AND TIE RODS . . . . . . . . . . . . . . . . . . 10
6.1. Tie rod tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2. Pressure accumulator and stabilator bolts . . . . . . . . . . . . . . . . . . . . . . 11
6.3. Flushing house bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.2. Maintenance tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3. Every day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.4. Every week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.5. Basic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.6. After rock drill service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.7. Service card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.8. Service follow-- up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
2 (16) B 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Operation and maintenance

1. GENERAL
These instructions describe in brief the main maintenance procedures for HLX5T and
HFX5T 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


2.1. Preparations

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

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 cavitation of the percussion
CAUTION
mechanism. This type of ”idling drilling” is the most critical while drilling
upwards or cleaning the holes with pumping motion.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
B 23700 - 5 en 0106 / TL 3 (16)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Operation and maintenance

3. HOSE CONNECTIONS

2 1

7
5 6

Fig 1. Hose connections

1. Stabilator 5. Rotation, pressure (H.P.)


2. Shank lubrication 6. Rotation, return (L.P.)
3. Percussion mechanism pressure side 7. Flushing
(H.P.)
4. Percussion mechanism return side
(L.P.)

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
4 (16) B 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
B 23700 - 5 en 0106 / TL 5 (16)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Operation and maintenance

4 1

Air

Fig 3. Shank lubrication

1. Rock drill 3. Drain valve


2. SLU 1/2/3 4. Filler cap

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 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
6 (16) B 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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

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
WARNING 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 (7).

6
3

1
5
4

Fig 4. Removing the flushing housing

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
B 23700 - 5 en 0106 / TL 7 (16)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Operation and maintenance

5.1. Replacing the flushing housing seals and the seal housing guide
rings
Flushing housing seals (A) 5 pcs and the seal housing guide rings (B) 2 pcs 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 on--site 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 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
8 (16) B 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Operation and maintenance

5.2. Changing the bearings of the flushing housing

The bearings must be changed if the wear indication--groove has


worn out from any area (as shown in the picture).

5.3. Coupling

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


A down to the level of the surface or the surface is damaged. Check
also that the sliding surfaces of the rotation sleeve’s 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 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
B 23700 - 5 en 0106 / TL 9 (16)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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

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

Manufacturing 2 mm
Reject 1 mm

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.
CAUTION

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
10 (16) B 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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, high-- quality torque wrench.

CAUTION

Fig 6. Rock drill bolts

1. Tie rod bolts


2. Pressure accumulator bolts
3. Flushing housing bolts

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
B 23700 - 5 en 0106 / TL 11 (16)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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 1--2--3--4--5--6--7--8.
3. Final tightening torque is 400 Nm (40 kpm). Same tightening order
(1--2--3--4--5--6--7--8) should be used.

1 4

5 6

3 2

7 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 1--2--3--4.
3. Final tightening torque is 200 Nm (20 kpm). Same tightening order (1--2--3--4)
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.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
12 (16) B 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Operation and maintenance

2 4

7
5

3 1

Fig 8. Pressure accumulator bolts tightening order

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 1--2--3--4.
3. Final tightening torque is 400 Nm (40 kpm). Same tightening order (1--2--3--4)
should be used.

Fig 9. Flushing housing bolts

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
B 23700 - 5 en 0106 / TL 13 (16)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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 required for maintenance:
1. Torque wrench
2. Socket, 24 mm
3. Ring spanner head, 24 mm
4. Spanner, 19 mm
5. Extension
6. Check gauge for low--pressure accumulator
7. Check gauge for high--pressure accumulator

1 6
5

2
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 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
14 (16) B 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Operation and maintenance

7.3. Every day


1. Check the flushing housing for water and air leaks.
2. Check flushing housing bolt tightness.
3. Check for possible oil leaks.
4. 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.
-- High pressure accumulator . . . 50 bar
-- Low pressure accumulator . . . 4 bar
-- Stabilator accumulator . . . . . . . 8 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
re--tightening 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 / 100--300 meters drilling:
1. Re--tighten the rock drill mounting bolts on the feed rail.
2. Re--tighten the rock drill tie rods and flushing device bolts.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
B 23700 - 5 en 0106 / TL 15 (16)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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 follow--up


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

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
16 (16) B 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Operation and maintenance

ROCK DRILL SERVICE CARD No


Equipment S/n
Rock drill S/n
Since previous service percusion hours
drill. shifts/rounds
drilled meters
SERVICE INFORMATION
Purpose of the service Serviceman
Arr.date Prev.service Prev.perc.hours Working Dism. Insp.
hours
Dep.date Prev.service card No Rep. Ass. Total

REPLACED PARTS/ PART INSPECTION


Repaired Replaced Remarks
Qty Part No Description / Batch / Batch OK
Piston

Pilot cylinder
Front bushing
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

Percussion Rotation
Remarks mechanism tested mechanism tested

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
D 23700 - 5 en 0106 / TL 1 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

CONTENTS

1. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1. Flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2. Replacing the flushing housing seals and the seal housing
guide rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3. Replacing bearings on flushing housing . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4. Replacing bearing inside rotation bushing . . . . . . . . . . . . . . . . . . . . . . 7
1.5. Pressure accumulators and rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6. Gear housing, primary gear and stabilizer accumulator . . . . . . . . . . 9
1.7. Removing spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.8. Percussion cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.9. Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.10. Stabilizer spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1. Percussion cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2. Rotation motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3. Assembling and centralizing the stabilizer piston seal . . . . . . . . . . . 28
3.4. Stabilizer spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.5. Installing bearings of gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6. Installing chuck, rotation bushing and rope mountings . . . . . . . . . . 34
3.7. Installing of flushing housing and stabilizer accumulator /
protective cower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.8. Pressure accumulators and rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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2 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


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Tel. +358 205 44 121
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EXIT
D 23700 - 5 en 0106 / TL 3 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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

Fig 1. Flushing housing disassembly

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4 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

1.2. Replacing the flushing housing seals and the seal housing guide
rings
The flushing housing seals (A) 5 pcs and the seal housing guide rings (B) 2 pcs 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
pre--assembled 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

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D 23700 - 5 en 0106 / TL 5 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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”)
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6 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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”)

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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D 23700 - 5 en 0106 / TL 7 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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”)

B
9

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, HFX5T


Repair instructions

C
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 O--ring
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, re--assembly, and filling of pressure accumulator, see
”Pressure accumulators, repair instructions“.
3

Fig 11. Disassembly of pressure accumulators and rear cover


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D 23700 - 5 en 0106 / TL 9 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

1.6. Gear housing, primary gear and stabilizer accumulator


Mount the rock drill (1) to the repair stand (16). Repair stand and lifting eye bolts (17) are
included in special tool set. Fasten bolts (4) on both side of rock drill firmly. Disassemble
the stabilizer accumulator (5a) or protective cover (5b). Remove the front (6) and rear (7)
brackets of the feed wires.

17

16
5a
5b

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

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10 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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.

3
1
4

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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D 23700 - 5 en 0106 / TL 11 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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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12 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

13
7

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

12 7

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

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D 23700 - 5 en 0106 / TL 13 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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. 4 and 10 (See
”Special tools”) as illustrated. Blows with the hammer make the grease drive the bearing
out. (Fig. 17).

4
10

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)

3
1 4

Fig 18. Removal of spacer


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14 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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

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D 23700 - 5 en 0106 / TL 15 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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. 20)

3
A

Fig 20. 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. 21). Disassembling HFX5T rock drill the rubber part
(A) is not used.

3 4 2 A

Fig 21. Disassembling the rear bearing, pilot cylinder and distributor
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16 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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

Fig 22. 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 23. Checking the piston seal grooves (A)

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D 23700 - 5 en 0106 / TL 17 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

1.9. Hydraulic motor


After every 500 operating hours, the condition of the hydraulic motor shall be checked and
the O --rings replaced. Open the rotation motor mounting bolts (2), and pull the motor out.
Check all parts carefully and if there is damaged (scratched, seized, cracked) parts,
replace the motor. (Fig. 24).

Fig 24. Disassembly of the hydraulic motor


If the O--rings are holding the balance plate (5) tight, it can be released by using grease
(2), spacer pin (3) and a punch (10) (Fig. 25).

3
5

10
2

Fig 25. Disassembly of the balance-- and the channel plates

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HYDRAULIC ROCK DRILL HLX5T, HFX5T


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.

1
3
4

Fig 26. 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.

Fig 27. Extracting the pin housing


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D 23700 - 5 en 0106 / TL 19 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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. Use special tool
no. 14 (See ”Special tools”) for inspecting the groove. Check also the groove visually.

14

Fig 28. 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 29. Removal of seal bushing

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20 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

Install O--ring (3) into groove in the seal bushing. When assembling the seal bushing the
temperature difference between the spacer and seal bushing has to be at least 60°C. Use
special tool (no. 15, See ”Special tools”)

3
15

Fig 30. Assembling the seal bushing

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D 23700 - 5 en 0106 / TL 21 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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.
Take measurements C, E, L, M. Measurement “L < (C--E+M)” (Fig. 31), otherwise the body
cylinder must be discarded.

Fig 31. Wear limits

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HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

Part Wear limits

A Shank bearings Replace bearings if wear indicator has


worn off at any point.
B Rotation bushing bearings
F Piston Replace if chamfer has worn off.
G Chuck 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.
H Shank bushing Replace if worn > 1mm or if wearing
surface is cracked.
I Rotation bushing Replace rotation bushing if wear shoulder
has worn down.
J Coupling piece Replace if teeth have worn pointed.
K Stabilizer piston Replace stabilizer piston if wear indicator
groove has worn away or if there are
seizures or hair cracks.
N Rotation bushing end float Replace gear housing if N < 0,5mm.

See Figure 32.

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D 23700 - 5 en 0106 / TL 23 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

A/B

G A
1 mm

H J
B
1 mm N
H F
I
I A

B
G
K
J

Fig 32. Wear limits


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24 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

3. ASSEMBLY
Before assembly:
-- Remove all old O--rings 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. +50_C). 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 33. Assembling the distributor, the piston rear seals and rear bearings

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D 23700 - 5 en 0106 / TL 25 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

Push the pilot cylinder assembly into the body cylinder (1). Mount piston into pilot cylinder
and push front bearing to it’s position inside pilot cylinder (2). (Fig. 334)

1. 2.

Fig 34. Assembling the pilot cylinder

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HYDRAULIC ROCK DRILL HLX5T, HFX5T


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 O--rings. Place
spring washer to the bottom of the housing. Push balance plate to it’s place, locate
according guide pin in housing. Place spacer pin inside balance plate.

11, 12
1

3
2

4
5
6
7
9
8
10

Fig 35. Assembly of rotation motor

1. Stud 7. Disc valve


2. Cardan shaft 8. Space pin
3. Flange 9. Balance plate
4. Gear wheel set 10. Spring washer
5. Channel plate 11. Hex. nut
6. Valve drive 12. Lock washer

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D 23700 - 5 en 0106 / TL 27 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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 (5 mm) is
mounted into the disc valve. Push channel plate to it’s 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.

Fig 36. 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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28 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

3.3. Assembling and centralizing the stabilizer piston seal


Fit the punch (21) to the piston (1). First mount the O--ring (3) on the punch and push the
seal (4) carefully in place by punch ( 20). Take off the punches. Centralizing the piston seal,
lightly push oiled punch (19) over the seal. The seal will settle into the correct position and
form.

4
3
19 20
21 1

Fig 37. Assembling and centralizing the stabilizer piston seal

Lubricate all stabilizer parts. Mount stabilizer pistons into their cylinders through 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 O--rings (1) on the spigots of stabilizer spacer and pin housing. Push (or tap gently
with rubber mallet) pin housing to it’s position.

VC 1

Fig 38. Assembling of stabilizer spacer and pin housing

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D 23700 - 5 en 0106 / TL 29 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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 O--rings (4).

3 4 2 4 1 4

Fig 40. Replacing the shaft seal and bearing


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30 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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. +50°C).

Fig 41. Installing the seals

Insert the bearing housing (1) and the spherical roller bearing (3) into the spacer (4).

1
3

Fig 42. Installing the seal housing and roller bearing

Turn the rock drill’s installation base to horizontal position.

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D 23700 - 5 en 0106 / TL 31 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

Install the O--rings 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. Pre--tighten (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. 150˚C).

11

Fig 44. Gear housing rear bearing


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32 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

2
6

11

Fig 45. Gear housing front bearing

Install the needle bearing into the bearing housing of the rotation shaft using punches 4
and 26 (See ”Special tools”).

4 26

Fig 46. Installation of needle bearing

Install the O--ring 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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Telefax +358 205 44 120
EXIT
D 23700 - 5 en 0106 / TL 33 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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 it’s 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,
tightening order (Fig. 48).

Fig 47. Assembling of gear housing and primary gear

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34 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

1 4

5 6

3 2

7 8

Fig 48. Tightening order

3.6. Installing chuck, rotation bushing and rope mountings

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).
Place front (8) and rear (9) feed rope mounting clamps to spacer claws, fasten with bolts
torque 240 Nm (Fig. 49).

1
2
5
3
4

Fig 49. Assembling of chuck, rotation bushing and rope mountings


E 2006 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
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Tel. +358 205 44 121
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EXIT
D 23700 - 5 en 0106 / TL 35 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

3.7. Installing of flushing housing and stabilizer accumulator /


protective cover
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.
3. Install stabilizer accumulator (3A) with new gasket (4A) or protective cower (3B)
with new gasket (4B). Tighten bolts in 2 phases, pre--tighten 100 Nm and final
torque 200 Nm.

3A
3B

4A
4B

Fig 50. Assembling of the flushing housing

Detach rock drill from assembly stand.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
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36 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

3.8. Pressure accumulators and 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 O--ring 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 and the rear cover

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
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Tel. +358 205 44 121
Telefax +358 205 44 120
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D 23700 - 5 en 0106 / TL 37 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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 Pressure [bar]


High pressure 50
Low pressure 4
Stabilizer accumulator 8

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
38 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


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.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


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D 23700 - 5 en 0106 / TL 39 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

6 4 6 5

120 bar 175 bar

7 8

10
10...210 bar

3 2 9
M
1

1. Tank 6. Pressure relief valve


2. Electric motor 7. Pressure gauge (percussion)
3. Double pump 8. Pressure gauge (rotation)
4. Control valve (percussion) 9. Return filter
5. Control valve (rotation) 10. 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.
E 2006 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN--33311 TAMPERE, Finland
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Telefax +358 205 44 120
EXIT
40 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

5. SPECIAL TOOLS

1. 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. 550 103 96

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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P.O.Box 100
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Tel. +358 205 44 121
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EXIT
D 23700 - 5 en 0106 / TL 41 (42)

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

19. 150 679 28 20. 150 680 98

21. 150 678 08

The table shows some special tools in the tool kit. A complete listing of the contents of the
tool kit is provided in the spare part manual.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
42 (42) D 23700 - 5 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5T, HFX5T


Repair instructions

Notes:

E 2006 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
D 28160-- 8 en 0905 / PIR 1 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL


Repair instructions

CONTENTS

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

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P.O.Box 100
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Tel. +358 205 44 121
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2 (12) D 28160-- 8 en 0905 / 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 2005 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
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Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
D 28160-- 8 en 0905 / PIR 3 (12)

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 b

1. Remove the cap (a).


2. Screw the pressure gauge to the filling valve.
3. Undo the lock nut (b).
4. Wait until the needle of the gauge stops and then read the gauge indication.
5. Close the lock nut (b).
6. 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 power pack if an accumulator is not in place in


the rock drill.

WARNING

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4 (12) D 28160-- 8 en 0905 / 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 2005 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
D 28160-- 8 en 0905 / PIR 5 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL


Repair instructions

6. ASSEMBLY

b
10 Nm
40 Nm secure with glue
20 Nm
b

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.

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL


Repair instructions

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

WARNING

D 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

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P.O.Box 100
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D 28160-- 8 en 0905 / PIR 7 (12)

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

D 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
11 10 13,14 15 4 1

1. Accumulator body
2. Filling valve
3. Locking nut
4. Cap
5. Quick coupling stem
6. Quick coupling sleeve
7. Hose
8. Accumulator pressure gauge
9. Gas bottle pressure gauge
10. Pressure reducing valve
11. Pressure regulating valve
12. Shut--off valve
13. Adapter
14. Seal
15. Elbow adapter

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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.

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P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
D 28160-- 8 en 0905 / PIR 9 (12)

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 it is 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

70
Filling pressure

60

50

40

30

20

10

0
100 120 140 160 180 200 220
Percussion pressure
Upper limit
Lower limit

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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 Percussion pressure

Lower limit

7.3.3. Pressure of stabilizer accumulator

HLX5 T . . . . . . . . . . 8 bar
HFX5 T . . . . . . . . . . 8 bar
HLX5 LT . . . . . . . . 30 bar
HL 800 T . . . . . . . . . 30 bar
HL 1500 . . . . . . . . . 50 bar
HL 1560 T . . . . . . . 40 bar

E 2005 SANDVIK TAMROCK CORP., Tampere Plant


P.O.Box 100
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D 28160-- 8 en 0905 / PIR 11 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL


Repair instructions

8. MOUNTING THE PRESSURE ACCUMULATOR ON THE ROCK


DRILL

D 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.

1 2

4 3

Tightening of the four--bolt accumulator

The four-- bolt accumulator must be tighten by using a cross-- tightening


method 1--3--2--4.
CAUTION

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL


Repair instructions

Notes:

E 2005 SANDVIK TAMROCK CORP., Tampere Plant


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