B 23710 - 3 en 0106 / TL1 (16) HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance CONTENTS 1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. TAKING A NEW ROCK DRILL IN USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 3. HOSE CONNECTIONS .............................................. 3 4. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5. REMOVING THE FRONT END WITH THE ROCK DRILL ON A FEED RAIL . 5.1. Replacing the flushing housing seals and the seal housing guide rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. Replacing the bearings of the flushing housing . . . . . . . . . . . . . . . . . 5.3. Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4. Rotation bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5. Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6. Rotation bushing bearings inside the gear housing . . . . . . . . . . . . . . 5.7. Wear limits of the shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6. CHECKING AND TIGHTENING BOLTS AND TIE RODS . . . . . . . . . . . . . . . . . . 6.1. Tie rod tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2. Pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3. Flushing housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 11 11 12 7. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2. Field service tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3. Every day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4. Every week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5. Basic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6. After rock drill service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7. Service card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8. Service follow-- up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 13 14 14 14 14 15 15 7 8 8 8 9 9 9 E 2006 SANDVIK TAMROCK CORP., Tampere Plant P.O.Box 100 FIN--33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120 possible oil leakages CAUTION Avoid use of full percussion power if the steel is not against the rock. Finland Tel. 2.shank lubrication -.. This will reduce the breakage of the accumulator’s diaphragm. TAKING A NEW ROCK DRILL IN USE 2. The qualified TAMROCK maintenance personnel of your TAMROCK dealer and original TAMROCK spare parts ensure reliable operation of your drilling equipment. Tampere Plant P. drilling tools and the cavitation of the percussion mechanism.O. Before a new rock drill is installed the drilling equipment hydraulic system must be checked and flushed thoroughly.3 en 0106 / TL HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 1. CAUTION Pressurize the accumulators according to the instructions. E 2006 SANDVIK TAMROCK CORP.2. GENERAL These instructions describe in brief the main maintenance procedures for HLX5 series hydraulic rock drills.2 (16) B 23710 . See “Pressure accumulator repair instructions”. Preparations New rock drills are delivered with the pressure accumulators not pressurized and the hose connections plugged. 2. the wear of flushing housing. +358 205 44 121 Telefax +358 205 44 120 . During test run observe: -. Service is always ready to help and give advice in all maintenance problems.flushing -.pressures and temperatures -.Box 100 FIN--33311 TAMPERE. Test run Test run the rock drill and make sure that it operates properly before starting production drilling. This type of ”idling drilling” is the most critical while drilling upwards or cleaning the holes with pumping motion.1. B 23710 .3 en 0106 / TL 3 (16) HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 3.O.) 3. Hose connections 1. return (L. Shank lubrication 2.Box 100 FIN--33311 TAMPERE.P.. pressure (H. Finland Tel. Percussion mechanism return side (L. Tampere Plant P. Rotation. Flushing E 2006 SANDVIK TAMROCK CORP. Percussion mechanism pressure side (H.) 5.) 4. HOSE CONNECTIONS 1 6 2 3 5 4 Fig 1.P. Rotation. +358 205 44 121 Telefax +358 205 44 120 .P.P.) 6. Finland Tel. CAUTION E 2006 SANDVIK TAMROCK CORP. The lubrication line from the lubrication unit is connected to end of the rock drill. Tampere Plant P. Lubrication scheme: 1 Surface model. LUBRICATION SYSTEM The rock drill percussion mechanism and the rotation motor are lubricated by the hydraulic oil flowing through them. coupling and the bushings of the flushing housing.Box 100 FIN--33311 TAMPERE. 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.4 (16) B 23710 .. 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. 2 UG model The rotation mechanism and the shank have oil mist lubrication. Leakage oil from the rear seals of the piston is also ducted to the front end of the rock drill through a channel.O. +358 205 44 121 Telefax +358 205 44 120 .3 en 0106 / TL HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 4. Never connect the used oil mist to the hydraulic system return line. 1 Grease nipple 2 Fig 2. (See the instruction manual for SLU 1/2/3).. Drain valve 4. Drain regularly the water that has collected in the receiver. Use only oils according to lubrication recommendation. The draining interval depends on the local conditions 4. The shank lubrication oil consumption can be adjusted.3 en 0106 / TL 5 (16) HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 1 4 2 3 Air Fig 3. Refill the receiver regularly.B 23710 . 2. Rock drill 2. +358 205 44 121 Telefax +358 205 44 120 . Filler cap 1. 5. Finland Tel. SLU 1/2/3 3. 3. Shank lubrication 1. 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).O.Box 100 FIN--33311 TAMPERE. E 2006 SANDVIK TAMROCK CORP. Tampere Plant P. The coupling can fall out and cause injury. REMOVING THE FRONT END WITH THE ROCK DRILL ON A FEED RAIL When you remove the flushing housing and shank. for example while changing the shank. carefully open the locking screw and let the air pressure out. Check the condition of the rotation bushing rear end (6) and the bearing (7).3 en 0106 / TL HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 5. 6 3 2 5 1 4 7 Fig 4. stop the compressor. the shank (2). Dismounting of the flushing housing E 2006 SANDVIK TAMROCK CORP.6 (16) B 23710 . and the coupling (3) can be pulled out without removing the rock drill from the feed rail. By opening the bolts (4) the flushing housing (1).O. +358 205 44 121 Telefax +358 205 44 120 . Otherwise the air pressure can blow / burst out the flushing housing and cause injury. Before opening the flushing housing bolts. WARNING WARNING If the shank lubrication is clogged (no air comes from the shank lubrication return hose). Finland Tel.Box 100 FIN--33311 TAMPERE. The lock--screw (5) holds the rotation bushing (6) in the housing.. turn the rock drill to a horizontal position. Tampere Plant P. Finland Tel. Replacing the flushing housing seals and the seal housing guide rings Flushing housing seals (A) 5 pcs and the seal housing guide rings (B) 2 pcs must be replaced when the flushing air or water escapes from the sides of the seal housing. CAUTION E 2006 SANDVIK TAMROCK CORP. +358 205 44 121 Telefax +358 205 44 120 .3 en 0106 / TL 7 (16) HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 5. and they should be checked whenever the shank is changed. as it speeds up on--site maintenance of the rock drill. Tampere Plant P. Seals are easier to install when they are lubricated.B 23710 . The use of a spare flushing housing is recommended.O.1.Box 100 FIN--33311 TAMPERE. The flushing housing seals must be installed facing the right direction.. Install the new flushing housing seals making sure they face the right direction (shown in the figure). determined by the flushing mode In addition. a damaged seal plate (1) must be replaced due to risk of corrosion. B 1 AIR FLUSHING A B 1 WATER FLUSHING A Fig 5. Finland Tel. Rotation bushing A The rotation bushing must be replaced if the shoulder A is worn to the same level with the face or damages are observed. E 2006 SANDVIK TAMROCK CORP.O.4.8 (16) B 23710 .3 en 0106 / TL HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 5. Check and replace. 5. Tampere Plant P. 5.3. Coupling Pull the coupling out from the rotation bushing.. Make sure that also the outer surfaces of the rotation bushing are in good conditions.Box 100 FIN--33311 TAMPERE. Replacing the bearings of the flushing housing The bearings must be replaced if the indicator groove is worn off any place. if the edges of the inner teeth are worn sharp or visible cracks are seen. +358 205 44 121 Telefax +358 205 44 120 .2. Wear limits of the shank max 1 mm CAUTION The shank must be changed if the 1 mm bevel of the striking max 1 mm head is worn out or any other wear limit is exceeded. Rotation bushing bearings inside the gear housing The bearings must be changed if the wear indication--groove has worn out from any area.7.O.B 23710 . B 1 mm 5.5. 5. Insert the shank carefully through the flushing housing. +358 205 44 121 Telefax +358 205 44 120 .Box 100 FIN--33311 TAMPERE. When installing a new shank. so that the flushing device seals are not damaged. 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.3 en 0106 / TL 9 (16) HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 5. take care that no dirt enters inside the rock drill with the shank. E 2006 SANDVIK TAMROCK CORP. Finland Tel..6. Tampere Plant P. the threads checked. 2. shortening the service life of the rock drill. Check the tightness of each bolt by using 10 % higher torque than specified and the correct tightening order. Tampere Plant P. +358 205 44 121 Telefax +358 205 44 120 . Rock drill bolts 1. high---quality torque wrench. CHECKING AND TIGHTENING BOLTS AND TIE RODS The most important maintenance task is to check the tightness of the bolts.10 (16) B 23710 . Following procedure is recommended for checking the bolt tightness during normal maintenance: 1. CAUTION 2 3 2 1 Fig 6. 3.O. In this case loosen all the bolts being tested and retighten with the correct order.Box 100 FIN--33311 TAMPERE. If the threads are not clean the bolts cannot be tightened correctly.. Pressure accumulator bolts 3. and lubricated with grease. particularly the tie rods and mounting bolts.3 en 0106 / TL HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 6. Finland Tel. Tie rod bolts 2. Use only an inspected. The joint being tested is loose if the wrench turns. Loose tie rods cause rapid wear of the body section faces. Flushing housing bolts 6 pcs 4+4 pcs 4 pcs E 2006 SANDVIK TAMROCK CORP. cleaned. In such cases the bolt must be removed. Lubricate the threads and the nut faces with grease. Correct tightening order is 1--2--3--4. Pretighten all four bolts to 100 Nm (10 kpm).3 en 0106 / TL 11 (16) HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 6. Same tightening order (1--2--3--4--5--6) should be used. Final tightening torque is 400 Nm (40 kpm). Tie rod tightening The tools required: -.. Pretighten to 200 Nm (20 kpm).1.24 mm socket 1. Lubricate the bolt threads with grease.24 mm ring end 1. Pressure accumulators The tools required: -. Correct tightening order is (1--2--3--4--5--6) 3. Tampere Plant P. 1 4 5 6 3 2 Tie rods.torque wrench -. 2.torque wrench -.2. tightening order 6. 2. +358 205 44 121 Telefax +358 205 44 120 . Final tightening torque is 200 Nm (20 kpm). Finland Tel.Box 100 FIN--33311 TAMPERE. 3. Fig 8. Fig 7.B 23710 . Same tightening order (1--2--3--4) should be used. 2 4 3 1 Pressure accumulator bolts tightening order E 2006 SANDVIK TAMROCK CORP.O. O. Tampere Plant P.3 en 0106 / TL HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 6. Final tightening torque is 400 Nm (40 kpm). 2.Box 100 FIN--33311 TAMPERE.24 mm ring end 1. +358 205 44 121 Telefax +358 205 44 120 .. Lubricate the bolt threads with grease. Same tightening order (1--2--3--4) should be used. 1 3 4 2 Fig 9. Pretighten all four bolts to 200 Nm (20 kpm). Correct tightening order is (1--2--3--4).3. Flushing housing bolts E 2006 SANDVIK TAMROCK CORP. Finland Tel.12 (16) B 23710 . 3.torque wrench -. Flushing housing bolts The tools required: -. Maintenance tools Make sure that you have also the flushing seals. 7. 5. Torque wrench 24 mm socket 24 mm ring end 19 mm wrench Extension Accumulator low pressure gauge Accumulator high pressure gauge 6 1 5 4 7 3 2 Fig 10. General The idea of periodic maintenance is that the rock drill is serviced before any breakdown occurs.2. Tampere Plant P.1. 4.O.3 en 0106 / TL 13 (16) HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 7.. and then lengthen the intervals until a period that suits the local conditions has been found. E 2006 SANDVIK TAMROCK CORP. Finland Tel. PERIODIC MAINTENANCE 7. The maintenance interval is 500 percussion hours. 7. but depends on the local conditions. gaskets and the shank adapter for the rock drill maintenance. it is advisable to start the periodic maintenance as specified. +358 205 44 121 Telefax +358 205 44 120 .B 23710 . 6. In addition the rock drill should always be taken in for service when the operator reports of a fault on the rock drill that can cause major damage or a production interruption. Searching for the correct maintenance interval. Field service tools 1.Box 100 FIN--33311 TAMPERE. 2. This way expensive additional damages and unwanted production interruption can be avoided. and it must therefore be determined according to this experience. 3. flushing housing. Check the condition of the shank. . 7. 5. 7. Basic maintenance Rock drill basic maintenance is recommended every 500 operating hours. .Low pressure .3 en 0106 / TL HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 7. Finland Tel.4.3. re--tighten the rock drill tie rods and flushing device bolts E 2006 SANDVIK TAMROCK CORP. Check the flushing housing for water and air leaks.6. Tampere Plant P. 2. Check for possible oil leaks. . coupling. according ch. . Fill in the service card of the rock drill. . chuck. If loose.High pressure . tighten them up. Check the tie rod tightness. Especially if the parts have worn surfaces it may result that the tie rods and the mounting bolts do not keep their tightness. 50 bar -.. re--tighten the rock drill mounting bolts on the feed rail 2. Check the accumulator pressures -. Every day 1.Box 100 FIN--33311 TAMPERE. Check the hour meter reading.14 (16) B 23710 . Every week 1. Check the accumulator filling valves and their protective caps and the accumulator bolt tightness. 4 bar 4. 6. .1. . This maintenance interval can be adjusted according to local conditions and experiences which are accumulated to the rock drill maintenance history. 7. 4.O. 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. Monitor percussion hour meter reading and/or drilled meters/shifts between each maintenance. Check the flushing housing bolt tightness. +358 205 44 121 Telefax +358 205 44 120 . After the rock drill service and 1 round / 100--300 meters drilling: 1. shank bushing and the rotation bushing. Do planned and preventive maintenance rather than repairs after damages. .5. 2. 3. 3. . “Repair Instructions’’. Cf. 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. Check the condition of the hoses and fittings. -.. a maintenance card presented on the next page can be used. Service card Each rock drill has its own service cards. the next maintenance date should be written down on the card.The cards help in determining maintenance required to prevent major damage.Wear of every specific component of each rock drill is clearly displayed.The cards help to determine the point when the rock drill should be scrapped.Box 100 FIN--33311 TAMPERE.3 en 0106 / TL 15 (16) HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance 7.Use service card presented on the next page.Properly filled cards show the complete maintenance history of the rock drill. Benefits of the card are: -. -.7. All relevant information about the maintenance must be written down on the card.8. +358 205 44 121 Telefax +358 205 44 120 . all the earlier cards should be at hand. Finland Tel.B 23710 . and by comparing the cards the effect of different circumstances and measures can be determined.O. When a rock drill is taken up for maintenance. Tampere Plant P. E 2006 SANDVIK TAMROCK CORP. -. -. 7. When the rock drill is again taken into use. Service follow--up In order to follow the maintenance of a rock drill. Dism.O. Insp. shifts/rounds drilled meters SERVICE INFORMATION Purpose of the service Serviceman Arr. shaft bearings Front cover/ body Flus. Total REPLACED PARTS/ PART INSPECTION Qty Part No Description Repaired / Batch Replaced / Batch OK Remarks Piston Pilot cylinder Front bushing Rear bushing Distributor LP accumulator HP accumulator Spacer Gear housing Rotation bushing Rot.bush.hours Working hours Rep.date Prev. Finland Tel.16 (16) B 23710 . Ass.bearing Chuck Connecting piece Rotation motor Rotation shaft Rot. Tampere Plant P.Box 100 FIN--33311 TAMPERE..date Prev.3 en 0106 / TL HYDRAULIC ROCK DRILL HLX5 Operation and Maintenance ROCK DRILL SERVICE CARD No Equipment Rock drill S/n S/n Since previous service percusion hours drill.service Dep.service card No Prev. +358 205 44 121 Telefax +358 205 44 120 .perc. seal housing Shank bearings Remarks Percussion mechanism tested Rotation mechanism tested E 2006 SANDVIK TAMROCK CORP.