S03 - 1 Rock Drill HLX5 Instructions (B)

Original instructions
BG00593295 en-US B.001.1 2015-06-09
Hydraulic rock drill HLX5 Operation,

maintenance and repair instructions
Hydraulic rock drill HLX5 Operation, maintenance and repair
instructions
WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and follow
operator's and maintenance manuals before installing, inspecting,
operating, servicing, testing, cleaning, transporting, storing,
dismantling or disposing of the product or a part or accessory of the
product. Keep this publication for future reference.
Copyright © Sandvik
ID: BG00593295 en-US B.001.1 2015-06-09
instructions
This page is intentionally left blank
ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Table of Contents
1 Introduction ................................................................... 7
1.1 The Purpose of these instructions ......................................................7
1.1.1 Validity of the manuals ................................................................ 7
2 Safety and environmental instructions .......................9

2.1 Safety precautions ................................................................................9
2.2 Lifting instructions ............................................................................... 9
3 Rock drill main components ........................................ 13

3.1 Main components ................................................................................. 13
3.2 Lubrication system ...............................................................................13
3.3 Hose connections .................................................................................16
4 Rock drill operation ...................................................... 17

4.1 Lifting points ......................................................................................... 17
4.2 Taking a new rock drill in use ..............................................................19
4.2.1 Preparations ................................................................................ 19
4.3 Test run ..................................................................................................19
5 Rock drill maintenance instructions ........................... 21

5.1 Scheduled maintenance .......................................................................21
5.2 Field service tools ................................................................................ 21
5.3 Daily maintenance ................................................................................ 22
5.3.1 Hydraulic rock drill HLX5 ............................................................. 22
5.4 Periodic maintenance ...........................................................................22
5.4.1 Before changing the bushings and bearings ............................... 22
5.4.2 Hydraulic rock drill HLX5 ............................................................. 23
5.5 Service card .......................................................................................... 31
5.6 Service follow-up .................................................................................. 32
5.7 HLX5 rock drill overhaul ...................................................................... 32
5.7.1 Repair facilities ............................................................................ 32
5.7.2 Rock drill overhaul instructions ....................................................33
5.7.3 Disassembly ................................................................................ 34
5.7.4 Wear limits ...................................................................................51
5.7.5 Assembly .....................................................................................54
5.7.6 Test run ........................................................................................70
5.8 Special tools ..........................................................................................73
ID: BG00593295 en-US B.001.1 2015-06-09
instructions
ID: BG00593295 en-US B.001.1 2015-06-09
instructions
1 INTRODUCTION
1.1 The Purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
Before operating, or performing maintenance or repair procedures for the
component or system described in this manual, read and understand the
information in operator´s and maintenance manuals supplied with the
machine. Pay special attention to the safety information in chapter "2 Safety
and environmental instructions" of those manuals.
1.1.1 Validity of the manuals
This manual, and especially the safety information, is valid only if no
unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include information
on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.
Copyright © Sandvik 7 (76)

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
8 (76) Copyright © Sandvik

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1 Safety precautions
DANGER
ENTANGLEMENT HAZARD!
Getting entangled in rotating parts will cause death or severe injury.
Carry out maintenance and repair work only when the rig is not
running. Make sure that the rig cannot be started unintentionally
during maintenance work.
Operating, service and adjustment procedures must be carried out

only by personnel with specialized operation and service training.
Read and ensure that you understand the operating, maintenance,
and safety instructions before using or servicing the component.
2.2 Lifting instructions
The maximum load capacity of the lifting eye is marked on the eye
circumference (A) or the frame (B).

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
CORRECT INCORRECT
Fasten the lifting eye bolt to the tapped hole. Screw the lifting eye bolt to
the object to be lifted, use washer if necessary.
If there is no thread in the lift hole, use nut to fasten the lifting eye. Use
suitable washers.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
45° 45°
90° 90°
180°
NOTE! Refer to the manufacturer's load tables for maximum load of the
lifting device in various positions.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
3 ROCK DRILL MAIN COMPONENTS

3.1 Main components
5
4
3
2
1 Flushing housing
2 Gear housing
3 Rotation motor
4 Body cylinder
5 Pressure accumulators
3.2 Lubrication system

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

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Lubrication scheme: 1 Surface model, 2 UG model
The rotation mechanism and the shank have oil mist lubrication. The
lubrication line from the lubrication unit 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 bushings of the flushing housing.
Leakage oil from the rear seals of the piston is also ducted to the front end
of the rock drill through a channel.
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 gear housing to the feed rail.
Note! Never connect the used oil mist to the hydraulic system return line.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Air
Shank lubrication
1 Rock drill
2 SLU 1/2/3
3 Drain valve
4 Filler cap
1. The shank lubrication oil consumption can be adjusted. (See the

instruction manual for SLU 1/2/3).
2. The shank lubrication does not work if the oil level in the receiver does
not lower during drilling. (See the instruction manual for SLU 1/2/3).
3. Drain regularly the water that has collected in the receiver. The draining
interval depends on the local conditions.
4. Use only oils according to lubrication recommendation.
5. Refill the receiver regularly.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
3.3 Hose connections
6
3
4 5
1 Shank lubrication 2 Percussion mechanism

pressure side (H.P.)
3 Percussion mechanism 4 Rotation, pressure (H.P.)
returne side (L.P.)
5 Rotation, return (L.P.) 6 Flushing

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
4 ROCK DRILL OPERATION

4.1 Lifting points
WARNING! HANGING LOAD HAZARD!
Incorrect lifting methods could result in severe injuries or death.
The hazard zone must be clear of people during lifting. Never lift the
load over anyone.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Tie lifting straps to the rock drill as shown in figure.

The weight of the rock drill is 210 kg.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
4.2 Taking a new rock drill in use

4.2.1 Preparations
Note! New rock drills are delivered with the pressure accumulators not
pressurized and the hose connections plugged.
Pressurize the accumulators according to the instructions. See “Pressure

accumulator for hydraulic rock drill; Repair instructions”.
Before a new rock drill is installed the drilling equipment hydraulic system
must be checked and flushed thoroughly.
4.3 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
Note! 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 mechanism. This type of ”idling drilling” is the most
critical while drilling upwards or cleaning the holes with pumping
motion.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5 ROCK DRILL MAINTENANCE INSTRUCTIONS

5.1 Scheduled maintenance
The idea of scheduled maintenance is to take the rock drill in for servicing
before a failure stops it during operation. This will prevent expensive
consequential failures and downtime that adversely affects production.
The maintenance interval varies according to local conditions and must
therefore be determined on the basis of experience.
When defining the correct maintenance interval, initially the scheduled
maintenance table should be consulted first and then the maintenance
interval should be adjusted until a suitable maintenance interval for local
conditions is determined.
In addition to this, the rock drill should undergo maintenance whenever the
operator reports a malfunction that could lead to a failure or production
downtime.
5.2 Field service tools
1 6
5
2
3
1 Torque wrench 2 24 mm socket

3 24 mm ring end 4 19 mm wrench
5 Extension 6 Accumulator low pressure
gauge
7 Accumulator high pressure
gauge
Make sure that you have also the flushing seals, gaskets and the shank
adapter for the rock drill maintenance.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5.3 Daily maintenance

5.3.1 Hydraulic rock drill HLX5
Checking the percussion hour-meter reading

Check the percussion hour-meter reading.
According to the reading of the percussion hour-meter, it is easier to
schedule the next maintenance date.
Checking the possible leaks

1. Check the rock drill for leaks.
Determine the cause for the leak and repair the leak source to avoid
further damage.
Checking the flushing housing seals

1. Start the flushing.
2. Check the condition of the flushing housing seals.
The flushing housing seals must be replaced when the flushing air or
water escapes through the drain hole(s).
3. Stop the flushing.
5.4 Periodic maintenance

5.4.1 Before changing the bushings and bearings
The best method for installing the bushings and bearings is to take
advantage of temperature differences. The force needed in installation is
smaller when using cooled bushings and warm parts.
Before starting of the maintenance work, put the new bushings in the
freezer.
After removing the bushings and/or bearings, wash the other parts with hot
water, do not heat the parts.
Note! Do not install seals to the cold parts, they may become brittle and
break. Let the parts warm up before installing the new seals.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5.4.2 Hydraulic rock drill HLX5
Checking the flushing housing seals and the seal housing guide rings
Flushing housing seals (1) 5 pcs and the seal housing guide rings (2) 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.
The flushing housing seals must be installed facing the right direction, determined by the flushing
mode: Water flushing (A), Air flushing (B)
Note! In addition, a damaged seal plate (3) must be replaced due to risk of
corrosion.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Inspection of the front end with the rock drill on a feed rail
WARNING! FALLING LOAD HAZARD!
The coupling could fall out and cause injury.
When you remove the flushing housing and shank, turn the rock drill
to a horizontal position.
WARNING! HIGH PRESSURE AIR INJECTION HAZARD!

The airpressure blow/burst out the flushing housing could cause
severe injury.
If the shank lubrication is clogged (no air comes from the shank
lubrication return hose), stop the compressor. Before opening the
flushing housing bolts, carefully open the locking screw and let the
air pressure out.
By opening the bolts (4) the flushing housing (1), the shank (2), and the
coupling (3) can be pulled out without removing the rock drill from the feed
rail. The lock-screw (5) holds the rotation bushing (6) in the housing, for
example while changing the shank. Check the condition of the rotation
bushing rear end (6) and the bearing (7).
6
3
5
1
4
Dismountling of the flushing housing

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Checking the bearings of the flushing housing
The bearings must be replaced if the indicator groove is worn off any place.
Coupling
1. Pull the coupling out from the rotation bushing.
2. Check and replace, if the edges of the inner teeth are worn sharp or
visible cracks are seen.
Rotation bushing
The rotation bushing must be replaced if the shoulder A is worn to the

same level with the face or damages are observed. Make sure that also the
outer surfaces of the rotation bushing are in good conditions.
Chuck
The chuck inside the rotation bushing must be changed if the wear is over 1
mm from the original surface B or if there are some hair cracks.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Rotation bushing bearings inside the gear housing
The bearings must be changed if the wear indication-groove has worn out
from any area.
Wear limits of the shank

The shank must be changed if the 1 mm bevel of the striking head is worn
out or any other wear limit is exceeded.
PROPERTY DAMAGE RISK!

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.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Checking and tightening bolts and tie rods

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.
Following procedure is recommended for checking the bolt tightness during
normal maintenance:
1. Check the tightness of each bolt by using 10 % higher torque than
specified and the correct tightening order.
2. The joint being tested is loose if the wrench turns. In this case loosen all
the bolts being tested and retighten with the correct order.
3. If the threads are not clean the bolts cannot be tightened correctly. In
such cases the bolt must be removed, the threads checked, cleaned, and
lubricated with grease.
Note! Use only an inspected, high-quality torque wrench.
2
1
Rock drill bolts

1 Tie rod bolts (6 pcs)
2 Pressure accumulator bolts (4+4 pcs)
3 Flushing housing bolts (4 pcs)
4 Flushing housing front cover bolts (4 pcs)

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Tie rod tightening

The tools required:
• torque wrench
• 24 mm ring end
1. Lubricate the threads and the nut faces with grease.
1 4
5 6
3 2
2. Pretighten to 200 Nm (20 kpm).

Correct tightening order is (1-2-3-4-5-6).
3. Final tightening torque is 400 Nm (40 kpm).
Same tightening order (1-2-3-4-5-6) should be used.
Pressure accumulator bolts

The tools required:
• torque wrench
• 24 mm socket
1. Lubricate the bolt threads with grease.
2 4
3 1
2. Pretighten all four bolts to 100 Nm (10 kpm).

Correct tightening order is (1-2-3-4).
Same tightening order (1-2-3-4) should be used.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Flushing housing bolts

The tools required:
• torque wrench
• 24 mm ring end
4
1
3

Flushing housing front cover bolts

The tools required:
• torque wrench
• 24 mm socket
1 4
3 2


ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Checking the charge gas pressure of the pressure accumulators

The charge gas pressure of a pressure accumulator must be checked once
a week. The check is performed by using a pressure gauge included in the
rock drill’s special toolkit. The pressure gauge range is 0 to 100 bar for the
high-pressure accumulators, and 0 to 10 bar for the low-pressure
accumulators. Use a gauge meant for gas pressure measurement. The
pressure gauge used must not be a liquid damped gauge.
3
2
1. Remove the rubber protection cap (1).

2. Remove the metal cap (2).
3. Screw the pressure gauge to the filling valve.
4. Open the locking nut (3).
5. Wait until the gauge pointer stops moving. Check the reading.
6. Close the locking nut (3).
7. Disconnect the gauge from the filling valve and replace the metal cap (2)
and the rubber protection cap (1).

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Rock drill overhaul

The rock drill should be disassembled and its components checked
regularly.
The recommended maintenance interval for the rock drill overhaul is 500
percussion hours, but the interval varies according to local conditions and
must therefore be determined on the basis of experience. It is better to
perform preventive maintenance than repair the machine after the damage
has already happened.
Write down the percussion hours and/or number of meters drilled per shift
during each maintenance interval. Fill in the rock drill maintenance card.
Overhaul instructions and maintenance tasks are defined in the rock drill
technical manual, chapter "Rock drill overhaul".
After rock drill service

After the rock drill service the reassembled parts will settle down to their
proper position during drilling under normal drilling loads. Especially if the
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 removed
and remounted on the feed rail.
After the 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.
5.5 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 are:
• 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.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5.6 Service follow-up

When a rock drill is brought in for maintenance, the previous maintenance
cards must be available. The card is filled in with as much information
about the maintenance as possible.
The maintenance card indicates the replacement rate of parts in each rock
drill, and the effect of different conditions and procedures can be seen by
comparing the various cards.
• The card must be available for preventive maintenance.
• A properly completed card contains the entire maintenance history of a
rock drill.
• The card simplifies the decision to scrap an old machine.
5.7 HLX5 rock drill overhaul

5.7.1 Repair facilities
Faultless operation of a rock drill stems largely from appropriate use of the
repair facilities. Make sure that the repair site is clean.
Characteristics of suitable repair facilities:
• well lit
• appropriate washing facilities
• compressed air available
• free of dust
• has all required documentation
• has the required tools.
Example of equipment available at repair facilities:
2 3
4 5
1
9
6 7 8
1 Spare part storage 2 Hydraulic press, 30 t

3 Washing bay 4 Rubber-coated work table
5 Vice 6 Bench drill
7 Tools 8 Assembly stand
9 Hoist
RISK OF PROPERTY DAMAGE!

NOTICE The drill bit grinding device should not be housed at the rock drill
repair facility.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5.7.2 Rock drill overhaul instructions

The following instructions are intended for persons servicing and repairing
Sandvik hydraulic rock drills. Disassembling and assembling the rock drill
requires expertise and familiarity with the rock drill.
WARNING
HIGH PRESSURE HAZARD!
High pressure could cause death or severe injury.
Release the accumulator pressure before performing maintenance
work on the rock drill.
Before pressurizing a pressure accumulator, install it to the rock
drill. Do not pressurize a pressure accumulator if it is not installed to
a rock drill.
WARNING
CRUSHING HAZARD!
Tilting assembly stand could cause severe injury.
Always use a hoist when tilting the rock drill in the assembly stand.
Follow the instructions in the regular maintenance table. With regular

preventive maintenance, optimal utilization is achieved. Replace any worn
part promptly to avoid more serious damage.
Before performing installation, carefully check 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 unauthorized, 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 of the rock drill frame's end faces.
Check the wear of the parts. See wear limits for section "Wear limits and
wear parts".
After the rock drill overhaul, perform a test run to the rock drill before
mounting it to the drill rig.
Disassembly of the rock drill

Before disassembly, the rock drill must be washed externally with, for
example, high-pressure water. In addition, we recommend that the rock drill
is washed externally with a brush and appropriate solvent before it is
brought to the final repair location.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Removing the seals

The seals are the most sensitive and important components of a rock drill.
When disassembling a rock drill, always replace all seals and O-rings.
Be careful not to scratch the seal grooves and components inside the rock
drill.
RISK OF PROPERTY DAMAGE!
NOTICE Do not scratch the seal grooves.
5.7.3 Disassembly
The rock drill should be disassembled and its components checked
regularly as specified in the maintenance table under ‘Scheduled
maintenance’. 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 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.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Replacing the flushing housing bearings

Note! Make sure that the lubrication channels are flushed clean with
compressed air.
Remove the front cover.
Removing the front cover.
Remove the bearings using a hydraulic press and punches from the toolkit.
Removing the shank bushing with special tools 3 and 5

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
1 7
Removing the front cover bearing with special tools 1 and 7.
1 7
Removing the bearing bushing from the shank bushing with special tools 1 and 7.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Checking the condition of the rotation bushing and chuck

The rotation bushing must be replaced if the shoulder A is worn to the
same level with the face or damages are observed. See the following
figure.
1. Replace the chuck inside the rotation bushing if there are hair cracks or
the shank end has worn more than 1 mm (B) from the original surface as
illustrated. Use special tool no. 2 and 5 for this purpose.
2. Install the new chuck using the same tools. Turn the tool no. 2 correct
way.
1 mm
2 5
5 2

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Removal of the pressure accumulators and the rear cover
WARNING
High pressure could cause death or severe injury.
Make sure that the accumulator pressure has been released before
removing an accumulator from the rock drill.
Release the accumulator pressure by opening the filling valve before

removing the pressure accumulators (1) from the rock drill.
1. Open the accumulator fastening bolts (2).
2. Remove the accumulators. Remove the O-ring and the gasket.
3. Put protective plugs into the openings of the rock drill body.
4. Open the rear cover fastening bolts (4).
5. Detach the rear cover (3) from the rock drill.
6. For disassembly, inspection, re-assembly, and filling of the pressure
accumulators, see ”Pressure accumulators of rock drills, repair
instructions”.
1 2
1 2

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Removal of the gear housing, primary gear and the protective cover
1. Mount the rock drill (1) to the stand (2) (see chapter Special tools, item
14).
2. The stand and the lifting eyes (3) (see chapter Special tools, item 15) are
included into the special tool set.
3. Tighten the bolts (4) on both sides of the rock drill.
4. Remove the protective cover (5) and the feed wire rope mounts (6).
1
3

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5. Open the cap nuts (1) of the tie rods (6 pcs).
4 3
6. Remove the gear housing (2). If the gear housing has stuck together with
body cylinder, they can be detached by unfastening the tie rods with a 19
mm spanner.
7. Remove simultaneously primary gear (3) and slide plates (4).
8. Check the gear and the slide plates. Replace if they are worn, seized or
they have hair cracks.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Removal and checking the bearings inside gear housing

Use lifting eyes and lifting device when handling the gear housing.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
1. Using a punch force out the front bearing (1) of the rotation shaft.
3 2
2. Pull out the ball bearing (2) and the bearing housing (3).

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
3. Check the gear housing front and rear bearing for wear. Bearings must
be replaced if the bearing surface is worn down to the bottom of indicator
groove at any point (1) or if grooves in face of rear bearing have worn to
lubrication hole size (2).
4. If the gear housing bearings are worn or damaged, remove them using a
hydraulic press and punches. See the following figures.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5. Press the front bearing out by using the special tools no. 5 and 12.
12
5
6. Remove the rear bearing using the special tools no. 2, 5 and 8.
8 2 5

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Removing the percussion cartridge

Turn the body cylinder to the horizontal position with a hoist.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
A 2 3
4 1
Pull the front bearing (1) and piston (2) out of the body cylinder (3). Check
the piston, and replace it if:
• The bevel on the percussion end (A) has worn off.
• There are cracks or seizure marks on the piston. The piston can be
polished with a cloth wheel. No grinding is allowed.
Check the bearing bushing (4) of the front bearing. If it is damaged (i.e.
there are scratches, seizure marks, or hot spots on it), replace the front
bearing. It is recommended that the front bearing be replaced every 2000
percussion hours.
Place the special tool (6) inside the rear bearing (2), and push the rear
bearing out together with the pilot cylinder (3) and distributor (4) (see the
figure “Removing the rear bearing, pilot cylinder, and distributor”). The
rubber part (A) is not used when disassembling the HFX5T rock drill.
3 4 2 A 6
Removing the rear bearing, pilot cylinder, and distributor

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Detach the rear bearing (1) and distributor (2) from the pilot cylinder (3).
Check parts for cracks, seizure marks, and other damage. Minor scratches
can be polished with a cloth wheel; grinding is not allowed. It is
recommended that the rear bearing be replaced every 2000 percussion
hours.
Removing the rear bearing and distributor
Check the grooves (A) of the rear bearing piston seals. The maximum width
for the grooves is 4.35 mm. The groove width can be checked with a gauge
(13). Also check the grooves visually; if the groove is too wide or damaged,
replace the rear bearing.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
A 13
Special tool for checking the groove

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Removing the hydraulic motor

After every 500 operating hours, the condition of the hydraulic motor must
be checked, and the O-rings replaced. Open the rotary actuator mounting
screws (2) and pull the actuator out. Check the components thoroughly. If
any component is damaged (cracked, seized up), replace the entire
actuator (see the figure “Removing the hydraulic motor”).
Removing the hydraulic motor
If the O-rings are fused to the balance plate (5), the plate can be removed
by means of grease (2), a spacer pin (3), and a punch (9) (see the figure
“Removing the balance plate”).
3 5 2
9
Removing the balance plate

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Lift the body cylinder off the repair stand using lifting straps and a hoist.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5.7.4 Wear limits

1. Make sure that the percussion cartridge goes into the body cylinder
together with the spacer.
2. Take measurements C, D and E. Measurement “C > (D+E)”. If not the
body cylinder must be discarded.
3. Take the measurements C, E, L, M. The measurement “L < (C-E+M)”. If
not the body cylinder must be discarded.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
G,F

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Part Wear limits

Shank bearings
A
Replace bearings if wear indicator
Rotation bushing groove has worn off at any point.
B
bearings
Replace if the bevel of the piston is
F Piston worn off or the piston has hair
cracks or seizure marks.
The chuck inside the rotation bush-
ing must be replaced if the shank
G Chuck end has worn more than 1 mm
from the original surface, or it has
hair cracks.
Replace if worn more than 1mm or
H Shank bushing
if wear surface has cracks.
Replace the rotation bushing if the
I Rotation bushing wear indicator (shoulder) has worn
down or the surface is damaged.
Replace if the inner teeth have
J Coupling
worn sharp.
Rotation bushing Replace the gear housing if
N
end play N < 0,5 mm.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5.7.5 Assembly
Installing the percussion cartridge

Place the O-rings in their grooves in the rear bearing and the pilot cylinder.
Lubricate the seals thoroughly, and soften them carefully with your fingers.
Alternatively, soften the seals in warm oil or water (max. +50 °C). Install the
piston seals in their grooves in the rear and front bearings.
Place the rear bearing and the distributor into the pilot cylinder. Check that
the distributor is the right way round.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Lift the body cylinder on the repair stand with a hoist.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Turn the body cylinder to the vertical position and support it with a hoist.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
1 2
Installing the pilot cylinder
Push the pilot cylinder assembly into the body cylinder (1). Install the piston
in the pilot cylinder and push the front bearing into its place inside the pilot
cylinder (2) (see figure "Installing the pilot cylinder").

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Installing the rotary actuator

Make sure that all parts and the motor housing in the body cylinder are
clean and that the studs are fully tightened. Lubricate the components and
the motor housing well. Install the O-rings. Place the spring washer at the
bottom of the motor housing. Push the balance plate into place, as
indicated by the guide pin. Place the spacer pin inside the balance plate.
11 12
10
Installing the rotary actuator

1 Stud 2 Shaft
3 Cover 4 Gear wheel set
5 Channel plate 6 Valve drive shaft
7 Valve plate 8 Spacer pin
9 Balance plate 10 Spring washer
11 Nut 12 Lock washer
Place the valve plate (1) on top of the balance plate, and mark (with chalk
or a marker) the drive spline, which lines up with the hole (A) on the outer
rim of the valve.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Mark the bottom of the valve drive shaft spline. Place the valve drive shaft
so that the marked bottom of the spline is aligned with the marked spline on
the valve and the wider splines (5 mm) are inside the valve. Push the
channel plate into place.
On the inner rotor, mark the spline gap that is aligned with the bottom of the
outer splines. Mount the gear wheel set and align the rotor (3) so that the
mark is aligned with the marked bottom of the spline of the drive shaft. Turn
the rotor anticlockwise until the splines engage with the splines on the drive
shaft.
Gear wheel set, OMS motor
Install the shaft and the hydraulic motor cover. Ensure that the studs are
fully tightened. Cross-tighten the nuts first to 40 Nm. The final tightening
torque is 80 Nm.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Installing the bearings of the gear housing

Use lifting eyes and lifting device when handling the gear housing.
1. Press the gear housing rear bearing (1) in using a hydraulic press and
punches (5 and 10, see chapter Special tools). In order to make the
installation easier, the gear housing can be warmed up (max. 150°C).
5 10 1

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
2. Press the gear housing front bearing (2) in using a hydraulic press and
punches (4, 10 and a limit bushing 4A, see chapter Special tools. In
order to make the installation easier, the gear housing can be warmed up
(max. 150°C).
4A 2
4
10
3. Replace the rotation shaft bearing bushing (1) every 500 operating hours.
Remove the bearing from the housing using grease (3) and a special tool
no. 9 as illustrated. Hit the tool (9) with a hammer so that the grease will
drive the bearing out.
3 9

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
4. Install a new rotation shaft bearing bushing (1) in the bearing housing
using a special tool (No. 8) and press as illustrated. Replace the O-ring
(4).
4 1 8
5. Push the bearing housing into the gear housing and make sure it is
completely in against the bottom.
6. Replace the rotation shaft middle needle bearing (2) every 500 operating
hours. Deform the bearing with a punch through the holes at the side of
the bearing housing. Remove the bearing.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
7. Install a new rotation shaft middle needle bearing (2) in the bearing
housing using a special tool (No. 8) and press as illustrated.
6 2 8
8. Replace the shaft seal (5) and the O-ring (6).

9. Push the bearing housing (1) and the ball bearing (2) into the gear
housing.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Assembling the gear housing and the primary gear

1. Turn the rock drill stand into vertical position.
2. Install the O-rings in spigots and on body cylinder mating face. Mount
them on the body cylinder side using grease to hold them on. Install also
both of the slide plates (3) using grease as well to hold them on.
3 2
3. Install the gear housing on. Use lifting eyes and lifting device. At the
same time install the primary gear (2) on.
4. Lubricate the threads and the nut faces (1) (6 pcs) with graphite grease.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5. Tighten the nuts (1) in two stages, first up to 200 Nm and then the final
tightening up to 400 Nm. Use the tightening order as shown in the
following figure.
1 4
5 6
3 2

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Installing the protective cover and removing the rock drill

1. Install the protective cover (1) with new gasket. Tighten bolts in 2 phases,
pre-tighten 100 Nm and final torque 200 Nm.
2. Place the feed rope rear mounting clamp (2) to the gear housing. Tighten
the bolts with a torque of 240 Nm.
3. Mount the lifting eyes (3), use lifting device.
4. Remove the bolts (4) and lift the rock drill from stand (5).

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Installing the flushing housing

1. Push the rotation bushing (1) into the gear housing. Install the coupling
(2).
2. Install the Allen screw (3) and the seal (4).
3. Check that the mating surfaces of the flushing housing and the gear
housing are clean.
4. Install the gasket to the mating surface of the flushing housing.
5. Push the flushing seal housing and the shank into the flushing housing.
6. Install the flushing housing assembly to the gear housing.
7. Lubricate the threads of the fastening bolts.
8. Cross tighten the bolts in two stages: first up to 200 Nm, and then the
final tightening up to 400 Nm.
3 4
1

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Assembling the accumulators, connector flanges and the rear cover

1. Remove the protective plugs from the pressure accumulator connection,
and check the mating surfaces of the accumulator and the rock drill body.
2. Install the O-ring and the gasket.
3. Install the lock washer pairs and grease the bolt threads. Cross tighten
the bolts in two stages: first up to 100 Nm, and then the final tightening
up to 200 Nm.
4. Install the rear cover on with gasket and cross tighten the bolts in 2
phases (50 Nm and 100 Nm)

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
SF
UG
SF Surface model
UG Underground model
Filling of pressure accumulators, see Pressure accumulator for hydraulic
rock drill, Repair instructions.
Accumulator type Pressure [bar]
High pressure 50
Low pressure 4
Pressurizing the accumulators
WARNING
A high pressure gas discharge could cause death or severe injury.
Before pressurizing a pressure accumulator, install it to the rock
drill. Do not pressurize a pressure accumulator if it is not installed to
a rock drill.
See detailed instructions for pressurizing the accumulators from the

manual ”Pressure accumulator for Hydraulic rock drill; Maintenance
instructions”.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5.7.6 Test run
New rock drills

Test run the rock drill and make sure that it operates properly. During the
test run, observe the following:
• the operation of shank lubrication
• the flushing operation
• the pressures and the temperature
• possible oil leaks
Note! Avoid using full percussion pressure when the drill bit is not in
contact with the rock, as this can strain the accumulator membranes
and cause cavitation in the percussion mechanism. Such "idle
drilling" is especially likely when drilling upward and when cleaning
holes by pumping.
Test run after maintenance

When the maintenance is complete, the rock drill can be tested in the
service container using the hydraulic power pack. The 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 purpose of the test run is to
check the operation of the percussion and rotation mechanisms of the rock
drill, and to detect any possible leaks. When testing the rotation
mechanism, the hoses to the percussion mechanism must be connected to
the rock drill in order to enable the operation of the internal lubrication of
the rotary actuator.
HIGH NOISE LEVELS! High levels of noise can damage your hearing.
Wear hearing protectors when the power pack is running!
Note! The rock drill may not be test run on the assembly stand! The shank
must be removed before the test run.
Before the test run

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

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
Use of rock drills
6 4 6 5
12 0 b ar 17 5 b ar
7 8
10
10 ...21 0 b ar
3 2 9
M
1
1 Tank 2 Electric motor

3 Double pump 4 Control valve (percussion)
5 Control valve (rotation) 6 Pressure-relief valve
7 Pressure gauge (percussion) 8 Pressure gauge (rotation)
9 Return filter 10 Differential pressure valve
Test run
1. Connect the rock drill according to the hydraulics diagram.
2. Make sure that:
• there is enough oil in the tank (1)
• the levers of the control valves (4) and (5) are in middle position

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
3. Turn on the power pack.

4. Start percussion by pulling the lever of the control valve (4) toward
yourself.
5. Start rotation by pulling the lever of the control valve (5) toward yourself.
You can change the rotation direction by pushing the lever to the
opposite extreme position.
6. Continue the test run for about five minutes, and note any possible leaks.

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
5.8 Special tools
1. 152 248 88 9. 150 551 68
2. 550 099 31 10. 550 098 93
3. 150 545 68 11. 550 099 24
550 098 84
4.
12. 550 054 80
4A 550 055 68
5. 151 866 08 13. 551 818 05
6. 550 056 20 14. 550 067 40
7. 150 546 98 15. 551 884 93
8. 550 103 96 16. 551 953 44
17. 551 897 48

ID: BG00593295 en-US B.001.1 2015-06-09
instructions
In this chart the Special Tool Kit is only partly shown. Refer to the Parts
Book for a complete list of tools of this Special Tool Kit.

ID: BG00593295 en-US B.001.1 2015-06-09
www.sandvik.com

S03 - 1 Rock Drill HLX5 Instructions (B)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

S03 - 1 Rock Drill HLX5 Instructions (B)

Uploaded by

Copyright:

Available Formats

Original instructions

BG00593295 en-US B.001.1 2015-06-09

Hydraulic rock drill HLX5 Operation,

This page is intentionally left blank

2 Safety and environmental instructions .......................9

3 Rock drill main components ........................................ 13

4 Rock drill operation ...................................................... 17

5 Rock drill maintenance instructions ........................... 21

This page is intentionally left blank

Copyright © Sandvik 7 (76)

This page is intentionally left blank

8 (76) Copyright © Sandvik

2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

Operating, service and adjustment procedures must be carried out

2.2 Lifting instructions

Copyright © Sandvik 9 (76)

10 (76) Copyright © Sandvik

Copyright © Sandvik 11 (76)

This page is intentionally left blank

12 (76) Copyright © Sandvik

3 ROCK DRILL MAIN COMPONENTS

3.2 Lubrication system

Copyright © Sandvik 13 (76)

Lubrication scheme: 1 Surface model, 2 UG model

14 (76) Copyright © Sandvik

1. The shank lubrication oil consumption can be adjusted. (See the

Copyright © Sandvik 15 (76)

3.3 Hose connections

1 Shank lubrication 2 Percussion mechanism

16 (76) Copyright © Sandvik

4 ROCK DRILL OPERATION

Copyright © Sandvik 17 (76)

Tie lifting straps to the rock drill as shown in figure.

18 (76) Copyright © Sandvik

4.2 Taking a new rock drill in use

Pressurize the accumulators according to the instructions. See “Pressure

4.3 Test run

Copyright © Sandvik 19 (76)

This page is intentionally left blank

20 (76) Copyright © Sandvik

5 ROCK DRILL MAINTENANCE INSTRUCTIONS

5.2 Field service tools

1 Torque wrench 2 24 mm socket

Copyright © Sandvik 21 (76)

5.3 Daily maintenance

Checking the percussion hour-meter reading

Checking the possible leaks

Checking the flushing housing seals

5.4 Periodic maintenance

22 (76) Copyright © Sandvik

5.4.2 Hydraulic rock drill HLX5

Copyright © Sandvik 23 (76)

WARNING! HIGH PRESSURE AIR INJECTION HAZARD!

Dismountling of the flushing housing

24 (76) Copyright © Sandvik

Checking the bearings of the flushing housing

The rotation bushing must be replaced if the shoulder A is worn to the

Copyright © Sandvik 25 (76)

Rotation bushing bearings inside the gear housing

Wear limits of the shank

PROPERTY DAMAGE RISK!

26 (76) Copyright © Sandvik

Checking and tightening bolts and tie rods