Hydraulic Rock Drill HL 800 T Lifting Instructions: Incorrect Correct

D 20106 - 1 en 0904 / JT 1 (1)
HYDRAULIC ROCK DRILL HL 800 T

LIFTING INSTRUCTIONS
CORRECT INCORRECT
Max.
55_
HL 800 T . . . . . . . . . . . . . . . . . . . . 245 kg
HL 800 T Power Extractor . . . . 300 kg
E 2004 SANDVIK TAMROCK CORP., Tampere Plant

P:O. Box 100
FIN--33311 TAMPERE,Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
B 22500 – 1 en 0803 / PIR 1 (24)
HL 800 T, HL 800 ST
Operation and maintenance

P.O. Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
2 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST

P.O. Box 100
Tel. +358 205 44 121
Telefax +358 205 44 120
B 22500 – 1 en 0803 / PIR 3 (24)
HL 800 T, HL 800 ST
CONTENTS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. BRINGING THE NEW ROCK DRILL INTO USE . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2. Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3. Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. HOSE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. LUBRICATION CIRCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1. Lubrication circulation, underground model . . . . . . . . . . . . . . . . . . . . 7
4.2. Lubrication circulation, surface model . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. INSPECTION AND MAINTENANCE OF THE FRONT END
WHEN THE ROCK DRILL IS IN THE CARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1. Installation directions for the seals and bearing bushing . . . . . . . . . 13
6.2. Replacing the front cover bearing of the flushing housing . . . . . . . 13
6.3. Assembling the flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4. Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.5. Rotation bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.6. Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.7. Shank bushing and lock ring pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.8. Shank wear limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.9. Installing the flushing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7. CHECKING THE TIGHTNESS OF THE BOLTS AND
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1. Tightening instructions – side bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2. Pressure accumulator bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.3. Intermediate gear pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.4. Installing the hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.5. Hydraulic motor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.6. Flushing housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8. REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.2. Maintenance tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3. Daily after drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.4. Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.5. Basic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.6. After the maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.7. Maintenance card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.8. Maintenance follow–up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

P.O. Box 100
Tel. +358 205 44 121
Telefax +358 205 44 120
4 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
1. GENERAL
These operation and maintenance instructions give a brief description of the primary
maintenance procedures to be followed for the HL 800 rock drill.
Tamrock Service is always willing to give advice and help with any maintenance–related
problems. The qualified maintenance staff at Tamrock dealerships and original Tamrock
spare parts ensure reliable operation of the rock drill.
2. BRINGING THE NEW ROCK DRILL INTO USE

2.1. Preparations
The new rock drill is supplied with unpressurised accumulators and
plugged hose connections.
CAUTION
1. Follow the instructions when pressurising the accumulators. See ‘Repair

instructions for pressure accumulators’.
2. With a new rock drill, a hydraulic check and system flushing must be performed
according to the instructions before the rock drill is installed.
2.2. Fastening
The rock drill is fastened to the feed carriage with four pairs of bolts. To avoid damage,
it is very important to use the correct tightening sequence. Tightening sequence:
B A C
Fig. 1. Fastening to the carriage
First, tighten lightly so that the mating surfaces meet (no clearance between the carriage
and rock drill).
1. Pre–tighten bolt set A to 300 Nm (30 kpm).
2. Pre–tighten bolt sets B and C to 300 Nm (30 kpm).
3. Tighten bolt set A to 600 Nm (60 kpm).
4. Tighten bolt sets B and C to 600 Nm (60 kpm).
When replacing the bolts, always loosen all the bolts and then re–tighten using the
correct tightening sequence.
P.O. Box 100
Tel. +358 205 44 121
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B 22500 – 1 en 0803 / PIR 5 (24)
HL 800 T, HL 800 ST
2.3. Test run

Test run the rock drill and make sure that it operates properly before beginning production
drilling.
During the test run, monitor:
– the operation of the shank lubrication
– the pressures and the temperature
– the flushing operation
– any possible oil leaks
Avoid using full percussion pressure. When the drill bit is not in contact
with the rock, full percussion pressure strains the accumulator
membranes and causes unnecessary wear of the flushing housing and
CAUTION
cavitation in the percussion mechanism. Such ‘idle drilling’ is especially
dangerous when drilling upward and cleaning holes by pumping.
3. HOSE CONNECTIONS
6 7
8
4
1 2
5 9 3
Fig. 2. Hose connections
1. Shank lubrication 6. Rotation, drain line
2. Percussion mechanism, pressure side (H.P.) 7. Rotation, receiver (L.P.)
3. Percussion mechanism, return side (L.P.) 8. Rotation, pressure (H.P.)
(orifice Ø 8 mm)
4. Flushing 9. Stabiliser
5. Shank lubrication, recovery

P.O. Box 100
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6 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
4. LUBRICATION CIRCULATION
The percussion mechanism and the hydraulic motor of the rock drill are lubricated using
the hydraulic oil that flows through them.
The rotation mechanism and shank are lubricated via oil mist lubrication. The lubrication
line from the central lubrication device is connected to the fitting (1) in the rock drill spacer
(Fig. 2). From there, the oil mist passes to the front end of the rock drill, where it lubricates
the stabiliser pins, rotation mechanism, chuck, coupling, and flushing housing bearing.
In the underground model (Fig. 3), the lubricating system’s air flow from the rear section
of the piston is led out through the passage (3).
In the surface model (Fig. 4), the drain oil from the rear section of the piston is led to the
front through the passage (2).
Do not let the rear cover make contact with water when the lubrication
blow is not on.
CAUTION
Oil mist that has travelled through the rock drill’s lubrication circulation system is removed
from the rock drill through the flushing housing fitting (5) (Fig. 2). This used lubrication oil
can be conveyed to a container with a hose.
In no event is oil mist to be conveyed into the hydraulic system return
line.
CAUTION

P.O. Box 100
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B 22500 – 1 en 0803 / PIR 7 (24)
HL 800 T, HL 800 ST
4.1. Lubrication circulation, underground model
Fig. 3. Lubrication circulation, underground model, HL 800 ST

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8 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
4.2. Lubrication circulation, surface model
Fig. 4. Lubrication circulation, surface model, HL 800 T

P.O. Box 100
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B 22500 – 1 en 0803 / PIR 9 (24)
HL 800 T, HL 800 ST
4
2
1
Air
Fig. 5. Shank lubrication (surface model)
1. Rock drill 3. Drain valve

2. SLU 1/2/3 4. Filling cap
1. The oil consumption of the lubrication system is adjustable. **

2. Oil level must decrease during drilling. **
3. Regularly drain the water that has accumulated in the bottom of the lubrication
device receiver, using the drain valve (3). The draining interval depends on local
conditions.
4. Use only oils specified in the lubricant recommendations.
5. Fill the lubrication device receiver regularly.
** Refer to the SLU 1/2/3 operating instructions

P.O. Box 100
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10 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
7
4
Air
6 1
3
2
Fig. 6. Shank lubrication (underground model)

1. Rock drill 5. Nipple
2. Oil receiver 6. Transparent orifice
3. Drain valve 7. Regulating valve
4. Filling cap
1. The shank lubrication oil consumption should be adjusted to a minimum of 400
g/hour for each rock drill and should be greater than this value if appropriate
for the hole size and other local conditions (for example, the use of guide tubes
and some rock types require more lubrication). Check the operation of the shank
lubrication visually by using the transparent orifice or by feeling the air coming from
the hose at shank lubrication nipple by hand.
2. If the oil level in the receiver does not drop during drilling:
– The regulating valve is clogged.
– Bronze debris from coupling wear has clogged the flushing housing
lubrication passage.
– The compressor’s oil separator is not working. Compressor oil travels
with compressed air to the lubrication device.
– The oil is too thick for the ambient temperature.
– In each case mentioned above, the fault must be repaired immediately.
3. Regularly drain the water that has accumulated in the bottom of the lubrication
device receiver, using the drain valve (3). The draining interval depends on local
conditions.
4. Use only oils specified in the oil recommendations.
5. Fill the lubrication device receiver regularly.
6. A water separator must be installed in the compressed air line if the compressed
air is taken from the mine’s pneumatic network or if the compressor does not have
a water separator.
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B 22500 – 1 en 0803 / PIR 11 (24)
HL 800 T, HL 800 ST
5. FLUSHING
1
5
2
Fig. 7. Rock drill with water flushing (for underground drilling)
1. Flushing housing
2. Water pressure gauge
3. Pre–controlled flushing valve
4. Drain holes for seal leakage, underground model
5. Drain holes for seal leakage, surface model
Except for the flushing housings, the construction of air and water–flushed rock drills is
identical.
Water is the most common reason for percussion piston seal failures. Water can enter the
rock drill from outside the flushing housing if the rock drill is in vertical position and shank
blow is not on.
Water can also flow with lubricating system air if water is not drained regularly from the
lubrication device.
Water in the front end of the rock drill can cause cavitation pitting in the body components
near the piston seal and wiper ring and in the piston.
To prevent water from entering the gear housing, the flushing housing
seals must be replaced immediately if water is leaking from the escape
holes (4). This is why leaving the rock drill’s front end pointing upward
CAUTION
during pauses in drilling is also prohibited. If this is not possible, blow
the flushing housing dry with air before the break in drilling.

P.O. Box 100
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12 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
6. INSPECTION AND MAINTENANCE OF THE FRONT END WHEN

THE ROCK DRILL IS IN THE CARRIAGE
In replacing the shank, the rock drill must be tilted as close to a
horizontal position as possible to prevent the chuck and coupling from
dropping.
WARNING
If the lubrication system becomes clogged (no air is coming from the
shank lubrication return hose), switch off the engine and release the air
pressure carefully by opening the lock screw before opening the
WARNING flushing housing bolts. Otherwise, the pressure can propel the flushing
housing outward and cause risk of injury.
The flushing housing can be pulled out without removing the rock drill from the carriage,
by opening the bolts (1) and nuts. This also releases the rod shank. When the clamp screw
(2) is opened, the coupling (3) and chuck (4) are released first. When the screw is opened
further, the rotation bushing (5) is released.
2
5
4
3
1
Fig. 8. Removing the flushing housing
Always check the condition of the coupling, chuck, and rotation bushing
when replacing the shank.
CAUTION
Use the shank when striking the locking washer pairs (1) off. Remove the cover (3) and
fitting flange (2) before removing the seal housing.
2
3
Fig. 9. Disassembling the tube–type flushing housing

P.O. Box 100
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B 22500 – 1 en 0803 / PIR 13 (24)
HL 800 T, HL 800 ST
6.1. Installation directions for the seals and bearing bushing

The seals are the most sensitive and important components of a rock drill. When
disassembling a rock dill, always replace all seals and O–rings.
90_ Drain holes Drain holes A
1 2 3
1
1 2 3
B
Fig. 10. Installation directions for the seals and bearing bushing
Install the seals (1, 2, and 3) using either option A (water flushing and water mist
flushing) or option B (air flushing).
Replace the flushing housing seals and install the bearing bushing (1) in the correct
position on the front cover, as shown in Fig. 10.
6.2. Replacing the front cover bearing of the flushing housing
ÇÇÇ The bearing must be replaced when the wear indicator groove
has worn as shown in the figure. Open the front cover and re-
move the bearing with a hydraulic press and the punches in-
ÇÇ
cluded in the toolkit.

P.O. Box 100
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14 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
6.3. Assembling the flushing housing

Lubricate the O–rings with petroleum jelly before assembly.
CAUTION
Align the holes in the flushing housing and seal housing and press the seal housing in.
Reinstall the fitting flange and front cover. Check the seals.
Tube flushing housing
Reinstall the shank and locking washer pair in the flushing housing. Turn the shank to a
vertical orientation and strike the locking washer pair with the shank.
A B 90_
8
7
Fig. 11. Installing the tube flushing housing lock rings
6.4. Coupling
Pull the coupling out from the rotation bushing. Check it and re-
place if the edges of the inner teeth are worn to a point.
NOTE! The length of the coupling in the HL 800 T rock drill is
82.5 mm (from the serial number 305 onwards); the spare part
number as the same as in the HL 700 rock drill (the length of the
previous model was 84.5 mm).
6.5. Rotation bushing

Check the wear of the rotation bushing teeth, bearing surfaces,
and bearing.
The bearing must be replaced when the wear indicator groove

has worn off. The bearing is replaced with a hydraulic press and
the punches included in the toolkit – refer to the repair instruc-
tions.

P.O. Box 100
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B 22500 – 1 en 0803 / PIR 15 (24)
HL 800 T, HL 800 ST
6.6. Chuck
The chuck must be replaced if the surface indicated in the figure
has worn over 1 mm or the chuck has cracks in it.
NOTE! When installing the chuck, ensure that it faces the right
direction.
6.7. Shank bushing and lock ring pair

The shank bushing and lock ring pair must be replaced if the
surface indicated in the figure has worn over 1 mm.
6.8. Shank wear limits

max. 1 mm max. 1 mm The shank must be replaced when 1 mm of the 2–mm bevel at its
rear has worn off or any other wear limit is exceeded.
Manufacturing: 2 mm
Reject limit: 1mm
When installing a new shank for the rock drill, ensure that no impurities
are carried into the rock drill with the shank. Push the shank carefully
through the flushing housing to avoid damaging the flushing housing
CAUTION
seals.

P.O. Box 100
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16 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
6.9. Installing the flushing housing
First, push the rotation bushing (5) into place and tighten the clamp screw (2) to secure
the rotation bushing. Push the chuck (4) into place, grooved end (A) first, then install the
coupling (3) and tighten the clamp screw (2).
Fit the flushing housing into place and pre–tighten the bolts to 300 Nm (30 kpm). The final
tightening torque is 600 Nm (60 kpm). Tighten the bolts in a crosswise pattern (refer to
the section ‘Flushing housing bolts’).
2
5
4
3
A
1
Fig. 12. Installing the flushing housing

P.O. Box 100
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B 22500 – 1 en 0803 / PIR 17 (24)
HL 800 T, HL 800 ST
7. CHECKING THE TIGHTNESS OF THE BOLTS AND TIGHTENING

TORQUES
Checking the tightness of the bolts, especially the side bolts, is probably the most
important maintenance procedure for a rock drill. Loose side bolts cause rapid wear of the
rock drill frame’s mating surfaces, shortening the service life of the rock drill.
The bolts cannot be tightened to the correct tightening torque if the threads are not clean.
Therefore, clean and check the threads if necessary, lubricating them with grease.
Checking the bolts during regular maintenance:
– When checking the tightness of the bolts, use the correct tightening
sequence and a tightening torque 10% greater than what is specified.
– A bolt is too loose if it can turn. In this case, other appropriate bolts must be
opened and re–tightened according to the tightening instructions.
Use only a calibrated, high–quality torque wrench.
CAUTION
3 2 7
5 (200 Nm)
4 400 Nm
6 (200 Nm)
3 1 2
3 1
Fig. 13. Rock drill bolts
1. Side bolts 5. Intermediate gear pin bolts

2. Pressure accumulator bolts 6. Fitting bolts and front cover bolts
3. Hydraulic motor bolts 7. Rear cover bolts
4. Flushing housing bolts
For the bolts marked with a circle in the figure, a new locking washer pair
must be used after each time the bolt is opened.
CAUTION

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18 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
7.1. Tightening instructions – side bolts

Required tools:
– torque wrench
– socket, 24–mm
1. First, lubricate the threads and nut faces with petroleum jelly.
2. Lightly turn the rearmost nuts (A) fully home.
3. Pre–tighten the frontmost nuts (B) to 200 Nm (20 kpm). Use the tightening
sequence 1–2–3–4.
4. The final tightening torque is 400 Nm (40 kpm). Use the same tightening sequence
(1–2–3–4).
2
(100 Nm) 200 Nm 3
3 2
4 1
4
B 1
A
(200 Nm) 400 Nm
Fig. 14. Tightening the side bolts and pressure accumulator bolts

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HL 800 T, HL 800 ST
7.2. Pressure accumulator bolts

Required tools:
– torque wrench
– socket, 24–mm
1. First, lubricate the bolts with petroleum jelly.

2. Pre–tighten all four bolts to 100 Nm (10 kpm) with a torque wrench. Use the
tightening sequence 1–2–3–4.
(1–2–3–4).
7.3. Intermediate gear pin

Required tools:
– torque wrench
– socket, 24–mm
1. Lubricate the bolts with petroleum jelly.

2. Install the washers and bolts (5). Pre–tighten the bolts to 100 Nm (10 kpm). The
final tightening torque is 200 Nm (20 kpm).
5
(100 Nm) (200 Nm)
Fig. 15. Washers and bolts (5)

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20 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
7.4. Installing the hydraulic motor
Fig. 16. Removing the flushing housing and rotation bushing
Remove the flushing housing (1) and rotation bushing (2) from the gear
housing before installing the hydraulic motor.
CAUTION
7.5. Hydraulic motor bolts

Required tools:
– torque wrench
– socket, 24–mm
1. First, lubricate the bolts with petroleum jelly.

2. Pre–tighten all four bolts to 100 Nm (10 kpm) with a torque wrench. Use the
(1–2–3–4).
(100 Nm) 150 Nm

3
2
1 4
Fig. 17. Hydraulic motor bolts

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B 22500 – 1 en 0803 / PIR 21 (24)
HL 800 T, HL 800 ST
7.6. Flushing housing bolts

Required tools:
– torque wrench
– socket, 36–mm
1. Lubricate the bolts and nuts with petroleum jelly.
2. Pre–tighten all four bolts (4) to 300 Nm (30 kpm) with a torque wrench. Use the
(1–2–3–4); see Fig. 18.
4
(300 Nm) 600 Nm
3 1
3
Fig. 18. Tightening sequence for the flushing housing bolts (4)
30_ Alternative tightening procedure for the flushing housing bolts:

Pre–tighten to 200 Nm (20 kpm) and then 30_.
8. REGULAR MAINTENANCE
8.1. General
The idea of regular preventive maintenance is to take the rock drill in for servicing before
a failure stops it during operation. This will prevent expensive consequential failures and
downtime that adversely affects production.
The maintenance interval varies according to local conditions and must therefore be
determined on the basis of experience.
In defining the correct maintenance interval, the regular maintenance table should be
consulted first and then the maintenance interval should be increased until a suitable
maintenance interval for local conditions is determined.
In addition to this, the rock drill can undergo maintenance whenever the operator reports
a malfunction that could lead to a failure or production downtime.
P.O. Box 100
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22 (24) B 22500 – 1 en 0803 / PIR
HL 800 T, HL 800 ST
8.2. Tools and parts used in maintenance

Ensure that the operator keeps the tools and parts required for maintenance with
the drilling rig.
The rock drill toolkit includes a torque wrench and sockets. A socket and extension are
required for tightening the rock drill/carriage’s front and rear end mounting bolts.
Fig. 19. Maintenance tools
The drilling rig should also carry a spare flushing housing seals, shank, and coupling for
maintenance.
8.3. Daily after drilling
1. Check the tightness of the flushing housing bolts.

2. Check the seals for leaks by monitoring the inspection holes during drilling (Fig.
10).
3. Check for possible oil leaks.
4. Check the hoses and hose connections.
5. Check the fastening of the rock drill to the carriage. If necessary, improve
fastening by first loosening the mounting bolt pairs and then re–tighten
them using the correct tightening sequence as indicated in the instructions
(Section 2). Check also the tightness of the side bolts when tightening the
fastening of the rock drill to the carriage.

P.O. Box 100
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B 22500 – 1 en 0803 / PIR 23 (24)
HL 800 T, HL 800 ST
8.4. Weekly
1. Check the hour–meter reading.
2. Check the accumulator filling valves, the cover plugs, and the tightness of the
fastening bolts.
3. Check the accumulator pressures (refer to the HL 800 T Repair Instructions).
4. Check the tightness of the hydraulic motor and rear cover bolts.
5. Check the tightness of the intermediate gear pin bolts.
6. Check the condition of the shank, chuck, flushing housing front cover bearing,
coupling, and rotation bushing (refer to the repair instructions for wear limits).
7. Check the tightness of the side bolts. If they are loose, the centremost
mounting bolt pairs of the rock drill must be loosened before re–tightening
the side bolts. After tightening the side bolts (Section 7.1), tighten the
centremost mounting bolt pairs.
8.5. Basic maintenance

Check the percussion hour meter reading. We recommend that the rock drill be
disassembled every 500 percussion hours (refer to the repair instructions, ‘Disassembly’
section). Fill in the maintenance card.
8.6. After maintenance

After the maintenance is complete, the reinstalled components, especially when surfaces
are worn, settle into their proper places for a while, causing the side bolts and mounting
bolts to loosen.
This is why the side bolts and mounting bolts must be re–tightened after drilling
about 10–20 metres following maintenance.
8.7. Maintenance card

The card is machine–specific. When a rock drill is brought in for maintenance, the previous
maintenance cards must be available. The card is filled in with as much information about
the maintenance as possible. When a rock drill enters use again after maintenance, the
date for the next servicing is marked on the card.
The maintenance card reveals the replacement rate of parts in each rock drill, and the
effect of different conditions and procedures can be seen by comparing the various cards.
– The card must be available for preventive maintenance.
– A properly completed card enables us to view the entire maintenance history of a
rock drill.
– The card simplifies the decision to scrap an old machine.
8.8. Maintenance follow–up

To monitor the maintenance of a rock drill, the attached type of maintenance card can be
used.
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HL 800 T, HL 800 ST
ROCK DRILL MAINTENANCE CARD No.

Rig S/n
Rock drill S/n
Hours drilled after maintenance
drilled shifts / downtimes
drill metres
MAINTENANCE INFORMATION
Purpose of the maintenance Serviced by
Date of arrival Prev. maintenance Prev. perc. hours Total Disass. Check.
hours
Date of departure Prev. maintenance card no. Repair Assembly Total
PARTS REPLACED / PARTS CHECKED
Qty. Part number Description Repaired Replaced OK Notes
Piston
Front cylinder
Front bearing
Rear cylinder
Rear bearing
Distributor
Accumulator l.p.
Accumulator h.p.
Spacer
Rotation bushing
Rot. bushing bearings
Chuck
Coupling
Rotary actuator
Rotation shaft
Rot. shaft bearings
Seal housing
Front cover /
flushing housing body
Flushing h. seals
Shank bearings
Interm. gear
Interm. gear bearing
Interm. gear pin
Percussion Rotation
Notes mechanism tested mechanism tested
Continued

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Repair instruction

P.O. Box 100
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2 (44) D 22500-- 2 en 1105 / PIR
HL 800 T, HL 800 ST
Repair instruction

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Repair instruction
CONTENTS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. REPAIR FACILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1. Disassembling the front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2. Removing the pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3. Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4. Removing the percussion mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5. Percussion mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.6. Body cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.7. Removing the stabiliser spacer and stabiliser pistons
from the gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.8. Checking the spacer sealing bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.9. Removing and installing the spacer sealing bushing . . . . . . . . . . . . 20
5.10. Removing the spacer bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.11. Installing the spacer bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.12. Removing and installing other stabiliser bearings . . . . . . . . . . . . . . . 25
5.13. Assembling the spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.14. Disassembling and assembling the gear housing . . . . . . . . . . . . . . . . 27
5.15. Checking and removing the rear bearing and installing
the bearing in the gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1. Installing the intermediate gear and spacer . . . . . . . . . . . . . . . . . . . . . 34
6.2. Installing the body cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3. Installing and tightening the side bolts . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4. Percussion mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.5. Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.6. Installing the hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.7. Installing the pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.8. Assembling the front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8. FLUSHING THE STABILISER CHANNELS WITH OIL . . . . . . . . . . . . . . . . . . . . 43
9. PERFORMING A TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Repair instruction
1. GENERAL
These instructions are intended for persons servicing and repairing 800 series hydraulic
rock drills. Read the instructions carefully and follow them when disassembling,
assembling, and servicing the rock drill.
Always use a hoist when tilting the rock drill in the assembly stand.
CAUTION
2. REPAIR FACILITIES
Follow the instructions in the regular maintenance table. With regular preventive
maintenance, optimal utilisation is achieved. Replace any worn part promptly to avoid
more serious damage.
Before performing installation, check carefully that the parts are clean since even new
parts can be dirty (a bottle brush is useful for cleaning the components of the rock drill
cylinder). The use of unauthorised, i.e. non--OEM, spare parts has been found to cause
increased costs in almost all cases. The warranty for the entire system becomes void
immediately if any part is replaced with a non--OEM part.
Checking the tightness of the side bolts is one of the most important maintenance
procedures for a rock drill. Neglecting this procedure can cause rapid wear of the rock drill
frame’s end faces. Faultless operation of a rock drill stems largely from appropriate use
of the repair facilities. Make sure that the repair site is clean.
Example of equipment available at repair facilities:
2 4 Characteristics of good repair facilities:

-- well lit
-- appropriate washing facilities
1 5 6
10 -- compressed air available
-- free of dust
7 8 9 -- has all required documentation
-- has the required tools
Fig. 1. Repair facility
1. Spare part storage 6. Vice

2. Hydraulic press, 30 t 7. Bench drill
8. Tools
4. Washing bay 9. Assembly stand
5. Rubber-- coated work table 10. Hoist
The drill bit grinding device should not be housed at the rock drill repair
facility.
CAUTION

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Repair instruction
3. TOOLS
Tamrock supplies complete special toolkits for repairs. Refer to the tool sets’ spare part
sheet.
Figures 2, 3, and 4 show the tools required for repair work, grouped by stages of the
process.
Fig. 2. Tools for disassembling and assembling the rock drill
Fig. 3. Tools for the hydraulic press
Fig. 4. Tools for disassembling, assembling, and testing the pressure accumulator

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OUT
092 864 58
OUT
151 738 08
150 738 98
OUT
150 175 88 152 585 18
150 675 18 150 675 18
IN OUT
087 856 18
087 856 18
150 737 68
152 589 28
151 738 08 151 738 08
IN OUT
150 738 98
150 738 98
Fig. 5. Special tools

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Repair instruction
OUT
087 853 38
152 497 58
087 856 18
152 098 78
IN IN
152 537 28
096 876 58
152 501 38
150 736 38
IN
152 583 68
OUT
152 583 68
092 864 58
IN OUT IN
152 585 18
152 585 18
152 586 48 096 904 68
IN
152 585 18 152 586 48

152 583 68

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Repair instruction
4. SEALS
The seals are the most sensitive and important components of a rock drill. When
disassembling a rock dill, always replace all seals and O--rings.
Removing the seals
Be careful not to scratch the seal grooves and components inside

the rock drill.
Fig. 6. Removing the seal

Do not scratch the seal grooves.
CAUTION
Installing the percussion piston seals
When installing the seal, press it lightly and equally from both sides
so that the seal settles in the correct position. In particular, the seal
lip (a) is easily damaged by, for example, careless handling during
installation of seals. Fig. 7.
Fig. 7. Installation method for the seal
Seals are easier to install if warmed in oil (50–60_C).

Use only fingers when installing the seals. Be careful, and do not use
a the fingernails.
Fig. 8. Seal lip
Apply oil to the seal groove. Bend the seal as shown in the figure.
Fig. 9. Bend the seal as shown in the figure

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Storing the seals
-- Keep the seals in their original packages and away from direct sunlight.
Ensure that the seals stay clean at the installation site.
CAUTION
Fig. 10. Centring the spacer and rear bearing piston seals, and installation directions
1. Centring the piston seals

So that the seals settle properly, apply oil on the piston and push it through the seals while
rotating it slowly in the direction indicated in the figure. Check that the seal lips are intact.
Pay attention to the correct position of the seal lip.
CAUTION

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If the seals do not last for the standard maintenance interval, usually the reason is one
of the following:
-- Dirty oil and the filter is either clogged or of the wrong type (non--OEM)
-- Incorrect oil grade
-- Incorrect installation of the seals
-- Seals damaged at the time of installation
-- Water in oil
-- Poor condition of the sliding surfaces
-- Piston is pitted or scratched
5. DISASSEMBLY
The HL 800 rock drill should be disassembled and its components checked every 500
operating hours.
Disassembling and assembling the rock drill requires expertise and familiarity with the
rock drill. The environment must be dry, free of dust, and clean. The facilities must include
a sink and compressed air for cleaning rock drill components.
Before disassembly, the rock drill must be washed externally with, for example,
high--pressure water. In addition, we recommend that the rock drill be washed externally
with a brush and appropriate solvent before it is brought to the final repair location. A split
barrel is ideal for this purpose.
Assembly stand
Attach the assembly stand carefully to the repair shop floor with the mounting
bolts.
2 1
2
Fig. 11. Assembly stand

Required tools:
-- Spanners: 30--, 36--, and 41--mm
Secure the mounting plate in a horizontal position to the assembly stand
with the latch (1) and bolts (3).
Attach the rock drill to the mounting plate with the front-- and rear--end
CAUTION
bolts (2).
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Repair instruction
Fig. 12. HL 800 hydraulic rock drill

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Repair instruction
5.1. Disassembling the front end
Fig. 13. When disassembling the front end, refer to the operation and maintenance
instructions.
5.2. Removing the pressure accumulators

Before removing the accumulator from the rock drill, release the
pressure by opening the filling valve.
CAUTION
Fit protective plugs immediately into the openings on the body cylinder.
CAUTION
Refer to the section ‘Pressure accumulators’.
CAUTION
Fig. 14. Removing the pressure accumulators

Required tools:
-- torque wrench
-- socket, 24--mm
Open the accumulator bolts (see figure). Detach the accumulator and remove the seal.
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Repair instruction
5.3. Hydraulic motor
Fig. 15. Removing the hydraulic motor
Required tool:
-- spanner
Remove the hydraulic motor mounting bolts and pull the hydraulic motor assembly out
from the gear housing. Remove the O--ring. Open the cover bolts. Pull the rotation shaft
out from the bearing housing with the puller (092 864 58) and punch (088 277 08).
16 4 3
8 5
12
12
6
11
10
15
6
14
7
13
Fig. 16. Hydraulic motor parts
2. Bearing housing 10. Rotation shaft

3. Lock nut 11. Thrust plate
4. Lock washer 12. Shaft seal
5. Spherical roller bearing 13. O--ring
6. Circlip 14. O--ring
7. Cover 15. Inner ring of cylindrical roller bearing
8. Bolt 16. Lock washer

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Assembling the hydraulic motor
15
1
3
4
10 7 12 5 2
Fig. 17. Assembling the hydraulic motor
To avoid damaging the seals, use the mounting punch (1) included in the
toolkit when pushing the rotation shaft into the cover.
CAUTION
Order of assembly (Fig. 17):

1. Install the inner ring of the bearing (15) on the shaft (10).
2. Seals. Install the cover seals (12) with the punch (152 537 28), and install the
circlips.
3. Attach the cover (7) with the seals to the shaft with the punch (1).
4. Install the bearing (5) on the shaft (10), tighten the nut (3) and secure with the tabs
of the locking plate (4) and adhesive.
5. Install the shaft assembly in the bearing housing (2).
6. Tighten the cover bolts (8) in a crosswise pattern.
-- pre--tightening torque: 10 Nm
-- final tightening torque: 32 Nm
Remember to use the lock washers and threadlocker!
CAUTION

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Repair instruction
Removing the side bolts
Fig. 18. Removing the side bolts

Open the side bolt nuts first from the front, then from the back, and push the side bolts out.
5.4. Removing the percussion mechanism
Fig. 19. Removing the rear cover and piston assembly

Removing the rear cover
Required tool:
-- spanner, 30--mm
Open the latch and bolts (2 pcs) from the rear of the mounting plate. Using a hoist, lower
the rock drill to a vertical position. Remove the bolts and lift the rear cover off (see figure).
Remove the O--ring also. Check the wear of the rear cover and body cylinder end.
Removing the percussion mechanism
Required tool:
-- puller
Thread the puller into the piston (see figure). Lift the piston out from the cylinder. This will
also extract the rear cylinder, rear bearing, and distributor.
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5.5. Percussion mechanism
Fig. 20. Percussion mechanism

Disassemble the piston assembly by removing the rear cylinder and distributor from the
top of the piston and the rear bearing from the rear cylinder.
Check the piston and replace it if:

D the bevel at the percussion end has worn off
D the piston has cracks or seizure marks in it
If necessary, the piston may be polished with a cloth wheel. Never grind the piston!
Check the distributor:

-- If the distributor has light scratches, remove them by polishing with a cloth
wheel.
-- If the distributor has seizure marks, replace the distributor.
Never grind the distributor.
CAUTION
Check the rear cylinder:

-- If the rear cylinder has scratches, remove them by polishing with a cloth
wheel.
-- Install new O--rings.
-- Replace the part if the sliding surface has scratches that can be felt with
a finger.
Never grind the rear cylinder.
CAUTION

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5.6. Body cylinder

Removing the body cylinder
Remove the body cylinder’s rear mounting

bolts. Lift the body cylinder off. Use the
accumulator bolts during lifting. Remove
the front cylinder also. Check the wear of
the end faces.
Fig. 21. Removing the body cylinder
Removing the front cylinder bearing
The front cylinder bearing bushing is

removed and replaced only if it is
damaged.
Using the screw, press the special tool (1)
pins in and fit them from the front into the
3 notches behind the front cylinder bearing
(2). Press the bearing out with the punch (3)
and die (4)..
2
1
Fig. 22. Removing the front cylinder bearing

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5.7. Removing the stabiliser spacer and stabiliser pistons from the
gear housing
1. Lift the spacer off.

2. Lift the short movement piston (92) and the long movement piston (93) out of the
gear housing.
3. Lift the spacing ring (91) out of the gear housing.
92
93
91
Fig. 23. Removing the stabiliser pistons

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5.8. Checking the spacer sealing bushing
Check the piston seal grooves (A) at the sealing bushing. Maximum groove width is 4.35
mm. The groove width can be checked with a gauge. Also check the grooves visually. If
a groove is too wide or damaged, replace the sealing bushing.
150 746 48
A
Fig. 24. Checking the spacer sealing bushing

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Repair instruction
5.9. Removing and installing the spacer sealing bushing

Remove the sealing bushing with special tools.
150 738 98
550 296 09
Fig. 25. Removing the spacer sealing bushing
Installing the stabiliser piston seal

Seals are easier to install if warmed in oil (50–60_C). Use only fingers when installing the
seals. Be careful, and do not use fingernails.
Lubricate the O--ring and the outer surface of the seal, and install the O--ring first.
Bend the seal with your fingers as shown in the figure so that the bend indicated with an
arrow is as smooth as possible.
When installing the seal, press it into its groove as indicated by the arrows (1, 2, and 3).
NOTE! At this stage, the outer edges of the seal (a) tend to spread out, impeding the
installation. Prevent the seal from spreading by squeezing it, and guide it into its groove
in the direction indicated by the arrow (4). The sealing surface (b) in particular is easily
damaged.
b
4
1 3
a
2
Fig. 26. Installation method for the seal

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Repair instruction
Centre the seal with the stabiliser piston.

Attach the O--ring (17) to the outer ring of the sealing bushing.
17
Fig. 27. Installing the stabiliser piston seal

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Attaching the sealing bushing to the spacer

If the spacer bearings (20 and 21) are replaced, this procedure must be performed prior
to the installation of the sealing bushing.
-- Lubricate the parts liberally!
-- Install the O--ring (14) on the spacer.
-- Align the sealing bushing groove (1) with the spacer groove.
-- Press the bushing into place with a punch and a press.
152 537 28
14
20
21
Fig. 28. Installing the spacer sealing bushing

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5.10. Removing the spacer bearings
550 296 17
550 296 12
Fig. 29. Removing the spacer’s outer bearing (21)
550 296 17
Fig. 30. Removing the spacer’s inner bearing (20)

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5.11. Installing the spacer bearings

Cool the bearings to --20°C before installation.
150 738 98
550 296 09
Fig. 31. Installing the spacer’s inner bearing (20)
152 537 28
550 296 09
Fig. 32. Installing the spacer’s outer bearing (21)

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5.12. Removing and installing other stabiliser bearings

Cool the bearings to --20°C before installation.
96
95
Fig. 33. Other stabiliser bearings
550 296 10
Out In
Fig. 34. Removing and installing the short movement piston bearing (96)
Out 550 296 11

In
Fig. 35. Removing and installing the spacing ring bearing (95)

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5.13. Assembling the spacer

Push the short movement piston (92) into the long movement piston (93) so that the
lubrication grooves (A) of the short movement piston are against the shoulder of the long
movement piston (see figure 36). The short movement piston has to be installed in
the correct way. Push the pistons together inside the stabiliser spacing seal (lubricate
the parts well).
A
92
93
Fig. 36. Installing the stabiliser pistons

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5.14. Disassembling and assembling the gear housing
Check the gear housing wear limits (refer to the section ‘Wear limits’).
Required tools:
-- spanner, 24--mm
-- puller
Remove the bolts, and remove the shaft
journal with a puller. Let the intermediate
gear drop down, and remove the support
plates. Check the wear of the support
plates and shaft surface. Replace the
parts, if necessary.
Fig. 37. Removing the intermediate gear
Required tools:
-- punch
-- die
The needle bearings must be replaced
every 500 percussion hours. Using a
hydraulic press, press the needle bearing
out from the intermediate gear with a punch
and die. If the surface of the intermediate
gear teeth is damaged, replace the gear.
Fig. 38. Replacing the intermediate gear needle bearings
Installing the needle bearing

Press the first needle bearing into the intermediate gear, using a hydraulic press. Turn the
gear the other way round, and press the other needle bearing in.
Ensure that the hard ends of the needle bearings (the sides with text) are
on the outside of the gear faces.
CAUTION

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1 7
10
5
9
2
9
10
11
9
25
8
Glued only prior to

8 fastening to the carriage
3
Fig. 39. Gear housing components
1. Gear housing 8. O--ring

2. Rear bearing 9. Usit seal
3. Front bearing 10. Plug
4. Sleeve 11. Clamp screw
5. Cylindrical roller bearing without the 25. O--ring
inner ring
7. Seal
Intermediate gear shaft bushings
Check the wear of the bushings, and

replace them if necessary. The first bushing
is removed by applying a punch inward.
The bottom bushing is removed with a
special tool and puller (see figure). The
bushings are installed with a punch.

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Repair instruction
Cylindrical roller bearing

Remove the plugs and U--seal. Remove the bearing with punches as shown in the figure.
Install the bearing with a plastic hammer

and punch. Check that the roller cage rivets
are pointing toward the rear of the rock drill.
The inner ring of the bearing is installed
with the rotary actuator shaft. The bearing
must be replaced every 500 percussion
hours.
Fig. 40. Removing the bearing

Gear housing front bearing
The bearing must be replaced with

mounting punches and a hydraulic press
when the patterns are worn out (as shown
in the figure).
Fig. 41. Gear housing front bearing
Removing the front bearing
Do not scratch the inner surface of the gear housing with a screwdriver.
CAUTION

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Installing the gear housing front bearing

Cool the bearing to --20°C before installation.
152 586 48
152 585 18
Fig. 43. Installing the front bearing

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5.15. Checking and removing the rear bearing and installing the
bearing in the gear housing
Remove the bearing from the gear housing with punch 152 585 18.
152 585 18
The rear bearing must be replaced if:

-- the bearing surface is worn to the level of the wear indicator groove at any point
-- surface (A) has worn to the level of surface (B)
Fig. 45. Wear limits for the rear bearing

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Repair instruction
Installing the stabiliser piston seal

Refer to the section ‘Installing the stabiliser piston seal’ (pages 20–21).
-- Attach the O--ring (25) to the outer ring of the rear bearing.
25
Fig. 46. Installing the stabiliser piston seal

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Install the rear bearing in the gear housing so that the locking surface (A) and hole (B) face
up.
152 586 48
152 585 18
Fig. 47. Installing the rear bearing

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Repair instruction
6. ASSEMBLY
Work especially carefully when assembling the rock drill. Check that all parts are
completely clean.
Before assembling the rock drill, check all parts subject to wear, such as bearings and
pressure accumulator diaphragms (refer to the section ‘Pressure accumulators’), and
replace if necessary. The wear limits for all parts are shown in the wear limit table (refer
to Section 7). The parts must be lubricated -- with, e.g., motor oil -- before assembly.
All mating surfaces must be completely dry and clean.
CAUTION
Assembly stand
When assembly of the rock drill commences, the mounting plate of the assembly stand
is in a horizontal position. Ensure that the mounting bolts (2 pcs) and the latch are closed.
Attach the gear housing to the assembly stand. Tighten the bolts.
6.1. Installing the intermediate gear and spacer

Installing the intermediate gear
Required tools:
-- torque wrench
200 Nm -- socket, 24--mm
Install the support plates and intermediate
gear in the gear housing. The shaft journal
must go up to the O--ring when pushed by
hand. Drive the shaft carefully into place
with a rubber mallet. Ensure that the
support plates stay in place during
assembly. Tighten the bolts to 200 Nm (20
kpm). Use new locking washer pairs.
Fig. 48. Installing the intermediate gear and shaft

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Repair instruction
Installing the spacer

1. Turn the gear housing to a vertical position.
2. Lubricate the parts well!
3. Place the spacing ring in the gear housing so that the rear bearing pins go into the
holes in the spacing ring (A).
4. Install the spacer assembly in the gear housing.
Check that the spacer and gear housing seals and O-- rings are in place.
CAUTION
Assembly stand
Lower the mounting plate to a vertical position with a hoist.
6.2. Installing the body cylinder

Lower the body cylinder carefully. Attach the rear mount of the body cylinder loosely to the
assembly stand.
Fig. 49. Installing the body cylinder

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Repair instruction
6.3. Installing and tightening the side bolts

Turn the mounting plate to a horizontal position with a hoist. Secure with the latch and bolts
(2 pcs) at the rear of the locking plate.
Required tools:
-- torque wrench
-- socket, 24--mm
1. Lubricate the threads and nut faces with grease.

2. Lightly turn the rearmost nuts (A) fully home. Pre--tighten the frontmost nuts
(B) to 200 Nm (20 kpm). Use the tightening sequence 1–2–3–4.
3. Tighten the rear mount of the body cylinder against the mounting plate.
4. The final tightening torque is 400 Nm (40 kpm). Use the same tightening
sequence.
24
4 1
3
A
400 Nm (200 Nm)
Fig. 50. Installing and tightening the side bolts

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Repair instruction
6.4. Percussion mechanism

Apply plenty of oil to the inner surface of the body cylinder.
CAUTION
Refer to the section ‘Seals’, and make sure that all seals are correctly
installed. Check also that the components are installed facing the right
direction.
CAUTION
Lower the assembly stand to a vertical position with a hoist. Attach the front cylinder to
the body cylinder. Install the rear bearing in the rear cylinder so that the surfaces are level.
Install the distributor and the rear cylinder with its rear bearing on the piston journal.
Lift the piston assembly into the body cylinder. Use the same special tool used for lifting
the percussion cartridge.
Fig. 51. Percussion cartridge
6.5. Rear cover

Required tools:
-- torque wrench
-- socket, 30--mm
Install the rear cover and bolts on the body cylinder. Place the O--ring in the rear cover
groove prior to installation. Use new locking washer pairs. The surfaces must be dry and
clean.

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Repair instruction
Tightening the rear cover bolts
Tightening torques
-- pre--tightening torque: 200 Nm (20 kpm)
-- final tightening torque: 400 Nm (40 kpm)
400 Nm (200 Nm) -- tighten in a crosswise pattern.
Fig. 52. Tightening the rear cover bolts
6.6. Installing the hydraulic motor
Install the hydraulic motor carefully in the

gear housing and tighten the bolts.
Required tools:
4 -- torque wrench
-- socket, 24--mm
150 Nm 1 Lubricate the threads with grease.
2
Pre--tighten all four bolts to 100 Nm (10
3 kpm) with a torque wrench. Use the
tightening sequence 1–2–3–4. Tighten to
150 Nm (15 kpm). Tighten in a crosswise
pattern (1–2–3–4).
Fig. 53. Tightening the hydraulic motor bolts
Apply grease to the hydraulic motor O-- ring and hub.
CAUTION
All mating surfaces must be absolutely dry and clean.
CAUTION
Always install the motor before the rotation bushing and flushing
housing.
CAUTION

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Repair instruction
6.7. Installing the pressure accumulators
Lubricate the O--rings and bolts.

Drive the accumulators into place with a
rubber mallet. Refer to the repair
instructions, ‘Pressure accumulators’
section.
3 2
Required tools:
-- torque wrench
200Nm(100Nm) -- socket, 24--mm
44
1
Pre--tighten all four bolts to 100 Nm (10
kpm) with a torque wrench. Use the
tightening sequence 1–2–3–4. The final
tightening torque is 200 Nm (20 kpm). Use
the same tightening sequence (1–2–3–4).
Fig. 54. Tightening the pressure accumulator bolts
The high-- pressure accumulator (H.P.) in located on the right side of the
rock drill when viewed from the rear. Correspondingly, the low-- pressure
accumulator (L.P.) is on the left. The stabiliser accumulator is on the top.
CAUTION
Accumulator pressures and types
Accumulator type Pressure [bar]

H.P. 80 (max)
L.P. 4
Stabiliser 30

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6.8. Assembling the front end
Fig. 55. Installation of the coupling, rotation bushing, chuck, and flushing housing. Use a
new seal plate (1). Assembly of the flushing housing: refer to the operation and
maintenance instructions.
Installing the clamp screw
Turn the mounting plate to a horizontal

position with a hoist. Secure the
mounting plate with the latch and bolts.
Required tools:
-- torque wrench
-- socket, 19--mm
Lubricate the threads. Use a new usit seal.
Tighten the screw to 120 Nm (12 kpm).
Fig. 56. Tightening the clamp screw

Tightening the flushing housing bolts
Required tools:
-- torque wrench
socket, 36 mm
24 -- spanner, 36--mm
Lubricate the bolt threads. Use the
3 tightening sequence 1–2–3–4. Pre--tighten
the bolts to 300 Nm (30 kpm). Tighten the
bolts to 600 Nm (60 kpm) in a crosswise
4 pattern. Use new locking washers.
1
Fig. 57. Tightening the flushing housing bolts

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Repair instruction
I G
N O
M K
D
E
S
B
Fig. 58. Wear limits

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Repair instruction
7. WEAR LIMITS
PART WEAR LIMIT
A. Flushing housing bearing The bearing must be replaced when the

wear indicator groove has worn down to
the level of the surface at any point.
B. Gear housing Manufacturing: 271 mm / Reject limit: 270
mm
C. Gear housing front bearing The bearing must be replaced when the
‘oil pockets’ are worn out at any point on
the bearing surface.
D. Gear housing rear bearing The bearing must be replaced if any of the
wear indicators has worn off.
E. Intermediate gear shaft Replace when the shaft/sleeve is worn or
if the shaft surface is damaged.
F. Piston Replace when the piston bevel is worn
out.
G. Chuck The chuck must be replaced if it has dents
or cracks that are over 1 mm deep.
I. Coupling The coupling must be replaced if the
edges of the inner teeth have worn to a
point.
K. Spacing ring bearing The bearing must be replaced every 500
percussion hours.
M. Shank Refer to the operation and maintenance
instructions.
N. Shank bushing The bushing must be replaced when 1 mm
has worn off the ends.
O. Rotation bushing bearing The bearing must be replaced when the
wear indicator groove has worn down to
the level of the surface at any point.
P. Short movement piston bearing The bearing must be replaced every 500
percussion hours.
R. Spacer bearings The bearings must be replaced every
1,000 percussion hours.
S. Spacer sealing bushing Check the piston seal grooves with a
gauge.

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Repair instruction
Percussion cartridge fitting between the spacer and rear cover
B
A
1 2
Fig. 59. Percussion cartridge / measuring points
Wash the percussion cartridge (1) components. Before assembly and measurement,
check that the components are clean and that no oil film is present.
Measure dimensions (A), (B), and (C). The difference between values (A) and (B) must
be greater than value (C). If this is not the case, reject parts (3) and (4).
8. FLUSHING THE STABILISER CHANNELS WITH OIL

Impurities that can prevent the pistons from moving must be flushed away from the
stabiliser channels after each time stabiliser maintenance is performed.
Fill the pressure accumulators (H.P. and L.P.).
3 2
Fig. 60. Connecting the flushing hoses

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Repair instruction
Replace the stabiliser accumulator with the flushing plate (3, ID: 550 055 32).
A) Flushing at the repair shop

Plug the percussion nipples (2) to prevent flushing oil from escaping
through them.
CAUTION
Connect the flushing hose (max. 10 bar) to the stabiliser nipple (1) and the receiver hose
to the flushing plate (1/2”) (3).
B) Flushing on the rig

Connect the stabiliser hose to the nipple (1) and the rotation drain hose to the nipple (3).
The percussion hoses must be connected.
CAUTION
C) Flushing
Flush the stabiliser with oil until all impurities are removed (about 10 minutes).
When finished, remove the flushing plate, then re--install the stabiliser accumulator and
fill it.
9. PERFORMING A TEST RUN

Test run the rock drill and make sure that it operates properly.
During the test run, monitor:
-- the mating surfaces of the components and the front end of the rock drill for oil leaks
-- the operation of the shank lubrication
-- the flushing operation
-- the pressures and the temperature

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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

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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

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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 power pack if an accumulator is not in place in

the rock drill.
WARNING

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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

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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.

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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

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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

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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.

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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 is 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

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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
HLX5 T . . . . . . . . . . 8 bar
HFX5 T . . . . . . . . . . 8 bar
HLX5 LT . . . . . . . . 30 bar
HL 800 T . . . . . . . . . 30 bar
HL 1500 . . . . . . . . . 50 bar
HL 1560 T . . . . . . . 40 bar

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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

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Repair instructions
Notes:

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D 28400 ---2 GB 0997TTi 1 (6)
HYDRAULIC MOTORS OMT, OMSU

Repair Instructions
OMSU
OMT
190 Nm
CONTENTS
1. Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Timing the motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 GB 0997TTi
1. SPECIFICATION
MOTOR MOUNTED ON ROCK DRILL HL 500/ HL 550
OMSU 80 OMSU 100 OMSU 125

Motor . . . . . . . . . . . . . . . . . Orbit type
Rotation rate . . . . . . . . . . . 0...250 rpm 0...250 rpm 0...200 rpm
Torque, max 175 bar
(max continuos) . . . . . . . . 400Nm 490Nm . . . . 630 Nm
Oil flow l / 1/min . . . . . . . . 46 / 250 58 / 250 58 / 200
MOTOR MOUNTED ON ROCK DRILL HL 600
OMT160 OMT 200 OMT 250 OMT 315

Motor . . . . . . . . . Orbit type
Rotation rate
rpm . . . . . . . . . . 0...200 . . . 0...200 0...200 0...200
Torque,
(max continuos) 635 Nm . . 795 Nm 985 Nm 1280 Nm
Oil flow l / 1/min 46 / 200 . . 58 / 200 74 / 150 64 / 100
OMT160 OMT 200 OMT 250 OMT 315

Rotation rate
rpm . . . . . . . . . . 0...200 . . . 0...200 0...200 0...200
Torque,
(max continuos) 872 Nm . . 1095 Nm 1355 Nm 1763 Nm
Oil flow l / 1/min 70 / 200 . . 66 / 150 55 / 100 71 / 100
OMT 250 OMT 315 OMT 500

Rotation rate . . . 0...130 rpm 0...130 rpm 0...80 rpm
Torque, max 175 bar
(max continuos) 1340 Nm 1760 Nm 2260 Nm
Oil flow . . . . . . . 65 l 125 1/min 71 l 100 1/min 67 l 60 1/min

P.O.Box 100
Telefax +358 205 44 4771
D 28400 ---2 GB 0997TTi 3 (6)

Repair Instructions
2. REPAIR
In all hydraulic machinery the cleanness is the most important

consideration to ensure the trouble---free operation. We therefore
recommend that all maintenance work of the hydraulic motors is done
in a clean and dustless room.
When dismantling the hydraulic motor, always change all seals.
Change the worn---parts for new ones in time to avoid more serious
damage.
1 45 Nm 60 Nm secure with glue
2 190 Nm
3
Use cross
24 Nm secure with glue 5---10 Nm tightening
method
Fig. 1 Hydraulic motor OMT
The spacer ring (2) has to be always changed with the roller bearings
(1) . After you have pressed the bearings onto the shaft, tighten the lock
nut (3) up to 60 Nm and secure with glue and by pressing the locking
nut collar to the groove of the shaft .

P.O.Box 100
Telefax +358 205 44 4771
4 ( 6) D 28400 ---2 GB 0997TTi
2
3
4
5
3
6
7
8 6
9
10
11
12 13
14 15 16 17 18
19
20 21
22 23 24
5---10 Nm 80 Nm
Use cross
tightening
method
Fig. 2 Hydraulic motor OMSU

2. O --- RING 10. CHANNEL PLATE 18. PLUG
3. SCREW 11. DISC VALVE 19. HOUSING
4. PLATE 12. PLATE 20. BALL
5. SHAFT 13. PIN 21. SPRING
6. O --- RING 14. O --- RING 22. WASHER
7. GEAR WHEEL SET 15. O --- RING 23. PLUG
8. PIN 16. SPACER 24. BOLT
9. SHAFT 17. SPRING WASHER
Never rotate the motor without the shaft, this will damage
! the disc.

P.O.Box 100
Telefax +358 205 44 4771
D 28400 ---2 GB 0997TTi 5 (6)

Repair Instructions
CHECKING THE MOTORS
2 1
5---10 Nm
Fig.3 Non ---return valve
Non---return valve
Check the condition of ball (1) and valve surfaces (2), if they are
damaged the valve leaks and the motor must be changed.
Gearwheel set
If there are fractures, seizing marks or georotor is worn the motor has to
be changed.
The gearwheel set must be used as a pair.

P.O.Box 100
Telefax +358 205 44 4771
6 ( 6) D 28400 ---2 GB 0997TTi
3 Nm
1 2 4
Fig.4 Hydraulic motor OMSU
Push the cover (2) firmly in place. Make sure the cap is
! even between the cover and body before tightening the
bolts (1). If the cap is not even the shaft (4) might be
jammed behind the corner (3) and while tightening the
mounting bolts the bearing (5) will damange the rear cover
of the motor.
If the motor is not used immediatly, fill with oil and close the oil supply
parts so that it stays full of oil until it is put into operation. Oil prevents
rust and provides lubrication for all moving parts when the motor is
started.
3. TIMING THE MOTORS

4
1 Replace the disc valve (1) so, that one

of the of the holes (A) which goes thru 3
the valve, is located on the center line.
2. Fit the shaft (2) into the disc valve. B
3. The drain hole (B) in the channel plate
2
(3) must be located on the same center
line .
4. The tooth of the gear (4) must be set on
the right side of the center line . 1
Fig.5 Timing the motors
A
P.O.Box 100
Telefax +358 205 44 4771
C 00640-1 en 0198
ROCK DRILL SERVICE CARD N:o

Equipment S/n
Rock drill S/n
Percussion hours since last
service
drill. shifts/rounds
drilled meters
SERVICE INFORMATION
Purpose of the service Service man
Arrival date Previous service Edell. iskutunnit Work. hours Dism. Insp.
Departure date Previous service card n:r Rep. Ass. Total
REPLACED PARTS / PART INSPECTION

Qty Part no. Description Repaired Replaced OK Remarks
Piston
Front cylinder
Front bearing
Rear cylinder
Rear bearing
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
Flushing seal housing
Shank bearings
Perc.mechanism Rot.mechanism
Remarks tested tested
Cont.
© 2000 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN-33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

Hydraulic Rock Drill HL 800 T Lifting Instructions: Incorrect Correct

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Hydraulic Rock Drill HL 800 T Lifting Instructions: Incorrect Correct

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D 20106 - 1 en 0904 / JT 1 (1)

HYDRAULIC ROCK DRILL HL 800 T

E 2004 SANDVIK TAMROCK CORP., Tampere Plant

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

2. BRINGING THE NEW ROCK DRILL INTO USE

1. Follow the instructions when pressurising the accumulators. See ‘Repair

2.3. Test run

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

4.1. Lubrication circulation, underground model

Fig. 3. Lubrication circulation, underground model, HL 800 ST

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

4.2. Lubrication circulation, surface model

Fig. 4. Lubrication circulation, surface model, HL 800 T

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

Fig. 5. Shank lubrication (surface model)

1. Rock drill 3. Drain valve

1. The oil consumption of the lubrication system is adjustable. **

** Refer to the SLU 1/2/3 operating instructions

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

Fig. 6. Shank lubrication (underground model)

Fig. 7. Rock drill with water flushing (for underground drilling)

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

6. INSPECTION AND MAINTENANCE OF THE FRONT END WHEN

Fig. 9. Disassembling the tube–type flushing housing

6.1. Installation directions for the seals and bearing bushing

90_ Drain holes Drain holes A

6.2. Replacing the front cover bearing of the flushing housing

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

6.3. Assembling the flushing housing

Fig. 11. Installing the tube flushing housing lock rings

6.5. Rotation bushing

The bearing must be replaced when the wear indicator groove

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

6.7. Shank bushing and lock ring pair

6.8. Shank wear limits

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

6.9. Installing the flushing housing

Fig. 12. Installing the flushing housing

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

7. CHECKING THE TIGHTNESS OF THE BOLTS AND TIGHTENING

Use only a calibrated, high–quality torque wrench.

Fig. 13. Rock drill bolts

1. Side bolts 5. Intermediate gear pin bolts

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

7.1. Tightening instructions – side bolts

2. Lightly turn the rearmost nuts (A) fully home.

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

7.2. Pressure accumulator bolts

1. First, lubricate the bolts with petroleum jelly.

7.3. Intermediate gear pin

1. Lubricate the bolts with petroleum jelly.

Fig. 15. Washers and bolts (5)

E 2003 SANDVIK TAMROCK CORP., Tampere Plant

7.4. Installing the hydraulic motor

Fig. 16. Removing the flushing housing and rotation bushing

7.5. Hydraulic motor bolts

1. First, lubricate the bolts with petroleum jelly.

(100 Nm) 150 Nm

Fig. 17. Hydraulic motor bolts

7.6. Flushing housing bolts