S03 Rock Drill HLX5 Maintenance

B 23710 -- 3 en 0106 / TL 1 (16)

HYDRAULIC ROCK DRILL HLX5Operation and Maintenance

2006 SANDVIK TAMROCK CORP., Tampere PlantP.O.Box 100FIN--33311 TAMPERE, FinlandTel. +358 205 44 121Telefax +358 205 44 120

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CONTENTS

1. GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. TAKING A NEW ROCK DRILL IN USE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1. Preparations 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. Test run 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. HOSE CONNECTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. LUBRICATION SYSTEM 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. REMOVING THE FRONT END WITH THE ROCK DRILL ON A FEED RAIL 6.5.1. Replacing the flushing housing seals and the seal housing

guide rings 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2. Replacing the bearings of the flushing housing 8. . . . . . . . . . . . . . . . .5.3. Coupling 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4. Rotation bushing 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5. Chuck 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6. Rotation bushing bearings inside the gear housing 9. . . . . . . . . . . . . .5.7. Wear limits of the shank 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. CHECKING AND TIGHTENING BOLTS AND TIE RODS 10. . . . . . . . . . . . . . . . . .6.1. Tie rod tightening 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2. Pressure accumulators 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3. Flushing housing bolts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. PERIODIC MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1. General 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2. Field service tools 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3. Every day 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4. Every week 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5. Basic maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6. After rock drill service 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7. Service card 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.8. Service follow--up 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1. GENERAL

These instructions describe in brief the main maintenance procedures for HLX5 serieshydraulic rock drills.

Service is always ready to help and give advice in all maintenanceproblems. ThequalifiedTAMROCK maintenance personnel of your TAMROCK dealer and original TAMROCKspare 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 notpressurized and the hose connections plugged.

Pressurize the accumulators according to the instructions. See “Pressure accumulatorrepair instructions”.

Before a new rock drill is installed the drilling equipment hydraulic system must bechecked and flushed thoroughly.

2.2. Test run

Test run the rock drill and make sure that it operates properly before starting productiondrilling.

During test run observe:-- shank lubrication-- flushing-- pressures and temperatures-- possible oil leakages

Avoid use of full percussion power if the steel is not against the rock.This will reduce the breakage of the accumulator’s diaphragm, the wearof flushing housing, drilling tools and the cavitation of the percussionmechanism.This typeof ”idlingdrilling” is themost critical while drillingupwards or cleaning the holes with pumping motion.

CAUTION

CAUTION

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3. HOSE CONNECTIONS

61

2

3

45

Fig 1. Hose connections

1. Shank lubrication

2. Percussion mechanism pressure side (H.P.)

3. Percussion mechanism return side (L.P.)

4. Rotation, pressure (H.P.)

5. Rotation, return (L.P.)

6. Flushing

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4. LUBRICATION SYSTEM

The rock drill percussionmechanismand the rotationmotor are lubricated by the hydraulicoil flowing through them.

1

2

Grease nipple

Fig 2. Lubrication scheme: 1 Surface model, 2 UG model

The rotation mechanism and the shank have oil mist lubrication. The lubrication line fromthe lubrication unit is connected to end of the rock drill. From there the oil mist is ductedthrough piston rear end to the front end of the rock drill where the flow will lubricate therotation 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 drillthrough a channel.

The oil that has circulated through the rock drill lubrication system is removed through theshank lubrication collector or can be led via return channels and gear housing to the feedrail.

Never connect the used oil mist to the hydraulic system return line.

CAUTION

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Air

1

2

4

3

Fig 3. 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 instructionmanual for SLU 1/2/3).

2. The shank lubrication does not work if the oil level in the receiver does not lowerduring drilling. (See the instruction manual for SLU 1/2/3).

3. Drain regularly the water that has collected in the receiver. The draining intervaldepends on the local conditions

4. Use only oils according to lubrication recommendation.5. Refill the receiver regularly.

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5. REMOVING THE FRONT END WITH THE ROCK DRILL ON AFEED RAIL

When you remove the flushing housing and shank, turn the rock drill to ahorizontal position. The coupling can fall out and cause injury.

If the shank lubrication is clogged (no air comes from the shanklubrication return hose), stop the compressor. Before opening theflushing housing bolts, carefully open the locking screw and let the airpressureout.Otherwise theairpressure canblow / burst out the flushinghousing and cause injury.

Byopening the bolts (4) the flushing housing (1), the shank (2), and the coupling (3) can bepulled out without removing the rock drill from the feed rail. The lock--screw (5) holds therotation bushing (6) in the housing, for example while changing the shank. Check thecondition of the rotation bushing rear end (6) and the bearing (7).

1

4

3

2

5

6

7

Fig 4. Dismounting of the flushing housing

WARNING

WARNING

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5.1. Replacing the flushing housing seals and the seal housing guiderings

Flushing housing seals (A) 5 pcs and the seal housing guide rings (B) 2 pcs must bereplaced when the flushing air or water escapes from the sides of the seal housing, andthey should be checked whenever the shank is changed. Seals are easier to install whenthey are lubricated. Install the new flushing housing seals making sure they face the rightdirection (shown in the figure). The use of a spare flushing housing is recommended, asit speeds up on--site maintenance of the rock drill.

AIR FLUSHING

WATER FLUSHING

1

1

A

B

A

B

Fig 5. The flushing housing sealsmust be installed facing the right direction, determinedby the flushing mode

In addition, a damaged seal plate (1) must be replaced due to risk ofcorrosion.

CAUTION

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5.2. Replacing the bearings of the flushing housing

The bearings must be replaced if the indicator groove is worn offany place.

5.3. Coupling

Pull the coupling out from the rotation bushing. Check andreplace, if the edges of the inner teeth are worn sharp or visiblecracks are seen.

5.4. Rotation bushing

AThe rotation bushing must be replaced if the shoulder A is wornto the same level with the face or damages are observed. Makesure that also the outer surfaces of the rotation bushing are ingood conditions.

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5.5. Chuck

1 mm

B

The chuck inside the rotation bushing must be changed if thewear is over 1 mm from the original surface B or if there are somehair cracks.

5.6. Rotation bushing bearings inside the gear housing

The bearings must be changed if the wear indication--groove hasworn out from any area.

5.7. Wear limits of the shank

max 1 mmmax 1 mm

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

When installing a new shank, take care that no dirt enters inside the rockdrill with the shank. Insert the shank carefully through the flushinghousing, so that the flushing device seals are not damaged.

CAUTION

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6. 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 thebody section faces, shortening the service life of the rock drill.

Following procedure is recommended for checking the bolt tightness duringnormal maintenance:

1. Check the tightness of each bolt by using 10% higher torque than specifiedand the correct tightening order.

2. The joint being tested is loose if the wrench turns. In this case loosen all thebolts being tested and retighten with the correct order.

3. If the threads are not clean the bolts cannot be tightened correctly. In suchcases the bolt must be removed, the threads checked, cleaned, andlubricated with grease.

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

3

2

21

Fig 6. Rock drill bolts

1. Tie rod bolts 6 pcs2. Pressure accumulator bolts 4+4 pcs3. Flushing housing bolts 4 pcs

CAUTION

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6.1. Tie rod tightening

The tools required:-- torque wrench-- 24 mm ring end1. Lubricate the threads and the nut faces with grease.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.

1

23

4

5 6

Fig 7. Tie rods; tightening order

6.2. Pressure accumulators

The tools required:-- torque wrench-- 24 mm socket1. Lubricate the bolt threads with grease.2. Pretighten all four bolts to 100 Nm (10 kpm). Correct tightening order is 1--2--3--4.3. Final tightening torque is 200 Nm (20 kpm). Same tightening order (1--2--3--4)

should be used.

1

2

3

4

Fig 8. Pressure accumulator bolts tightening order

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6.3. Flushing housing bolts

The tools required:-- torque wrench-- 24 mm ring end1. Lubricate the bolt threads with grease.2. Pretighten all four bolts to200Nm(20kpm).Correct tightening order is (1--2--3--4).3. Final tightening torque is 400 Nm (40 kpm). Same tightening order (1--2--3--4)

should be used.

1

4

2

3

Fig 9. Flushing housing bolts

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7. PERIODIC MAINTENANCE

7.1. General

The idea of periodic maintenance is that the rock drill is serviced before any breakdownoccurs. This way expensive additional damages and unwanted production interruptioncan be avoided.

The maintenance interval is 500 percussion hours, but depends on the local conditions,and it must therefore be determined according to this experience.

Searching for the correct maintenance interval, it is advisable to start the periodicmaintenance as specified, and then lengthen the intervals until a period that suits the localconditions has been found.

In addition the rock drill should always be taken in for service when the operator reportsof a fault on the rock drill that can cause major damage or a production interruption.

7.2. Field service tools1. Torque wrench2. 24 mm socket3. 24 mm ring end4. 19 mm wrench5. Extension6. Accumulator low pressure gauge7. Accumulator high pressure gauge

1

23

4

56

7

Fig 10. Maintenance tools

Make sure that you have also the flushing seals, gaskets and the shank adapter for therock drill maintenance.

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7.3. Every day1. Check the flushing housing for water and air leaks.2. Check the flushing housing bolt tightness.3. Check for possible oil leaks.4. Check the condition of the hoses and fittings.

7.4. Every week1. Check the hour meter reading.2. Check the accumulator filling valves and their protective capsand the accumulator

bolt tightness.3. Check the accumulator pressures-- High pressure 50 bar. . . . .-- Low pressure 4 bar. . . . . .4. Check the condition of the shank, chuck, flushing housing, coupling, shank

bushing and the rotation bushing.5. Check the tie rod tightness. If loose, tighten them up, according ch. 6.1.

7.5. Basic maintenance

Rock drill basic maintenance is recommended every 500 operating hours, Cf. “RepairInstructions’’. Thismaintenance interval can be adjusted according to local conditions andexperiences which are accumulated to the rock drill maintenance history. Do planned andpreventive maintenance rather than repairs after damages.

Monitor percussion hour meter reading and/or drilled meters/shifts between eachmaintenance. Fill in the service card of the rock drill.

7.6. After rock drill service

After the rock drill service the reassembled parts will settle down to their proper positionduring drilling under normal drilling loads. Especially if the parts haveworn surfaces itmayresult that the tie rods and the mounting bolts do not keep their tightness. Therefore are--tightening of these bolts is required after each rock drill service or if the rock drill hasbeen 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 rail2. re--tighten the rock drill tie rods and flushing device bolts

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7.7. Service card

Each rock drill has its own service cards. When a rock drill is taken up for maintenance,all the earlier cards should be at hand. All relevant information about the maintenancemust be written down on the card. When the rock drill is again taken into use, the nextmaintenance 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 bycomparing the cards the effect of different circumstances and measures can bedetermined.

-- The cards help in determining maintenance required to prevent major damage.-- Properly filled cards show the complete maintenance history of the rock drill.-- The cards help to determine the point when the rock drill should be scrapped.-- Use service card presented on the next page.

7.8. Service follow--up

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

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Purpose of the service Serviceman

Arr.date Prev.service Prev.perc.hours Workinghours

Dism. Insp.

Prev.service card NoDep.date Ass. Total

REPLACED PARTS/ PART INSPECTION

Qty Part No Repaired ReplacedOK

Piston

Distributor

Rotation bushing

Rot.bush.bearing

Rotation motor

Rotation shaft

LP accumulator

HP accumulator

Rotationmechanism tested

Percussionmechanism testedRemarks

ROCK DRILL SERVICE CARD NoEquipment S / nRock drill S / n

SERVICE INFORMATION

Rep.

Description / Batch / Batch Remarks

Front bushing

Rear bushing

Spacer

Gear housing

Chuck

Connecting piece

Rot. shaft bearings

Front cover/ body

Flus. seal housing

Shank bearings

Since previous service percusion hoursdrill. shifts/rounds

drilled meters

Pilot cylinder

Documents

S03 Rock Drill HLX5 Maintenance