Maintenance Manual All Cylinders: Original Instructions

Original instructions
Maintenance Manual
All Cylinders
-V
DD
ALL CYLINDERS MAINTENANCE MANUAL
WARNING
IGNORING INSTRUCTION HAZARD
To avoid death or injury you MUST read, understand and follow Operator’s
and Maintenance Manuals before installing, inspecting, operating,
servicing, testing, cleaning, transporting, storing, dismantling or disposing
of the product or a part or accessory of the product.
2 (26) Copyright © Sandvik Mining and Construction

ID: EN - B-20-02-2012 FB-DGA-GP
Table of Contents
1. GENERAL AND SAFETY .............................................................................. 6

1.1. General ........................................................................................ 6
1.2. Safety ........................................................................................ 6

1.2.1. Operator instructions ..............................................................................................7
1.2.2. Main safety hazards in use or maintenance work ..................................................8
1.2.3. User obligations ................................................................................................... 10
2. MAINTENANCE OPERATIONS .................................................................. 12
2.1. Release pressure ............................................................................ 13
2.2. Description ...................................................................................... 14

2.3. Disassembly .................................................................................... 15
2.3.1. Disassembly ......................................................................................................... 15
2.3.2. Disassembling a cylinder .....................................................................................15
2.3.3. Disassembling a ball joint .................................................................................... 17
2.4. Reassembly ..................................................................................... 18

2.4.1. Reassembling a ball joint .....................................................................................18
2.4.2. Reassembling of the cylinder ...............................................................................20
2.5. Tightening torques / Lubricants .................................................... 22
2.6. Maintenance operations schedule ................................................ 23
2.7. Periodic maintenance table ........................................................... 24
Copyright © Sandvik Mining and Construction 3 (26)

ID: EN - B-20-02-2012 FB-DGA-GP

ID: EN - B-20-02-2012 FB-DGA-GP
1. General and safety

ID: EN - B-20-02-2012 FB-DGA-GP
1. GENERAL AND SAFETY

1.1. General
The present manual is destined for the use of personnel in charge of carrying out servicing and
maintenance operations on the Cylinders.
It contains maintenance operations schedule and operating methods for the main components.
Note that servicing and maintenance operations must be carried out by personnel with the
required qualifications, technical knowledge, and proper training on the machine.
1.2. Safety
The informations contained in this manual must be studied and thoroughly assimilated before
undertaking any maintenance work on the equipment.
Remember: SAFETY FIRST!

Always observe the warnings accompanied by the following symbols.
The following safety instructions are general rules.
Before carrying out any maintenance read and understand the maintenance instructions. Make
sure that you have skills and authorization needed before starting any maintenance work. The
maintenance instructions support maintenance personnel performing preventive maintenance
for the product. The maintenance instructions also provide information for maintenance and
operating personnel on scheduled mechanical inspections of components and installed
equipment.
Ensure all necessary machinery isolations have been carried out prior to commencing any
maintenance work. Before carrying out any maintenance work ensure that necessary original
spare parts or materials are available, or can be ordered and supplied in time to meet the work
schedule. Note all completed maintenance activities in a maintenance log or maintenance
program:
Daily inspections and tasks allowed for operators (which do not require special skills):
- maintenance tasks can be found from Operating instructions section.
Tasks which require definite technical skills and Maintenance training:

• Hydraulic maintenance
• Electric maintenance
• Tyre maintenance
• Any maintenance which should not be attempted by operators or users (i.e., maintenance
which should only be performed by a representative of the manufacturer)

ID: EN - B-20-02-2012 FB-DGA-GP
1.2.1 Operator instructions
WARNING
Operation, maintenance and adjustments are only allowed to persons with
specific training in operation and maintenance of the equipment. Read the
operating and maintenance instructions before using or servicing the
equipment.
Plan your work carefully in advance to avoid possible accidents and injuries.
The operator must be familiar with the functions of the equipment before
taking it into use.
The operator must always wear required personal protection, such as safety
helmet, protective overall, safety boots, hearing protectors, safety goggles
etc...
Always ensure that those protections are in good shape before using them.
Adequate ventilation must always be provided.

Make sure that ventilation is sufficient to prevent exhaust fumes and dust.
Exhaust fumes can be lethal.
When operating in confined conditions the exhaust gases and dust must be
directed in such a way that they do not return to the working area and create
a hazard.
Check regularly the exhaust purifier clogging according to its maintenance
manual.
Always have a fire extinguisher at hand and learn how to use it.
Have the extinguisher inspected and serviced regularly according to the
local regulations and to the extinguisher maintenance manual.
Take care of sufficient lighting.

Insufficient scaling of drilling site.

ID: EN - B-20-02-2012 FB-DGA-GP
1.2.2 Main safety hazards in use or maintenance work
WARNING
Before starting any maintenance operation ensure that the machine is in a

safe location with good safety, ventilation and lighting conditions. Ensure
that lifting equipments and pedestals are compatible with elements’ weight.
Follow all the safety instructions and ware safety protections as gloves,
goggle, helmet, safety boots, ear protectors.
Before any operation stabilize and fix steadily all the elements on suitable
pedestals. Stop the power packs, switch the general power breaker. Place a
tag or a board to warn other members of the personnel that maintenance
work on the machine is in progress.
Pressurized oil jets could cause severe injuries. Before any operation on
hydraulic circuit, STOP the power packs and release remaining pressure in
components by operating hydraulic control levers several times. Always
release the static pressure in cylinders before disassemble them.
NEVER WORK ON AN OPERATING CIRCUIT.
While tests are in progress, do not allow any other member of the personnel
to stand in the area surrounding the machine. Stay at the control station to
be able to stop the movement and switch off the power pack.
Maintenance, adjustment and repairs are restricted to qualified personnel

with special training for the particular equipment. Always read the
instructions carefully before starting any maintenance work.
Always use suitable tools and work in a clean place when dismantling and
assembling hydraulic components. After removing cylinders the hydraulic
inlet/outlet ports must be plugged to prevent dirt and air intrusion during
operation.

ID: EN - B-20-02-2012 FB-DGA-GP
The operator must always wear required personal protection, such as safety
helmet, protective overall, safety boots, hearing protectors, safety goggles
etc.
Danger of high pressure oil jets.

High pressure oil jets can cause serious personal injuries.
Release the pressure in the hydraulic circuits before opening caps or
connections (accumulators, cylinders and hydraulic circuit).
Danger of hot surface.

Hot surface can cause serious injuries.
Components as diesel engine, exhaust gas purifier, rod, shank or hydraulic
components can be hot and before starting a maintenance work, please let
them cool off.
The operator must have adequate wears as gloves.
Crushing hazard : do not stay in dangerous area, for instance: central

articulation between front chassis and rear chassis.

ID: EN - B-20-02-2012 FB-DGA-GP
1.2.3 User obligations

Always follow the marked safety instructions, and observe caution while working.
The following safety instructions are general rules.
DANGER
Keep tools and drilling equipment clean.
Dot not attempt any such repairs or adjustments that you do not fully
understand.
ABOUT THE SAFETY OF REPAIRS
DANGER
Certain workstages require the use of the feed mechanism during the repair.
- No danger is caused to anybody.

- The machine can be immediately stopped when necessary.
- The prepack is stopped again before the repair work is continued.
DANGER
Before starting any repair-work move away from the area where you have
just drilled.
Use proper tools.
Always wear protective clothing, eye protection, earmuffs, safety footwear

and other safety equipment required by the work.

ID: EN - B-20-02-2012 FB-DGA-GP
2. Maintenance operations

ID: EN - B-20-02-2012 FB-DGA-GP
2. MAINTENANCE OPERATIONS
WARNING
Pressurized oil jets could cause severe injuries. Before any operation on
hydraulic circuit, STOP the power packs and release remaining pressure in
components by operating hydraulic control levers several times. Always
release the static pressure in cylinders before disassemble them. NEVER
WORK ON AN OPERATING CIRCUIT.
WARNING
Do not work under a device or component that is held up only by the
hydraulics. Use separate supports in conjunction with maintenance and
repair.
Make sure that the boom is properly supported before any maintenance
operation on the hydraulic system.
Do not remove boom cylinders or their non-return valves before the boom,
the feed or turret, and the rock drill are properly supported

ID: EN - B-20-02-2012 FB-DGA-GP
2.1. Release pressure
RELEASING PRESSURE
• Place the moving part on adapted support
to prevent a sudden fall of moving parts
1 1 when releasing the pressure trap in the
cylinder chambers.
• Release remaining pressure in hydraulic
components and hoses by operating
control levers several times.
• Slowly loosen remaining static pressure.
1
1 • Same operation on the other end of the
cylinder or rotary actuator.
NOTE: Do not fully untighten bleed plugs and

retighten them after operation to keep free
translation of the piston and the rod.
WARNING
Cover the bleed plug 1 with a cloth and thoroughly undo the plug in order to
avoid unexpected oil jet.
BLEEDING A CYLINDER
1 1 After installing a cylinder, bleed the air in the

chambers.
• Tighten bleed plugs 1.
• Start up the power pack.
• Operate control levers several times and
1 carry out movement from stop to stop.
1 • Stop the power pack.
• Thoroughly untighten bleed plugs and
breeze the air.
WARNING
While tests are in progress, do not allow any other member of the personnel
to stand in the area surrounding the moving parts. Stay at the control station
to be able to stop the movement and switch off the power pack.

ID: EN - B-20-02-2012 FB-DGA-GP
2.2. Description
Each cylinder consists essentially of:

2
• a body (1) with a ball joint (2) attached,
• a rod (3) with the other ball joint (2) attached,
8
• a piston (4) screwed to the rod and fitted with
seals (*),
5
• a pin (5) to prevent the piston unscrewing,
* • a guide (6) screwed to the body and fitted with
seals (*).
*
7 Some cylinders are also fitted with spacers
4 rings (7) or have yokes or threaded housings
instead of ball joints. Grease nipples (8) are
* sometimes mounted directly on the ball joint
yokes and not on the taper pins.
1 Disassembly and reassembly are the same for
all types of cylinder.
3
Figure 3

ID: EN - B-20-02-2012 FB-DGA-GP
2.3. Disassembly
2.3.1 Disassembly
The greatest cleanliness must be observed when disassembling and reassembling to avoid rapid
deterioration of the seals and scratches on the moving parts. Use non fluffy cloths and products
without solvent for cleaning.
Always carry out disassembly and reassembly operations in properly equipped, dust free
premises.
Assembly products, recommended lubricants and the required tools must also be available.
2.3.2 Disassembling a cylinder

Three major types of cylinder can be found out on the machine see page 16.
• Hold the body (1) firmly at the level of the ball joint (2) or fixing plate (2).
• Unblock and unscrew the guide (3).
• Extract the fitted rod assembly (4) from the body.
• Hold the rod (4) firmly at the level of the ball joint (5) or the yoke (5).
• Drive out the pin (6) or remove the screw (6).
• Unscrew the piston (7) from the rod.
• Remove the spacer ring (8) if fitted.
• Remove the guide (3) from the rod (4).
• Remove the grease nipples (9) if fitted.
• Remove all the seals, rings and/or scrapers (*), noting their position and mounting
direction.

ID: EN - B-20-02-2012 FB-DGA-GP
9 * * 3 * 4 * 7 * * 6 9
5 1 8 2
2 1
5 * 3 * * * 4 * 7 * 6
6
8
*
*
3
4 1
Figure 4

ID: EN - B-20-02-2012 FB-DGA-GP
2.3.3 Disassembling a ball joint
Liquid nitrogen-mounted ball joints:

• Extract the ball joint (1) using a press.
Figure 5
Ball joint mounted with circlips:

• Extract the dust protector (1).
• Remove the circlips (2).
• Extract the ball joint (3) using a press.
1
2
3
Figure 6
Welded ball joint or yoke:

• Grind the welding (1) to the level of the cylinder body or the rod (2).
• Remove the ball joint (3) or unscrew the yoke (4).
• Smooth off the parts.
2 1 4
2 1 3
Figure 7

ID: EN - B-20-02-2012 FB-DGA-GP
2.4. Reassembly
2.4.1 Reassembling a ball joint
It is strongly recommended to use liquid nitrogen instead of a press for assembling a new ball
joint.
WARNING
Handling of nitrogen-cooled objects requires great caution and proper
protection (gloves and safety glasses).
Ball joints must be installed prior to reassemble the cylinder itself.
Nitrogen-mounted ball joint:
• Cool the ball joint (1) with nitrogen.

• Remount the ball joint in its housing until it stops at the shoulder and allow the assembly to
warm to ambient temperature.
Figure 8

ID: EN - B-20-02-2012 FB-DGA-GP
Ball joint mounted with circlips
• Remount a circlip (2) in its groove.

• Cool the ball joint (3) with nitrogen.
• Remount the ball joint in its housing until it stops at the circlip and allow the assembly to
warm to ambient temperature.
• Remount the other circlip.
• Remount and crimp the protecting hoods (1).
1
2
3
Figure 9
Welded ball joint or yoke:
Engage the centering pin (1) of the ball joint (2) or screw the yoke (3) to the rod (4).
• Place a line of solder (5) round the ball joint or yoke.
• Allow time for welding to cool down
.
4 5 3
4 5 2
Figure 10

ID: EN - B-20-02-2012 FB-DGA-GP
2.4.2 Reassembling of the cylinder
WARNING
All seals must be replaced when reassembling of the cylinder, use
genuine Sandvik seal kits. Replace all damaged parts.
Lubricate the seals using hydraulic oil prior to reinstall.
REASSEMBLE THE ROD FIRST:

• Hold the rod (4) firmly at the level of the ball joint or the yoke (5).
• Remount the notched nut guide (3) or ball joint side pin housing (5).
• Install the spacer ring (8) if used.
• Retighten the piston (7) on the rod to a maximum and check that the piston and rod holes
are aligned (unscrew slightly to do this if necessary) for pin-equipped pistons.
• Re-insert the pin (6).
• For pistons equipped with lock screws:
• Tighten the piston (7) on the rod to a maximum,
• Mount and tighten the screw (6).
• On guide (3) and on cylinder (7):
• Reassemble all the seals (*), rings and/or scrapers, taking care of their
respective positions and assembly direction.
ASSEMBLING OF THE ROD INTO THE BODY

• Hold the body (1) firmly at the level of the ball joint or fixing plate (2).
• Insert the fitted rod, taking care not to damage the seals on insertion.
• Retighten the guide (3) after coating the threads with "LOCTITE 270".
• Mount the grease nipples (9) if fitted.
FINAL TEST:
• Place the cylinder on a hydraulic bench and connect up.
• Bleed the cylinder.
• Increase the pressure and check for tightness and correct operation.

ID: EN - B-20-02-2012 FB-DGA-GP
9 * * 3 * * 7 * * 9
1 2
2 1
* 3 * * * * 7 *
*
*
3
Figure 11

ID: EN - B-20-02-2012 FB-DGA-GP
2.5. Tightening torques / Lubricants

For basic genuine SANDVIK screws and nut use the following tightening torque:
metric dimension HEX BOLTS “ALLEN” BOLTS

GRADE 8.8 GRADE 12.9
M6 10Nm (7.37ft.lbs) 16Nm (11.79ft.lbs)

M27 1000Nm (737ft.lbs) 1650Nm (1216.05ft.lbs)
M39 3000Nm (2211ft.lbs) 5050Nm (3721.85ft.lbs)
LUBRICANTS:
Recommended grease: Mobilith SHC 220, Mobilgrease HP 222 or equivalent.

Recommended oil: Mobilfluid 316M, Mobil DTE 15M.
Refer to lubricant dedicated booklet in section 1 of the maintenance manual.

ID: EN - B-20-02-2012 FB-DGA-GP
2.6. Maintenance operations schedule
WARNING
The safety of users, the reliability of the Cylinder, and therefore the
efficiency of operation, depend on the proper use of the machine, on its
maintenance and the use of genuine SANDVIK spare parts. All damaged
parts must be replaced.
Starting or daily operations

• Before starting up: Grease the ball joints at the level of the taper pins.
• After starting up: Check for oil leakage.
50-hour or weekly operations

• Check the tubes and hydraulic connections.
100-hour or monthly operations

• Carry out the 50-hour or weekly operations.
200-hour operations
• Carry out the 100-hour or monthly operations.
600-hour operations
• Carry out the 200-hour operations.
1200-hour or annual operations

• Carry out the 600-hour operations.
3600-hour operations
General inspection or reconditioning.
• Strip and reassemble the cylinders.
• Replace damaged parts.

ID: EN - B-20-02-2012 FB-DGA-GP
2.7. Periodic maintenance table
Serial number: Percussion hours : Name:
Date: Diesel hours : Firm:
CHECK LUBRICATE CLEAN REPLACE

TEST FLUSH SERVICE
PERIODS DONE
Eac 50 200 600 1200 1800 2400 3600 ALL CYLINDERS YES NO
h PH PH PH PH PH PH PH
shift
Leakage detection
Check all equipments condition
Check hose, unions and fitting condition
Lubricate all joints
Overall inspection and tests

Removal and check of all assembly
Replace damaged parts

ID: EN - B-20-02-2012 FB-DGA-GP

ID: EN - B-20-02-2012 FB-DGA-GP
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2 (26) Copyright © Sandvik Mining and Construction

1. GENERAL AND SAFETY .............................................................................. 6

1.2. Safety ........................................................................................ 6

2. MAINTENANCE OPERATIONS .................................................................. 12

2.1. Release pressure ............................................................................ 13

2.2. Description ...................................................................................... 14

2.4. Reassembly ..................................................................................... 18

2.5. Tightening torques / Lubricants .................................................... 22

2.6. Maintenance operations schedule ................................................ 23

2.7. Periodic maintenance table ........................................................... 24

Copyright © Sandvik Mining and Construction 3 (26)

4 (26) Copyright © Sandvik Mining and Construction

1. General and safety

Copyright © Sandvik Mining and Construction 5 (26)

1. GENERAL AND SAFETY

Remember: SAFETY FIRST!

The following safety instructions are general rules.

Tasks which require definite technical skills and Maintenance training:

6 (26) Copyright © Sandvik Mining and Construction

1.2.1 Operator instructions

Adequate ventilation must always be provided.

Take care of sufficient lighting.

Copyright © Sandvik Mining and Construction 7 (26)

1.2.2 Main safety hazards in use or maintenance work

Before starting any maintenance operation ensure that the machine is in a

Maintenance, adjustment and repairs are restricted to qualified personnel

8 (26) Copyright © Sandvik Mining and Construction

Danger of high pressure oil jets.

Danger of hot surface.

Crushing hazard : do not stay in dangerous area, for instance: central

Copyright © Sandvik Mining and Construction 9 (26)

1.2.3 User obligations

The following safety instructions are general rules.

ABOUT THE SAFETY OF REPAIRS

- No danger is caused to anybody.

Use proper tools.

Always wear protective clothing, eye protection, earmuffs, safety footwear

10 (26) Copyright © Sandvik Mining and Construction

Copyright © Sandvik Mining and Construction 11 (26)

12 (26) Copyright © Sandvik Mining and Construction

2.1. Release pressure

NOTE: Do not fully untighten bleed plugs and

1 1 After installing a cylinder, bleed the air in the

Copyright © Sandvik Mining and Construction 13 (26)

Each cylinder consists essentially of:

14 (26) Copyright © Sandvik Mining and Construction

2.3.2 Disassembling a cylinder

Copyright © Sandvik Mining and Construction 15 (26)

16 (26) Copyright © Sandvik Mining and Construction

2.3.3 Disassembling a ball joint

Liquid nitrogen-mounted ball joints:

Ball joint mounted with circlips:

Welded ball joint or yoke:

Copyright © Sandvik Mining and Construction 17 (26)

Nitrogen-mounted ball joint:

• Cool the ball joint (1) with nitrogen.

18 (26) Copyright © Sandvik Mining and Construction

Ball joint mounted with circlips

• Remount a circlip (2) in its groove.

Welded ball joint or yoke:

Copyright © Sandvik Mining and Construction 19 (26)

2.4.2 Reassembling of the cylinder