Rock Drill
Rock Drill
Rock Drill
1 (1)
HE 122 / HE 119 39 kg
HL 1000/ HL 1000 S 290 kg rod, 300 kg versin de tubo HL 1500/ HL 1500 S 450 kg
B 23700 2 en 0602 / JS
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CONTENTS
1. 2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAKING A NEW ROCK DRILL IN USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOSE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING FRONT END WITH ROCK DRILL ON FEED RAIL . . . . . . . . . . . . 5.1. Replacing the flushing housing seals . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. Changing the bearings of the flushing housing . . . . . . . . . . . . . . . . . . 5.3. Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4. Rotation sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5. Chuck bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6. Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7. Rotation bushing bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8. Wear limits of the shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND TIGHTENING BOLTS AND TIE RODS . . . . . . . . . . . . . . . . . . 6.1. Tie rod tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2. Pressure accumulator and stabilator bolts . . . . . . . . . . . . . . . . . . . . . . 6.3. Flushing house bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2. Maintenance tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 followup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120
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1.
GENERAL
These instructions describe in brief the main maintenance procedures for HLX5 series hydraulic rock drills. Service is always ready to help and give advice in all maintenance problems. The qualified TAMROCK maintenance personnel of your TAMROCK dealer and original TAMROCK spare parts ensure reliable operation of your drilling equipment.
2.
2.1. Preparations
Pressurize the accumulators according to the instructions. See Pressure accumulator, Repair instructions. Before a new rock drill is installed the drilling equipment hydraulic system must be checked and flushed thoroughly.
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3.
HOSE CONNECTIONS
3 4 7 5 6
Fig 1.
1. Stabilator 2. Shank lubrication 3. Percussion mechanism pressure side (H.P.) 4. Percussion mechanism return side (L.P.)
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4.
LUBRICATION SYSTEM
The rock drill percussion mechanism and the rotation motor are lubricated by the hydraulic oil flowing through them.
Fig 2.
Lubrication scheme
The rotation mechanism and the shank have oil mist lubrication. The lubrication line from the central oiler 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 bushing of the flushing housing. Leakage oil from the rear seals of piston is also ducted to the front end of the rock drill through hole. 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 spacer to the feed rail. Never connect the used oil mist to the hydraulic system return line.
CAUTION
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1. The shank lubrication oil consumption can be adjusted. ** 2. If the oil level in the oiler does not lower during drilling. ** 3. Drain regularly the water that has collected in the oiler. The draining interval depends on the local conditions. 4. Only the oils mentioned in the oil recommendation are allowed. 5. Refill the oiler regularly.
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5.
WARNING
WARNING
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. Otherwise the air pressure can blow / burst out the flushing housing and cause injury.
The flushing housing can be removed when the rock drill is in the feed rail. Through opening the bolts (4), the flushing housing (1), shank (2), and coupling (3) can be removed without removing the rock drill from the feed rail. The rotation sleeve (6) can be pulled out by opening the screw (5). The screw (5) prevents the rotation sleeve from dropping, for example, when the shank is changed. Check the condition of the stabilizer pins.
6 3
2 1 5 4
Fig 4.
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AIR FLUSHING
WATER FLUSHING
Fig 5. The flushing housing seals must be installed facing the right direction, determined by the flushing mode In addition, a damaged seal plate (1) must be replaced due to risk of corrosion.
CAUTION
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5.3. Coupling
The bearings must be changed if the wear indicationgroove has worn out from any area (as shown in the picture).
Pull the coupling out from the rotation bushing. Check and replace, if the edges of the inner teeth are worn sharp.
Check the chuck bearing inside the rotation sleeve. The bearing must be replaced when the bearing surface is worn to the level of the wear indicator groove at any point.
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5.6. Chuck
1 mm C The chuck inside the rotation sleeve must be replaced every 500 percussion hours; it has worn over 1 mm from its original level, the surface against the stabilizer is worn to the level of the wear indicator groove C; or the chuck has cracks in it.
The bearings must be changed if the lubrication groove has worn out from any area (as shown in the picture).
CAUTION
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.
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6.
Perhaps the most important maintenance task is to check the tightness of the bolts, particularly the tie rods and mounting bolts. Loose tie rods cause rapid wear of the body section faces, shortening the service life of the rock drill. If the threads are not clean the bolts cannot be tightened correctly. In such cases the bolt must be removed, and the threads checked, cleaned, and lubricated with Vaseline. Following procedure is recommended for checking the bolt tightness during normal maintenance: 1. Check the tightness each bolt by using 10 % higher torque than specified. 2. The joint being tested is loose if the wrench turns. In this case loosen all the bolts being tested and retighten in the correct order. 3. If the threads are dirty, clean the threads, check them, and lubricate with grease. Use only an inspected, highquality torque wrench.
CAUTION
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1 5 3 7
4 6 2 8
Fig 7.
6 5 7
3 Fig 8.
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Fig 9.
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7.
PERIODIC MAINTENANCE
7.1. General
The idea of periodic maintenance is that the rock drill is serviced before any breakdown occurs. This way expensive additional damages and unwanted stops can 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 periodic maintenance as specified, and then lengthen the intervals until a period that suits the local conditions has been found. In addition the rock drill should always be taken in for service when the operator reports of a fault that can cause major damage or a production stop.
4 7 3 Fig 10. Maintenance tools Other rock drill parts which are to be available at the rig for maintenance are flushing housing gasket, flushing seals and shank adapter.
E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120
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SERVICE INFORMATION
Purpose of the service Arr.date Dep.date
REPLACED PARTS/ PART INSPECTION Qty Part No Description Piston Front cylinder Fron bushing Rear cylinder Rear bushing Distributor LP accumulator HP accumulator Spacer Gear housing Rotation bushing Rot.bush.bearing Chuck Connecting piece Rotation motor Rotation shaft Rot. shaft bearings Front cover/ body Flus. seal housing Shank bearings Idle gear Idle gear bearing Idle gear pin Percussion mechanism tested Repaired / Batch Replaced / Batch OK Remarks
Remarks
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CONTENTS
1. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. Flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. Replacing seals of flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3. Replacing bearings on flushing housing . . . . . . . . . . . . . . . . . . . . . . . . 1.4. Replacing bearing inside rotation bushing . . . . . . . . . . . . . . . . . . . . . . 1.5. Pressure accumulators and rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6. Gear housing, primary gear and stabilizer accumulator . . . . . . . . . . 1.7. Removing spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8. Percussion cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9. Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10. Stabilizer spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1. Percussion cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2. Rotation motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3. Assembling and centralizing the stabilizer piston seal . . . . . . . . . . . 3.4. Stabilizer spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5. Installing bearings of gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6. Installing chuck, rotation bushing and stabilizer accumulator . . . . 3.7. Installing of flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8. Pressure accumulators, hose connector flanges, rear cover . . . . . . TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 4 5 7 8 9 13 15 17 18 20 24 24 26 28 29 31 34 35 36 38 40
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1.
DISASSEMBLY
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2 1 4 5
Fig 1.
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AIR FLUSHING
WATER FLUSHING
Fig 2. The flushing housing seals must be installed the correct way according the type of flushing Due to risk of corrosion, also replace the gasket (1) if it is damaged.
CAUTION!
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The bearings must be replaced if the indicator groove is worn away from any place. (Fig. 3)
Fig 3.
Flushing housing bearings Make sure that the lubrication channels are flushed clean with pressured air.
CAUTION!
Detach the front cover (Fig. 4) and press the bearings out (Fig. 5, 6, 7) using a hydraulic press and the punches in the tool kit in the direction indicated by the arrows in the illustration.
Fig 4.
Fig 5. Pressing the shank bushing out by using the special tools no. 5 and 7 (See Special tools)
E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120
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9 2
Fig 6. Pressing the front bearing out of front cover by using the special tool no. 2 and 9(See Special tools) 9 2
Fig 7. Pressing the rear bearing out of the shank bushing by using the special tool no. 2 and 9 (See Special tools)
Pull the coupling out from the rotation bushing. Check and replace, if the edges of the inner teeth are worn sharp or visible cracks are seen. Fig 8. Coupling
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Fig 9. Rotation bushing, chuck bearing
The chuck inside the rotation bushing must be replaced after 500 percussion hours or if shank end has worn more than 1 mm from original surface, shoulder on stabilizer end has worn down to end face level C (Fig. 10) or it has hair cracks.
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WARNING!
Open the accumulator fastening bolts (2). Remove the accumulators. Remove the Oring and the gasket. Put protective plugs into the openings on the rock drill body. Open the rear cover s fastening bolts (4). Detach the rear cover (3) from the rock drill. On disassembly, inspection, reassembly, and filling of pressure accumulator, see Pressure accumulators, repair instructions. 3 4
2 1
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3 6
1 2
Fig 12. Mounting rock drill to repair stand and disassembling stabilizer accumulator
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Fig 13. Disassembling of gear housing and primary gear Remove the gear housing side bolts (4 pcs). Clean the bores carefully through the side bolt holes.
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13
Fig 15. Pressing the front bearing out by using the special tools no. 7 and 13 (See Special tools)
12
Fig 16. Disassembly of rear bearing with steel frame with special tools no. 7 and 12 (See Special tools)
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3 1
10
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Fig 19. Detaching the body cylinder from the spacer Detach hose jointing flanges (1) from body cylinder. 1
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4 1 Fig 21. Removing the piston Place special tool (8) inside rear bearing (2), and push rear bearing out together with pilot cylinder (3) and distributor (4). (Fig. 22) 3 4 2 8
Fig 22. Disassembling the rear bearing, pilot cylinder and distributor
E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120
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3 2 1
Fig 23. Dismantling of rear bearing and distributor Check the piston seal grooves (A) at the rear bearing. Maximum groove width is 4.35 mm. The width of the groove can be checked with gauge no. 14 (see page 40). Also check the grooves visually; if the groove is too wide or damaged, replace the rear bearing.
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Fig 25. Disassembly of the hydraulic motor If the Orings are holding the balance plate (5) and the channel plate (6) tight, they can be released by using grease (2) (Fig. 26), spacer pin (3) (Fig. 26) and a punch (10) (Fig. 26). 10 6 3 5 2
Fig 26. Disassembly of the balance and the channel plates
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2 4 1
Fig 27. Disassembling the stabilizer spacer Extract pin housing (1). Rotate housing so that lower spigot (2) of pin housing does not fit in its hole. Put pin housing partly back on to stabilizer spacer spigot and carefully puff stabilizer pistons (3) out of their cylinders by compressed air through stabilizer oil channels (Fig. 27, 6 and 7). If the pistons do not come loose, fit the threaded holes (6 and 7) with grease nipples. Secure the pin housing (1) axially to the spacer (3). Apply grease inside the unit with a grease gun until the stabilizer pistons come loose. Clean the grease from the channels. 3 1
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14
Fig 29. Special tool for checking the groove The seal bushing can be removed by special tool (no. 3 and 7, See Special tools) and press.
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2.
WEAR LIMITS
Make sure that the percussion cartridge goes into the body cylinder together with the spacer. Take measurements C, D, E. Measurement C > (D+E) (Fig. 31), otherwise the body cylinder must be discarded.
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H I J K
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A/B
1 mm
H H 1 mm H I J B N F I A B G J K
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Before assembly: Remove all old Orings and seals. Clean all parts thoroughly. Lubricate parts liberally ! Mount body cylinder to repair stand.
Fig 34. Assembling the distributor, the piston rear seals and rear bearings
E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120
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1.
2.
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3 6 4 5 7 8 9 10
Fig 36. Assembly of rotation motor 1. 2. 3. 4. 5. 6. Stud Cardan shaft Flange Gear wheel set Channel plate Valve drive 7. 8. 9. 11. Disc valve Space pin Balance plate Hex. nut
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A 1
Fig 37. Gearwheel set, OMS motor Install the shaft and the hydraulic motor cover. Ensure that the studs are fully tightened. Tighten the nuts in a crosswise pattern first to 40 Nm. The final tightening torque is 80 Nm.
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Lubricate stabilizer all parts. Mount stabilizer pistons into their cylinders thru seal centralizing punch (5) in order to avoid seal damages during assembly. Make sure, that coated (marked with VC on bottom face) stabilizer pistons are aligned with the 3 recesses in pin housing. Mount Orings (1) on the spigots of stabilizer spacer and pin housing. Push (or tap gently with rubber mallet) pin housing to its position. 1
VC
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Fig 39. Removing the bearing Press a new needle bearing (2) into its position with a special tool (no. 1, page 40). Replace the rotation shaft seal (3) and Orings (4).
Fig 40. Replacing the shaft seal and bearing
E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120
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Fig 41. Installing the seals Insert the bearing housing (1) and the spherical roller bearing (3) into the spacer (4).
4 1 3 Fig 42. Installing the seal housing and roller bearing Turn the rock drills installation base to horizontal position.
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2 Fig 45. Gear housing front bearing Install the needle bearing into the bearing housing of the rotation shaft using a punch 26 (See Special tools).
26
Fig 46. Installation of needle bearing Install the Oring into its groove and install the bearing housing into its position in the gear housing. Make sure that the bearing housing is pushed fully home.
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1 5 3 7
4 6 2 8
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2 3
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2 1
Fig 50. Assembling of the flushing housing Detach rock drill from assembly stand.
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Fig 51. Assembling of accumulators, connector flanges and the rear cover
5. Attach hose connector flanges, use lubricating grease to hold the Orings in their grooves during assembly. Check, that shank lubrication can flow through rock drill from connector flange to lubrication outlet.
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Surface model
UG model
Fig 52. Oil outlet in rock drill Filling of pressure accumulator, see Pressure accumulators, repair instructions.
Accumulator pressures Accumulator type High pressure Low pressure Stabilizer accumulator Pressure [bar] 50 4 8
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4.
TEST RUN
General After completed maintenance, the rock drill can be tested in the TAMROCK Service Container using the hydraulic powerpack. 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 rock drill may not be test run on the assembly stand! The shank must be removed before test run.
CAUTION!
The purpose of test run is to check the operation of the percussion and rotation mechanism of the rock drill, and to see if any major leaks are observed. When testing the rotation mechanism, the hoses to the percussion mechanism must be connected to the rock drill to enable the internal lubrication of the rotation motor to operate. Wear hearing protectors when the powerpack is running!
WARNING!
Before test run 1. Using a double nipple, connect the hoses of the powerpack to make a loop so that the lines of both pumps form their own closed circuits. 2. Start the powerpack. 3. Pull the levers of both control valves into operating position, whereby oil starts flowing through the systems in free circulation. 4. Allow the powerpack to run for about 3 minutes, after which it is ready for test run.
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6
120 bar
6
175 bar
10
10...210 bar
2 M
9 1
1. 2. 3. 4. 5.
Tank Electric motor Double pump Control valve (percussion) Control valve (rotation)
6. 7. 8. 9. 10.
Pressure relief valve Pressure gauge (percussion) Pressure gauge (rotation) Return filter Differential pressure valve
Test run 1. Connect the rock drill according to the hydraulic flowchart. 2. Make sure that: There is enough oil in the tank (1). The control valve (4) and (5) levers are in neutral position. 3. Start the powerpack. 4. Start percussion by pulling the control valve (4) lever towards yourself. 5. Start rotation by pulling the control valve (5) lever towards yourself. You can change the direction of rotation by pushing the lever to the other extreme position. 6. Continue the test run for about 5 minutes, and observe possible leaks.
E 2002 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120
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SPECIAL TOOLS
550 056 57 10. 150 551 68
2.
550 055 57
3.
550 054 94
4.
550 054 80
5.
150 746 48
6.
152 249 08
7.
550 057 16
8.
449 701 50
9.
449 697 70
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19.
20.
21.
22
26.
Fig 53. Tool kit id. number: 550 065 07 The table shows some special tools in the tool kit 550 065 07. A complete listing of the contents of the tool kit is provided in the spare part manual.
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CONTENTS
1. 2. 3. 4. 5. 6. 7. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FILLING GAS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE PRESSURE ACCUMULATOR FROM THE ROCK DRILL . DISMANTLING THE PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1. Filling device of pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . 7.2. Filling instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3. Filling pressures of accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1. Low pressure accumulator (LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2. High pressure accumulator (HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.3. Pressure of stabilizer accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOUNTING THE PRESSURE ACCUMULATOR ON THE ROCK DRILL . . . . 2 3 3 4 4 5 7 7 8 9 9 9 10 11
8.
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As in all hydraulic machinery so also in hydraulic drill rigs cleanness is the most important consideration if trouble--free operation is to be ensured. We therefore recommend that all maintenance work of the accumulators is done in a clean and dustless room. The condition of pressure accumulator should be checked always when the accumulator is dismantled and when the rock drill is overhauled. The rock drill special tool set includes all the tools needed in maintenance and checking the accumulators. Experiences have shown that the first (originally fitted) accumulator diaphragm does not reach the normal service life, particularly if the time interval between the pressurization and taking into use is long. For this reason the accumulators supplied as spares are unpressurized. There is a note of this on the accumulator. The accumulator bottom and cover should always be kept as a pair. Tamrock supplies covers and bottoms only as a pair; other parts such as diaphragms and filling valves can be obtained separately.
Only qualified service personnel may service the pressure accumulators. The following instructions must be strictly observed; failure to do so may cause a danger of accident.
WARNING
Before removing the accumulator from the rock drill, discharge the accumulator pressure by opening the filling valve.
WARNING
While using the gauge, the pressure relief hole must always be pointed to the opposite direction from any persons close by to avoid personal injures in case the sudden pressure discharge.
WARNING
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Check the accumulator filling gas pressure once a week. The rock drill special tool set includes two pressure gauges for this purpose: one gauge with the scale 0...100 bar for the high pressure accumulator, and the other with the scale 0...10 bar for the low pressure accumulator.
a 1. 2. 3. 4. 5. 6.
Remove the cap (a). Screw the pressure gauge to the filling valve. Undo the lock nut (b). Wait until the needle of the gauge stops and then read the gauge indication. Close the lock nut (b). Unscrew the gauge from the filling valve and fit the cap (a) in place.
3.
Pressure accumulator can be changed without demounting the rock drill from the feed. If you for some reason cannot immediately install a new accumulator, must the open oil channels be covered thoroughly with eg. plastic plugs. 1. Discharge the accumulator pressure by opening the filling valve! 2. Undo the accumulator bolts (wrench size 24 mm). Do not start the hydraulic powerpack if an accumulator is not in place in the rock drill.
WARNING
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WARNING
1. Fasten the assembly stand (1) in the vice, and place the accumulator in the stand with the bottom upwards. 2. The same number appears both on the accumulators cover as well as on the bottom. The cover and the bottom must remain paired. 3. Make sure that the filling valve is open! 4. Open the accumulator bottom with the opener (2).
5.
If the threads are badly corroded or worn, the accumulator must be scrapped!
WARNING
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a b b
40 Nm secure with glue
10 Nm
20 Nm
1. Fit a new or inspected diaphragm in the cover. Make sure that the diaphragm is in the groove and fitted the right way down. 2. Lubricate the surface (a) with vaseline or lanolin.
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WARNING
The high pressure accumulator is marked with uneven numbers and the low pressure accumulator with even numbers. HP LP
3. Lubricate the threads of the bottom with vaseline or lanolin. 4. Screw the bottom all the way in and tighten it with the special tool to a torque of 150 Nm. D When the pressure accumulator diaphragm is changed, the O--rings (b) should also be changed.
Check the wear limit marks of the threads always after tightening (150 Nm) of the bottom. If the mark (I) in the bottom remains after the tightening between the dot (S) and the mark (R) in the cover, the thread is in order. If the mark (I) in the bottom goes beyond the mark (R), are the threads of the accumulator cover and bottom too much worn. Replace the accumulator and discard the old one. A worn-out or damaged pressure accumulator must be discarded immediately.
WARNING
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WARNING
You can refill the accumulator while mounted to the rock drill.
N2
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
11
10
13,14 15
Accumulator body Filling valve Locking nut Cap Quick coupling stem Quick coupling sleeve Hose Accumulator pressure gauge Gas bottle pressure gauge Pressure reducing valve Pressure regulating valve Shut--off valve Adapter Seal Elbow adapter
E 2001 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100 FIN-33311 TAMPERE, Finland Tel. +358 205 44 121 Telefax +358 205 44 120
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Low pressure accumulator damps hydraulic vibrations in the return line. It also prevents cavitation in return lines and channels. To get the optimum result of LP--accumulator, gas pressure should be half of the return line pressure. Normally its from 3 to 5 bars. 7.3.2. High pressure accumulator (HP)
The main function of high pressure accumulator is to store pressurised oil during the return stroke of the piston. This stored pressure can be utilized during the next piston stroke. Another vital function is to dampen vibrations. HP--accumulator gas pressure should be related to the set max. percussion pressure according to graph below.
Filling pressure
Percussion pressure
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Filling pressure
70 60 50 40 30 20 10 0
100
120
140
160
180
200
220
Percussion pressure
7.3.3.
Pressure of stabilizer accumulator HLX 5 T . . . . . . . . . HL 700 T . . . . . . . . . HL 700 ST . . . . . . . HL 1500 . . . . . . . . . 8 bar 30 bar 30 bar 50 bar
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1. Before mounting the accumulator on the rock drill, remove the cover plugs from the accumulator connection port, and clean the joint surfaces both in the accumulator and in the rock drill. 2. Check that the bolts move easily in their threads in the drill body. Lubricate the threads of the bolts. 3. Fit the O--ring and the gasket. 4. Tighten the pressure accumulator bolts in two phases: pretightening 100 Nm, final tightening 200 Nm.
Tightening of the four-bolt accumulator The four---bolt accumulator must be tighten by using a cross---tightening method 1-3-2-4.
CAUTION
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Notes: