D 20100 ---2 pt 0498 / PIR 1/1

INSTRUÇÕES DE ELEVAÇÃO PARA

PERFURADOR DE ROCHA

HE 122 / HE 119
39 kg
HE 300 HL 300 HL 300 S
89 kg 94 kg 92 kg

HL 500/ HL 500S/ HL500G/

HL550super/ HL 500F : 130 kg

HL 600 / HL 600 S
180 kg

HL 700 245 kg

HL 1000/ HL 1000 S
290 kg rod, 300 kg tube
version

HL 1500/ HL 1500 S 450 kg

E 1998 TAMROCK CORP., Tampere Plant, Service
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 1 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

CONTENTS

1. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1. Flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.1. Replacing seals of flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.2. Replacing bearings on flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2. Gear housing, intermediate flange, and rotation shaft . . . . . . . . . . . . 7
2.3. Pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4. Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5. Percussion cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6. Body cylinder seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1. Body cylinder seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2. Percussion cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3. Intermediate flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3.1. Seals and O rings for intermediate flange sealing housing . . . . . . . . . 18
3.3.2. Bearing housing of intermediate flange . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.3. Installing intermediate flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4. Installing rotation shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5. Installing bearings of gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.6. Installing chuck and rotation bushing . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.7. Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7.1. Installing bearings onto shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.8. Pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.9. Installing of flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2000 sANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
2 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

1. SPECIAL TOOLS

 




 

 










 
 





 


2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 3 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

Ref Order No. Description Standard designation Qty

1 098 067 71 STAND FOR ROCK DRILL 1

2 093 333 78 TOOL SET INCL. torque wrench, sockets 19, 22, 24, 30, 36, hammer,
wrench 19, 24, 27, 30, 41, torque wrench head 19 1
3 153 936 18 FILLING DEVICE FOR ACCUMULATOR INCL. PARTS 23 1
4 090 300 38 CHECKING GAUGE HP (0...100 BAR) 1
5 090 845 48 CHECKING GAUGE LP (0...10 BAR) 1

6 869 598 69 PRESSURE SEAL FOR PARTS 5,6 (ELBOW FITTING) 2

7 833 710 99 SEALS REMOVING SET 1
8 095 170 98 STAND ASSY ACCUM. 1
9 151 806 48 OPENER ACCUM. BOTTOM 1
10 090 345 01 PULLER REAR CYLINDER 1

11 151 866 08 EXTENSION ROD FOR PUNCHES 1

12 150 545 68 PUNCH FRONT BEARINGS, MOTOR SHAFT ASSY IN 1
13 867 284 49 HEX SOCKET HEAD SCREW ROTATION SEAL HOUSING OUT 2
14 152 248 88 PUNCH FRONT BEARINGS 1
15 151 867 28 PUNCH FRONT BEARING OF THE GEAR HOUSING OUT 1

16 150 291 18 PUNCH FRONT BEARING OF THE GEAR HOUSING IN 1

17 150 290 98 PUNCH REAR BEARING OF THE GEAR HOUSING, MOTOR SHAFT BEARINGS 1
18 150 288 08 PUNCH CHUCK 1
19 150 546 98 THRUST FRONT BEARINGS OUT 1
20 152 249 08 PUNCH ROTATION NEEDLE BEARINGS 1

21 150 551 68 PUNCH FRONT NEEDLE BEARING OUT 1

22 152 262 38 SOCKET ROTATION BEARINGS NUT 1
23 152 280 08 HOSE ASSY FOR FILLING DEVICE 1
24 886 364 09 TORQUE WRENCH HEAD 30 REAR MOUNTING TO CARRIAGE 1

PARTS TO BE ORDERED SEPARATELY

25 154 830 38 STAND ASSY 1
26 154 825 68 FITTING PLATE FOR ROCK DRILL STAND 1
27 880 817 19 SPECIAL TOOL KIT FOR THE SITE INCL.PARTS 2,3,7,8,9,11,12,14,19,24 1

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
4 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

2. DISASSEMBLY
2.1. Flushing housing
The flushing housing (1), the shank, and the coupling (9) can be pulled out without
removing the rock drill from the carriage, just open the bolts (49 and 50) and the nuts.
When the retaining screw (27) is opened, the rotation bushing (8) can also be pulled out.
The retaining screw (27) prevents the rotation bushing from accidentally falling out when,
for instance, the shank is being replaced.






 

2.1.1. Replacing seals of flushing housing
The flushing housing seals must be replaced if flushing air or water is leaking out past the
sealing housing, and checked whenever the shank is being replaced. Lubricate the seals
with grease before installation. Install the new seals in the right direction, as illustrated.
We recommend that a preassembled spare flushing housing is used, it saves time in rock
drill maintenance at the drilling site. Due to risk of corrosion, also replace the gasket
(7) if it is damaged.

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 5 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

2.1.2. Replacing bearings on flushing housing

The bearings (3 and 5) must be replaced if

ÎÎÎÎ
ÎÎÎÎ
the indicator groove is worn down as
illustrated. Open the front cover and press
the bearings out using a hydraulic press
and the drifts in the tool kit in the direction

ÎÎÎ
indicated by the arrows in the illustration.

ÎÎÎ

5
3

152 246 68

150 546 98

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 6 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

151 866 08
150 545 68

150 546 96
152 246 68

1. Pull the coupling piece (9) out of the

rotation bushing. Check the bushing
A and replace it if the inner teeth are worn
pointed.

2. Open the Allen screw (27) and remove

the seal.

3. Pull the rotation bushing (8) out of the
gear housing. Check the teeth and
bearing surfaces for wear. The rotation
bushing must be replaced if the
shoulder (See ill.) is worn down to end
face level or damaged is observed.

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 7 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

4. The chuck (69) inside the rotation

bushing (8) must be replaced if the
recesses on it are more than 1 mm in
ÎÎÎÎÎÎÎÎÎ depth (See ill.) or it has cracks. To

ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎ
replace a worn rotation bushing, use a
hydraulic press and a drift included in
the tool kit.

150 288 08

151 866 08

2.2. Gear housing, intermediate flange, and rotation shaft

1. Mount the rock drill to the repair stand (cf. Special Tools).









2. Open the cap nuts (51) of the tie rods (26) and remove the tie rods.

2000 sANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
8 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

18




 15

3. Remove the gear housing (2). The rotation shaft (18) and the bearing housing (15)
are removed with the housing. Remove the rotation shaft (18). Remove the
bearing housing (15) using a drift and a hammer. Remove the O ring (39).
Grease
15 150 551 68

73

4. Replace the needle bearing (73) every 500 operating hours. (Use grease and the
special tool as illustrated). Blows with the hammer make the grease drive the
bearing off.

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 9 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

151 867 28
67
151 866 08

68

159 290 98
151 866 08

5. Check the gear housing front bearing (67) and rear bearing (68) for wear. Bearing
must be replaced if the bearing surface is worn down at some point of the indicator
groove.

6. If the gear housing bearings are worn or damaged, remove them using a hydraulic
press and drifts.

7. Remove the intermediate flange (3) from the body cylinder. If the hard metal studs
on the intermediate flange are worn or blue, lubrication has been insufficient.
Ensure proper operation of lubrication before each shift.

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
10 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

 

 





 




8. Remove the O rings (43 and 44) and the gasket (45).
9. Remove the sealing housing (46) of the intermediate flange.
10. Remove the rotation shaft bearing housing (16) with its bushings from the
intermediate flange
11. Remove the bushing (17) from the bearing housing.
12. Remove the O ring (40). Always replace the needle bearing (74) every 500
operating hours.

152 249 08

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 11 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

2.3. Pressure accumulators

Release the accumulator pressure by opening the filling valve before

removing the pressure accumulator from the rock drill.



1. Open the accumulator fastening screws. Remove the accumulator. Remove the
O ring and the gasket. Put protective plugs into the openings on the rock drill body.
2. On disassembly, inspection, reassembly, and filling of pressure accumulator, see
“Three–bolt pressure accumulators of rock drills, repair instructions“.

2.4. Hydraulic motor

After every 500 operating hours, the condition of the hydraulic motor shall be checked,
and the O rings and needle bearings replaced.

1. Open the rotation motor mounting screws, and pull the motor out.

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
12 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

2. Use a puller to remove the shaft together with its bearings.

090 345 01

3. Install the screws to the sealing housing (20) and pull it out, and remove the sealing
(36) and the O ring (41).

20



867 284 49

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 13 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

4. Open the locking plate (34); open the shaft nut (33) using the special tool and
remove the bearings (35) by cautiously tapping them out with a hammer.

152 262 38











5. Check the shaft (19) for wear at the sealing.

2.5. Percussion cartridge

1. Pull the piston out of the body cylinder. The front cylinder will come out with the
piston.

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
14 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

2. Check the piston, and replace it

– if the chamfer has worn off
– if the piston has cracks or seizure
marks. The piston may be polished
with a cloth pad disc. No grinding is
allowed!

3. Check the bearing bushing of the front cylinder. If it is damaged, replace the
cylinder.

4. Remove the distributor from the body cylinder. If the distributor has signs of
seizure, replace it. The distributor can be polished with a cloth pad disc, if
necessary, but no grinding is allowed!
5. Remove the rear cylinder with a puller.

43

090 345 01

6. Remove the O rings (43).

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 15 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

14

7. Check the rear cylinder bearing bushing (14). If it is damaged, tap the rear bearing
out with the aid of the piston.

2.6. Body cylinder seals





1. Remove the seals (37) from the body cylinder.

2. Remove the O ring (70).

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
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HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

3. ASSEMBLY

Before assembly:
– Clean all parts thoroughly!
– Mount body cylinder to repair stand.
– Lubricate parts liberally!

3.1. Body cylinder seals

37

1. Liberally lubricate the seals and cautiously rub them softer with your fingers. An
alternative is to soften the seals in warm water (max. +50
C).
2. Install the body cylinder seals (37) as illustrated.

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 17 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

3.2. Percussion cartridge

 

13

1. Using a plastic mallet, tap the bearing bushing (14) of the rear cylinder into
position.
2. Install the O rings (43) of the rear cylinder (13) into their grooves.
3. Push the rear cylinder into the body cylinder.

 





4. Push the distributor (12) into the piston (10).

5. Install the O rings (43) of the front cylinder (11) into their grooves.
6. Push the front cylinder (11) into the piston (10). Check that the distributor (12) and
the front cylinder (11) are the right way round!
7. Push the piston into the body cylinder.

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
18 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

Turn the rock drill stand into vertical position.

3.3. Intermediate flange

3.3.1. Seals and O rings for intermediate flange




 

1. Liberally lubricate the seals (38) and cautiously rub them softer with your fingers.
An alternative is to soften the seals in warm water (max. +50C).
2. Install the seals (38) of the sealing housing (46) as illustrated.
3. Install the O rings (87) of the sealing housing (46).
4. Install the sealing housing (46) to the intermediate flange (3).
5. Install the O ring (43) of the intermediate flange (3).

2000 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
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HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

3.3.2. Bearing housing of intermediate flange


 3





152 249 08



1. Install the needle bearing (74) into the bearing housing (16) of the rotation shaft
using a drift.
2. Install the O ring (40) into its groove in the bearing housing.
3. Using a plastic mallet, tap the bushing (17) into the bearing housing.
4. Install the assembly to the intermediate flange (3).
5. Install the O rings (41) of the bearing housing and the bushing into their respective
grooves.
3.3.3. Installing intermediate flange



6. Install the O ring (70) of the body cylinder into its groove. Use glue in the corners.
7. Check that the mating surfaces of the intermediate flange and the body cylinder
are clean, and install the intermediate flange into position.

2000 sANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
20 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

3.4. Installing rotation shaft



1. Install the gasket (45) and the O ring (44) of the intermediate flange into position
as illustrated.
2. Insert the rotation shaft (18) through the intermediate flange.
3. Lubricate the end of the rotation shaft and the hard metal studs on the intermediate
flange with graphite grease.

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 21 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

3.5. Installing bearings of gear housing

67
151 867 28

151 866 08

68

159 290 98
151 866 08

1. Press the gear housing bearings (67 and 68) into position using a hydraulic press
and drifts. In order to make installing easier, the gear housing can be cautiously
warmed up (max. 150°C).

152 249 08

39 15

73
15

2. Install the needle bearing (73) into the bearing housing (15) of the rotation shaft
using a drift.
3. Install the O ring (39) into its groove and install the bearing housing (15) into its
position in the gear housing. Make sure that the bearing housing is pushed fully
home.

2000 sANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
22 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

4. Install the gear housing into position.

5. Lubricate the threads of the cap nuts

(51) (4 pcs) with graphite grease.
Tighten the nuts crosswise in two
stages, first to 150 Nm and final
tightening to 400 Nm.

6. Turn the rock drill stand into horizontal

position.

51

3.6. Installing chuck and rotation bushing

150 288 08
151 866 08 

 




1. Using a hydraulic press and a drift, press the chuck (69) into the rotation bushing
(8).
2. Push the coupling piece (9) into the rotation bushing (8) and install the assembly
into the gear housing.
3. Install the Allen screw (27) and the seal (55).

2000 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 23 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

3.7. Hydraulic motor

3.7.1. Installing bearings onto shaft









1. Install the bearings (35) and the bushing (21) to the shaft (19) as illustrated.
Tighten the nut (33) with the special tool (torgue 25 Nm) and bend the edges of
the locking plate (34) over the nut (33).






ÎÎÎ
ÎÎÎ
ÎÎÎ

2. Install the seal (36) and the O ring (41) into the sealing housing (20).

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
24 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions


 





3. Push the shaft assembly and the bushing (22) into the body cylinder.
4. Install the seal (66) to the mating surface of the hydraulic motor (5), and install the
hydraulic motor into position. Install locking washer pairs and lubricate the threads
of the fastening screws. Tighten the bolts (89) crosswise to 80 Nm.
5. Install the sealing (77) and the O ring (42) to the rear cover (23).
6. Tighten the rear cover bolts (47) crosswise in two stages, first to 100 Nm and final
tightening to 200 Nm.

3.8. Pressure accumulators

1. Remove the protective plugs from the pressure accumulator connection, and
clean the mating surfaces of the accumulator and the rock drill body.
2. Install the O ring and the gasket.
3. Check that the accumulator fastening bolts turn freely in the threads on the rock
drill body. Install locking washer pairs and lubricate the fastening bolt threads.
Tighten the bolts in two stages: first to 100 Nm, and final tightening to 200 Nm.

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 25 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

3.9. Installing of flushing housing




1. Check that the mating surfaces of the flushing housing and the gear housing are
clean. Install the gasket (1) to the mating surface of the flushing housing. Install
the flushing housing into position.
2. Lubricate the threads of the fastening bolts (2) and nuts (2), and install the locking
washer pairs into position. Tighten the bolts in two stages: first to 150 Nm, and final
tightening to 300 Nm.
3. Check that the lubricating channels (3) for lubricating air and oil running through
the rock drill are clear.

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
26 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

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 installation stand!
The shank must be removed before test run.




The purpose of test run is to check the operation of the percussion and rotation
mechanisms 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.

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 27 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

 

 


 







  



1. Tank 6. Pressure relief valve

2. Electric motor 7. Pressure gauge (percussion)
3. Double pump 8. Pressure gauge (rotation)
4. Control valve (percussion) 9. Return filter
5. Control valve (rotation) 10. Differential pressure valve

2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
28 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

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.

5. WEAR LIMITS
Make sure that the percussion cartridge goes into the body cylinder together with the
intermediate flange.

D
C

Take measurements C, D, E. Measurement C must be greater than D+E, otherwise the

body cylinder must be discarded.

w1
w2

Wear of mountings.
Measure the wear of mounting surfaces. If the difference in wear is greater than 1mm,
reface the surfaces to the same level. Also remember to check/repair the carriage. We
recommend that a carriage and a rock drill are kept as a pair.

2000 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 D 21220 – 9 en 0500 / MAH 29 (30)

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

 















2000 sANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 30 (30) D 21220 – 9 en 0500 / MAH

HL 510 SERIES and HL 560 SUPER SERIES

Percussion Mechanism: Repair Instructions

Part Wear limits

A Shank bearings Replace bearings if wear indicator has

worn off at any point.
B Rotation bushing bearings
N Rotation bushing end float Replace gear housing if
(H) N < 0,5mm. Gear housing discard limit
H=170.
O, P Axial play at rotation bushing Gear housing is worn down if O = 0 or
bearings P=0
O Tightening length of tie rod Q > 42mm Tightening range at bottom.
Use washer.
F Piston Replace if chamfer has worn off.
G Chuck Replace if recess depth is > 1mm
H Shank bushing Replace if worn > 1mm or if wearing
surface is cracked.
I Rotation bushing Replace rotation bushing if 1 mm wear
shoulder has worn down.
J Coupling piece Replace if teeth have worn pointed.

2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 B 21260 ---1 en 1298TTi 1 ( 15)

HL 510/560-- SERIES HYDRAULIC ROCK DRILLS

Maintenance

CONTENTS

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2. Taking a new rock drill in use ...................... 2
3. Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Inspection and service of the front end with rock
drill on the carriage .... 5
6. Inspection and service of the rear end with rock
drill on the carriage .... 9
7. Checking and tightening bolts and tie rods . . . . . . . . . . . . 10
8. Periodic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
2 ( 15) B 21260 ---1 en 1298TTi

1. GENERAL
These instructions describe in brief the main maintenance procedures
for HL 510/560 --- series hydraulic rock drills .
Service is always ready to help and give advice in all
maintenance problems. The qualified maintenance personnel of your
dealer and original spare 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 not pressurized and the hose
connections plugged.
CAUTION

1. Pressurize the accumulators according to the instructions.

See “Pressure accumulator reparation instructions”.
2. Before a new rock drill is installed the drilling equipment hydraulic
system must be checked and flushed thoroughly. See “Hydraulic
jumbo users manual”.

2.2. MOUNTING

The rock drill is mounted on the carriage with four pairs of bolts.
Clean the carriage mounting surfaces from paint before mounting. In
order to avoid damage it is important to follow the tightening order and
use specifield mounting bolts, nuts and lock washers:

F=0 A C

Fig. 1.

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 B 21260 ---1 en 1298TTi 3 ( 15)

HL 510/560-- SERIES HYDRAULIC ROCK DRILLS

Maintenance

---1. By tightening (100 Nm) the bolts A remove the axial clearance (F)
between the rock drill and the cradle.
---2. Tighten bolts B and C to 100 Nm
---3. Tighten bolts A to 400 Nm
---4. Tighten bolts B and C to 400 Nm.
2.3. TEST RUN
Check the lubrication air+oil flow through the rock drill.

HL 510; Check the lubrication of the front bearing by

CAUTION pressing grease into the grease nipple 5---10 times or until
the grease comes out front sides of the seal housing.

Test run the rock drill and make sure that it operates properly before
starting the production drilling. During test run observe:
--- flushing ---pressures and temperatures
--- possible oil leakages. ---shank lubrication

Avoid use of full percussion power if the steel is not

against the rock. This will reduce the breagage of the
accumulator diagrams, the wear of flushing housing and
CAUTION 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.

3. HOSE CONNECTIONS
5
1. Rotation (pressure) 3
2. Rotation (return)
2 1
3. Percussion pressure
4. Percussion return
5. Shank lubrication LP HP

Fig. 2.
Percussion return hose adapter may be of such a type which restricts
the return flow from the rock drill. The adapter is used when the rig
hydraulic system generates a low back pressure, ie. below 10 bar
at the rock drill return hose. In this case the restrictor adapter
generates a small pressure loss which decreases and prevents
cavitation inside the rock drill. Generally the adapter is not used with
rock drills for tunneling jumbos. The adapter is typically used with rock
drills for bolters and production drilling rigs where large and short
hoses generate low back pressure at the rock drill.
E 1998 TAMROCK OY, SERVICE TAMPERE PLANT
P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 4 ( 15) B 21260 ---1 en 1298TTi

4. LUBRICATION SYSTEM

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

Fig. 3. Water flushing models ; HL 510/560 --- series

Rotation shaft bearings, rotation mechanism and the shank are

lubricated by oil mist lubrication. The oil mist passes throught the
chamber of the rotation shaft and further into the front end of the rock
drill and will go out from the flushing housing . ( See pictures)

HL 510; The front bearing of the shank is lubricated by grease

through the grease nipple (1).

Fig. 4. Air flushing model HL 510

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 B 21260 ---1 en 1298TTi 5 ( 15)

HL 510/560-- SERIES HYDRAULIC ROCK DRILLS

Maintenance

5. INSPECTION AND SERVICE OF THE

FRONT END WITH ROCK DRILL ON
CARRIAGE

When you are taking off flushing housing and shank turn
the rock drill to horizontal position, because the rotation
WARNING bushing and coupling can fall out and you can be hurt.

Without removing the rock drill from the carriage, the flushing housing
(1) , the shank (2) and the coupling (3) can be pulled off after undoing
the bolts (4) and the nuts. After releasing the lock---screw (5) you can
pull the rotation bushing (6) out. The lock---screw holds the rotation
bushing in the housing, for example while changing the shank.

6
3
1

Fig. 5.

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 device, so that the flushing
CAUTION device seals are not damaged.

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
6 ( 15) B 21260 ---1 en 1298TTi

5.1. INSTALLATION DIRECTIONS OF THE FLUSHING HOUSING

SEALS
Always replace all the seals and O---rings when the rock drill is
dismantled. Lubricate the seals well before assembling. The seals must
be installed on the right direction as shown in the picture.

The damaged gasket (1) must be changed to prevent

corrosion.
CAUTION

Fig. 6. Air flushing model HL 510

2
1

Fig. 7. Water flushing models; HL 510/560---series

To prevent the water entering into the rock drill gear

housing the flushing housing seals must be chanced
immediately if the flushing water starts leaking out front
CAUTION sides of the seal housing (2) .fig. 7.
The front of rock drill should also be tilted down wards to
prevent the water entering inside the rock drill while not
drilling.

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 B 21260 ---1 en 1298TTi 7 ( 15)

HL 510/560-- SERIES HYDRAULIC ROCK DRILLS

Maintenance

5.2. SPECIAL TOOLS FOR THE FRONT END

CHANGE OF THE FRONT COVER BUSHING CHANGE OF THE CHUCK

OUT IN

OUT
IN

OUT FROM THE FLUSHING HOUSING

OUT

IN

INTO THE
FLUSHING
HOUSING

CHANGE OF THE SHANK BUSHING / BEARING

Fig. 8. Tools for the front end

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
8 ( 15) B 21260 ---1 en 1298TTi

5.3. CHANGING THE BEARINGS OF THE FLUSHING HOUSING

The bearings must be changed if

the wear indication---groove has
worn out as shown in the picture.
If that case open the front cover and
push the bearings out by hydraulic
press and the punch to the direction
of the arrows in the picture 8.

5.4. COUPLING

Pull the coupling out from the

rotation bushing. Check and
replace if the edges of the inner
teeth are worn sharp.

5.5. ROTATION BUSHING

Check the teeth and the bearing A

surface for wear. Replace the
rotation bushing when the shoulder
(see picture) is worn down to the
surface.

5.6. CHUCK

The chuck inside the rotation

bushing must be chanced if the
wear is over 1 mm (picture) or if
there are some hair cracks . The
chuck is changed by hydraulic
press and the punch incl. to the tool
set. max.2 mm max.2 mm
5.7. WEAR LIMITS OF THE SHANK 1 mm

The shank must be chanced if the

1mm bevel of the striking head is
worn out or any other wear limit is max.
exeeded. 11 mm
min. 56 mm

HL 510 ; Press grease through the flushing housing nipple

5---10 times or until the grease comes out on front sides of
the flushing housing after every front service .
CAUTION

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 B 21260 ---1 en 1298TTi 9 ( 15)

HL 510/560-- SERIES HYDRAULIC ROCK DRILLS

Maintenance

6. INSPECTION AND SERVICE OF THE

REAR END WITH ROCK DRILL ON
CARRIAGE
The hydraulic motor with shaft, bearings and seals can removed
without removing the rock drill from the carriage .

OUT
4
3 25 Nm
OUT Secure with glue

5
6
IN

IN

Fig. 9. Tools of the rear end

1. Open the hydraulic motor nuts and take off the motor.
2. Pull out the shaft with the special tool.
3. Tighten the screws to the seal housing and pull it out.
4. Open the nut with special tool and take off the bearings carefully
with hammer.
5. New bearings must be installed with punch. Tighten the nut (4) up
to 25 Nm and secure the nut (4) with glue and with locking plate .
6. Shaft must be installed together with the seal housing in order to
avoid the seal damage.

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 10 ( 15) B 21260 ---1 en 1298TTi

7. TIGHTENING TORQUES
Perhaps the most important maintenance task is to check the
tightness of the bolts, particularly the tie rods and mounting bolts..
The loose tie rods cause rapid wear of the body section faces,
shortening up the operational 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 grease.
Following procedure is recommended for checking the bolt
tightness during normal maintenance:
1. Check the tightness each bolt by using 10 Β 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.

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

!
Pretightening 200 Nm Pretightening 100 Nm
Final tightening 400 Nm Final tightening 200 Nm
80 Nm
Pretightening 100 Nm
Final tightening 200 Nm

Pretightening 100 Nm
Final tightening 400 Nm

Pretightening 150 Nm Pretightening 100 Nm Pretightening 100 Nm

Final tightening 300 Nm Final tightening 400 Nm Final tightening 400 Nm

Fig. 10.
Circle means that new lock washer pair must be used for
locking after every opening of the bolts.

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 B 21260 ---1 en 1298TTi 11 ( 15)

HL 510/560-- SERIES HYDRAULIC ROCK DRILLS

Maintenance

Tie rods, back cover and the rotation motor bolts are tightened with the
cross---tightening method 1---2---3---4, see picture .

Pretightening 100 Nm
Final tightening 200 Nm

LP HP
1 4
Tightening torque 80 Nm
3 2

Fig. 11.

8. PERIODIC MAINTENANCE

8.1. GENERAL
The idea of periodic maintenance is that the rock drill is serviced before
any breakdown occurs . This way expensive additional damages and
unwanteddown time can be avoided.
The maintenance intervals are different depending on the local
conditions, and they must therefore be determined according to the
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 result in major damage or a
production stop.

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 12 ( 15) B 21260 ---1 en 1298TTi

8.2. MAINTENANCE TOOLS AND PARTS

Ensure that the operator has on the rig proper tools and parts for
daily and weekly maintenance tasks.
The rock drill tool set includes torque wrench and sockets. Due to tight
dimensions a special socket and wrench adapter is required for
tightening the rock drill tie rods and middle mounting bolts on the
carriage.

Wrench 30 mm
Torque wrench ID---87050139
ID---87049219 Socket 30 mm
ID---87049629

Open end socket 30 mm

ID---87252459
Torque wrench head 19 mm
ID---87051309

Fig. 12. Maintenance tools

Other rock drill parts which are to be available at the rig for maintenance
are gasget, flushing seals and shank adapter. See picture

Bolt ID---15057748
Lock washer M20 ID---85128339
Bolt M20x1,5x130 ID---81015929 "Torque wrench head 19 mm Nut ID---15179608
Nut M20x1,5 ID---80139189
Lock washer M20 ID---85128339 "Torque wrench head
"Socket 30 mm 19 mm
Gasket
Shank adapter

Flushing seals

Bolt ID---15060148
Lock washer ID---85128339 Bolt M20x1,5x50 ID---80055889
"Socket 24 mm Lock washer M20 ID---85128339
"Socket 30 mm

Fig. 13. Mounting parts and other rock drill parts that are needed
for maintenance at the rig.

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 B 21260 ---1 en 1298TTi 13 ( 15)

HL 510/560-- SERIES HYDRAULIC ROCK DRILLS

Maintenance

8.3. EVERY ROUND DRILLED

1. HL 510; Press grease into the grease nipple of the flushing

housing 5---10 times (about 8 ccm) or until it comes out front sides
of the seal housing .
2. Check that lubrication system operates;
check air+lubrication oil flow from rock drill front end (section 4):
check oil level.
3. Check possible oil leaks.
4. Check hoses and connections.
5. See the condition of the flushing seals during the drilling.
6. Check the mounting of the rock drill to the carriage. If any of the
mounting bolts or tie rods are not tight, open all the mounting bolts
and tie rods. After that, fasten up first the tie rods and then the
mounting bolts with the right order (section 7 and 2 )

8.4. EVERY WEEK

1. Check hour meter reading.

2. Check accumulator filling valves, their protective caps and
the accumulator bolt tightness.
3. Check accumulator pressures.
4. Check rotation motor bolt and flushing housing bolt tightness.
5. Check the condition of the shank, rotation bushing, chuck and
coupling (section 5.4---5.7).
6. Check the condition of the shank bearings and gear
housing bearings.
7. Check the tie rods tightness. If these are not tight, loosen up the
front and back pairs of mounting bolts. After that fasten up the tie
rods and then the mounting bolts with the right order (Section 7
and 2).

8.5. BASIC MAINTENANCE

Rock drill basic maintenance is recommended every 500 operating

hours, Cf. “Repair Instructions’’. This maintenance interval can be
adjusted according to local conditions and experiences which are
accumulated to the rock drill maintenance history. Do planned and
preventive maintenance rather than repairs after damages.
Monitor percussion hour meter reading and/or drilled meters/shifts
between each maintenance. Fill in the service card of the rock drill.

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
14 ( 15) B 21260 ---1 en 1298TTi

8.6. AFTER ROCK DRILL SERVICE

After rock drill service the reassembled parts find their proper position
irelation to each other during drilling under normal drilling loads.
Especially when parts have worn surfaces it may result that the tie rods
and mounting bolts do not keep their tigthness. Therefore
retightening of bolts is required shortly after each rock drill
service or if the rock drill has been off from the feed.
After the rock drill service and 100---200 meters drilling during the first
shift or pattern :
1. retighten the rock drill tie rods and flushing unit bolts.
2. retighten the rock drill mounting bolts on the carriage.

8.7. SERVICE CARD

Each rock drill has its own maintenance cards. When a rock drill is
taken up for maintenace, all the earlier cards should be at hand. All
relevant information about the maintenance is adviced to 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;
--- 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.
--- Use service card presented on the next page.

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 B 21260 ---1 en 1298TTi 15 ( 15)

HL 510/560-- SERIES HYDRAULIC ROCK DRILLS

Maintenance
8.8. MAINTENANCE FOLLOW ---UP
In order to follow the maintenance of a rock drill, a maintenance card
presented below can be used.

ROCK DRILL SERVICE CARD No

Equipment S/n
Rock drill S/n
Since previous service percusion hours
drill. shifts/rounds
drilled meters
SERVICE INFORMATION
Purpose of the service Serviceman
Arr.date Prev.service Prev.perc.hours Working Dism. Insp.
hours
Dep.date Prev.service card No Rep. Ass. Total

REPLACED PARTS/ PART INSPECTION

Repaired Replaced Remarks
Qty Part No Description / Batch / Batch OK
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

Percussion Rotation
Remarks mechanism tested mechanism tested

E 1998 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100 FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 D 28160 - 6 en 1201 / PIR 1 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. CHECKING THE FILLING GAS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. REMOVING THE PRESSURE ACCUMULATOR FROM THE ROCK DRILL . 3
4. DISMANTLING THE PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . 4
5. CHECKING THE PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.1. Filling device of pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . 7
7.2. Filling instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.3. Filling pressures of accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3.1. Low pressure accumulator (LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3.2. High pressure accumulator (HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3.3. Pressure of stabilizer accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8. MOUNTING THE PRESSURE ACCUMULATOR ON THE ROCK DRILL . . . . 11

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
2 (12) D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

1. GENERAL
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

Repair of a pressure accumulator by welding or by other means is strictly

forbidden.

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

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
 D 28160 - 6 en 1201 / PIR 3 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

2. CHECKING THE FILLING GAS PRESSURE

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 b

1. Remove the cap (a).

2. Screw the pressure gauge to the filling valve.
3. Undo the lock nut (b).
4. Wait until the needle of the gauge stops and then read the gauge indication.
5. Close the lock nut (b).
6. Unscrew the gauge from the filling valve and fit the cap (a) in place.

3. REMOVING THE PRESSURE ACCUMULATOR FROM THE ROCK

DRILL
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

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
4 (12) D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

4. DISMANTLING THE PRESSURE ACCUMULATOR

Before dismantling the accumulator, be sure it has no pressure.

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. CHECKING THE PRESSURE ACCUMULATOR

1. Check the accumulator visually for wear, damage, corrosion, etc.

2. Clean and check the threads carefully.

If the threads are badly corroded or worn, the accumulator must be

scrapped!

WARNING

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
 D 28160 - 6 en 1201 / PIR 5 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

6. ASSEMBLY

b
10 Nm
40 Nm secure with glue
20 Nm
b

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.

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
6 (12) D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

Check that the number on the cover and the bottom is the same.

WARNING

D 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

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
 D 28160 - 6 en 1201 / PIR 7 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

7. FILLING
The only allowable filling gas is nitrogen (N2).

WARNING

Do not fill an unchecked or a too worn accumulator.

WARNING

D You can refill the accumulator while mounted to the rock drill.

7.1. Pressure accumulator filling device

12 9 8 7 6 5 3 2

N2
11 10 13,14 15 4 1

1. Accumulator body
2. Filling valve
3. Locking nut
4. Cap
5. Quick coupling stem
6. Quick coupling sleeve
7. Hose
8. Accumulator pressure gauge
9. Gas bottle pressure gauge
10. Pressure reducing valve
11. Pressure regulating valve
12. Shut--off valve
13. Adapter
14. Seal
15. 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
8 (12) D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

7.2. Filling instruction

1. Remove the cap (4).

2. Screw the elbow adapter (15) to the filling valve (2).
3. Push the quick coupling sleeve (6) onto the stem (5).
4. Undo the locking nut (3).
5. Turn the pressure regulating valve (11) open.
6. Open the nitrogen bottle valve (12). The gauge (9) indicates the pressure in the
bottle.
7. Adjust the pressure in the low pressure accumulator to 5 -- 10 bar by turning the
regulating valve (11). Gauge (8) indicates the pressure in the accumulator.
8. Adjust the pressure in the H.P. accumulator with the pressure control valve (11),
according to the instructions. Gauge (8) indicates the pressure in the accumulator.
Max. pressure is marked on the accumulator.
9. Adjust the pressure of the stabilizer accumulator with the pressure control valve,
according to the instructions. Gauge (8) indicates the pressure in the accumulator.
10. Close the filling valve (2) by turning the locking nut (3).
11. Close the nitrogen bottle valve (12).
12. Turn the pressure regulating valve (11) open.
13. Disconnect the quick couplings (5) and (6).
14. Release the elbow adapter (15) from the filling valve (2).
15. Mount the checking gauge (0--10 bar) in to the low pressure accumulator filling
valve (2) and by opening the locking nut (3) let the pressure flow out until the gauge
shows 3 -- 5 bar.
16. Tighten the locking nut (3) to 20 Nm.
17. Refit the cap (4).
18. Assure the tightness of the accumulator by immersing it in water. Dry the
accumulator carefully for example with compressed air.
19. If the accumulator is not taken into use directly, release the pressure and store it
in a dry place protected from dirt.

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
 D 28160 - 6 en 1201 / PIR 9 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

7.3. Filling pressures of accumulators

7.3.1. Low pressure accumulator (LP)

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 it’s 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.

Stem-- type diaphragm

100

90

80

70
Filling pressure

60

50

40

30

20

10

0
100 120 140 160 180 200 220
Percussion pressure
Upper limit
Lower limit

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
10 (12) D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

Normal (stemless) diaphragm

100

90

80
Filling pressure

70

60

50

40

30

20

10

0
100 120 140 160 180 200 220

Upper limit Percussion pressure

Lower limit

7.3.3. Pressure of stabilizer accumulator

HLX 5 T . . . . . . . . . 8 bar
HL 700 T . . . . . . . . . 30 bar
HL 700 ST . . . . . . . 30 bar
HL 1500 . . . . . . . . . 50 bar

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
 D 28160 - 6 en 1201 / PIR 11 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

8. MOUNTING THE PRESSURE ACCUMULATOR ON THE ROCK

DRILL

D See “Hydraulic rock drill, repair instructions“.

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.

1 2

4 3

Tightening of the four--bolt accumulator

The four---bolt accumulator must be tighten by using a cross---tightening

method 1--3--2--4.
CAUTION

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
 12 (12) D 28160 - 6 en 1201 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

Notes:

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
 D 28400-- 2 PT 1097 / EK 1 (6)

MOTORES HIDRÁULICOS OMT, OMSU

Instruções de Reparação

OMSU

100 Nm fixar com cola

OMT

24 Nm fixar com cola

190 Nm

INDICE
1. Especificação . . . . . . . . . . . . . . . . . . . . . . . . . . . . Página 2
2. Reparação . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Regulação dos motores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

E 1997 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100
FIN-- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
2 ( 6) D 28400-- 2 PT 1097 / EK

1. ESPECIFICAÇÃO

1.1. Motor montado na perfuradora HL 500/ HL 550

OMSU 80 OMSU 100 OMSU 125
Motor tipo Orbit
Gama de rotação 0...250 rpm 0...250 rpm 0...200 rpm
Binário max 175 bar(máx. 400 Nm 490 Nm 630 Nm
contínuo)
Caudal de óleo l / 1/min 46 / 250 58 / 250 58 / 200

1.2. Motor montado na perfuradora HL 600

OMT 160 OMT 200 OMT 250 OMT 315
Motor tipo Orbit
Gama de rotação 0...200 rpm 0...200 rpm 0...200 rpm 0...200
rpm
Binário (máx. contínuo) 635 Nm 795 Nm 985 Nm 1280 Nm
Caudal de óleo l / 1/min 46 / 200 58 / 200 74 / 150 64 / 100

1.3. Motor montado na perfuradora HL 700

OMT 160 OMT 200 OMT 250 OMT 315
Motor tipo Orbit
Gama de rotação 0...200 rpm 0...200 rpm 0...200 rpm 0...200
rpm
Binário (máx. contínuo) 872 Nm 1095 Nm 1355 Nm 1763 Nm
Caudal de óleo l / 1/min 70 / 200 66 / 150 55 / 100 71 / 100

1.4. Motor montado na perfuradora HL 1000

OMT 250 OMT 315 OMT 500
Motor tipo Orbit
Gama de rotação 0...130 rpm 0...130 rpm 0...80 rpm
Binário max 175 bar 1340 Nm 1760 Nm 2260 Nm
(máx. contínuo)
Caudal de óleo l / 1/min 65 / 125 71 / 100 67 / 60

E 1997 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100
FIN-- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 D 28400-- 2 PT 1097 / EK 3 (6)

MOTORES HIDRÁULICOS OMT, OMSU

Instruções de Reparação

2. REPARAÇÃO
Em toda a maquinaria hidráulica a limpeza é o factor mais importante
para assegurar um funcionamento sem problemas. Recomendamos
por isso que todos os trabalhos de manutenção de motores hidráulicos
sejam feitos numa sala limpa e sem poeiras.
Quando desmontar um motor hidráulico substitua todos os vedantes.
Substitua atempadamente as peças gastas por peças novas a fim de
evitar danos mais sérios.

1 45 Nm 60 Nm fixar com cola

190 Nm
2 Use método de
3
aperto cruzado
24 Nm fixar com cola 5-- 10 Nm

Fig. 1 Motor hidráulico OMT

O anel espaçador (2) tem sempre que ser substituído ao mesmo

tempo que os rolamentos (1). Depois de ter montado os rolamentos no
veio aperte a contra--porca (3) até 60 Nm e fixe--a com uma pancada
de punção.

E 1997 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100
FIN-- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 4 ( 6) D 28400-- 2 PT 1097 / EK

2
3
4
5
3
6
7
8 6

9
10
11
12 13
14 15 16 17 18
19
2021
22 23 24

5-- 10 Nm
80 Nm
Use método de
aperto cruzado

Fig. 2 Motor hidráulico OMSU

2. O--RING 10. PLACA DE CANAIS 18. TAMPÃO

3. PARAFUSO 11. VÁLVULA DE DISCO 19. CAIXA
4. PLACA 12. PLACA 20. ESFERA
5. VEIO 13. PINO 21. MOLA
6. O--RING 14. O--RING 22. ANILHA
7. CONJUNTO DE RODAS DENTADAS 15. O--RING 23. TAMPÃO
8. PINO 16. ESPAÇADOR 24. PARAFUSO
9. ACCIONAMENTO DE VÁLVULA 17. ANILHA DE MOLA

Nunca rode o motor sem o veio, o que danificaria o disco.

AVISO !

E 1997 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100
FIN-- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 D 28400-- 2 PT 1097 / EK 5 (6)

MOTORES HIDRÁULICOS OMT, OMSU

Instruções de Reparação

VERIFICAÇÃO DOS MOTORES

2 1
5--10 Nm

Fig.3 Válvula anti--retorno

Válvula anti--retorno

Verificar o estado da esfera (1) e das superfícies da válvula (2); se

estiverem danificadas a válvula tem fuga e o motor deve ser
substituído.

Conjunto de rodas dentadas

Se houver fracturas, marcas de gripagem ou o rotor estiver gasto, o

motor deve ser substituído.

E 1997 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100
FIN-- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
 6 ( 6) D 28400-- 2 PT 1097 / EK

3 Nm
1 2 4
Fig.4 Motor hidráulico OMSU

Coloque a tampa (2) firmemente no seu lugar. Certifique-- se de

que a cap está à face entre a tampa e o corpo antes de apertar os
parafusos (1). Se a cap não estiver à face o veio (4) pode ser
AVISO ! apertado pelo canto (3) e ao apertar os parafusos de montagem
o apoio (5) danificará a tampa posterior do motor.
Se o motor não for utilizado imediatamente, encha--o de óleo e tape os
pontos de entrada de óleo para que se mantenha cheio até ser
colocado em serviço. O óleo evita a corrosão e fornece lubrificação a
todas as partes em movimento quando o motor arranca.

3. REGULAÇÃO DOS MOTORES

1 Substitua a válvula de disco (1) 4
de modo que o furo que a atravessa
se localize na linha de centro (A).
2. Coloque o dente marcado no 3
veio na mesma linha de centro.
3. O furo de drenagem (B) da B
placa (3) deve ser posicionado na
2
mesma linha de centro.
4. O dente da engrenagem (4)
deve ser posicionado para a direita
da linha de centro. 1

A
E 1997 TAMROCK OY, SERVICE TAMPERE PLANT
P.O.Box 100
FIN-- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771