B 23710 - 3 en 0106 / TL

1 (16)

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance

CONTENTS
1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.

TAKING A NEW ROCK DRILL IN USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2. Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
2
2

3.

HOSE CONNECTIONS

..............................................

4.

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.

REMOVING THE FRONT END WITH THE ROCK DRILL ON A FEED RAIL .
5.1. Replacing the flushing housing seals and the seal housing
guide rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2. Replacing the bearings of the flushing housing . . . . . . . . . . . . . . . . .
5.3. Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4. Rotation bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5. Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6. Rotation bushing bearings inside the gear housing . . . . . . . . . . . . . .
5.7. Wear limits of the shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.

CHECKING AND TIGHTENING BOLTS AND TIE RODS . . . . . . . . . . . . . . . . . .

6.1. Tie rod tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2. Pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3. Flushing housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10
11
11
12

7.

PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2. Field service tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3. Every day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4. Every week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5. Basic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6. After rock drill service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7. Service card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8. Service follow-- up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
13
13
14
14
14
14
15
15

7
8
8
8
9
9
9

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

2 (16)

B 23710 - 3 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
1.

GENERAL

These instructions describe in brief the main maintenance procedures for HLX5 series
hydraulic rock drills.
Service is always ready to help and give advice in all maintenance problems. The qualified
TAMROCK maintenance personnel of your TAMROCK dealer and original TAMROCK
spare parts ensure reliable operation of your drilling equipment.

2.

TAKING A NEW ROCK DRILL IN USE

2.1. Preparations
New rock drills are delivered with the pressure accumulators not
pressurized and the hose connections plugged.
CAUTION

Pressurize the accumulators according to the instructions. See Pressure accumulator

repair instructions.
Before a new rock drill is installed the drilling equipment hydraulic system must be
checked and flushed thoroughly.

2.2. Test run

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

CAUTION

Avoid use of full percussion power if the steel is not against the rock.
This will reduce the breakage of the accumulators diaphragm, the wear
of flushing housing, drilling tools and the cavitation of the percussion
mechanism. This type of idling drilling is the most critical while drilling
upwards or cleaning the holes with pumping motion.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

B 23710 - 3 en 0106 / TL

3 (16)

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
3.

HOSE CONNECTIONS

2
3
5
4
Fig 1.

Hose connections

1. Shank lubrication
2. Percussion mechanism pressure side (H.P.)
3. Percussion mechanism return side (L.P.)
4. Rotation, pressure (H.P.)
5. Rotation, return (L.P.)
6. Flushing

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

4 (16)

B 23710 - 3 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
4.

LUBRICATION SYSTEM

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

1
Grease nipple

Fig 2.

Lubrication scheme: 1 Surface model, 2 UG model

The rotation mechanism and the shank have oil mist lubrication. The lubrication line from
the lubrication unit is connected to end of the rock drill. From there the oil mist is ducted
through piston rear end to the front end of the rock drill where the flow will lubricate the
rotation mechanism, coupling and the bushings of the flushing housing.
Leakage oil from the rear seals of the piston is also ducted to the front end of the rock drill
through a channel.
The oil that has circulated through the rock drill lubrication system is removed through the
shank lubrication collector or can be led via return channels and gear housing to the feed
rail.
Never connect the used oil mist to the hydraulic system return line.
CAUTION

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

B 23710 - 3 en 0106 / TL

5 (16)

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance

1
4
2

3
Air
Fig 3.

Shank lubrication

1. Rock drill
2. SLU 1/2/3
3. Drain valve

4. Filler cap
1. The shank lubrication oil consumption can be adjusted. (See the instruction
manual for SLU 1/2/3).
2. The shank lubrication does not work if the oil level in the receiver does not lower
during drilling. (See the instruction manual for SLU 1/2/3).
3. Drain regularly the water that has collected in the receiver. The draining interval
depends on the local conditions
4. Use only oils according to lubrication recommendation.
5. Refill the receiver regularly.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

6 (16)

B 23710 - 3 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
5.

REMOVING THE FRONT END WITH THE ROCK DRILL ON A

FEED RAIL
When you remove the flushing housing and shank, turn the rock drill to a
horizontal position. The coupling can fall out and cause injury.

WARNING

WARNING

If the shank lubrication is clogged (no air comes from the shank
lubrication return hose), stop the compressor. Before opening the
flushing housing bolts, carefully open the locking screw and let the air
pressure out. Otherwise the air pressure can blow / burst out the flushing
housing and cause injury.

By opening the bolts (4) the flushing housing (1), the shank (2), and the coupling (3) can be
pulled out without removing the rock drill from the feed rail. The lock--screw (5) holds the
rotation bushing (6) in the housing, for example while changing the shank. Check the
condition of the rotation bushing rear end (6) and the bearing (7).

6
3

2
5

1
4

Fig 4.

Dismounting of the flushing housing

E 2006 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

B 23710 - 3 en 0106 / TL

7 (16)

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
5.1. Replacing the flushing housing seals and the seal housing guide
rings
Flushing housing seals (A) 5 pcs and the seal housing guide rings (B) 2 pcs must be
replaced when the flushing air or water escapes from the sides of the seal housing, and
they should be checked whenever the shank is changed. Seals are easier to install when
they are lubricated. Install the new flushing housing seals making sure they face the right
direction (shown in the figure). The use of a spare flushing housing is recommended, as
it speeds up on--site maintenance of the rock drill.
B
1

AIR FLUSHING

B
1

WATER FLUSHING

A
Fig 5.

The flushing housing seals must be installed facing the right direction, determined
by the flushing mode
In addition, a damaged seal plate (1) must be replaced due to risk of
corrosion.

CAUTION

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

8 (16)

B 23710 - 3 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance

5.2. Replacing the bearings of the flushing housing

The bearings must be replaced if the indicator groove is worn off
any place.

5.3. Coupling
Pull the coupling out from the rotation bushing. Check and
replace, if the edges of the inner teeth are worn sharp or visible
cracks are seen.

5.4. Rotation bushing

The rotation bushing must be replaced if the shoulder A is worn

to the same level with the face or damages are observed. Make
sure that also the outer surfaces of the rotation bushing are in
good conditions.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

B 23710 - 3 en 0106 / TL

9 (16)

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance

5.5. Chuck
The chuck inside the rotation bushing must be changed if the
wear is over 1 mm from the original surface B or if there are some
hair cracks.

B
1 mm

5.6. Rotation bushing bearings inside the gear housing

The bearings must be changed if the wear indication--groove has
worn out from any area.

5.7. Wear limits of the shank

max 1 mm

CAUTION

The shank must be changed if the 1 mm bevel of the striking

max 1 mm head is worn out or any other wear limit is exceeded.

When installing a new shank, take care that no dirt enters inside the rock
drill with the shank. Insert the shank carefully through the flushing
housing, so that the flushing device seals are not damaged.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

10 (16)

B 23710 - 3 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
6.

CHECKING AND TIGHTENING BOLTS AND TIE RODS

The most important maintenance task is to check the tightness of the bolts,
particularly the tie rods and mounting bolts. Loose tie rods cause rapid wear of the
body section faces, shortening the service life of the rock drill.
Following procedure is recommended for checking the bolt tightness during
normal maintenance:
1. Check the tightness of each bolt by using 10 % higher torque than specified
and the correct tightening order.
2. The joint being tested is loose if the wrench turns. In this case loosen all the
bolts being tested and retighten with the correct order.
3. If the threads are not clean the bolts cannot be tightened correctly. In such
cases the bolt must be removed, the threads checked, cleaned, and
lubricated with grease.
Use only an inspected, high---quality torque wrench.
CAUTION

2
3

2
1
Fig 6.

Rock drill bolts

1. Tie rod bolts

2. Pressure accumulator bolts
3. Flushing housing bolts

6 pcs
4+4 pcs
4 pcs
E 2006 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

B 23710 - 3 en 0106 / TL

11 (16)

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
6.1. Tie rod tightening
The tools required:
-- torque wrench
-- 24 mm ring end
1. Lubricate the threads and the nut faces with grease.
2. Pretighten to 200 Nm (20 kpm). Correct tightening order is (1--2--3--4--5--6)
3. Final tightening torque is 400 Nm (40 kpm). Same tightening order
(1--2--3--4--5--6) should be used.

Fig 7.

Tie rods; tightening order

6.2. Pressure accumulators

The tools required:
-- torque wrench
-- 24 mm socket
1. Lubricate the bolt threads with grease.
2. Pretighten all four bolts to 100 Nm (10 kpm). Correct tightening order is 1--2--3--4.
3. Final tightening torque is 200 Nm (20 kpm). Same tightening order (1--2--3--4)
should be used.

Fig 8.

Pressure accumulator bolts tightening order

E 2006 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

12 (16)

B 23710 - 3 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
6.3. Flushing housing bolts
The tools required:
-- torque wrench
-- 24 mm ring end
1. Lubricate the bolt threads with grease.
2. Pretighten all four bolts to 200 Nm (20 kpm). Correct tightening order is (1--2--3--4).
3. Final tightening torque is 400 Nm (40 kpm). Same tightening order (1--2--3--4)
should be used.

1
3

4
2
Fig 9.

Flushing housing bolts

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

B 23710 - 3 en 0106 / TL

13 (16)

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
7.

PERIODIC MAINTENANCE

7.1. General
The idea of periodic maintenance is that the rock drill is serviced before any breakdown
occurs. This way expensive additional damages and unwanted production interruption
can be avoided.
The maintenance interval is 500 percussion hours, but depends on the local conditions,
and it must therefore be determined according to this experience.
Searching for the correct maintenance interval, it is advisable to start the periodic
maintenance as specified, and then lengthen the intervals until a period that suits the local
conditions has been found.
In addition the rock drill should always be taken in for service when the operator reports
of a fault on the rock drill that can cause major damage or a production interruption.

7.2. Field service tools

1.
2.
3.
4.
5.
6.
7.

Torque wrench
24 mm socket
24 mm ring end
19 mm wrench
Extension
Accumulator low pressure gauge
Accumulator high pressure gauge

4
7
3

Fig 10. Maintenance tools

Make sure that you have also the flushing seals, gaskets and the shank adapter for the
rock drill maintenance.
E 2006 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120

14 (16)

B 23710 - 3 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
7.3. Every day
1.
2.
3.
4.

Check the flushing housing for water and air leaks.

Check the flushing housing bolt tightness.
Check for possible oil leaks.
Check the condition of the hoses and fittings.

7.4. Every week

1.
2.

Check the hour meter reading.

Check the accumulator filling valves and their protective caps and the accumulator
bolt tightness.
3. Check the accumulator pressures
-- High pressure . . . . . 50 bar
-- Low pressure . . . . . . 4 bar
4. Check the condition of the shank, chuck, flushing housing, coupling, shank
bushing and the rotation bushing.
5. Check the tie rod tightness. If loose, tighten them up, according ch. 6.1.

7.5. Basic maintenance

Rock drill basic maintenance is recommended every 500 operating hours, Cf. Repair
Instructions. This maintenance interval can be adjusted according to local conditions and
experiences which are accumulated to the rock drill maintenance history. Do planned and
preventive maintenance rather than repairs after damages.
Monitor percussion hour meter reading and/or drilled meters/shifts between each
maintenance. Fill in the service card of the rock drill.

7.6. After rock drill service

After the rock drill service the reassembled parts will settle down to their proper position
during drilling under normal drilling loads. Especially if the parts have worn surfaces it may
result that the tie rods and the mounting bolts do not keep their tightness. Therefore a
re--tightening of these bolts is required after each rock drill service or if the rock drill has
been removed and remounted on the feed rail.
After the rock drill service and 1 round / 100--300 meters drilling:
1. re--tighten the rock drill mounting bolts on the feed rail
2. re--tighten the rock drill tie rods and flushing device bolts

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

B 23710 - 3 en 0106 / TL

15 (16)

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance
7.7. Service card
Each rock drill has its own service cards. When a rock drill is taken up for maintenance,
all the earlier cards should be at hand. All relevant information about the maintenance
must be written down on the card. When the rock drill is again taken into use, the next
maintenance date should be written down on the card. Benefits of the card are:
-- Wear of every specific component of each rock drill is clearly displayed, and by
comparing the cards the effect of different circumstances and measures can be
determined.
-- The cards help in determining maintenance required to prevent major damage.
-- Properly filled cards show the complete maintenance history of the rock drill.
-- The cards help to determine the point when the rock drill should be scrapped.
-- Use service card presented on the next page.

7.8. Service follow--up

In order to follow the maintenance of a rock drill, a maintenance card presented on the
next page can be used.

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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

16 (16)

B 23710 - 3 en 0106 / TL

HYDRAULIC ROCK DRILL HLX5

Operation and Maintenance

ROCK DRILL SERVICE CARD No

Equipment
Rock drill

S/n
S/n

Since previous service percusion hours

drill. shifts/rounds
drilled meters

SERVICE INFORMATION
Purpose of the service

Serviceman

Arr.date

Prev.service

Dep.date

Prev.service card No

Prev.perc.hours

Working
hours
Rep.

Dism.

Insp.

Ass.

Total

REPLACED PARTS/ PART INSPECTION

Qty

Part No

Description

Repaired
/ Batch

Replaced
/ Batch

OK

Remarks

Piston
Pilot cylinder
Front bushing
Rear bushing
Distributor
LP accumulator
HP accumulator
Spacer
Gear housing
Rotation bushing
Rot.bush.bearing
Chuck
Connecting piece
Rotation motor
Rotation shaft
Rot. shaft bearings
Front cover/ body
Flus. seal housing
Shank bearings

Remarks

Percussion
mechanism tested

Rotation
mechanism tested

E 2006 SANDVIK TAMROCK CORP., Tampere Plant

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