Rock Drill

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.
C 00640-2 en 0607 1 (2)

C 00640-2 en 0607 2 (2)
Hydraulic rock drill HL 1010, HL 1010 S; Lifting instructions
HYDRAULIC ROCK DRILL HL 1010, HL 1010 S

LIFTING INSTRUCTIONS
CORRECT INCORRECT
Max.
55_
HL 1010--52 / - 60 . . . . . . . . . . . . . 290 kg
HL 1010 Power Extractor . . . . . 350 kg
HL 1010--80 . . . . . . . . . . . . . . . . . 325 kg
HL 1010 S--52 . . . . . . . . . . . . . . . . 290 kg
HL 1010 S--80 . . . . . . . . . . . . . . . . 300 kg
D 20119--2 en 0507 / MS 1 (1)

HYDRAULIC ROCK DRILL HL 1010
CONTENTS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. TAKING A NEW ROCK DRILL IN USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2. Mounting and hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3. Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. INSPECTION AND SERVICE OF FRONT END WITH ROCK DRILL
ON CARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1. Changing the bearings of the flushing housing . . . . . . . . . . . . . . . . . . 8
5.2. Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3. Rotation bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.4. Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.5. Bushing / locking ring pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.6. Wear limits of shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.7. Front bearing of the gear box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.8. Installing directions of the seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.9. Assembly of flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6. CHECKING AND TIGHTENING BOLTS AND TIE RODS . . . . . . . . . . . . . . . . . . 13
6.1. Pressure accumulator bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2. Tie rod tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.3. Rotation motor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4. Flushing device bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.5. Rear cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.6. Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2. Maintenance tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3. Every round drilled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.4. Every week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.5. Basic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.6. Maintenance card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.7. Maintenance follow--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B 23570--2 en 0507/LH 1 (20)

1. GENERAL
These instructions describe in brief the main maintenance procedures for HL 1010
--series hydraulic rock drills.
Sandvik Service is always ready to help and give advice in all maintenance problems. The
qualified maintenance personnel of your Sandvik dealer and original Sandvik 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

pressureless and the hose connections plugged.
WARNING
1. Pressurize the accumulators according to the instructions. See “Pressure

accumulator reparation instructions”.
2. Before a new rock drill is installed the drilling equipment hydraulic system must be
checked and flushed thoroughly. See carrier “Operator’s manual”.
2.2. Mounting and hose connections

The rock drill is mounted on the carriage with four pairs of bolts. In order to avoid damage
it is important to follow the rock drill mounting order.
The circle means that new lock washer pair must be installed whenever
the bolts have been opened.
2 (20) B 23570--2 en 0507/LH

10 11
12
8 5 7 6
D (36 mm)
9 B (36 mm) A (36 mm) C (30 mm)

Fig 1. Rock drill mounting and hose connections 5--12
Tightening order:
-- Tighten nuts A to 300 Nm.
-- Tighten bolts B to 300 Nm.
-- Tighten bolts C to 200 Nm and D to 300 Nm.
-- Tighten nuts A to 600 Nm.
-- Tighten bolts B to 600 Nm.
-- Tighten bolts C to 520 Nm and D to 600 Nm.
Hose connections:
5. Shank lubrication 1/2”
6. Percussion mechanism pressure side 1” (H.P.)
7. Percussion mechanism return side (L.P.)
8. Flushing
9. Shank lubrication collector 1/2”
10. Rotation, leakage line 1/2”
11. Rotation, 3/4”
12. Rotation, 3/4”
2.3. 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 risk of accumulator diagram breakage, the wear of
flushing housing and the cavitation of the percussion mechanism. This
WARNING type of ”idling drilling” is most critical while drilling upwards or cleaning
holes with a pumping motion.
B 23570--2 en 0507/LH 3 (20)

3. LUBRICATION SYSTEM
The rock drill percussion mechanism and the rotation motor are lubricated by the hydraulic
oil flowing through them.
The rotation mechanism and the shank have oil mist lubrication. The lubrication line from
the central oiler is connected to the rear end of the rock drill (connection 5). From there,
the oil mist is ducted to the front end.
4 5 1
Fig 2. Shank lubrication (surface drilling)

1. Rock drill
2. Oiler
3. Drain cock
4. Filling cap
5. Connection nipple
6. Sight glass
1. The shank lubrication oil consumption should be adjusted to min. 300 grams an
hour per drill or more depending on the hole diameter and other local
conditions. Check the function of the shank lubrication by looking at the sight
glass of the oiler and check with hand that the oil is coming to the shank lubrication
nipple (see chapter 4).
4 (20) B 23570--2 en 0507/LH

2. If the oil level in the oiler does not lower during drilling, the reason may be that:
-- the regulating valve is blocked up.
-- the compressor’s oil separation does not function. The compressor oil
flows with air to the oiler.
-- the oil is too heavy for the temperature.
-- in each of the above--mentioned cases the fault should be remedied
without delay.
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. Top up the oiler regularly.
6. If compressed air is taken from the mine’s air supply network or the drill rig’s
compressor does not have a water separator, the compressed--air line should be
fitted with such a separator.
Only underground model HL 1010 S:
Drain holes
2 x ∅ 2 mm
Rear cover cup
Continuous lubrication air blow out!
Check that there is continuous air blow out from the drain holes. If the
holes are plugged, clean them immediately.
WARNING
If the holes are plugged when drilling upholes the oil can fill the rear cover cup and the
piston will hit into the ”oil cushion”. This might loosen the rear cover bolts and cause
eventually severe damage.
B 23570--2 en 0507/LH 5 (20)

4. FLUSHING
2
3 1 4
Fig 3. Rock drill provided with water flushing (underground drilling)
1. Drill
2. Water pressure gauge
3. Pilot--controlled flushing valve
4. Drain holes
The construction of the rock drill equipped with air or water flushing is the same in both
arrangements, except the flushing housing.
The most common reason for seal failures is water. Water may get into the drill if the
machine is in upright position and the shank--blowing is not on.
Water may come with the lubrication air if the oiler has not been drained of water regularly.
Water in the drill’s front end can cause cavitation corrosion in the body parts near the seal
and the wiper ring, and also in the piston.
To prevent the water from entering the rock drill gear housing, the
flushing housing seals must be changed immediately if flushing water
starts leaking through the drain hole (4) fig. 3. The front of the rock drill
WARNING should also be tilted downwards to prevent water from entering the rock
drill when drilling is stopped.
6 (20) B 23570--2 en 0507/LH

5. INSPECTION AND SERVICE OF FRONT END WITH ROCK DRILL

ON CARRIAGE
When taking off flushing housing and shank, turn the rock drill
horizontal, because the rotation bushing and coupling can fall out and
cause injury.
WARNING
Without removing the rock drill from the carriage, the flushing housing (1), the shank (2)
and the coupling (3) can be pulled off after undoing the bolts (4) and the nuts. After
releasing the locking screw (5) you can pull out the rotation bushing (6) with the chuck (7).
The front bearing of the gear box (8) can now be changed too. The locking screw holds
the rotation bushing in the housing, for example, while changing the shank.
5
4
3
1
4
8
7 6
Fig 4. Rod model
1 5 3
4
5 2
Fig 5. Tube model: Disassembly of flushing housing
Tube model: Use the shank as a hammer to get out the locking ring pair (1). Remove the
adapter (2) and the seal (3) before pressing out the seal housing (4) and the bearings (5).
Rod model: Remove the front cover, adapter and seal housing before pressing out the
bearings with a hydraulic press and special tools.
B 23570--2 en 0507/LH 7 (20)

5.1. Changing the bearings of the flushing housing
The bearings must be changed if the wear

indication groove has worn out as shown in
the picture. In such cases, push the
bearings out with a hydraulic press and
punch.
5.2. Coupling
Pull the coupling out from the rotation

bushing. Check and replace if the edges of
the inner teeth are worn sharp.
5.3. Rotation bushing
Check the teeth and the bearing surface for

wear.
5.4. Chuck
The chuck inside the rotation bushing must

be chanced if the wear is over 1 mm
(picture) or if there are some hair cracks.
The chuck is changed by using a hydraulic
press and the punch incl. in the tool set.
5.5. Bushing / locking ring pair
The bushing / locking ring pair must be

changed if the wear is over 1 mm (picture).
8 (20) B 23570--2 en 0507/LH

5.6. Wear limits of shank
max.2 mm max.2 mm The shank must be changed if the 2 mm

2 mm bevel of the striking head is worn out or any
other wear limit is exceeded.
max. 21 mm
min. 92 mm
5.7. Front bearing of the gear box
The bearing must be changed if the wear

indicating grooves have worn out as shown
in the picture.
B 23570--2 en 0507/LH 9 (20)

5.8. Installing directions of the seals

Seals are the most sensitive and important parts of the rock drill. Always replace all the
seals and O--rings when a rock drill is dismantled.
When assembling new seals, grease them well before mounting.
WARNING
Fig 6. Seal housing for rod equipment / water flushing
Fig 7. Seal housing for rod equipment / air flushing
Fig 8. Seal housing for tube equipment / water flushing
10 (20) B 23570--2 en 0507/LH

Fig 9. Seal housing for tube equipment / Air flushing
Fig 10. Flushing housing seals / Water flushing
Fig 11. Flushing housing seals/ Air flushing
If there is a failure at the front end or the rock drill, some pieces might
enter through the hole of the piston to the rear cover. For this reason also
the rear end of the rock drill must be cleaned by taking of the rear cover.
WARNING
B 23570--2 en 0507/LH 11 (20)

5.9. Assembly of flushing housing
6 5
4 3
1
3
6 2
Fig 12. Rod model Tube model
Rod model: Press the bushing (1) in with the bearing and the seal.
Tube model: Press the lowermost bearing bushing (2) fully to the bottom.
Check that the hole for the flushing adapter in the flushing housing and the body
are lined up. Press the seal housing (3) in. Check that the lowermost seal stays in place
during pressing. For this purpose, use a lot of grease on the seal before pressing.
Rod model: Press the bearing to the front cover (4) and install it with the bolts. Tightening
torque is 400 Nm (40 kpm). Use new lock washer pairs. Fit the seal (6) to the neck.
Tube model: Press the uppermost bearing bushing (5) in and fit the seal (6) to the neck.
Install the shank (7) and the pair of the locking rings (8) into the flushing housing. Turn the
flushing housing upside down and tap the locking ring pair in with the shank.
Fig 13. Tube model, shank and locking rings
When installing a new shank, take care that no dirt enters the rock drill
with the shank. Insert the shank carefully through the flushing device, so
that the flushing device seals are not damaged.
WARNING
Use a new gasket when you install the flushing housing unit back to the rock drill, and
tighten the bolts and nuts according to instructions.
12 (20) B 23570--2 en 0507/LH

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 grease.
The following procedure is recommended for checking bolt tightness during
normal maintenance:
1. Check the tightness each bolt by using a 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.
Use only an inspected, high-- quality torque wrench.
3 6
WARNING
5
8
4 1
Fig 14. Rock drill bolts (rod model)
1. Tie rods
2. Pressure accumulator bolts
3. Rotation motor bolts
4. Flushing housing bolts
5. Intermediate gear shaft bolts 250 Nm (25 kpm)
6. Rear cover bolts
7. Front cover bolts 400 Nm (40 kpm)
8. Locking screw 80 Nm (8 kpm)
B 23570--2 en 0507/LH 13 (20)

3
2
1
4
4
1
3
2
Fig 15. Pressure accumulator bolts Tie rod tightening
6.1. Pressure accumulator bolts

The tools required:
-- torque wrench
-- 24 mm socket
1. Lubricate the bolt threads with grease.

2. Pretighten all four bolts to 100 Nm (10 kpm). Correct tightening order is 1--3--2--4.
3. Final tightening torque is 150 Nm (15 kpm). Same tightening order (1--3--2--4)
should be used.
6.2. Tie rod tightening

The tools required:
-- torque wrench
-- 36 mm socket
1. Lubricate the threads and the nut faces with grease.

2. Tighten first slightly the rear nuts to bottom.
3. Pretighten all four nuts to 300 Nm (30 kpm). Correct tightening order is 1--3--2--4.
4. Final tightening torque is 600 Nm (60 kpm). Same tightening order (1--3--2--4)
should be used.
60_ Alternative for tightening: Pretighten up to

300 Nm and then turn 60_ more, see
picture.
14 (20) B 23570--2 en 0507/LH

2
3
1
Fig 16. Rotation motor bolts Flushing device bolts
6.3. Rotation motor bolts

The tools required:
-- torque wrench
-- 24 mm socket
1. Lubricate the bolt threads with grease.

2. Tighten all four bolts to 150 Nm (15 kpm). Correct tightening order is 1--3--2--4.
6.4. Flushing device bolts

The tools required:
-- torque wrench
-- 36 mm socket
1. Lubricate the bolt and nut threads with grease.

2. Tighten the bolts step by step up to 600 Nm (60 kpm).
B 23570--2 en 0507/LH 15 (20)

Fig 17. Rear cover bolts Setscrew
6.5. Rear cover bolts

The tools required:
-- torque wrench
-- 30 mm socket
1. Lubricate the bolt threads with grease. Use new lock washer pairs.
2. Pretighten all four bolts to 200 Nm (20 kpm). Use cross--tightening method. See
tie rod tightening.
3. Final tightening torque is 400 Nm (40 kpm). Same tightening order should be used.
6.6. Setscrew
The tools required:
-- torque wrench
-- 19 mm socket
1. Lubricate the bolt threads with grease. Use new bonded seal.
2. Tighten the bolt to 80 Nm (8 kpm).
16 (20) B 23570--2 en 0507/LH

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 damage and unwanted stops can be avoided.
The maintenance intervals are different depending on the local conditions, and they must,
therefore, be determined according to 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
a fault that can result in major damage or a production stop.
7.2. Maintenance tools and parts

Ensure that the operator has proper tools and parts on the rig for the daily and
weekly maintenance tasks.
The rock drill tool set includes a torque wrench and sockets. Due to the tight dimensions
a special socket and wrench adapter is required for tightening the rock drill tie rods and
middle mounting bolts on the carriage.
Fig 18. Maintenance tools
Other rock drill parts that should be available at the rig for maintenance are gasket,
flushing seals, and shank adapter.
7.3. Every round drilled

1. Check seal tightness during drilling by observing check holes of flushing device.
2. Check flushing device bolt tightness.
3. Check possible oil leaks.
4. Check hoses and connections.
5. Check the mounting of the rock drill to the carriage. If it is not tight, loosen
up the front and back pairs of mounting bolts. After that fasten up the bolts
with right order (Section 2). Also check the retighten the tie rods always when
the rock drill mounting to the carriage has required retightening.
B 23570--2 en 0507/LH 17 (20)

7.4. Every week

1. Check hour meter reading.
2. Check accumulator pressures and protective caps.
3. Check intermediate gear locking plate, and bolt tightness.
4. Check shank, chuck, and coupling.
5. Check rotation motor and accumulator bolt tightness.
6. Check the tie rods tightness. If these are not tight, loosen up the front and
back pairs of mounting bolts. After that fasten up the tie rods and then the
mounting bolts with the right order (Section 6 and 2).
7.5. Basic maintenance

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

Each rock drill has its own maintenance 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 the 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 maintenance card presented on the next page.
18 (20) B 23570--2 en 0507/LH

7.7. Maintenance follow--up

In order to follow the maintenance of a rock drill, a maintenance card of the type presented
below can be used.
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
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
Flush. housing seal
Shank bearings
Intermediate gear
Interm. gear bearing
Interm. gear pin
Percussion Rotation
Remarks mechanism tested mechanism tested
Cont.
B 23570--2 en 0507/LH 19 (20)

Notes:
20 (20) B 23570--2 en 0507/LH

Hydraulic rock drill HL 1010; Repair instructions

Repair Instructions
D 23570--2 en 0507 / MS 1 (32)

CONTENTS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. REPAIR FACILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1. Installing the percussion piston seals . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2. Rotary actuator seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1. Removing the flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2. Removing the rotation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3. Removing the rear cover and percussion mechanism . . . . . . . . . . . . 13
5.4. Percussion mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.5. Removing the pressure accumulators and front cylinder . . . . . . . . . 16
5.6. Removing and installing the spacer bearings and sealing bushing 18
5.7. Removing and installing the bearings of the gear housing . . . . . . . 21
6. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1. Installing the intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2. Installing the hydraulic motor and spacer . . . . . . . . . . . . . . . . . . . . . . . 23
6.3. Installing the front and body cylinders and tightening
the side bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4. Installing the pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5. Percussion mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.6. Installing the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.7. Installing the coupling and the rotation bushing . . . . . . . . . . . . . . . . . 28
6.8. Installing the flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 (32) D 23570--2 en 0507 / MS

1. GENERAL
These instructions are intended for persons servicing and repairing 1010 series hydraulic
rock drills. Read the instructions carefully and follow them when disassembling,
assembling, and servicing the rock drill.
Always use a hoist when tilting the rock drill in the assembly stand.
CAUTION
2. REPAIR FACILITIES
Follow the instructions in the regular maintenance table. With regular preventive
maintenance, optimal utilisation is achieved. Replace any worn part promptly to avoid
more serious damage.
Before performing installation, check carefully that the parts are clean since even new
parts can be dirty (a bottle brush is useful for cleaning the components of the rock drill
cylinder). The use of unauthorised, i.e. non--OEM, spare parts has been found to cause
increased costs in almost all cases. The warranty for the entire system becomes void
immediately if any part is replaced with a non--OEM part.
Checking the tightness of the side bolts is one of the most important maintenance
procedures for a rock drill. Neglecting this procedure can cause rapid wear on the rock
drill frame’s end faces. Faultless operation of a rock drill stems largely from appropriate
use of the repair facilities. Make sure that the repair site is clean.
Example of equipment available at repair facilities :
2 4 Characteristics of good repair facilities:

-- well lit
-- appropriate washing facilities
1 5 6
10 -- compressed air
-- free of dust
7 8 9 -- has all required documentation
-- has the required tools
Figure 1. Repair facility
1. Spare part storage 6. Vice

2. Hydraulic press, 30 t 7. Bench drill
8. Tools
4. Washing bay 9. Assembly stand
5. Rubber-- coated work table 10. Hoist
The drill bit grinding device should not be housed at the rock drill repair
facility.
CAUTION
D 23570--2 en 0507 / MS 3 (32)

3. TOOLS
Sandvik supplies complete special toolkits for repairs. Refer to the tool sets’ spare part
sheet.
Figures 2, 3 and 4 show the tools required for repair work, grouped by stages of the
process.
Figure 2. Tools for disassembling and assembling the rock drill
Figure 3. Tools for the hydraulic press
Figure 4. Tools for disassembling, assembling, and testing the pressure accumulator
4 (32) D 23570--2 en 0507 / MS

4. SEALS
The seals are the most sensitive and important components of a rock drill. When
disassembling a rock dill, always replace all seals and O--rings.
Removing the seals:
Be careful not to scratch the seal grooves and components inside

the rock drill.
Figure 5. Removing the seal

Do not scratch the seal grooves.
CAUTION
4.1. Installing the percussion piston seals

When installing the seal, press it lightly and equally from both
sides so that the seal settles in the correct position. In particular,
the seal lip (a) is easily damaged by, for example, careless han-
dling during installation of seals. Fig. 7.
Figure 6. Installation method for the seal
Seals are easier to install if warmed in oil (to 50–60_C).

Use only your fingers when installing the seals. Be careful, and
do not use your fingernails.
a
Figure 7. Seal lip
Apply oil to the seal groove. Bend the seal as shown in the figure.
Figure 8. Bend the seal as shown in the figure.
D 23570--2 en 0507 / MS 5 (32)

Storing the seals:

-- Keep the seals in their original packages and away from direct sunlight.
Ensure that the seals stay clean at the installation site.
CAUTION
Pay attention to the correct position of the seal lip.
CAUTION
Seal housing
Figure 9. Seal housing
Spacer
Figure 10. Spacer
6 (32) D 23570--2 en 0507 / MS

4.2. Rotary actuator seals

It is recommended to replace the O--rings of the rotary actuator (1) and (2), the needle
bearing in the intermediate gear (3) and the O--ring (5) of the pin (4) every time the piston
seals are replaced. Check the wear on the pin and the needle bearing as well (6).
4 3 2 1
Figure 11. Rotary actuator seals
If the seals do not last for the standard maintenance interval, usually the reason is one
of the following:
-- The filter is clogged or of the wrong type (non--OEM)

-- Incorrect oil grade
-- Incorrect installation of the seals
-- Seals damaged at the time of installation
-- Water in oil
-- Poor condition of the sliding surfaces
-- Piston is pitted or scratched
D 23570--2 en 0507 / MS 7 (32)

5. DISASSEMBLY
The HL 1010 rock drill should be disassembled and its components checked every 500
operating hours.
Disassembling and assembling the rock drill requires expertise and familiarity with the
rock drill. The environment must be dry, free of dust, and clean.
The facilities must include a sink and compressed air for cleaning the rock drill
components.
Before disassembly, the rock drill must be washed externally with, for example,
high--pressure water. In addition, we recommend that the rock drill be washed externally
with a brush and appropriate solvent before it is brought to the final repair location. A split
barrel is ideal for this purpose.
Assembly stand
Attach the assembly stand (1) carefully to the repair shop floor with the mounting bolts.
Figure 12. Assembly stand
Install the rock drill on assembly stand no. 098 380 88. Fit and attach the bolts (3) (2 pcs)
and the latch (4) on the rear end of the rock drill, and the front end bolts (2) (2 pcs).
8 (32) D 23570--2 en 0507 / MS

41
28 4
30 92
34 32
31 15
41,44,50 (H.P)
29
42,45,50 (L.P) 13
11
43,46,52
1
32,37,7 37
8,32,37,89
10
20,21
14
35
3
25
27
18
2
25
16
42
17
39
22
40
57
36
43
71
59
Figure 13. Reference numbers
The reference numbers in this figure are used as instructions for disassembling and
assembling the rock drill.
D 23570--2 en 0507 / MS 9 (32)

5.1. Removing the flushing housing
24
40
10 57
36
Figure 14. Flushing housing

-- Remove the nuts (40) and bolts (36) of the flushing housing.
-- Pull out the flushing housing and its shank.
-- Remove the seal (57).
-- Remove the shank from the flushing housing.
-- Remove the nipple (24).
-- Remove the bolts (10) and the flushing housing cover.
-- Pull the flushing housing assembly out.
5.2. Removing the rotation mechanism

22
16
17
Figure 15. Coupling and rotation bushing

Remove the clamp screw (22) and pull out the coupling (17) and rotation bushing (16).
10 (32) D 23570--2 en 0507 / MS

Checking the coupling and the rotation bushing:

-- wear on the outer surface
-- is there too much wear on the pulling side of the inner tooth?
-- are there craters in the teeth?
Refer to the section ‘Operation and maintenance’. Replace the parts if necessary.
Detaching the chuck
Figure 16. Detaching the chuck
Required tools:
-- Punch 150 169 88
-- Die 151 738 08
Use a hydraulic press and special tool when pressing the chuck out from the rotation
bushing. When assembling, also use a press and a special tool (page 15).
Removing the hydraulic motor
38
20,21
27
Figure 17. Removing the hydraulic motor
D 23570--2 en 0507 / MS 11 (32)

Turn the rock drill to the vertical position.

Remove the nuts of the side bolts (20) and pull out the side bolts (21).
Remove the hydraulic motor mounting bolts (38) and pull the hydraulic motor out from the
gear housing. Remove the O--ring (27).
Removing the intermediate gear and replacing the bearings
19
39 42 1
25 18 25
Figure 18. Removing the intermediate gear and replacing the bearings
Remove the screws (39) and the lock washer pairs (42) (see Figure 17). Remove the shaft
journal (19) and the O--ring. Let the intermediate gear (18) drop down, and remove the
spacers (25).
Check the wear on the spacers and shaft surface. Replace the parts if necessary.
Replacing the intermediate gear bearings
Required tools
-- Punch 085 964 88
-- Die 087 855 98
Always replace the needle bearings after 500 percussion hours. Use a hydraulic
press, punch (1), and die (2) to push the needle bearing (2) out of the intermediate gear
(see Figure 18).
Check the wear on the intermediate gear teeth.
Replace the parts if necessary.
Assembling the intermediate gear
Required tool
-- Punch 085 964 88
Press the first needle bearing into the intermediate gear, using a hydraulic press. Turn the
gear the other way round, and press the other needle bearing in.
Ensure that the hard ends of the needle bearings are on the outside of the gear
faces.
12 (32) D 23570--2 en 0507 / MS

5.3. Removing the rear cover and percussion mechanism

Removing the rear cover
41
4
28
92
Figure 19. Removing the rear cover
Open the latch and bolts (2 pcs) from the rear of the assembly stand. Turn the rock drill
to vertical position.
Remove the bolts (41), and lift the rear cover (4) off (see Figure 19). Remove the seal (92).
Remove the O--ring (28).
Check the wear on the rear cover (refer to the section ‘Wear limits’).
Removing the percussion mechanism
Figure 20. Removing the percussion mechanism
Required tool
-- Punch 151 738 08
Thread the puller into the piston (see Figure 20). Lift the piston out of the cylinder. This
will also extract the rear cylinder, rear bearing, distributor and seal housing.
D 23570--2 en 0507 / MS 13 (32)

5.4. Percussion mechanism
11
12
Figure 21. Percussion mechanism

Disassemble the piston assembly by removing the rear cylinder, front bearing and the
distributor as well.
Check the piston
-- If there are light contact tracks on the piston, it can be polished with a felt wheel
-- If there is wear on the impact surface, refer to the section ‘Wear limits’
-- If there are cracks or cuts in the piston or if its edge is worn, replace the piston
-- The piston sealing surface can be polished with a felt wheel if necessary.
Never grind the piston.
CAUTION
Check the distributor

-- If the distributor has minor damage, remove light scratches by polishing with a felt
wheel.
-- If the distributor has seizure marks, replace the distributor.
Never grind the distributor.
CAUTION
Removing the seal housing
11
Figure 22. Removing the seal housing from the rear bearing
14 (32) D 23570--2 en 0507 / MS

Required tools
-- Punch 151 169 88
-- Punch 151 738 08
Use punches when removing the seal housing (see Figure 22). Screw the short punch to
the seal housing and push the long punch through the cylinder and screw it on the short
punch. Use a rubber mallet when striking the seal housing out from the rear cylinder (11)
(see Figure 21).
Removing the rear bearing
13
11
Figure 23. Removing the rear bearing from the rear cylinder
Required tools
-- Punch 151 169 88
-- Punch 151 738 08
Use the punches that are screwed together when removing the rear bearing. Use a rubber
mallet and strike the bearing (13) out from the rear cylinder (11) (see Figure 23).
Check the rear cylinder.

-- If there are cavitation marks on the rear cylinder, remove them by polishing with
a felt wheel.
-- Install new O--rings.
-- Replace the parts if necessary.
Never grind the rear cylinder.
CAUTION
D 23570--2 en 0507 / MS 15 (32)

5.5. Removing the pressure accumulators and front cylinder

Removing the pressure accumulator
Before removing the accumulator from the rock drill, release the
pressure by opening the filling valve.
CAUTION
37
8
89
Figure 24. Removing the pressure accumulator

Open the accumulator bolts (37) (see Figure 24). Remove the accumulator (8). Use a
screwdriver. Remove the seal (89).
Fit a protective plug immediately into the opening on the body cylinder.
Refer to the section ‘Pressure accumulators’.
Removing the body cylinder
Figure 25. Removing the front cylinder

Lift the body cylinder off (see Figure 25). Use the accumulator bolts during lifting. Remove
the front cylinder as well.
Check the wear limits of the end faces.
16 (32) D 23570--2 en 0507 / MS

Replacing the front cylinder bearing
Figure 26. Replacing the front cylinder bearing

Required tools
-- Punch 150 173 28
-- Die 087 969 38
Remove the bearing bushing from the front cylinder only when it is damaged.
Use a hydraulic press and push the bearing bushing out from the front cylinder. The new
bearing is assembled as shown in Figure 26.
D 23570--2 en 0507 / MS 17 (32)

5.6. Removing and installing the spacer bearings and sealing

bushing
Remove the spacer from the gear housing and check the wear on the bearing surface.
Replace the bearing if the indicator grooves (A) are worn out.
Removing the bearing
2
1
A
Figure 27. Removing the bearing

Required tools
-- Second punch (1)
-- Punch (2) 550 342 15
Installing the bearing

Cool the bearing to –20°C prior to installation.
Install the bearing so that the spring pin (1) lines up with the spacer hole (2), and the
bearing hole (3) on the spring pin. Thus, the grooves (4) of the bearing and spacer are
aligned.
2
3
Figure 28. Installing the bearing
18 (32) D 23570--2 en 0507 / MS

Checking the sealing bushing

Remove and replace the sealing bushing if the seal groove width is 4.35 mm or more. Use
a gauge (1) 150 746 48 for checking.
Figure 29. Checking the groove width of the sealing bushing of the spacer
Removing the sealing bushing
Figure 30. Removing the sealing bushing of the spacer
Required tools
-- Second punch (1)
-- Locking plates (2)
D 23570--2 en 0507 / MS 19 (32)

Installing the sealing bushing

Install the O--ring (1) on the spacer and install the seal housing using a suitable punch (2).
1
2
Figure 31. Installing the spacer sealing bushing
20 (32) D 23570--2 en 0507 / MS

5.7. Removing and installing the bearings of the gear housing

Removing the bearings
A B
Figure 32. Removing the bearings

Required tools:
-- Punch 151 171 78
-- Punch 150 172 08
-- Screwdriver
-- Hammer
Using a hydraulic press, remove the rear bearing bushing from the gear housing.
Remove the front bearing bushing. Use a screwdriver and a hammer. Do not scratch the
inner surface of the bearing housing.
Installing the bearings
A B
Figure 33. Installing the bearings

Required tool:
-- Punch 150 171 78
Use a hydraulic press and push the new bearing bushings into the gear housing.
D 23570--2 en 0507 / MS 21 (32)

6. ASSEMBLY
Work especially carefully when assembling the rock drill. Check that all parts are
completely clean.
Before assembling the rock drill, check all parts that are subject to wear, such as bearings
and pressure accumulator diaphragms, and replace if necessary. The wear limits for all
parts are shown in the wear limit table. (Refer to section 9.)
The parts must be lubricated -- with, e.g., motor oil -- before assembly.
All mating surfaces must be absolutely dry and clean.
CAUTION
Assembly stand
When assembly of the rock drill commences, the platform of the assembly stand is in a
horizontal position. Ensure that the mounting bolts (2 pcs) and the latch are closed.
Attach the gear housing assembly to the assembly stand. Tighten the bolts and nuts
6.1. Installing the intermediate gear
42
19
39 42 39
250 Nm
25 18 25
Figure 34. Assembling the intermediate gear and tightening the pin
Install the support plates (25) (use grease to keep the plates in place) and the intermediate
gear (18) to the gear housing. Check that the O--ring is in the shaft journal (19) and strike
the shaft journal carefully into place. Ensure that the support plates stay in place during
assembly.
Tighten the screws (39) to 250 Nm (25 kpm). Use new locking washer pairs (42).
22 (32) D 23570--2 en 0507 / MS

6.2. Installing the hydraulic motor and spacer
Turn the assembly stand to the vertical position and lock it in this position by installing a
bolt in the bottom of the stand.
38
26 2
6
3 1
27
23 3
150 Nm 4
Figure 35. Installing the rotary actuator and spacer
Lubricate the face of the hydraulic motor with grease. Place the hydraulic motor (6),
O--ring (27) and screws (38) in the gear housing (2) . Tighten the bolts as follows:
Required tools:
-- Torque wrench
-- 22 mm socket
Lubricate the screws with grease.
Tighten to 150 Nm (15 kpm). Tighten in a crosswise pattern (1--3--2--4).
Install the O--rings (23 and 26) before installing the spacer (3) in the gear housing.
Check that the flange seals and O--rings are in place. Refer to the section ‘Seals’ for the
correct way to install the seals to the flange.
D 23570--2 en 0507 / MS 23 (32)

6.3. Installing the front and body cylinders and tightening the side
bolts
600 Nm (300 Nm)
10
4
1
3
2
20
21
Figure 36. Installing the front and body cylinders and tightening the side bolts
Install the front cylinder (10). Check that the bearing bushings are in place. Lower the body
cylinder (1) carefully.
Install the side bolts (20) and the nuts (21) in their proper position.
Tighten the side bolts
Tighten the side bolts as follows:
Required tools:
-- Torque wrench
-- Socket, 36 mm
Screw the rear nuts all the way down. Install the side bolts (see Figure 34).
Lubricate the threads.
Install the front nuts and pre--tighten all 4 nuts to 300 Nm (30 kpm) using the torque
wrench. Use the tightening sequence 1--3--2--4.
The final tightening torque is 600 Nm (60 kpm). Use the same tightening sequence.
24 (32) D 23570--2 en 0507 / MS

6.4. Installing the pressure accumulators
2 3
1 44 150 (100) Nm
Figure 37. Tightening the pressure accumulator bolts
Lubricate the O--rings and bolts (37).

Strike the batteries (7 and 8) into place using a rubber mallet. Refer to the section
‘Pressure accumulators’ for repair instructions.
The high---pressure accumulator (H.P.) in located on the right side of the

rock drill when viewed from the rear. Correspondingly, the low---pressure
CAUTION
accumulator (L.P.) is on the left.
Tightening the pressure accumulator bolts

Install the bolts and tighten as follows:
Required tools:
-- Torque wrench
-- Socket, 24 mm
Lubricate the screws.
Pre--tighten all four bolts to 100 Nm (10 kpm) with a torque wrench. Use the tightening
sequence 1--3--2--4.
The final tightening torque is 150 Nm (15 kpm). Use the same tightening sequence
(1--3--2--4).
D 23570--2 en 0507 / MS 25 (32)

6.5. Percussion mechanism
11
12
Install the distributor (12), rear cylinder (11) and the sealing bushing on the piston (9)
journal as shown in Figure 36.
Install the gear housing in the rear cylinder so that the surfaces are level.
Piston and rear cylinder
Required tool:
-- Punch 151 738 08
Apply plenty of oil to the inner surface of the body cylinder.
CAUTION
Lift the percussion cartridge into the body cylinder. Use a lifting strap and the same special
tool used for lifting the percussion cartridge (20).
Place the rear cylinder on a clean table. Install the rear bearing on the opening and strike
the rear bearing lightly to the bearing seal so that the surfaces are level.
Install the rear cylinder and the rear bearing assembly to the body cylinder.
Refer to the section ‘Seals’, and make sure that all seals are correctly
installed. Also check that the components are installed facing the right
CAUTION
direction.
26 (32) D 23570--2 en 0507 / MS

6.6. Installing the rear cover
41
4 400 (200) Nm
53
28
92
Figure 38. Installing the rear cover
Required tools:
-- Torque wrench
-- Socket 30 mm
Install the rear cover and screws (41) on the body cylinder (1). Place the O--ring (28) in
the rear cover (4) groove prior to installation. Use new locking washer pairs (53). The
surfaces must be dry and clean.
Tightening the rear cover bolts
Tightening torques
-- Pre--tighten to 200 Nm (20 kpm).
-- Final torque is 400 Nm (40 kpm)
-- Tighten in a crosswise pattern.
D 23570--2 en 0507 / MS 27 (32)

6.7. Installing the coupling and the rotation bushing
22
56 80 Nm
16
17
20,21
Figure 39. Installing the coupling and the rotation bushing

Remove the assembly stand and turn it to the horizontal position. Close the screws of the
assembly stand and the trigger.
Install the rotation bushing (16) and the coupling (17) in the gear housing. Turn the clamp
screw (22) in place. Remember to use the Usit seal (56).
Tighten the clamp screw (22) to 80 Nm (8 kpm).
6.8. Installing the flushing housing
350 (100) Nm
40
57
36
Figure 40. Installing the flushing housing

Tightening the flushing housing bolts:
Required tools:
-- Torque wrench and 36 mm socket
-- Spanner 27 mm
-- Install the flushing housing, seal (57), screws (36) and nuts (40).
Lubricate the threads.
Pre--tighten all four nuts to 100 Nm (10 kpm) with a torque wrench.
The final tightening torque is 350 Nm.
28 (32) D 23570--2 en 0507 / MS

7. TEST RUN
Test run the rock drill, and make sure that it operates properly.
During the test run, monitor:
-- the mating surfaces of the components and the front end of the rock drill for oil leaks
-- the operation of the shank lubrication
-- flushing operation
-- the pressures and the temperature
8. WEAR LIMITS
F
I
D
E B
H
C
G
A
Figure 41. Wear limits
D 23570--2 en 0507 / MS 29 (32)

PART NAME WEAR LIMIT
A Shank bearings The bearing must be replaced when the

wear indicator groove has worn down to
the level of the surface at any point.
B Gear housing Manufacturing 240 mm
Reject limit 239 mm
C Gear housing front bearing The bearing must be replaced when the
D Gear housing rear bearing The bearing must be replaced when the
E Intermediate gear Replace when the shaft/sleeve is worn
or if the shaft surface is damaged.
F Piston Replace when the piston bevel is worn
down.
G Chuck The chuck must be replaced if it has
dents or cracks that are over 1 mm
deep.
H Coupling The coupling must be replaced if the
edges of the inner teeth have worn to a
point.
I Spacer bearing The bearing must be replaced when the
lubrication grooves have worn down to
the level of the surface.
J Sealing bushing The seal groove wear limit is 4.35 mm.
30 (32) D 23570--2 en 0507 / MS

Percussion cartridge fitting between the spacer and rear cover
B A
Figure 42. Percussion cartridge / measuring points

Wash the percussion cartridge (1) components. Before assembly and measurement,
check that the components are clean and that no oil film is present.
Measure values (A), (B), and (C). The difference between the values (A) and (B) must be
greater than value (C). If this is not the case, reject parts 3 and 4.
D 23570--2 en 0507 / MS 31 (32)

Notes:
32 (32) D 23570--2 en 0507 / MS

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
D 28160--9 en 0507 / MS 1 (12)

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. Sandvik 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
2 (12) D 28160--9 en 0507 / MS

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
D 28160--9 en 0507 / MS 3 (12)

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
4 (12) D 28160--9 en 0507 / MS

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.
D 28160--9 en 0507 / MS 5 (12)

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
6 (12) D 28160--9 en 0507 / MS

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
D 28160--9 en 0507 / MS 7 (12)

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.
8 (12) D 28160--9 en 0507 / MS

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
D 28160--9 en 0507 / MS 9 (12)

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
10 (12) D 28160--9 en 0507 / MS

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
D 28160--9 en 0507 / MS 11 (12)

Notes:
12 (12) D 28160--9 en 0507 / MS

Hydraulic motors OMSU, OMT and MTA; Repair instructions
OMSU
OMT
MTA
CONTENTS
1. REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1. Checking the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2. Timing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3. OMSU hydraulic motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1. Assembling the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2. Installing the bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4. OMT hydraulic motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.1. Fastening the gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5. MTA hydraulic motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D 28400--4 en 0507 / MS 1 (8)

1. REPAIR
In order to ensure uninterrupted use, cleanliness must be considered in all maintenance

and repair procedures related to hydraulic equipment. We recommend that all
maintenance and repair procedures for hydraulic motors be performed in a clean and
dust--free room.
When disassembling a hydraulic motor, always replace all seals and O--rings.
1.1. Checking the motor
2 1
5 to 10 Nm
Non--return valve
Check the condition of the ball (1) and the valve surfaces (2). If they are damaged, the
valve will leak and the motor must be replaced.
Gear wheel set

If the parts have cracks or indications of motor jamming, or if the gear wheel set is worn
out, the motor should be replaced. Retain and install the outer and inner ring of the same
gear wheel set as a pair.
2 (8) D 28400--4 en 0507 / MS

1.2. Timing the motor
Place the valve plate (1) on top of the balance plate, and mark (with chalk or ink) the drive
spline, which lines up with the hole (A) on the outer rim of the valve.
Mark the bottom of the valve drive shaft spline. Place the valve drive shaft such that the
marked spline bottom is aligned with the marked spline on the valve and the end with the
widest splines (5 mm) is mounted in the valve. Push the channel plate into place.
Mark the inner rotor with the spline bottom that acts against the bottom of the outer splines.
Mount the gear wheel set, and align the rotor (3) such that the mark is aligned with the
bottom of the marked spline of the valve drive shaft. Turn the rotor anticlockwise until the
splines engage with the splines on the drive shaft splines.
D 28400--4 en 0507 / MS 3 (8)

1.3. OMSU hydraulic motors
3 Nm
2 3 3 Nm
4
5
3
6
7
8 6
9
10
11
12 13
14 15 16 17 18
19
20 21
22 23 24
5 to 10 Nm 80 Nm
The motor seal set includes parts 2, 6, 14, and 15. Refer to the spare parts manual.
Never rotate the motor without a shaft, as this could damage the plate.
CAUTION
4 (8) D 28400--4 en 0507 / MS

1.3.1. Assembling the motor
3 Nm
1 4
Carefully press the cover (2) into place. Make sure that the clearance
between the cover and the frame is equal on all sides before you tighten
the bolts (1). Otherwise the shaft (4) can be behind the corner (3) and the
CAUTION
bearing (5) will break the rear cover when the bolts are tightened.
1.3.2. Installing the bearings
33
34
35
21
35
19
Install the bearings (35) and the bushing (21) on the shaft (19) as shown in the figure.
Tighten the nut (33) with a special tool (tightening torque: 25 Nm), and bend the edges
of the locking plate (34) on top of the nut (33).
D 28400--4 en 0507 / MS 5 (8)

1.4. OMT hydraulic motors
100 Nm
Secure with glue
2
2
3
24 Nm
Secure with glue
4
5
5
60 Nm
Secure with glue
and point pin
6
7
190 Nm
The motor seal set includes parts 1 through 7. Refer to the spare parts manual.
6 (8) D 28400--4 en 0507 / MS

1.4.1. Fastening the gear wheel

Two different gear wheels are used on the OMT hydraulic motors. Depending on the gear
wheel type, you must use sealing bushings (A) of different length (37 mm or 32 mm); refer
to the figure.
Old gear wheel
37 mm
New gear wheel

100 Nm; secure with glue
(Loctite 270)
24 Nm; secure with glue

(Loctite 270) 190 Nm
Pressed--on fit
preheat max.: 150°C;
seal with glue (Loctite 250)
60 Nm; secure with
32 mm glue and point pin
D 28400--4 en 0507 / MS 7 (8)

1.5. MTA hydraulic motors
160 Nm
Secure with glue
5,8
2
11
10
6
9
3
9
12
24 Nm
Secure with glue 13
14
14
15
19
20
7
60 Nm
20
Secure with glue
and point pin
21
22
18
190 Nm
The motor seal set includes parts 9, 11, 12, and 19 through 22. Refer to the spare parts
manual.
8 (8) D 28400--4 en 0507 / MS

Rock Drill

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ROCK DRILL SERVICE CARD N:o

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

REPLACED PARTS / PART INSPECTION

C 00640-2 en 0607 1 (2)

HYDRAULIC ROCK DRILL HL 1010, HL 1010 S

D 20119--2 en 0507 / MS 1 (1)

B 23570--2 en 0507/LH 1 (20)

2. TAKING A NEW ROCK DRILL IN USE

New rock drills are delivered with the pressure accumulators

1. Pressurize the accumulators according to the instructions. See “Pressure

2.2. Mounting and hose connections

2 (20) B 23570--2 en 0507/LH

9 B (36 mm) A (36 mm) C (30 mm)

2.3. Test run

B 23570--2 en 0507/LH 3 (20)

Fig 2. Shank lubrication (surface drilling)

4 (20) B 23570--2 en 0507/LH

Only underground model HL 1010 S:

B 23570--2 en 0507/LH 5 (20)

Fig 3. Rock drill provided with water flushing (underground drilling)

6 (20) B 23570--2 en 0507/LH

5. INSPECTION AND SERVICE OF FRONT END WITH ROCK DRILL

Fig 4. Rod model

Fig 5. Tube model: Disassembly of flushing housing

B 23570--2 en 0507/LH 7 (20)

5.1. Changing the bearings of the flushing housing

The bearings must be changed if the wear

Pull the coupling out from the rotation

5.3. Rotation bushing

Check the teeth and the bearing surface for

The chuck inside the rotation bushing must

5.5. Bushing / locking ring pair

The bushing / locking ring pair must be

8 (20) B 23570--2 en 0507/LH

5.6. Wear limits of shank

max.2 mm max.2 mm The shank must be changed if the 2 mm

5.7. Front bearing of the gear box

The bearing must be changed if the wear

B 23570--2 en 0507/LH 9 (20)

5.8. Installing directions of the seals

Fig 6. Seal housing for rod equipment / water flushing

Fig 7. Seal housing for rod equipment / air flushing

Fig 8. Seal housing for tube equipment / water flushing

10 (20) B 23570--2 en 0507/LH

Fig 9. Seal housing for tube equipment / Air flushing

Fig 10. Flushing housing seals / Water flushing

Fig 11. Flushing housing seals/ Air flushing

B 23570--2 en 0507/LH 11 (20)

5.9. Assembly of flushing housing

Fig 12. Rod model Tube model

Fig 13. Tube model, shank and locking rings

12 (20) B 23570--2 en 0507/LH

6. CHECKING AND TIGHTENING BOLTS AND TIE RODS

Use only an inspected, high-- quality torque wrench.

Fig 14. Rock drill bolts (rod model)

B 23570--2 en 0507/LH 13 (20)

Fig 15. Pressure accumulator bolts Tie rod tightening

6.1. Pressure accumulator bolts

1. Lubricate the bolt threads with grease.

6.2. Tie rod tightening

1. Lubricate the threads and the nut faces with grease.

60_ Alternative for tightening: Pretighten up to

14 (20) B 23570--2 en 0507/LH