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İnstruction, Overhaul Rock Drill RD 14S, 18S, 22S Ver. F
İnstruction, Overhaul Rock Drill RD 14S, 18S, 22S Ver. F
Original Instructions
2019-03-28 | No: 9853 7185 01e. 6817495179.3.18014405330832779 en-US
Hydraulic Rock Drill RD 14S/ 18S/ 22S Ver. B Table of Contents
Table of Contents
1 Introduction ........................................................................................................... 7
1.1 Safety first................................................................................................................................... 7
1.2 The Purpose of This Publication .............................................................................................. 7
1.3 Target Group .............................................................................................................................. 8
1.4 Feedback and Contact Information .......................................................................................... 8
4 Tools..................................................................................................................... 15
4.1 Standard Tools ......................................................................................................................... 15
4.2 Special Tools ............................................................................................................................ 16
5 Torques ................................................................................................................ 19
5.1 Tightening Torques.................................................................................................................. 19
5.2 Retighting Side Bolts............................................................................................................... 21
9 Accumulators ...................................................................................................... 39
9.1 General...................................................................................................................................... 39
10 Back Head............................................................................................................ 41
10.1 Replacing Piston Seals, Back Head ....................................................................................... 41
10.2 Installing Piston Seals and Seal Housing Back Head .......................................................... 42
16 Lubricating......................................................................................................... 105
16.1 Hydraulic and Lubricant Recommendations....................................................................... 105
16.1.1 Hydraulic Fluid...................................................................................................................... 105
16.1.2 Pneumatic Tool Oil ............................................................................................................... 106
1 Introduction
WARNING
Serious injury
Risk of personal injury!
u Never operate the Rock Drill in any explosive environment.
u Always read the machine Safety Manual before start maintenance work on the Rock
Drill.
u Always observe local regulations.
u Always let the Rock Drill to cool down before maintenance work.
u Always carry out a documented risk analysis and take the necessary precautions be-
fore maintenance work.
u Only use clean, calibrated tools in good condition.
u Only use approved handling and working equipment in good condition.
u Always use personal protective equipment.
u During maintenance work, the equipment should be shut down, in service mode, and
the main switch turned off and locked.
u Attach WORK IN PROGRESS signs according to local regulations, or at least at the
main switch and operator's station.
WARNING
Serious injury or death
Serious danger when working on the hydraulic system!
u Ensure that the air, water and hydraulic system is depressurised before starting work.
u Adjacent moving units should always be anchored before working on a system part.
u Always stop work if there is an unforeseen or suspected risk.
The maintenance instructions are intended for use by maintenance and service personnel.
Persons working to these instructions must have completed relevant Epiroc training for the
Rock Drill.
2 General Information
2.3 Cleaning
WARNING
Serious Injury
Risk of personal injury
u Always read general safety regulations before starting maintenance work. Refer to
Safety manual.
u Always turn off the equipment and the main switch before cleaning and maintenance
work is carried out. Set up WORK IN PROGRESS warning signs at the main switch
and control positions.
u Be aware of the units kinetic energy due to accumulated hydraulic pressure. Relieve
pressure in hydraulic, water, and compressed air systems and always secure moving
units.
2.3.2 Cleaning
1. Clean the Rock Drill frequently from rock fragments, drill cuttings and accumulations
of dust.
2. Clear away fragments of rock and other objects from air, water and hydraulic hoses
and cables frequently to avoid the risk of chafing on sharp edges.
3. Rinse the Rock Drill with water after every work shift. Use only rinsing pressure and
avoid spraying directly at seals. Wipe away any accumulations of water.
WARNING
Serious injury
Risk of serious injury to the eyes, hands and skin.
u Never work on the lubrication system when it is pressurized. Lubrication air and oil may
spray out.
u Never use hands or fingers to locate a leakage.
u Always use gloves and eye protection.
WARNING
Serious Injury
Risk of abrasions and crushing injuries.
u Always change damaged hoses and couplings.
• Wet areas around hoses and connections is a sign for leaks that can cause spurting oil
or burst hoses if the leak worsens.
• The hose casing must be intact without any swelling (sign of inner hose or cord break-
age).
• Couplings must not have indentations or cracks and must make a secure connection.
Retighten or feel the coupling connection manually if a leak is suspected.
• Check that all hose attachments and clamps are intact. Loose attachments means that
hoses are damaged or get jammed during angle adjustment or when lowering the ma-
chine.
• Replace or rectify in the event of any faults.
2.4.1 General
The hydraulic system is sensitive to contamination. The environment where the machine is
normally used is generally an unsuitable place for repairing hydraulic components. Inter-
vention in hydraulic systems in workplaces must be limited. Components must be repaired
in an adapted environment, refer to Hydraulic Workshops.
Observe the following points to avoid breakdowns and interruptions in operation due to
fouled hydraulic oil:
• Keep the machine clean. Hose it down at regular intervals using a degreasing additive.
• Before opening any connection, clean the area around it.
• Use clean tools and work with clean hands.
• Always plug hydraulic connections immediately after they have been detached. Use
clean protective plugs.
• Hydraulic components like hoses, valves, engines must always be stored with suitable
protective plugs fitted in place.
• Be separate from activities which generate dust and particles, such as welding, grind-
ing, the transportation of machines.
• Have own suitable washing equipment required for repairing the components.
• Use only tools from a hydraulic workshop consisting of standard and special tools.
• Have a ventilation system that does not admit dust into the premises.
• Use trained mechanics.
2.5 Welding
• All welding on the Rock Drill is forbidden.
WARNING
Risk of Lifting the Rock Drill
Incorrect handling can cause serious crushing injury or death.
u Use extreme caution when strapping and lifting heavy objects.
u Lifting must be done through the center of gravity.
u Only use straps that are intact and designed for the load they will carry.
u Do not approach a suspended load.
2. Check that the lifting eyes are aligned with the Rock Drill, use both lifting eyes when
lifting.
3. Lift the Rock Drill carefully, make sure that the straps do not slip.
RD 14S 227 kg
RD 18S 231 kg
RD 22S 231 kg
4 Tools
A1 Plastic mallet
A2 Sledge hammer
A6 Screwdriver
A15 Magnet
5 Torques
1. Always tighten the side bolts and front side bolts in numerical order as in shown in the
table (ref. no. 2 and 3). Lubricate the dome nuts threads and the contact surfaces on
the washers with the recommended lubricant in the table .
Table 2: Torque
Recommended Oil
1. Retighten the dome nuts (4) to full torque 300 Nm (221 lbf-ft).
2. Retighten the dome nuts (6) to full torque 500 Nm (369 lbf-ft).
6 Main Parts
201 Gear Housing Rotation Chuck, Rotation Chuck Bushing, Driver, Damping
Piston, Sliding Bearing
301 Cylinder Impact Piston, Piston Guides, Valve Piston, Front Seal
Housing
2 Hydraulic Motor
WARNING
Risk of Crushing Injuries
Can cause serious personal injury or damage to property.
u Use extreme caution when strapping and lifting heavy objects.
u Secure Rock Drill, adapter plate, and fixture with proper fasteners.
u Work surface must be strong enough to hold the Rock Drill weight, even in tilted posi-
tion.
1. If a fixture (D) is used, attach the fixture (D) to a suitable work surface.
The work surface must be strong enough to support the rock drill weight, even when
dropped into tilted position.
2. Attach the adapter plate (C) with the screws (B) to a suitable work surface or on the
fixture (D).
3. Attach the Rock Drill to the adapter plate (C) with screws (A).
2. Use the break out notches in the cover (205) for loosen the front head (101) from the
cover.
3. Lift the front head (101) away from the side bolts (216).
2. Install the connection adapter (A13a), and the nitrogen gas (N2) in the accumulators
are released.
3. Remove the connection adapter (A13a) and install the charging valve protective cap
(2).
4. Undo the screws (354) and remove the cover (353). Maintain a small counterpressure
against the cover since it is easy to drop the cover when the spring (350) presses the
cover out.
2. Tap with a plastic mallet and carefully pry with a prybar or similar to loosen the back
head (310) if necessary.
3. Pull out the piston (330) with the rear piston guide (334), place the piston where it
cannot be scratched or damaged.
2. Use the break out notches in the cover (205) for loosening it from the gear housing
(201).
3. Remove the rotation chuck (208) from the gear housing (201).
4. Separate the gear housing (201) from the cylinder (302) with a plastic mallet.
8 Front Head
3. Remove the stop ring (15) with manual force. If it is jammed, tap it out carefully from
the front with a plastic mallet and a mandrel.
6. Remove the cup seals (114) carefully with a pointed tool so that the sealing grooves
are not damaged.
7. Use tool (A7) or an internal puller to press out the guide (107).
8. Remove the fitting (7), connection (119), and the O-ring (120) from the front head
(101).
1. Use compressed air for inspect that the restriction (A) is open and the lubrication
channels are clean.
3. Replace the guide (107) if the inside diameter exceeds 53 mm (max. dimension).
a. any point within the wear surface (S) is worn more than 1 mm, compare with a
new stop ring.
M Measurement surface
S Wear surface
4. Install three new cup seals (114) in the front head (101).
! NOTE: The cup seals must be turned in accordance with the figure
5. Install the fourth new cup seal (114) in the guide (107).
7. Use tool (A2) to press in the guide (107) in the front head (101).
8. Use compressed air for check that the air channels are clean and open.
9. Apply oil on the (5) front head cover screws (115). Install cover (110) and tighten the
screws alternately to full torque 80 Nm (59 lbf-ft).
11. Install a new cylinder pin (106) in the front head (101) if the cylinder pin has been re-
moved.
12. Lubricate the O-ring (16) and install it on the stop ring (15). Install the stop ring in the
front head (101), Groove (A) must align with the cylinder pin (106).
13. Lubricate the O-rings (117) with silicone grease and install O-rings.
14. Install the shank adapter (1) in the front head (101)
Recommended Oil
9 Accumulators
9.1 General
It is important that all the signs are in the correct location, clean, and fully legible on the
machine. Check and replace damage signs.
Warning sign
• Read the instruction manual thoroughly before performing service
or replacement
Warning sign
• Charge only with nitrogen gas
A Return Accumulator
B Intake Accumulator
WARNING
Damaged Screws, Threads, and Covers
Risk of personal injury.
Incorrect quality or length of screws, and damaged or corroded threads on screws,
housings, and covers can lead to dangerous oil leakage or cause the accumulator to
work loose.
u Parts that work loose can cause serious personal injury.
u Always replace incorrect and damaged screws, housings, and covers.
u Always replace all screws, even if only one screw is damaged.
Precondition p The parts must be washed with grease solvent before the inspection.
1. Replace the diaphragm (352) if there is any indication of cracks or other damage.
2. Check the charging valve (355) for rubber pieces from the broken diaphragm. Re-
place the charging valve if it is damaged.
3. Check the spring (350), diaphragm support (351), and cover (353).
5. Check the sealing surface for the diaphragm, a damaged sealing surface can cause
leaks. Check the accumulator threads for damage.
6. Replace the screws (354) if the threads are corroded or damage. Always replace all
screws, not just the corroded or damaged ones.
10 Back Head
2. Use a puller with expander 37–46 mm to remove the seal housing (321) from the
back head (310).
3. Remove the O-rings (323, 324) from the seal housing (321)
2. Use tool (A5) and a press to install the seal housing (321) into the back head (310).
The press is needed due to the tight fit to the back head.
3. Install the piston seals (322) in the seal housing (321) in accordance with the figure.
(A seal kit consists of an O-ring and a Teflon ring)
! NOTE: The seal lips must be turned in accordance with the figure.
4. Lubricate the O-ring and check that the seal groove is clean, Install the sealing groove
and bend the O-ring in accordance with the figure. Bend the Teflon ring as shown in
the figure, and guide it into the seal housing (321).
5. Press the Teflon ring into the seal groove using a tool shank for example, so that no
creases remain in the seal after assembly. Otherwise the seals risk being cut apart
during assembly of the impact piston.
2. Remove the wear ring (232) and pin (if it is worn or damaged) (233) from the cover.
3. Remove the bushing (211) using a chisel or cold chisel and mallet, do not damage the
bushing position in the cover.
2. Remove the shaft (219) by threading an M12 screw into the shaft and pull out the
shaft use a sliding hammer if necessary.
4. Remove the gear wheel (220) by tapping it from behind, using a mandrel and a plas-
tic mallet.
5. Remove the damper piston (217), tap it out from behind if necessary using a mandrel
and a plastic mallet.
6. Remove the seal housing (341) by tapping it out from the front using a mandrel and a
plastic mallet.
7. Remove the damper piston seals (230, 231) carefully with a pointed tool so that the
sealing grooves in the gear housing (201) are not damaged.
8. Remove the bushing (212) using a chisel or cold chisel and mallet, exercise cau-
tion so that the gear housing is not damaged.
10. Remove the driver (222) and the pins (215) by hand from the rotation chuck (208).
11. Remove the rotation chuck bushing (221) from the rotation chuck (208).
1. Replace the front side bolts (216) in pairs during each overhaul, never mix new and
old side bolts.
2. Replace the side bolts in the event of heavy rusting, cracks, or damage threads.
3. Replace the wear ring (232) when the dimension is less than 17.3 mm.
4. Replace the driver (222) when the boom width is less than 2 mm.
5. Replace the driver pin (215) if the length dimension is less than 98.0 mm or the diam-
eter is less than 12.0 mm.
6. Replace the rotation chuck bushing (209) if its damage or the inner diameter exceeds
75.5 mm.
a. Remove the bushing (209) If needed, using a chisel or cold chisel and mallet. Do
not damage the bushing position in the rotation chuck.
7. Replace the rotation chuck (208) if it is deformed or have cracks or the ring gear is
worn. Polish the bearing surfaces if bronze from the sliding bearings has attached to
the surfaces.
8. Replace the rotation chuck bushing (221) if it has cracks, scoring marks or if the sur-
face (S) against the adapter is worn more than 1.00 mm.
9. Replace the damper piston (217) if the seals are worn more than 0.1 mm, compare
with a new damper piston. Polish minor damage.
10. Check the seal housing (341) for damage and that there are no burrs in the seal or O-
ring grooves.
11. Check for damage and wear on the needle bearing (213), rotation shaft (219), gear
wheel (218), plain washer(225) and replace the O-ring (226).
12. Use a bearing puller for removing the needle bearings (213) since the gear wheel
(218) has a partition wall between the bearings. If there is no puller, use a small man-
drel or screwdriver to tap out the needle bearing through the shaft hole from behind.
13. Use the rotation shaft (219) for fit the new needle bearing (213).
14. Replace the ball bearings (210) in the event of noise or damage, replace the gear
wheel (220) in the event of deformation or cracks.
b. Use a mandrel and a plastic mallet to assemble the ball bearings on the gear
wheel.
WARNING
Pressurized Systems
Can cause serious injury.
u Never stand in front of the rock drill during the test.
u Only the operator is to be around the rock drill during the test.
7. Turn the flow restrictor (4) slowly clockwise until the flow meter reaches 10 l/min maxi-
mum.
b. Make sure that rotation is constant and without any abnormal noise.
10. Move the lever (1) up and down a couple of times to release the pressure in the
hoses.
11. Loosen and remove the hoses carefully, a small pressure can remain in the system.
Plug all connections to secure them from dirt.
WARNING
Pressurized Systems
Can cause serious injury.
u Never stand in front of the rock drill during the test.
u Only the operator is to be around the rock drill during the test.
1. Connect the hydraulic hoses P (Pressure) to port (A) and R (Return) to port (T) on the
hydraulic motor.
7. Turn the flow restrictor (4) slowly clockwise until pressure manometer (2) reaches 210
bar.
10. Move the lever (1) up and down a couple of times to release the pressure in the
hoses.
11. Loosen and remove the hoses carefully, a small pressure can remain in the system.
Plug all connections to secure them from dirt.
WARNING
Pressurized Systems
Can cause serious injury.
u Never stand in front of the rock drill during the test.
u Only the operator is to be around the rock drill during the test.
2. Install the hydraulic motor on the fixture with 2 hydraulic motor nuts and tighten alter-
nately to the tightening torque 70 Nm (52 (lbf-ft)).
3. Connect the return hose (R) and the drainage port (T) to the return port (B) with a T-
coupling.
9. Turn the flow restrictor (4) slowly clockwise until pressure manometer (2) reaches the
correct value according to the table. Make sure to use the correct pressure for current
motor type.
a. Measure the flow from the drainage (T) and port (B).
b. Replace the motor if the flow exceeds the permitted flow from the drainage (T)
and return port (B) according to the table.
12. Move the lever (1) up and down a couple of times to release the pressure in the
hoses.
13. Loosen and remove the hoses carefully, a small pressure can remain in the system.
Plug all connections to secure them from dirt.
MS 80– 140 10
160
MS 200– 110 10
315
MS 400– 70 10
475
3. Install the O-ring (224), guide pins (223), and fitting (9).
2. Lubricate the rotation chuck bushing (221) with pneumatic oil and Install it in the rota-
tion chuck (208).
3. Install the pins (215) and the driver (222) in the rotation chuck (208).
4. Use tool (A2, A3) to press the bushing (212) into the gear housing (201).
5. Install the damper piston seals (230, 231) in accordance with the figure. (A seal kit
consists of an O-ring and a Teflon ring)
! NOTE: The seal lips must be turned in accordance with the figure.
6. Lubricate the O-ring and check that the sealing groove is clean. Bend the O-ring in
accordance with the figure. Bend the Teflon ring as shown in the figure and guide it
into the gear housing (201).
7. Press the Teflon ring into the seal groove using a tool shank for example, so that no
creases remain in the seal after assembly. Otherwise the seals are cut apart during
assembly of the damper piston.
9. Overview of sample measurements to the gear housing (A) and rear seal housing (B).
a. Measure the rear seal housing depth in the gear housing (201).
c. Calculate the difference between the rear seal housing depth (17.23 mm) and
the rear seal housing measure (16.96 mm), add 0.05 mm and round off to the
nearest 0.05 mm increment.
e. Add correct number of shims from the shims set (380-382) to achieve 0.30 mm.
10. Install the shims into the gear housing (201) according to the figure.
11. Install the seal housing (341) using the tool (A5) and a plastic mallet. Make sure that
the seal housing guides in correctly.
12. Install the seal housing (341) using the tool (A5) and a plastic mallet. Make sure that
the seal housing guides in correctly.
13. Lubricate the O-ring and install the sealing groove, bend the O-ring in accordance
with the figure. (A seal kit (342) consists of one O-ring and one Teflon ring)
! NOTE: The seal lips must be turned in accordance with the figure.
14. Bend the Teflon ring as shown in the figure and guide it into the seal housing (341).
Press the Teflon ring into the seal groove using a tool shank for example, so that no
creases remain in the seal after assembly.
15. Lubricate the damper piston (217) with hydraulic oil and install it carefully so that the
seals are not damaged.
16. Install the gear wheel (220) from the front using a plastic mallet, make sure that the
rear bearing aligns correctly.
17. Install gear wheel (218) and plain washer (225) in the gear housing (201).
18. Install shaft (219) by threading an M12 screw (A) into the shaft.
a. Use a plastic mallet and carefully tap on the screw until the shaft end is leveled
to the gear housing (201) surface.
19. Install side bolts (216) in the gear housing (201) by threading the nut (A) onto the side
bolts. Thread the dome nut (4) against the nut (A) and tighten the side bolt by turning
the dome nut.
2. Remove the restriction (307), seal rings (375, 376), guide pin (372), and fittings (10,
11) from the cylinder (301).
3. Remove the front piston guide (334) and O-ring (336) by inserting the piston (330)
and tapping carefully using manual force.
4. Loosen the screws (361) holding the valve covers (360, 364) with seal rings (363).
5. Remove the valve piston liner (365) using manual force. If necessary, carefully tap
with tool A16 and a plastic mallet.
6. Only remove the cylinder liner (331) when replacing the liner. Replace the liner using
a hydraulic press and tool (A4).
7. Wash the cylinder (301) and clean the channels with compressed air.
1. Replace all four side bolts (370) every recondition 1200/2400 hours. Never mix new
and old side bolts.
2. Replace the piston guides (A, C) if they show signs of wear, cavitation, or other dam-
age.
3. When replacing the impact piston (B) both the piston guides must be replaced.
4. Check the impact piston (330) and the valve liner piston (362) for scoring and
scratches as well as the impact surface regarding wear and chipping. Minor scoring
and scratches on the piston can be polished with fine emery cloth.
5. If the cylinder (301), cylinder liner (331) or valve liner (365) show signs of cutting dam-
age or scratches then the parts must be replaced. Minor cutting damage can be pol-
ished with a fine abrasive cloth or honing tool. Only press out the cylinder liner when
the liner is replaced.
2. Lubricate and install the O-ring (336) in the cylinder liner (331).
b. Press in the cylinder liner (331) using tool (A4). Alternatively the liner can be
cooled down in a climate camber or with dry ice and then fitted without pressing.
4. Use tool A16 to install the valve piston liner (365) in the cylinder (301) using manual
force. The right-hand side marking (B), in the end of the liner must align with the
marking (A) on the cylinder (see figure). The notch (C) is intended for the guide pin on
the right-hand cover.
5. Install the valve piston (362). The valve piston is symmetrical and can be turned either
way.
a. Clean guide pin and valve cover (364) with grease solvent.
b. Assemble the guide pin with the strongest locking adhesive, ex. Loctite 270.
7. Install valve covers (360, 364) with new seal rings (363). The guide pin (366) in the
right-hand valve cover (364) must meet the notch in the cylinder liner. The covers
must slide smoothly and cannot not be tapped in.
b. Install and tighten the screws alternately to full torque 200 Nm (148 lbf-ft).
8. Install piston guide (334) using the impact piston (330) as guide.
b. Use tool (A1) to tap the piston guide (334) into place.
c. Remove the impact piston (330) and place the piston where it cannot be
scratched or damaged.
9. Apply Loctite 2700 or Loctite 270 on the threads of the restriction (307).
10. Install the restriction (307), seal rings (375, 376), fittings (10, 11), and the guide pin
(372).
11. Install side bolts (370) in the gear housing (301) by threading the nut (A) and dome
nut (4) onto the side bolts.
Recommended Oil
2. Lubricate the bearing surfaces on the rotation chuck (208) with oil and install it in the
gear housing (201).
4. Apply anti-seize paste on the 4 side bolt threads, dome nuts (4), and the contact sur-
faces of the washers (3).
5. Install washers (3) and the dome nuts (4) on to the side bolts.
6. Tighten the dome nuts alternately to full torque 300 Nm (221 lbf-ft).
3. Install screws (229) through the cover and the gear housing. Check that the screw
heads lock against the groove in the cover.
4. Install a new O-ring (214) on the hydraulic motor (2). Install the hydraulic motor to the
gear housing (201).
5. Apply oil on the 4 hydraulic motor nuts (228). Install and tighten the nuts alternately to
full torque 70 Nm (52 lbf-ft).
Recommended Oil
2. Insert the piston to the cylinder bore. When the piston reaches the front pistons seals,
turn the piston in.
! NOTE: If the piston is tapped in, the piston seals are damaged.
3. Fit the rear piston guide (333), use tool A1, and a plastic mallet to carefully tap the
piston guide in.
4. Check that the impact piston (330) can be moved forward and back with a turning mo-
tion.
6. Fit the back head (310) to the cylinder using the screws (315) be careful not to dam-
age the piston or piston seals.
7. Tighten the back head screws (315) alternately to full torque 60 Nm (44 lbf-ft).
Recommended Oil
2. Apply anti-seize paste on the 2 dome nuts (6) threads and the contact surfaces of the
washers (5).
3. Install washers (5) and the dome nuts (6) on to the front side bolts.
4. Tighten the dome nuts alternately to full torque 500 Nm (369 lbf-ft).
1. Apply oil on the 3 accumulator charging valves (355). Install and tighten to full torque
28 Nm (21 lbf-ft).
5. Install side accumulator cover with screws (354) and the charging valve (355) aimed
backward on the rock drill.
6. Install top accumulator cover with screws (354). The charging valve should be aimed
slightly backward and to the left or right to make space for the lifting eye.
Recommended Oil
A Return Accumulator
B Intake Accumulator
WARNING
Explosion Risk
There is a risk of personal injury or death when using wrong gas.
u Only use dry nitrogen (N2).
1. Check that the gas cylinder (20) contains Nitrogen (N2) gas.
2. Secure the gas cylinder (20) so that it cannot fall over and cause damage.
4. Remove protective nut (18) from the gas cylinder valve and check that the gas cylin-
der valve threads are undamaged and clean.
5. Check that the bottle connection (110) and the o-ring (1) are undamaged and clean.
6. Connect the hose connection (110) to the gas cylinder valve (19) hand tight. Check
that the hose (60) is not twisted or stretched.
9. Open the gas cylinder valve (19) slowly by turning it counterclockwise and check that
the high-pressure gauge (50) shows full pressure reading.
1. Remove the protective cap (B) from the accumulator valve (A).
2. Check that the threads of the accumulator valve (A) are undamaged and clean.
4. Connect the hose connection (130) to the accumulator valve (A) hand tight. Check
that the hose (70) is not twisted or stretched.
b. Intake Accumulator (B) Base Setting RD 14S: 60 bar. Max setting: 70 bar.
c. Intake Accumulator (B) Base Setting RD 18S, RD 22S: 80 bar. Max setting: 90
bar.
4. Open the pressure regulator (140) slowly by turning the knob clockwise while monitor-
ing the manometer (100) until correct filling pressure is achieved.
a. Slowly open the needle valve (40) by turning the knob counterclockwise until cor-
rect pressure is achieved.
7. Close the hose valve (3) by turning it clockwise. When using connection (90) with the
earlier version of accumulator valve, the accumulator valve (16) must be closed.
3. Open needle valve (40) to evacuate the gas, check that the manometers (50) and
(100) drops to 0.
6. Disconnect hose connection (110) from the gas cylinder valve (19).
8. Transport the gas cylinder (20) to the designated location and secure it.
WARNING
Pressurized Systems
Can cause serious injury.
u Never stand in front of the rock drill during the test.
u Only the operator is to be around the rock drill during the test.
Precondition p Accumulators are charged with nitrogen gas according to maintenance instructions.
p Front head including shank adapter must be assembled during this test.
6. Press down and hold the lever (1) to pressurize the rock drill.
7. Turn the flow restrictor (3) slowly clockwise until pressure manometer (2) reaches 50
bar and the piston starts to move.
a. If percussion does not start, gradually increase the pressure up to max 75 bar.
11. Move the lever (1) up and down a couple of times to release the pressure in the
hoses.
12. Carefully loosen and remove the hoses, a small pressure can remain in the system.
Plug all connections to secure them from dirt.
WARNING
Pressurized Systems
Can cause serious injury.
u Never stand in front of the rock drill during the test.
u Only the operator is to be around the rock drill during the test.
6. Press main power switch (E) to start the portable test unit.
8. Turn the flow restrictor (D) slowly clockwise until pressure manometer (C) reaches 40
bar or the rotation starts.
9. Check that the rotation runs smoothly, without noise and external leakage and in the
correct direction. Keep the rotation running for 30 seconds with 40 bar.
12. Move the lever (B) up and down a couple of times to release the pressure in the
hoses.
13. Carefully loosen and remove the hoses, a small pressure can remain in the system.
Plug all connections to secure them from dirt.
3. Check that the runout on the impact piston guide surface is within 0.02 mm.
Norton-3SG60KVX
Tyrolit-454A60K5V3
n Use a grinding disc with ceramic binding agent with grain size 60-80.
The impact piston must be checked for scoring and scratches, and the impact surface re-
garding to wear and chipping.
3. Align the grinding disc carefully against the pistons impact surface.
4. Apply plenty of cooling mixture between the impact surface and the grinding disc.
6. Check that the impact surface is smooth and free of cracks. Max. grinding of impact
surface is 0.50 mm
15.5 Piston
The specified length dimension (see table) is the minimum length measurement for the pis-
ton. Exterior and interior radii must be reset (see table) to make a smooth transition (no
sharp edges). The piston must be washed so all residue from grinding is removed, exam-
ine the impact surface to make sure that it is free of cracks.
Radius B R1 R3 R3
Radius C R2 R2 R2
16 Lubricating
Normal Operat- Min. Start Temp Max. Operating Viscosity Grade Viscosity Index
ing Temp °C °C Temp °C VG VI
Viscosity 25-50 ISO 3448
cSt
! NOTE: In compliance with ISO 4406, the hydraulic fluid must be filtered to the purity
class of 20/18/15.
• Flow losses in the hydraulic lines are increased. The high flow losses amplify energy
consumption and pressure levels, and put increased strain on seals.
• The risk of cavitation increases, which leads to the risk of damage to the rock drill and
hydraulic pumps.
The hydraulic fluid must be changed at regular intervals
Oil viscosity changes during the period that the hydraulic fluid is used. In general, viscosity
will drop with increased operating hours. To ensure that the viscosity of the fluid does not
drop to a critical level before the recommended service interval, a hydraulic fluid of suffi-
cient stability must be used. In compliance with DIN 51350-6, viscosity of suitable hydraulic
fluids shall drop a maximum of 25% when tested at 100 ºC for shear stability.
Factors influencing the interval between changes are:
• Viscous stability of the hydraulic fluid as specified above. The hydraulic fluid must be
changed before the viscosity drops to a critical level.
• Contamination with water. If the hydraulic fluid becomes cloudy and light grey, the wa-
ter content has become such that the hydraulic fluid must be changed.
• Deterioration of properties such as oxidation inhibition and anti-foaming.
-30 to ±0 VG 32-68
The tool oil must have an EP additive which covers the following load-bearing properties:
www.epiroc.com