Original instructions

887 1 en 2011-08-10

Power Extractor HLX 5 -series

Maintenance and repair
Table of Contents

1. DESCRIPTION ............................................................................................................................... 5

2. GENERAL ...................................................................................................................................... 6

3. PRINCIPLE OF OPERATION ........................................................................................................ 7

4. OPERATION .................................................................................................................................. 8

5. HOSE CONNECTIONS .................................................................................................................. 9

6. DETACHING AND FASTENING OF THE POWER EXTRACTOR WHEN THE ROCK DRILL
IS FASTENED TO THE FEED ....................................................................................................... 10
6.1. Detaching the Power Extractor ..................................................................................................................... 11
6.2. Attaching the Power Extractor ...................................................................................................................... 13

7. CROSS SECTION OF THE POWER EXTRACTOR, LUBRICATION CIRCULATION AND THE

MOUNTING DIRECTION OF THE SHANK SEALS ...................................................................... 14
7.1. Cross section ..................................................................................................................................................... 14
7.2. Lubrication circulation .................................................................................................................................... 15
7.3. Installation direction of the shank and shank bushing seals ............................................................... 16

8. DISASSEMBLY .............................................................................................................................. 17
8.1. Detaching the front cover and the seal housing ...................................................................................... 17
8.2. Replacing the shank bearing ......................................................................................................................... 18
8.3. Detaching the pull bushing and the damping cylinder .......................................................................... 19
8.4. Replacing the damping cylinder bearings ................................................................................................. 20
8.5. Replacing the shank bushing ....................................................................................................................... 22
8.6. Detaching the sealing bushing ..................................................................................................................... 23

9. ASSEMBLY .................................................................................................................................... 24
9.1. Installing the sealing bushing ....................................................................................................................... 24
9.2. Installing the damping cylinder and the pull bushing ............................................................................ 25
9.3. Installing the adapter flange .......................................................................................................................... 26
9.4. Installing the seal housing and the front flange ...................................................................................... 28

10. SPECIAL TOOLS ........................................................................................................................... 30

10.1. Toolkit .................................................................................................................................................................. 30

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ID: 887 1 en 2011-08-10
 Power Extractor HLX 5 -series
Maintenance and repair

1. DESCRIPTION

The Power Extractor is an accessory for the hydraulic rock drill. It is used when the drilling equipment
becomes stuck in the drilled hole so tightly that it cannot be loosened by using the feed, rotation, and
percussion, or when the threading of the drilling equipment cannot be opened. The Power Extractor
is guided with a switch on the operating panel. The switch activates a valve that applies some of the
percussion power for loosening the equipment. The Power Extractor is used with air-flushing rock
drills and water- or water- mist-flushing rock drills (underground rigs).

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ID: 887 1 en 2011-08-10
Power Extractor HLX 5 -series
Maintenance and repair

2. GENERAL

These operation and maintenance instructions give a brief description of the primary maintenance
procedures to be followed for the Power Extractor. The service and repair site must meet the same
requirements as the service and repair site of a rock drill.
The Power Extractor must be disassembled and its parts checked in conjunction with the rock drill’s
basic maintenance, usually after every 500 operating hours.
Monitor the drain holes of the Power Extractor every day during drilling. Air, oil mist, water, or oil
coming out of the drain holes is a sign of a damaged shank seal. Damaged seals must be replaced
immediately.
When replacing the shank, always check the condition of the shank bearing. If the wear limit has been
exceeded, replace the bearing and the shank seals. In difficult circumstances, such as underground
drilling, the inspection should be conducted weekly even if the shank is not replaced.
Sandvik Service is always willing to give advice and help with any maintenance-related problems.
The skills of the qualified maintenance staff at Sandvik dealerships and the use of original Sandvik
spare parts ensure reliable operation of the rock drill.

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 Power Extractor HLX 5 -series
Maintenance and repair

3. PRINCIPLE OF OPERATION

During normal drilling, the power extractor holds tank pressure, the shank bushing is in the front
position, and the shank is not in contact with it. Once the power extractor is pressurized, the shank
bushing moves toward the percussion piston so that the piston reaches far enough to strike the shank.
This causes a stress wave that goes through the drilling equipment and facilitates the opening of the
threadings and the loosening of the drilling equipment.

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ID: 887 1 en 2011-08-10
Power Extractor HLX 5 -series
Maintenance and repair

4. OPERATION

The power extractor (PE) is used with a switch in the cabin when the drilling equipment becomes
stuck so tightly in the drilled hole that it cannot be loosened by using the pull of the feed, or if the
threading of the drilling equipment cannot be opened. In loosening a stuck rod, it is important to get
the drill bit to rotate.
Loosening a stuck rod: Turn the anti-jamming automatics off, and turn on the power extractor (PE),
rotation in the direction that tightens the threadings, feed backward, and percussion. This way,
approximately 30 to 40 per cent of the percussion power is directed into the equipment to facilitate
the loosening. Loosening can be quickened by changing the feed direction every now and then.
Before feeding forward, switch the PE pressure off. The recommended maximum continuous
operation time for the Power Extractor is 5 min. in max. 10 s periods. Too long a use causes the oil
to overheat and causes unnecessary wear to the rock drill and the equipment.
Opening the threading: Hammer with the power extracting on.

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 Power Extractor HLX 5 -series
Maintenance and repair

5. HOSE CONNECTIONS

1 2 3
4

1 Flushing
2 PE, pressure
3 PE, return
4 Percussion, return

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Power Extractor HLX 5 -series
Maintenance and repair

6. DETACHING AND FASTENING OF THE POWER EXTRACTOR WHEN THE

ROCK DRILL IS FASTENED TO THE FEED

Turn the feed to horizontal orientation before removing the

Power Extractor and shank; otherwise, the coupling could fall
and cause injury.

If the shank lubrication has become clogged (no air comes from
the shank lubrication return hose), unscrew the lock screw
carefully and let the air out before unfastening the Power
Extractor bolts. Otherwise, air pressure can detach the Power
Extractor and cause injury.

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 Power Extractor HLX 5 -series
Maintenance and repair

6.1. Detaching the Power Extractor

Detach the hoses from the Power Extractor and plug the hoses and nipples.
1. Remove the flushing nipple (1).
2. Remove the fastening bolts (2).
• Use the special tool (8).

3. Remove the Power Extractor (4) and the shank (5).

• Be careful not to let the coupling (6) fall.

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ID: 887 1 en 2011-08-10
Power Extractor HLX 5 -series
Maintenance and repair

4. Open the screw (7), and pull out the rotation bushing (8) and drill sleeve (9).
• The screw (7) prevents the rotation bushing from dropping, for example, when the shank is
changed.

9
7
8
6
5

5. Note the installation direction of the coupling (6).

6. Check the parts of the rock drill (consult the rock drill repair instructions for the wear limits):
• rotation bushing
• drill sleeve
• coupling
• shank
7. Check the parts of the Power Extractor (see the wear limits in these instructions) :
• shank bushing
• shank bearing
• flushing seals

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 Power Extractor HLX 5 -series
Maintenance and repair

6.2. Attaching the Power Extractor

1. Install the above-mentioned parts in their places, and fasten the locking screw (7).

2. Fasten the bolts (2) using the special tool (8).

• lubricate the threads of the fastening bolts.
• always install new lock washers after the bolts have been unfastened.
• use a crosswise tightening pattern, tightening in three phases: 200 Nm, 400 Nm, and the final
tightening torque of 600 Nm.
3. Tighten the flushing nipple (1).

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ID: 887 1 en 2011-08-10
Power Extractor HLX 5 -series
Maintenance and repair

7. CROSS SECTION OF THE POWER EXTRACTOR, LUBRICATION

CIRCULATION AND THE MOUNTING DIRECTION OF THE SHANK SEALS

7.1. Cross section

A B

A B

A and B are drain holes. Air, oil mist, water, or oil coming out of the drain holes is a sign of a damaged
shank seal.

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 Power Extractor HLX 5 -series
Maintenance and repair

7.2. Lubrication circulation

Water flushing

Air flushing

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Power Extractor HLX 5 -series
Maintenance and repair

7.3. Installation direction of the shank and shank bushing seals

Seals (1), (2), (3) and (4) can be changed without removing the shank.

Water flushing

1 2 3 4

Air flushing

1 2 3 4

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 Power Extractor HLX 5 -series
Maintenance and repair

8. DISASSEMBLY

8.1. Detaching the front cover and the seal housing

Detach the front cover (4) and the seal housing (3) by unfastening the fastening bolts (25).

25

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Power Extractor HLX 5 -series
Maintenance and repair

8.2. Replacing the shank bearing

The bearing must be replaced when the bearing surface has worn down to the bottom level of the
wear indicator groove at any point.

1. Remove the bearing by using a hydraulic press and special tools (1 and 5).

1
5

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 Power Extractor HLX 5 -series
Maintenance and repair

2. Install the bearing.

• Make use of temperature differences by heating the cover and cooling the bearing (a difference
of 60 ºC is sufficient).

8.3. Detaching the pull bushing and the damping cylinder

1. Remove screws (1)

2. Adapter flange (2)
3. Pull bushing (5)
4. damping cylinder (6)

6
5
2
1

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ID: 887 1 en 2011-08-10
Power Extractor HLX 5 -series
Maintenance and repair

8.4. Replacing the damping cylinder bearings

Both damping cylinder bearings must be replaced every 500 percussion hours.
1. Remove the bearing (1) by using a hydraulic press and special tools (2, 3, and 5).

1 5
3

2. Remove the bearing (2) by using a hydraulic press and special tools (2, 4, and 5).s

5
2

4 2

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 Power Extractor HLX 5 -series
Maintenance and repair

3. Install the bearing (1) by using a punch (6). Make use of temperature differences by heating the
damping cylinder and cooling the bearing (a difference of 60°C is sufficient).

4. Install the bearing (2) by using a punch (6). Make use of temperature differences by heating the
damping cylinder and cooling the bearing (a difference of 60°C is sufficient). Note! The lubrication
grooves (A) on the bearing and damping cylinder must be aligned, as in the picture.

6 2

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ID: 887 1 en 2011-08-10
Power Extractor HLX 5 -series
Maintenance and repair

8.5. Replacing the shank bushing

The shank bushing must be replaced when the surface has worn down to the bottom level of the wear
indicator groove at any point or if there are cracks on the surface.

1. Remove the shank bushing (3) by using a hydraulic press and special tools (2 and 7).

2 7 3

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 Power Extractor HLX 5 -series
Maintenance and repair

2. Install the shank bushing (3) by using a punch (1).

• Make use of temperature differences by heating the pull bushing and cooling the shank bushing
(a difference of 60 °C is sufficient).

3 1

8.6. Detaching the sealing bushing

Remove the sealing bushing (7) with special tools (2 and 4).

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ID: 887 1 en 2011-08-10
Power Extractor HLX 5 -series
Maintenance and repair

9. ASSEMBLY

Before assembly:
• remove all old O-rings and seals
• clean all the parts
• lubricate all parts carefully!

9.1. Installing the sealing bushing

The seals and the O-rings must be replaced every 500 percussion hours.
1. Install the O-rings and the seals (12, 13, and 32) on the sealing bushing.

32

12
13

2. Install the sealing bushing (7) in its place.

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 Power Extractor HLX 5 -series
Maintenance and repair

9.2. Installing the damping cylinder and the pull bushing

1. Install the damping cylinder (6) so that the positioning marks (A) are aligned, as in the picture.

2. Install the seal (17) on the pull bushing, and install the pull bushing (5) in its place.
Note the installation direction of the seal! 1 Water flushing, 2 Air flushing.

17

17

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ID: 887 1 en 2011-08-10
Power Extractor HLX 5 -series
Maintenance and repair

9.3. Installing the adapter flange

The seals and the O-rings must be replaced every 500 percussion hours.
1. Install the O-rings and the seals (10, 11, 18, and 19) on the adapter flange.

18 19

11
10

2. Install the O-rings (29, 30 (4 pcs.), and 31 (2 pcs.)) on the face of the adapter flange.

31

30

29

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 Power Extractor HLX 5 -series
Maintenance and repair

3. Place the adapter flange (2) and tighten screws (1) to 40 Nm.
Place seal plate (14) in place.

2 1 14

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Power Extractor HLX 5 -series
Maintenance and repair

9.4. Installing the seal housing and the front flange

1. Install the seals (17 –3 pcs.) and the O-ring (33) in their place on the seal housing.
Note the installation direction of the seals! 1 Water flushing, 2 Air flushing.

33

17 17 17

33

17 17 17

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 Power Extractor HLX 5 -series
Maintenance and repair

2. Install the seal (17) in place on the front cover.

Note the installation direction of the seal! 1 Water flushing, 2 Air flushing.

1 2

17 17

3. Install the seal plate (9), seal housing (3), seal plate (8), and front cover (4) in their places.
1. Pretighten all four bolts to 100 Nm. The correct tightening sequence is 1-2-3-4.
2. The final tightening torque is 200 Nm. Use the same tightening sequence (1-2-3-4).

3
8
4
25

1 4

3 2

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ID: 887 1 en 2011-08-10
Power Extractor HLX 5 -series
Maintenance and repair

10. SPECIAL TOOLS

10.1. Toolkit

151 866 08
1 550 690 80 2 Ø 41 x 185
Ø 65 x 100 M22

550 690 76 550 690 78

3 Ø 49 x 25 4 Ø 92 x 20
M22 M22

550 690 81
550 690 79
5 6 Ø 130 x 30
Ø 140 x 90
M22

550 687 50
550 690 90
7 Ø 50 x 30 8
Ø 20 x 165
M22

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