USA 0805 / PIR , a, ee RANGER Rock Pilot 700 oeAN < : Technical manual 106T10581-1 INFORMATION 1 B00112-2GB 0405 _ Safety instructions B.00300-1GB0198 Technical tables; Measurement conversions and tightening torques ' ROCK DRILL poms 2 D 20105-1 en 0904 Hydraulic rock drill HL 700, HL 710, HL 7008, HL 7108; Lifting instructions , B22310-1 en 0304. HL710, HL710.S; Operation and maintenance 1D 22310-3en 0604 HL710, HL710 S; Repair instructions D 28160-8 en 0905 = Pressure accumulator for hydraulic rock drill; i Repair instructions I D 28400-2 GB0997 Hydraulic motors OMT, OMSU i ©.00640-1 en 0198 Rock drill service card FEED atl 3 ©.31360-4 en 0904 Chain feed CF 145 H + RH 714 ! ROD HANDLER = 4 t (© 35700-6 en 0406 Rod handler RH 714; Ranger, Scout t S == | = BOOM a) C.45660-8 en 1204 Boom DB 800; Ranger, Scout ©47150-3 on 0205 Hydraulic cylinders; Repair and‘€gjustment CRAWLER BASE Sik, 6 © 13951-1 en 0306 Crawler base, Ranger Rock Pilot 500, 680, 700, 780 | © 16300-1 GB 0198 Final drive V 16320-1 en 0198 Driving motor A10VEC; Repair instructionsUSA 0606 /PIR RANGER Rock Pilot 700 7) Pm ‘ o Technical manual oe 106T10581-1 DRILLING HYDRAULICS Ru 7 C 52931-5 en 1205 THC 700 Rock Pilot; Testing and adjusting B57200-2GB0197 Variable Displacement Pump V 57220-2 en 0602 Variable Displacement Pump A10VSO B58200-1GB0198 Symbols for hydraulic and pneumatic equipment HyGraulic and pneumatic circuit diagrams SOMPRESSOR AND AIR CIRCUIT @S 8 iC 62955-2 en 0804 Air end and pneumatic circuit; Ranger, Scout 'B 63250-8 en 1102 Shank lubrication unit SLU 1/2/3 —~——V 64450-2 en 0106 Tamrotor Enduro 25 G; Repair Instructions ELECTRIC SYSTEM yy 92 B 75500-5 en 0702 Electrical drawings; Reading and symbols | Electric diagram i DUST COLLECTOR g 40 ~~" #7470-1 en 0505 Dust Collector DC 800 H; Maintenance oo MEASURING SYSTEM 1 84050-1 GB 1097 P & Q Angle indicator; Maintenance and troubleshooting OTHER COMPONENTS 12 B85400-1GB0198 Air Conditioner; Operation and maintenance (R134a) ©.81080-1 en 1200 Rod greasing device; Operation and maintenance B 86210-3.en0404 Flushing control automatics; Operation and maintenance 1B 65850-2en 1105 — DustMizer; Operation and use __B.86500-4 en 1105 Water heater; Operating instructions8 00t12-2.6B 0408/7 SAFETY INSTRUCTIONS IN MAINTENANCE MANUAL MAINTENANCE MANUAL ee if TDAIMTROCIES® SANOVIK TANROCK OY SROUSSESMTRMPERE INLAND. NAME, RANGER. TYPE 700 SERIAL _106110581-1 ID-CODE _ 550.778 21 YEAR OF CONSTRUCTION 2006 ENGINE POWER 151 kW [ELECTRIC POWER _V/_Ha/_kW TOTAL WEIGHT 14 800 kg INORMAL HOOK LOAD OF WINCH/TOWING HOOK 7OkN i ph When there is a need for an operator or helper to work on the rig in the wo! area or danger zone and this involves activation of one or several machine functions such work shall only be done under the following conditions: _ there shall always be two people present, both being fully instructed on the safety issues. One of them shall supervise, from the main operator's position, the safety of the service man doing the work. — the supervisor shall have immediate access to an emergency stop in all situations. the area where the service work is to be carried out shall be properly illuminated. ~ communication between the service man and supervisor at the main operator's position shall be established in a reliable manner. — only when the drill rig is shut down completely and the means of starting are isolated is a person allowed to perform repair and maintenance work alone on the drill rig. Cee ROCK CORP, Tampere Plant—2 “a19) TECNICAL TABLES surement conversions and tightening torques ‘8 00300-1 GB 0198 / ROV Mea:TECHNICAL TABLES Measurement conversions and tightening torques 1, 1. TIGHTENING TORQUES FOR BOLTS AND NUTS j The table bellow shows tightening torque for the bolts and nuts, (Don't exceed the given values.) [wanna] Strenght of bolt Thread 88 10.9 12.9 Me 10Nm 13.Nm 16Nm me 25 33 40 mio 50 66 80 m2 85 110 140 Mia 120 180 210 m6 200 Nm 280 Nm 330 Nm mie 280 380 460 20 400 540 650 ze 530 740 880 M24 670 940 1130 M27 1000 Nm 1400 Nm 1650 Nm M30 1330 1800 2200 Mss 1780 2450 3000 M36 2300 3200 3850 M39 3000 4200 5050 Maz 3700 5200 6250 ~ values above are for bolts and nuts which have metric ISO ~ thread i Aways use the good qu: [wanna] “THANINETTRO CIE tools to avoid personal injuries. (© 1988, TAMROCK CORP, Tampere Plant, Service PO-ox 100 FIN-3311 TAMPERE, Friand Tel 1358 208 44 121, Yolen 22385 patts Tole +388 205 44 477113 00900- 1 G5 0198 / FOV 30) TECNICAL TABLES Measurement conversions and tightening torques 2, METRIC MEASUREMENT CONVERSIONS Symbol When Yuo [Multiply By To Find Symbol Know LENGHT in inch 2,54 centimeter om in inch 25,4 millimeter mm ft foot 30,48 centimeter cm tt foot 0,3048 meter m mm millimeter 0,04 inch in om centimeter 04 inch in m meter 3,28 foot tt AREA ine square inch |645,16 square millim. mm? 2 square foot __|0,0929 square meter__m2 MASS Ib pound 0,454 kilogram kg kg kilogram 2,203 pound b RESSURE psi pound/sq.in. |0,069 bar bar psi pound/sq.in _|0,0069 mega pascal MPa(N/mm?) bar bar 145 pound/sqin. psi TORQUE fulbs foot pound 1,356 Newton-meter Nm Nm Newton-meter |0,737 foot pound ——ft.lbs KNm kiloNewton-m. |737 foot pound _ft.lbs VOLUME gal gallon (US) |3,79 liter 1 1 liter 0,26 gallon (US) gal ins cubic inch 16387 cubic millim. mms ft cubic foot 0,02832 cubic meter m3 FLOW gal (usy/min 3,79 liter/min Vein Vmin liter/min 0,29 gal (US)/min FORCE N Newton 0.2245 pound b kN kiloNewton __|224,5 pound Ib aer ae ee t so papomsce12% HL 710, HL 710S Operation and maintenance 8.223101 on 0904 / JTAL 710, HL 710S Operation and maintenance CONTENTS 1. GENERAL . 3 2. TAKING A NEW ROCK DRILL INTO USE 3 2.4. Preparations . 3 2.2. Mounting , 3 2.3. Test run. 4 3. HOSE CONNECTIONS 4 4. LUBRICATION SYSTEM ... 5 4.1. Lubrication system, underground model . 6 4.2. Lubrication system, surface model . 7 5. FLUSHING . 10 6. INSPECTION AND MAINTENANCE OF FRONT END WITH ROCK DRILL IN CARRIAGE "1 6.1. Assembly directions of seals and bearing bushing . 12 6.2. Changing the bearing of the flushing housing 12 6.3. Assembling the flushing housing 13 6.4. Coupling. 13 65. 13 66. 14, 67. 14 6.8. Chuck and lock ring pair 14 6.8. Wear limits of shank .. 14 7. CHECKING AND TIGHTENING BOLTS AND TIE RODS. 15 7.1. Tie rod tightening .... 16 . Pressure accumulator bolts . 7 Idle gear shaft . 17 Assembly of rotation motor . 18 Rotation motor bolts 18 Flushing device bolts . 19 8. PERIODIC MAINTENANCE . 19 8.1, General 19 20 be 20 8.4, Every week . 24 8.5. Basic maintenance at a. 21 8.7. Service card at 8.8, Service follow-up . at (© 2004 SANOVIK TAMAOGK CORP, Tampere Plant =e AN CK =< Telefax +288 205 40'1203.22910- 1 n 0804 / JT 32) HL 710, HL 710S Operation and maintenance 41. GENERAL These instructions describe in brief the main maintenance procedures for HL710 series hydraulic rock dls. Jamrock Service is always ready to help and give advice in all maintenance problems. The qualified maintenance personnel of your Tamrock dealer and original Tamrock spare parts ensure reliable operation of your drilling equipment. 2. TAKING A NEW ROCK DRILL INTO USE 2.1. Preparations New rock drills are delivered with the pressure accumulators not pressurized and the hose connections plugged. [_ruomo | 4. Pressurize the accumulators according to the instructions. See “Pressure accumulator reparation instructions”. 2. Before a new rock drillis installed the drilling equipment hydraulic system must be checked and flushed thoroughly. 2.2. Mounting The rock drill is mounted on the carriage with four pairs of bolts. In order to avoid damage it is important to follow the tightening order; | : ay | | ih | | l B A c | Fig 1. Mounting to carrier Put the drill and carriage mounting faces first slightly together. (no clearance between drill and carriage ) 1. Retighten bolts A to 300 Nm. 2. Retighten bolts B and C to 300 Nm. 3, Tighten bolts A to 600 Nm. 4, Tighten bolts B and C to 600 Nm. When replacing bolts, loosen all bolts and ri correct order.AL 710, HL 710S Operation and maintenance se 2.3, Test run Test run the rock drill and make sure that it operates properly before starting production drilling. Check during test run = shank lubrication - pressures and temperatures - flushing - possible oil leakages Avoid use of full percussion power if the steel is not against the rock. This will reduce the breakage of the accumulator diagrams, the wear of flushing housing 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. 3. HOSE CONNECTIONS Fig 2. Hose connections 1. Shank lubrication 6. Rotation, case drain line 2. Percussion mechanism pressure side (H.P.) 7. Rotation, return (L.P.) 3. Percussion mechanism return side (LP) (@8 8. Rotation, pressure (H.P) mm) 4. Flushing 5. Shank lubrication collector (© 2004 SANDVIK TAMAOCK CORP, Tampere Plant i TANUROGE “Faire Telefax +988 205 44 120B22910- 1 on 0908 / JT 52) HL 710, HL 710S Operation and maintenance 4, LUBRICATION SYSTEM ‘The rock drill percussion mechanism andthe rotation motor are lubricated by the hydraulic il flowing through them. ‘The rotation mechanism and the shank have oll mist lubrication. The lubrication line from the central oiler is connected to the spacer of the rock drill (Fig. 2, connection 1). From there the oil mist is ducted to the front end of the rock drill where the flow will lubricate the stabilizer pins, rotation mechanism, coupling and the bushing of the flushing housing. In the UG- version (fig. 3) the continue lubrication airflow is conducted out via the canal (3), to the drain hole. Inthe SF-version (fig. 4) the excess oil is conducted out via the canal (2), tothe drain hole. (4) Don't let the rear cover go in the water pond when the lubrication is off. CAUTION The oil that has circulated through the rock drill lubrication system is removed through the shank lubrication collector (5) fig. 2. The used oil can be led with a hose into a container. peal Never connect the used oil mist to the hydraulic system’s return line.0, HL 710S Operation and maintenance Ee 4.1. Lubrication system, underground model Fig 3. Lubrication system; underground model, HL 710 S 2004 SANDVIK TAMROGK CORP, Tampere Pant © Po.ox 100 FIN-38311 TAMPERE, Finland Tel 1358 205 44 121, “Telefax +358 205: 4412022910-1 en 0804 / JT 7122) HL 710, HL 710S Operation and maintenance 4.2. Lubrication system, surface model Fig 4. Lubrication system; surface model, HL 710AL 710, HL 7108 Operation and maintenance Fig 5. Shank lubrication (Surface - model) 1. Rock drill 8. Drain valve 2 SLU 1/23 4. Filling cap 1. The oil consumption of the shank lub is adjustable, * 2. Ifthe oil level don't decrease during drilling. * 3. Drain regularly the water that has collected in the oiler. The draining interval depends on the local conditions. 4. Only use oil mentioned in the oil recommendation instructions, 5. Refill the SLU 1/2/3 oiler regularly * Please refer to the SLU 1/2/3 instructions ~ TAIMIROCHK “Esivem Telefax =356 205 44 12022310-1 en 0908 / JT 9 (22) HL 710, HL 710S Operation and maintenance 2 X 5 Fig 6. Shank lubrication (Underground - mode!) 4. lock drill 5. Connection nipple 2. Oller 6. Sight glass 3. Drain valve 7. Reguiating valve 4. Filing cap 4. The shank lubrication oil consumption should be adjusted to min. 400 grams an hour per drill or more depending on the hole diameter and other local conditions. Check the function of the shank lubrication by looking at the sight glass of the oiler and check with hand that the oil is coming to the shank lubrication nipple. 2. -If the oil level in the oiler does not lower during drilling, the reason may be that = the regulating valve (7) is blocked up. = the compressor’s oil separation does not function . The compressor oi flows with air in to the oiler. — the oil is too thick for the temperature. = In each of the above-mentioned cases the fault should be remedied without delay. 3. Drain regularly the water that has collected in the oiler. The draining interval depends on the local conditions. Only the oils mentioned in the oil recommendation are allowed. Refill the oiler regularly. 6. If compressed air is taken from the mine's air supply network or the drill rig’s compressor does not have a water separator, the compressed-air line should be fitted with such a separator. osAL 710, HL 710S Operation and maintenance pes 5. FLUSHING Fig 7. Rock drill with water flushing (underground drilling) Flushing housing Water pressure gauge Pilot-controlled flushing valve. Drain holes for seal leakages for underground version. 5. Drain holes for seal leakages for surface version. The structure of the air- and water flushed rock drills are, except for the flushing housings, identical. SOs ‘The most common reason for seal damages is water. The water can get into the rock drill from outside the flushing housing, if the rock drill is in a vertical position, and the flushing is off. The water can also get in with the flushing air, ifthe water hasn't been drained regularely. The water in the front end of the rock drill can cause cavitation corrosion in parts of the body and the piston located near the piston seal and the wiper ring. To prevent water from getting in to the flushing housing is to immediately replace the seals if there’s any water coming out from the drain holes. This is also why you should not leave the rock drill facing upwards on drilling breaks. If this isn’t possible, blow the flushing housing dry before taking a break. (© 2004 SANDVIK TAMROCK CORP, Tampere Plant TARUROGIE Eafe Telefax +356 205 46 1208.22310 - 1 en 0908 / JT 11 (22) HL 710, HL 710S Operation and maintenance 6. INSPECTION AND MAINTENANCE OF FRONT END WITH ROCK DRILL IN CARRIAGE as possible in a horizontal position. This way you eliminate that the In order to replace the shank, the rock drill has to b ted as much /\ rotation bushing and coupling won't drop. lubrication) turn off the motor, slowly let the pressurized air escape via the locking bolt before loosening the bolts of the (aaa) flushing housing. Otherwise the flushing housing can burst out due to the pressure and cause damages. i If the lubrication clogges up, (no air coming from the shank You can also detach the flushing housing without having to remove the rock drill from the carriage by opening the bolts (1) andthe nuts. The coupling and the shank will also detach, 28 well as the rotation bushing and the chuck opening the lock bolt (2). Always check these items when replacing the shank. f Fig 8. Dismantle of flushing housing ‘Always check the condition of the rotation bushing and the chuck when replacing the shank. CAUTION Use the shank when removing the lock washers (1). Remove the cover (8) and the connector flange (2) before removing the seal housing. f - 4 | | + + | s J mantle of tube-version flushing housingAL 710, HL 710S Operation and maintenance 6.1. Assembly directions of seals and bearing bushing The seals are the most delicate and important parts of the rock drill. Always replace all of the o-rings and the seals when dissembling the the rock drill. a) Drainholes > Drainholes ] (aE A : Pane \ x ( { + 5 : t 2 \B) - | = pearl —t—| 1 HEE OOe) Fig 10. Assembly directions of seals and bearing bushing Assemble the seals (1, 2 and 3) either according to A (water flushing and water mist flushing), or B (air flushing). Replace the flushing house seals and assemble the bearing bushing (1) correctly, accordingly to fig 10. 6.2, Changing the bearing of the flushing housing ‘The bearing must be changed if the wear indication-groove has worn out (see picture). Open the front cover and press out the bearing by using a hydraulic press and the special tools’ punches. (© 2004 SANDVIK TAMAOOK CORP, Tampere Plant Rae TRAN, oc Spans rae glare Toietax +886 205 44 120(8.22310 - 1 en 0904 / JT 1322) HL 710, HL 710S Operation and maintenance 6.3. Assembling the flushing housing Lubricate the o-ring with vaseline before assembly. [eaurion ] Place the connector flanges’ holes of the flushing housing and the seal housing in line and press the flushing housing in. Assemble the conneotor flange and the front cover. Check the seals. Tube flushing housing ‘Assemble the shank and the lock washers into the flushing housing. Turn the shank in a vertical position, and hit the lock washers in with the help of the shank. | A 0H Fig 11. Assembly of the tube flushing housing lock rings. 6.4. Coupling Pull the coupling out from the rotation bushing. Check and re- place, if the edges of the inner teeth are worn sharp. 6.5. Rotation bushing ry ® Check the teeth and the bearing surface for wear.AL 710, HL 710S Operation and maintenance bs 6.6. Chuck “|The chuck inside the rotation bushing must be replaced if the sur- face has worn down 1 mm (see picture), it has oracks or if the shoulder has worn down to the surface. Use a hydraulic press and @ appropriate punch for the job. 6.7. Front bearing of gear housing The bearing must be changed if the wear indicating grooves have worn out as shown in the picture. Remove the bearing by using punch and hydraulic press. ‘Must be changed if the pair depression is 1 mm /if there are cracks on the surface or chuck’s shoulder is worn down in the surface. 6.9. Wear limits of shank maxim maximn |The shank must be changed if the 2 mm bevel of the striking — head or 1 mm of the splines is worn out or any other wear limit is — exceeded. —=1 (i Manufacture, 2 me Reject imm When installing a new shank, take care that no dirt enters inside the rock drill with the shank. Insert the shank carefully through the flushing device, so that the flushing device seals are not damaged. (CAUTION (© 2004 SANDVIK TAMROCK CORP, Tampere Pian! P.0.B0x 109 FIN-38311 TAMPERE, Firtans Tel 43585 205 48 123, “Telefax «366-205 44 120B22910- 1 en 090 / JT 152) HL 710, HL 710S Operation and maintenance 7. CHECKING AND TIGHTENING BOLTS AND TIE RODS Perhaps 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 Ifthe threads are not clean the bolts cannot be tightened correctly. In such cases the bolt must be removed, and the threads checked, cleaned, and lubricated with grease. Following procedure is recommended for checking the bolt tightness during normal maintenance: check the tightness each bolt by using 10% higher torque than specified. — the joint being tested is loose if the wrench turns. In this case loosen all the bolts being tested and retighten in the correct order. (2 ‘CAUTION Use only an inspected, high-quality torque wrench. Fig 12. Rock drill bolts 1. Tie rods 5. Idle gear shaft bolts 2. Pressure accumulator bolts 6. Connecting piece bolts and front cover bolts 3. Rotation motor bolts 7. Rear cover bolts 4, Flushing device bolts Circleo means that new lock washer pair must be used for locking after [Pal every opening of the bolts. f CAUTIONAL 710, HL 710S Operation and maintenance es 7.1. Tie rod tightening The tools required: - torque wrench 24 mm socket Lubricate the threads and the nut faces with grease. . Tighten first slightly the rear nuts (A) to bottom. Pre-tighten the front nuts (B) to 200 Nm (20 kpm). Correct tightening order is 1-2-3-4, Final tightening torque is 400 Nm (40 kpm). Same tightening order (1-2-3-4) should be used. epost > (200 Nm) 400 Nm Fig 13. Tie rod tightening 2004 SANDVIK TAMROCK CORP, Tampere Pant - RE TANOROCHE “fete Telefax +356 205 44 120p.20105 - 1 en 0904 / JT 1m HYDRAULIC ROCK DRILL HL 700, HL 710, HL 700 S, HL710S LIFTING INSTRUCTIONS » RK CORRECT INCORRECT HL 700, HL 710 HL 710 Power Extractor HL 700 S, HL710S ...-..2e005OQ OQ2210-1 en 0904 / JT 1709 HL 710, HL 710S Operation and maintenance 7.2. Pressure accumulator bolts Required tools: = torque wrench - 24mm socket 4. Lubricate the threads and the nut faces with grease 2. Pre-tighten 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. 7.3. Idle gear shaft Required tools: 1. torque wrench 24 mm socket Lubricate the threads and the nut faces with grease Install the washers and the bolts. Pre-tighten the bolts to 100 Nm (10 kpm). Final tightening torque is 200 Nm (20 kpm). Fig 14, Washers and bolts (5)AL 710, HL 710S Operation and maintenance jit 7.4. Assembly of rotation motor etach the flushing housing (1) and the gear housing before assembling he motor. 7.5. Rotation motor bolts Required tools: = torque wrench 24 mm socket 1. Lubricate the threads and the nut faces with grease 2. Pre-tighten all four bolts to 100 Nm (10 kpm). Correct tightening order is 1-2-3-4, 3. Final tightening torque is 150 Nm (15 kpm). Same tightening order (1~ should be used. Fig 15. Rotation motor bolts 2004 SANDVIK TAMMROCK CORP, Tampere Pint POBon 1 - ; TAMIROGI “Salve “ele 386-205 44 120B22310-1 on 008 / JT 19 (22) HL 710, HL 710S Operation and maintenance 7.6. Flushing device bolts The tools required: - torque wrench 36 mm socket Lubricate the bolt and nut threads with grease. Pre-tighten all four bolts to 300 Nm (80 kpm). Correct tightening order is 1-2-3-4. Final tightening torque is 600 Nm (60 kpm). Same tightening order (1 -2-3-4) should be used. eps Fig 16. Flushing device (4) tightening order 30° [Alternative for tightening flushing device bolts: Pre-tighten up to 200 Nm and then turn 30° more , see picture. 8. PERIODIC MAINTENANCE 8.1. General The idea of periodic maintenance is that the rock drill is serviced before any breakdown occurs. This way expensive additional damages and unwanted stops can be avoided. ‘The maintenance intervals are different depending on the local conditions, and they must therefore be determined according to the experience. Searching for the correct maintenance interval, it is advisable to start the periodic maintenance as specified, and then lengthen the intervals until a period that suits the local conditions has been found. In addition the rock drill should always be taken in for service when the operator reports of a fault that can result in major damage or a production stop.AL 710, HL 710S Operation and maintenance 8.2. Maintenance tools- and parts Ensure that the operator has on the rig proper tools and parts for daily and weekly maintenance tasks. The rock drill tool set includes torque wrench and sockets. Due to tight dimensions a socket and wrench adapter is required for tightening the rock drill front and rear mounting bolts on the carriage. AL A Fig 17. Maintenance tools Other rock drill parts which are to be available at the rig for maintenance are flushing device gasket, flushing seals and shank adapter. 8.3. Daily, after work shift 1. Check flushing device boit tightness. 2. Check seal tightness during drilling by observing the check holes (1) and (3), Fig. 3 2 Check possible oil leaks Check hoses and connections 5. Check the mounting of the rock drill to the carriage. If it is not tight, loosen up the mounting bolts. After that fasten up the bolts with right order (Section 2). Also check the retighten the tie rods always when the rock drill mounting to the. carriage has required retightening. p ‘© 2004 SANDVIK TAMROCK CORP, Tampere Pint POBox 100 OGES FIN-22611 TAMPERE, Fnand ‘els008 208 a0 121 ‘Telefax «356 205 40 120sic [ono aernm ODIRCHE DA INDICARE SULL'OROINE: 1) CODIFICA DEL MOTORE COME INDICATA SULLA TARGHETTA 2) NUMERO DI MATRICOLA (PUNZONATO SUL COPERCHIO DISTRIBUTORE ) 3) DESCRIZIONE DELLA PARTE 4) NUMERO DI CODICE DELLA PARTE 0 BE SHOWN ON ALL ORDERS: 1) COMPLETE MOTOR CODE AS SHOWN ON THE NAMEPLATE 2) MOTOR SERIAL NUMBER (PUNCHED ON THE ROTARY VALVE HOUSING) 3) PART DESCRIPTION 4) PART DRAWING NUMBER VoINVNIGOTIO INOZTY, Weal | OOF Wan “TSHE¥L_301009 Or Va OOINDAL” 301009 67159 “SiC a8229101 en 0804 / JT 21 (22) HL 710, HL 710S Operation and maintenance 8.4. Every week Check hour meter reading. Check accumulator filling valves and their protective caps and the accumulator bolt tightness. Check accumulator pressures. Check rotation motor and rear cover bolts tightness. Check idler gear shaft bolts for tightness. Check condition of shank, chuck, flushing housing, coupling, shank and rotation bushing. 7. Check tie rod tightness. If they are not tight, loosen up the middle pair of mounting bolts. After that fasten up the tie rods with right fastening order (Section 7.1) and then fasten the middle pair of mounting bolts. po 2aae 8.5. Basic maintenance Check percussion hour meter gauge. Rock drill basic maintenance is recommended ‘every 500 operating hours, Cf. “Repair Instructions”. Fill out the service card. 8.6. After rock drill service After rock drill service the reassembled parts will settle down to their proper position during drilling under normal drilling loads. Especially when parts have worn surfaces it may result that the tie rods and mounting bolts do not keep their tightness. Therefore retightening of bolts is required shortly after each rock drill service or if the rock drill has been off from the feed. 8.7. 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; Wear of every specific component of each rock drillis 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. 8.8. Service follow-up In order to follow the maintenance of a rock drill, a maintenance card presented below can be used.AL 710, HL 710S Operation and maintenance a ROCK DRILL SERVICE CARD No Equipment__________ s/n Rock dri! 0 Sfp Since previous service percusion hours drill. shifts/rounds drilled meters ‘SERVICE INFORMATION Purpose ofthe service Serviceman a reasenice reuparahours Worn a date Pr Prevpera Perna P aE Dep date Preuseres Gard No Fp. Toad REPLACED PARTS) PART INSPECTION Rapared _‘Repiaces eke” eae ay | Pano Descristion Remaris Piston Front cylinder Fron bushing Rear oyinder Rear bushing Distributor LP accumulator HP accumulator ‘Spacer Geer housing Rotation bushing ot. bush bearing (Chuck ‘Connecting piece olation motor Rotation shat Rot shaft bearings Front cover body Flos, seal housing ‘Shank bearings Idle gear ole gear bearing tole gear Din OOOO gO O00) 00/0/00 )/0\0/O/OO0/0/0 QO) 9/0 /0)0}0)Q)0;0)0I0/0|0)0)O/0}0/0%8 OOOO Ooo 0/O 0) 0/O/0/0/0\o/o}ooO|o}¢ sansa Fea ees enw C) GO 4 SANDVIK TAUROCK COFP. 7 ~AMTROCK “Sie ae oe228103 en 0608 / JT 102 HL 710, HL 710S Repair instructionsRepair instructions pte ‘© 2004 SANDVIK TAMROCK CORP, Tampere Plant 100 “TDANINTI RRO)CIAS Bh MNP re Te “Telefax +358 205 48 1200.22310 -3 en 0604 / ST 302 HL 710, HL 710S Repair instructions SS CONTENTS 1, GENERAL 2. REPAIR INSTRUCTIONS 3, TOOLS . 4 5. e 5.1. Disassembly of the front end . 12 5.2. Removal of the pressure accumulators .. 12 5.3, Hydraulic motor ... 13 5.4, Removal of the percus: 15 5.5. Percussion mechanism .. 16 5.6. Body cylinder 17 5.7. Disassembly and assembly of the spacer bearing and seal housing . 18 5.8. Disassembly and assembly of the gear housing . 20 6. ASSEMBLY .... ae 23 6.1. Assembly of the idler gear and the spacer 23 6.2. Assembly of the front cylinder and the body cylinder . 24 6.3. Tightening the tie rods . 25 . Percussion mechanism 26 Rear cover . 26 6.6. Assembly of hydraulic motor 27 6.7. Assembly of the pressure accumulators 28 6.8. Assembly of the front end 29 7. WEAR LIMITS .. 31 8. TESTRUN... 32AL 710, HL 7105 Repair instructions 1 4. GENERAL These instructions are intended for persons who have to service and repair the 710-series hydraulic rock drills. Familiarize yourself thoroughly with these instructions and utilize the information contained therein when dismantling, assembling and servicing the drill, Always use a crane when tilting the rock frill in the assembly stand. 2, REPAIR INSTRUCTIONS Follow the instructions of the periodic maintenance chart. Properly arranged advance maintenance helps to achieve maximum machine availability. Change worn parts for new ones in time to avoid more serious damage. Check the cleanness of the parts carefully before the assembly; new paris, too, may be dirty (a bottle brush is a useful aid for the cleaning of the dril’s cylinder parts). The use of pirate components (components other than original spare parts) has been found to increase costs in nearly all cases. The warranty of the entire system will terminate immediately if any one of the parts is found to have been replaced with a pirate component. Checking of the tie rods’ tightness is one of the most important maintenance measures to be done to the drill. Neglect of this measure can lead to rapid wear of the face surfaces between the body parts. Good functioning of the drill depends very much on the place where it is repaired. Keep the repair place clean, Repair place furnishing example: Features of a good repair place are: = good lighting - good washing facilities 7 - compressed air available - dustless 7 z 9 - needed literature - adequate tools Fig 1. Repair place 1. Spare part store 6. Vice 2. Hydraulic press, 30 t. 7. Drilling machine 8. Tools 4. Washing 9. Assembly stand 5. Rubber surfaced work bench 10. Hoist It’s forbidden to use the drill bit grinder in the repair place. © 2004 SANDVIK TAMROGK CORP, Tampere Pent ae THAMUROCHE aire “Toletax +388 206 44120223103 en 0608 / JT 5082) HL 710, HL 710S Repair instructions 3. TOOLS ‘Tamrock supplies ready tool set for drill repair work. See the tool sets’ spare part sheet. Figures 2,3 and 4 show the tools needed in repairs, the tools being grouped according to the work phases. Fig 3. Tools used with the hydraulic press Ur ee Fig 4. Tools for the disassembly, assembly and testing of the pressure accumulatorHAL 710, HL 7108S Repair instructions Fig 5. Special tools “TDA ROCIAS (© 2004 SANDVIK TANROCK CORP. Tampore Par "09 FNt38311 TAMPERE, Foland Tl 50 205 1 Telefax +956-205 48 120D.22310-3 en 0608 / JT 7 (82) HL 710, HL 710S Repair instructionsAL 710, HL 710S Re, instructions 4. SEALS Seals are some of the most delicate and important parts of the rock drill. When the rock drill is dismantled, all the seals and O-rings has to be changed. Seals removin: Be careful not to scratch the drill's interior parts and sealing '¥ grooves. Fig 6. Removing of seals (0 Do not scratch the sealing grooves. ‘CAUTION Assembly of percussion piston seals: When fitting the seal in place , push lightly it to both directions at same time 80 that o-ring will settle in the correct position. (see arrows in the picture). The lip of the seal (a) is especially vulner- able for damages Eg. if handled carelessly when assembling the seal (fig 7). Fig 7. The way to fit the seal ~~ Heating the seals in oil to 50 - 60°C makes it easier to fit them in place. When fitting the seals do not use other tools than your fingers. Be careful not to use your nails. Fig 8. The lip of the seal Lubricate the seal groove with oil. Bend the seal as shown in pic- ture 9. Fig 9. The way to bend the seal ‘© 2004 SANDVIK TAMAOGK CORP, Tampere Plant ae TAMIROGE fire Stes “Telex +388 205 44 120D.22910-3 en 0604 / JT 92) HL 710, HL 710S Repair instructions Preservation of seals: - Keep the seals in their package, away from direct sunlight. At the installation keep the seals clean. CAUTION Fig 10. Spacer and seal housing Installing directions and centralizing of piston seals Centralizing the piston seals ; Lightly push and rotate oiled piston through the seals in the direction indicated by the arrows => in the picture. The seals will settle in the correct position Check that the seals sealing lips are undamaged. Install the O-rings of the front and rear cylinders in their grooves. =a Note the correct position of the seal lip.AL 710, HL 7105 Repair instructions ie If the seals do not last a normal changing interval, the reason is usually one of the following: = The filter is plugged or of wrong type (not original) = Wrong oil quality - Seals have been fitted wrong - Seals have been damaged on assembly - Water in oil - The condition of the sliding surfaces is poor 5. DISASSEMBLY Rock drill HL 710 has to be disassembled and the components to be checked after every 500 drilling hours. Disassembly and assembly of the rock drill requires from the performer professional skill and practical knowledge of these machines. The working room should be dry, dustless and clean. There should also be a wash-basin and compressed air available for the cleaning of the drill components. Before the disassembly the drill should be washed on the outside for example with a high-pressure water spray. In addition to this we recommend that the drill is washed on the outside also with a brush and suitable solvent before it is taken to the actual servicing place. A split barrel suits this purpose well. Fig 11. Assembly stand Required tools: - 30,36, 41 mm spanner Fit and secure the locking latch (1) with bolts (3). Mount the drill to the assembly stand with front and rear bolts (2). (© 2004 SANDVIK TAMAOCK CORP, Tampere Plant i TAIMOROGHE Faire “elo «368 205 44 120(0.22910 -3 en 0604 / JT 162) HL 710, HL 710S Repair instructions Fig 12. Hydraulic rock drill HL 710, HL 7108AIL 710, HL 710S Repair instructions 5.1. Disassembly of the front end Fig 13. Disassembly of the front end , See operation and maintenance 5.2. Removal of the pressure accumulators (4 Before removing the accumulators from the drill release the pressure by ‘opening the filling valves CAUTION (4) Fit immediately a cover plug to the opening in the body. 4] See instructions ”Pressure Accumulators”. Fig 14. Removal of pressure accumulators Required tools: ~ Torque wrench - 24mm socket Open the fastening bolts of the accumulator (fig 14). Dismount the accumulator and the gasket. © 2001 SANDVIK TAMROGK CORP, Tampore Plant THANIVTROCH “Berens Tolfax +358 205 44 120D.22310-3 en 0604 / JT 1362) HL 710, HL 710S Repair instructions wy Fig 15. Disassembly of the hydraulic motor Required tool: - spanner Open the hydraulic motors fastening bolts, and pull the hydraulic motor package from the gear housing, Remove the O-ring. Open the cover bolts. Pull the rotation shaft from the bearing housing with the puller (092 864 58) and punch (088 277 08) Fig 16. Parts of the hydraulic motor 2. Housing 10. Rotation shatt 3. Lock nut 11. Button 4. Lock washer 12, Shaft seal 5. Spherical roller bearing 13. O-rings 6. Circlip 14. O-rings 7. Cover 15. Cylindrical roller bearing inner ring 8. Bolt 16. Lock washerAL 710, HL 710S Repa structions Hydraulic motor assy Fig 17. Hydraulic motor assy ‘shaft through the cover so seals do not damaged. zl Use the assembling punch (1) from the tool set when you pull rotation Assembling order (fig 17): 1 2. 3, Bearings inner track (15) on shaft (10) Seals. Assemble the cover seals (12) by using a punch (152 537 28) and the circles. Assemble the cover (7) with it seals on the shaft by using the punch (1) Assemble the bearing (5) onto the shaft (10), tighten the nut (3) and secure it with the locking washer and some glue. Assemble the shaft sassy. into the bearing housing (2). Cross-tighten the cover-bolts (8) pre-tightening 10 Nm final tightening 32 Nm Observe the locking of locking washers and threads with glue. ‘SANDVIK TAMROCK CORP, Tampere Plant om Bes ap OG 1 ene en a Soiree Telefax +358 205 44 120D22s10- 3 en 0608 / JT 152) HL 710, HL 710S Repair instructions Removal the tie rods Fig 18. Removal the tie rods Open the nuts of the tie rods and push the tie rods out. 5.4. Removal of the percussion mechanism Fig 19. Removing the rear cover and the piston unit Removal of the rear cover Required tools: = Spanner 30 mm Release the locking latch and the bolts (2 pcs) from the assembly stand rear end. Turn the drill upright position by using a hoist. Undo the bolts and lift the rear cover off (see figure), Remove the O-ring. Check the wear of the rear cover (see chapter "Wear limits’) Removal of the percussion mechanism Required tool: = Punch Screw the puller into the piston (see figure ). Lift the piston out from the cylinder. The rear cylinder, rear bearing, distributor and the seal housing will follow the pistonAL 710, HL 710S Repair instructions 5.5. Percussion mechanism Fig 20. Percussion mechanism Disassemble the piston assembly by removing the rear cylinder, the rear bearing and also the distributor. Examine the piston and replace it, if: © the striking head is worn as deep as the bevel is © there are fractures and seizing marks on the piston. When necessary, piston can be polished with a butfing wheel. Piston must not be ground. Examine the distributor i ~ If there are burrs in the distributor, remove them by polishing with a buffing wheel (light scratches) - Ifthere are seizing marks in the distributor, change a new part. ial} Rear cylinder must not be ground. (CAUTION. Examine the rear cylinder if: ~ _ Ifthere are burrs in the rear cylinder, remove them by polishing with a buffing wheel (light scratches). ~ Use a new part if there is grooves which you noticed by finger on the cylinders sliding surface. - Change new o-rings Rear cylinder must not be ground, ‘2004 SANDVIK TAMROCK CORP. Tampere Pant o Bes oc Saran, ne aauare Taleax +358 205 48 120D22310-3 on 0608 / JT 17062) HL 710, HL 710S Repair instructions 5.6. Body cylinder Removal of the body Take off the rear mounting bolts from the assembly table. Lift the body cylinder off (fig 21). Use the accumulator bolts for the lifting. At the same time remove the front cylinder. Inspect the wear limit measures of the face surfaces. Fig 21. Removal of the body Removal of the front cylinder bearing fareeeteeecaaeraeeecatea Replace the bearing bushing of the | front cylinder only, if itis damaged. S| Press the bolts on the special tool (1) [| against each other and fit the tool into the i |) bearing (2) groove of the front cylinder. Press the bearing out by using a punch (3) and a thrust (4). Fig 22. Removal of the front cylinder bearingAL 710, HL 710S Repair instructions é 5.7. Disassembly and assembly of the spacer bearing and seal housing Detach the spacer from the gear housing and check the bearing surface for wearing, Replace the spacer if the indication grooves (A) have worn out. 1. Disassembly Fig 23. Removing the bearing 2. Auxiliary punch 550 055 27 3. Punch for removing 550 342 21 2. Assembly Cool the bearing to -20°C before installation. Align long groove B of the bearing with spacer marking C. Pay attention to locking surface, “Telefax «356 205 44 1200.223103 en 0604 / JT 19 (2) HL 710, HL 710S Repair instructions Seal housing mustbe replaced if the seal groove in the spacer is wider than 4,35 mm. Use the tool 150 746 48 to check the width. Fig 25. Removal and installation of the spacer seal housing. Use a hydraulic press. Disassembly Assembly Locking rings 550 055 28 Punch for removing 550 055 27 O-ring Use proper punch for assembling the seal housing, Install to the level of the spacer surface. Position the groove B of the seal housing in line with the groove A of the spacer. easen st ean the spacer and the seal bushing carefully before installation.FIL #10, AL 7105 Repair instructions 5.8. Disassembly and assembly of the gear housing Turn the rock drill into horizontal position with a hoist. Lock the mounting plate with bolts (2pes) and the latch located in the rear end of plate. Required tools: = 24 mm spanner - puller Remove the screws and remove the shaft with puller. Let the idler gear to fall down and remove the rings. Check the wear of the rings and the shaft surface. If necessary, change new parts. Fig 26. Removing the idler gear Required tools: } - Punch - Thrust The needle bearings must be changed after every 500 drilling hours. Use a hydraulic press to press with the punch the needle bearings out from the idler gear. Check the wear of the idler gear teeth.When necessary, change a new part. Fig 27. Assembly of the needle bearings Assembly of the needle bearings Using a hydraulic press push the first needle bearing into the idler gear. Turn the gear around and press the second needle bearing in. (1 Make sure the thicker edge of the needle bearing points outwards and comes flush with the surface of the idler gear. ‘CAUTION (© 2004 SANDVIK TAMROCK CORP, Tarpare Plant TANMUROGHE “Esive “Telefax +388 205 24 1200.22310 -3 en 0604 / JT 21 (82) HL 710, HL 710S Repair instructions Disassembly and assembly of the gear housing Check the wear limits of the gear housing (see page 31). é x | 8 | (ie, | cS Don't glue the o-rings _— until you mount the rock ‘3 <= 8 drill to the carriage Fig 28. Parts of the gear housing 4. Housing 8. O-ring 2, Rear bushing 9. Bonded seal 3, Front bushing 10. Plug 4, Bushing 11. Retaining screw 5. Cylindrical roller bearing without inner ring 12. Socket 7. Seal Bushings of the idler gear shaft Check the wear of the bushings and shaft. When necessary, change new parts. Push the first bushing out by hydraulic press and | punch. The second bushing is removed by using special punch and puller. See the picture. Assembly the bushings with a punch. | at a l RaiaAL 710, HL 710S Repair instructions ). Front bushing of the gear housing GENERAL . CHECKING THE FILLING GAS PRESSURE ......-.2--0--0eeeeeeeeeeeee REMOVING THE PRESSURE ACCUMULATOR FROM THE ROCK DRILL . DISMANTLING THE PRESSURE ACCUMULATOR - CHECKING THE PRESSURE ACCUMULATOR ASSEMBLY FILLING . 7.2. Filling instruction ........-+++++ 7.3. Filling pressures of accumulators . 7.3.1. Low pressure accumulator (LP) . 7.3.2. High pressure accumulator (HP) 7.3.3. Pressure of stabilizer accumulator . MOUNTING THE PRESSURE ACCUMULATOR ON THE fe ROCK DRILL COOIN AR ROH 230PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions ps 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 dismantied 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. Before removing the accumulator from the rock drill, discharge the accumulator pressure by opening the filling valve. Repair of a pressure accumulator by welding or by other meansis strictly forbidden. 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. PEPE (© 2005 SANDVIKTAMROCK CORP, Tampere Plant TAMIROGIE “Faure Telefax 386 205 4@ 1200 26160-8 en 0905/FIR 312) PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions 2. CHECKING THE FILLING GAS PRESSURE Check the accumulator filling gas pressure once a week. The rock drill special tool set includes two pressure gauges for this purpose: one gauge with the scale 0...100 bar for the high pressure accumulator, and the other with the scale 0...10 bar for the low pressure accumulator. Remove the cap (a). Screw the pressure gauge to the filling valve. Undo the lock nut (b). Wait until the needle of the gauge stops and then read the gauge indication. Close the lock nut (b). Unscrew the gauge from the filling valve and fit the cap (a) in place. Pw PPP = 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 oll channels be covered thoroughly with eg. plastic plugs. 4. 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 J the rock drill. Lwannine]PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions 4. DISMANTLING THE PRESSURE ACCUMULATOR i Before dismantling the accumulator, be sure it has no pressure. [warning] on 2 oe 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. Hf the threads are badly corroded or worn, the accumulator must be /\\ scrapped! (© 2005 SANDVIK TAMROGK CORP, Tampore Park " 8 TRAIT ROCTRE RES Barat emus Se “Telefax +358 205 4a 1209.26160-8en 0805/PIA 512) PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions 6. ASSEMBLY 4. 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.PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Re instructions i Check that the number on the cover and the bottom is the same. Lwarning] © The high pressure accumulator is marked with uneven numbers and the low Pressure accumulator with even numbers. 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. © 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. tthe mark (I) in the bottom remains after the tightening between the dot (+) and the mark (R) in the cover, the thread is in order. lf 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] © 2005 SANDVIKTAMROGK CORP, Tampere Plant ROCK “Hie Telefax +358 205 44 1200 26160-8en 0905/ PIR 7012) PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions 7. FILLING j The only allowable filling gas is nitrogen (N2). Lwarnina] i Do not fill an unchecked or a too worn accumulator. Lwannine] e You can refill the accumulator while mounted to the rock drill. 7.1. Pressure accumulator filling device a) a of 6 6 3 2 131415 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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions pea 7.2. Filling instruction Remove the cap (4). Screw the elbow adapter (15) to the filling valve (2). Push the quick coupling sleeve (6) onto the stem (5). Undo the locking nut (3). Tur the pressure regulating valve (11) open. 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. Tum the pressure regulating valve (11) open. 13. Disconnect the quick couplings (6) 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 filing valve (2) and by opening the locking nut (8) 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 ina dry place protected from dirt. PPP pP = © 2005 SANDVIK TAMROGK CORP, Tampere Plant 00. z TAMUROCGHE “Sei — “Telolax 356 205 4¢ 12028160-86n 0905 #1R ara) PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions nS 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 LPaccumulator, gas pressure should be half of the return line pressure. Normally itis from 3 to § 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 : | oo so 2m T 1 = — a B 60] t - B sol ee na = 40} __— > =a so 2a 1a = 3 | “00 ‘20 140 160 780 200 220 ; Percussion pressute Upper limit —- > — Lower limitPRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions ye Normal (stemless) diaphragm 109, 20} 80. 70) Z s 5 2 = 100 120 140 160 180 200 220 Upper limit Percussion pressure —s—-— Lower limit Pressure of stabilizer accumulator HLXST .......... 8 bar HFXST . 8 bar HLXS LT 30 bar HL 800 T 30 bar HL 1500 50 bar HL1560T ....... 40 bar 'SANDVIK TAMROCK CORP, Tampere Plant oR Bae OCT Saree rane sears Telex +388 205 48 1202a160-8en 0005/PIA 11 (10) PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions 8. MOUNTING THE PRESSURE ACCUMULATOR ON THE ROCK DRILL © 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 dil. 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. Tightening of the four-bolt accumulator The four-bolt accumulator must be tighten by using a cross-tightening [eA metnod 13-204 ‘CAUTION,PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL Repair instructions Notes: TANI ROCIA © 2005 GANDVIK TAUROCK CORP, Tampore Part FR-aott TAMPERE, Fland ‘al 1958 203 Telefax 358205 4 1202 28400-2 GB 0997771 1 (8) HYDRAULIC MOTORS OMT, OMSU Repair Instructions OMT / 24 Nm secure with glue CONTENTS 1. Specification . 2, Repair........ 3, Timing the motors ...SPECIFICATION MOTOR MOUNTED ON ROCK DRILL HL 500/ HL 550 OMSU 80 OMSU100 OMSU 125 Maton ccc ot ses emmem. 1c 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 I / t/min . . 46/250 58/250 58/200 MOTOR MOUNTED ON ROCK DRILL HL 600 OMT160 OMT200 OMT250 OMT315 Motor ......... Orbit type Rotation rate (PM we aarh vias 0...200 ...0..200 0.200 0...200 Torque, (maxcontinuos) 635Nm ..795Nm 985Nm 1280 Nm Oilfiow!/1/min 46/200 ..58/200 74/150 64/100 MOTOR MOUNTED ON ROCK DRILL HL 700 OMT160 OMT200 OMT 250 OMT315 Motor ......... Orbit type Rotation rate rpm + 0..200 ...0..200 0.200 0...200 Torque, (max continuos) 872Nm ..1095Nm 4855Nm 1763 Nm Oil flow!/4/min 70/200 .. 66/150 55/100 71/100 MOTOR MOUNTED ON ROCK DRILL HL 1000 OMT 250 OMT 315 OMT 500 Motor . - Orbit type Rotation rate... 0..130rpm ——0...130pm_—O...80 rpm Torque, max 175 bar (max continuos) 1340 Nm 1760 Nm 2260 Nm. Oilflow .. 651125 1/min 711100 1/min 671.60 1/min'D 22400-2 G8 0987771 3 (6) HYDRAULIC MOTORS OMT, OMSU Repair Instructions Oe 2. REPAIR A Cems ae Pe eeeceeeeeeececeeeaee 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 ina 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 45Nm 60 Nm secure with glue 190 Nm Use cross 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 shaff, 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 .om 5-10Nm ae Use cross tightening method Fig. 2 Hydraulic motor OMSU 2. o-RING 10. cHannen PLATE 18. pus 3. screw 11. piso vauwe 19. Housina 4. pute 12. pute 20. sau 5. SHAFT 13. piv 21. sprine 6. one 14, o-Fne 22. washer 7. GEAR WHEEL SET 15. o-ane 23. pues 8. PIN 16. spacer 24. sour 9. SHAFT 17. sprINewasHER Never rotate the motor without the shaft, this will damage A the disc. {R27 TAMROCK ox sence TAMPERE PANT'D 204002 G8 0997771 5 (6) HYDRAULIC MOTORS OMT, omsuU Repair Instructions CHECKING THE MOTORS CON [ 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 Ifthere are fractures, seizing marks or georotor is worn the motor has to be changed The gearwheel set must be used as a pair.3Nm Fig.4 Hydraulic motor OMSU Push the cover (2) firmly in place. Make sure the cap is A 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. Ifthe motor is not used immediatly, fll with oil and close the oil supply Parts so that it stays full of oil until it is put into operation. Oil prevents ust and provides lubrication for all moving parts when the motor is started. 3. TIMING THE MOTORS 1 Replace the disc valve (1) so, that one Of the of the holes (A) which goes thru the valve, is located on the center line. 2. Fit the shaft (2) into the disc valve. 3. The drain hole (B) in the channel plate (8) must be located on the same center line 4. The tooth of the gear (4) mustbeset on the right side of the center line . Fig.5 Timing the motors THA IVI ROCIE ©©.00640.1 en 0708 ROCK DRILL SERVICE CARD N:o Equipment Sin Rock drill, sin Percussion hours since last service SERVICE INFORMATION. ice Se ar aaa Tana Ea aR Ts — | Wa Faas [Da Tr aE TESTE 3 7 sor Remarks, arto. REPLACED PARTS / PART INSPECTION scription Repaired Replaced OK ston, O x oinder beating cat over a beara stor acsumior P,socumultor pacer ear hous on busting tah. bearng = noc Beco cation Mate aton sat ha beannas ont cover body usning seal rousing hank beerngs Pere mechanism ot tested o mechanism tested ‘© 2000 SANDVIK TAMROCK CORP. P.0.Box 100. cal ‘Tampere Plant(691960- 4 en 0904 / JT 1@2 CHAIN FEED CF 145 H + RH 714 Maintenance instructionCHAIN FEED CF 145 H + RH 714 Maintenance instruction CONTENTS 1. GENERAL .... 3 2. SAFETY INSTRUCTIONS... 3 3. STRUCTURAL DESCRIPTION . 4 4. MAIN COMPONENTS 5 4.1. Feed mechanism . 6 4.11. Feedgear ... : 6 41.2. Direct drive motor . ie 6 4.2. Feed chain and shock absorber 7 4.2.1. HL 600, HL 700/710, HL 800 T series rock drills .. 7 4.2.2. HL 510, HLXS series rock drills... a 7 4.3. Centralizing pito retainer and pito retainer (Ranger K6, K7) . 7 4.4, Safety wire .. 8 4.4.1. Adjusting the safety wire 8 5. FEED CHAIN TIGHTENING .... 9 6. ADJUSTING SLIDING CLEARANCES 10 7, HOSE GUIDE MOVEMENT TIMING . 12 7.1. Effects of incorrect timing 12 7.2. Timing adjustment 13 8. REPLACING FEED CHAIN 14 9. FEED MECHANISM .. 15 9.1. Feed gear... 16 10. SHOCK ABSORBER . 18 11. CENTRALIZING PITO 12 H RETAINER 19 11.1. Replacing jaw pieces 19 11.2. Retainer maintenance 20 11.3, Retainer alignment .. 20 12, ROUTINE MAINTENANCE .. 21 12.1. Every day ... at 12.2. Every 50 hours 2 12.3. Every 200 hours . at 12.4, Every 1200 hours ..... a ‘2004 SANDVIK TAMROCK CORP, Tampere Pant - =e TAMIROCK “ive “Telefax +356 205 44 120(©.91060- 4 n 0904 / JT 3 (@2) CHAIN FEED CF 145 H + RH 714 Maintenance instruction 1. GENERAL ‘The chain feed CF 145 H + RH714 is designed for use with track-carrier rigs of 700 series. The feed is equipped with a Pito retainer. The CF 145 H + RH 714 feeds are normally equipped with the HL 510, HLXS, HL 600, HL 710, HL 800T series rock drills. 2. SAFETY INSTRUCTIONS Always follow safety instructions and be careful with your work. Maintenance, adjustments or repairs are only allowed to persons with 2) specifictraining to service the rig. Read the instructions before servicing, |=" adjusting or repairing the rig. Pressurized hydraulic hoses must not be touched by hand. The hoses may have unnoticeable hairline cracks that let out high—pressure oil sprays that may penetrate the skin. Beware of moving machine parts. Do the service and repair work only with the rig stopped. Make also sure that the rig cannot be accidentally [aasene] Started during maintenance or repair work. Do not go under an unsupported rig. Do not disconnect hydraulic hoses a or valves unless you are certain that the system has no static load. beer all static loads always before starting repair work by 2 WARNING | mechanical support or by driving a cylinder to its extreme position. OBSERVE ABSOLUTE CLEANNESS WHEN DISMANTLING AND REASSEMBLING HYDRAULIC EQUIPMENT. Whenever a cylinder has been removed, the hydraulic circuit must be vented and flushed. Thisis to prevent dirt and air in the cylinder from causing functional disturbances.CHAIN FEED CF 145 H + RH 714 Maintenance instruction 3. STRUCTURAL DESCRIPTION The feed movement is transferred to the rock drill through the carriage. Changes in the force affecting the chain are counteracted by a shock absorber mounted between the carriage and the chain when the drill carriage is run with fast feed against the rear stopper. This arrangement increases the operational life and reliability of the chain. When required, the chain tension is easily adjustable with a single adjusting screw. The beam profile allows the sliding clearances between the carrier and the rail to be adjusted with shims. This adjustment has to be be done when regularly. The required adjustments are done by loosening the bolts of the carriage and removing or adding shims under the wear pieces, ‘The drill rod is supported by a hydraulically operated Pito 12 H retainer. When the whole ‘ength of a rod has been drilled in, the extension sleeve of the rod is gripped with the Pito retainer while a new extension rod is added. During drilling, the retainer operates as a fixed retainer, guiding the drill rod. The feed chain is driven by a hydraulic motor with brake via a two-stage reduction gear or by a direct drive motor via a sprocket. (© 2006 SANDVIK TAMROGK CORP, Tampere Plant = TAIMUROCH “Seiwa “Tolotax +388 205 44 120©.91960 - 4 en 0804 / JT 5 (2) CHAIN FEED CF 145 H + RH 714 Maintenance instruction 4, MAIN COMPONENTS 1. Feed beam 8 Hosereel 2. Feed mechanism 9 Rod changer RH 714 3. Drill carriage 94. 14’ extension rods 4, PITO 12H centraliser 9.2. extension rods and 14’ MF rods 5. Chain tightener 93. extension rods and 12’ MF rods 6. Suction head 10. Safety wire 7. Stinger 1. Safety wire release switchCHAIN FEED CF 145 H + RH 714 Maintenance instruction 4.1, Feed mechanism 4.1.1. Feedgear - Gearwheel reduction gear. Gear ratio 1:7,92 2. Hydraulic motor Danfoss OMR 80 4.1.2. Direct drive motor Hydraulic motor Calzoni MRA 400 (© 2008 SANDVIK TaNROGK CORP. PO Bo 109 0 TROC FIN-8517 TAMPERE, Find Bas 1 2 120 Tel 1358208 “Telotax +358 208,€31960-4 en 0904 / JT 7(@2) CHAIN FEED CF 145 H + RH 714 Maintenance instruction 4.2. Feed chain and shock absorber The feed chain (3) is connected to the rock drill carriage with the aid of a shock absorber 4). 4.2.1. HL600, HL 700 /710, HL 800 T series rock drills ai 2 [OU | 4 3 4.2.2. HL 510, HLXS series rock drillsCHAIN FEED CF 145 H + RH 714 Maintenance instruction 44. Satety wire The safety wire is located at the lower end of the feed. When the safety wire is pulled with sufficient force or the wire loosens, the drilling and rod handling functions and the dust collector stop, and a red warning light on the operating panel comes on. The motor still runs. The system is reset by pressing the safety wire reset button. Check the operation of the stopping device daily. Before resetting, check that the rod handling and drilling joysticks are /\\ not in the operating position. 4.4.1. Adjusting the safety wire 1. During adjustment, the diesel engine must be stopped. 2. Adjustthe wire length from point A so that the edge of the attachment linkis at mark Boon the switch lever. 3. Tum the power on with the ignition key, and test the switch by pulling the wire. When the switch is activated, a red warning light on the operating panel comes on. 4. The switch is reset by pressing button C on the switch, and the indicator turns off after the reset. Hf the wire is not adjusted properly, the switch can be activated during tramming or drilling. ‘© 2004 SANDVIK TAMROCK CORP, Tampere Pant TRANUROCIE “Share me Slee Telefax +986 205 44 1206.91960 - 4 en 0304 / JT 902) CHAIN FEED CF 145 H + RH 714 Maintenance instruction 5, FEED CHAIN TIGHTENING ra Checking the chain tightness Run the rock drill up (not against the limiter). Ensure that the drill bit does not rise through the suction head rubber. Also ensure that the chain is free from strain. Push the chain laterally. The tightness of the chain is correct when the chain only just touches the inner edge of the feed rail. Otherwise, adjust the chain tightness according to the instructions below. 4 The feed chain is tightened by moving poe the rear sprocket (3). The axle of the sprocket is moved by turning the bolt (1) Tre 2 going through the end casing of the SS beam. rN | Chain-tightening IW Loosen the locking nuts (2 and 4). Lf Turn the clamp bolt (1) clockwise until the chain tightness is correct. Do not i tighten the chain too much! : Tighten the locking nuts (2 and 4). Clamp bolt Lock nut Rear sprocket Shaft-locking nut Rone Nee eeCHAIN FEED CF 145 H + RH 714 Maintenance instruction ee 5. FEED CHAIN TIGHTENING D Checking the chain tightness Run the rock drill up (not against the limiter). Ensure that the drill bit does not rise through the suction head rubber. Also ensure that the chain is free from strain. Push the chain laterally. The tightness of the chain is correct when the chain only just touches the inner edge of the feed rail. Otherwise, adjust the chain tightness according to the instructions below. 4 The feed chain is tightened by moving the rear sprocket (3). The axle of the oH sprocket is moved by turning the bolt (1) Fi. going through the end casing of the ry ry beam. Chain-tightening Loosen the locking nuts (2 and 4). J BL Turn the clamp bolt (1) clockwise until pss the chain tightness is correct. Do not aa [D> 8 tighten the chain too much! Tighten the locking nuts (2 and 4) 1 Clamp bolt 2 Lock nut 3. Rear sprocket 4 Shaft-locking nut ‘2004 SANDVIK TAMFOCK CORP, Tampere Plant - MOROCGK “FSi Tefex +956 20 44-120,31860 - 4 en 0006 / JT 11@@) CHAIN FEED CF 145 H + RH 714 Maintenance instruction Make the adjustment with the feed beam in horizontal position and the rock drill carriage run to the rear end of the beam; this way the clearances are the smallest. After the adjustment make sure that the carriage moves freely on the beam. The clearance between the feed rail and drill carriage/hose reel is adjusted by adding or removing the shims (1, 2). By removing shims the clearance is decreased; by adding shims it increases. The optimum clearance is about 0,5 to 1,0 mm. Tightening torque for the bolts (3) is 260 Nm. When urethane coating of the upper slide piece (4) has been worn to half (approx. 4mm) an extra shim (5) has to be added between the slide piece and carriage. Otherwise the drilling centre moves out of alignment as ‘the drill carriage moves lower i.e. nearer the feed rail. In that case the centralizer and drill shank are not in alignmer this will cause problems with drilling tools. ‘One shim is needed for each upper slide piece (two pieces for carriage and four pieces for hose reel). When replacing the slide pieces the shim is removed and stored until needed again. The slide pieces have to be replaced when urethane coating is nearly worn out. It is important that they are changed in time; uncoated piece wears out the feed rail quickly. Too small clearances strain the feed chain and wear down the beam unnecessarily, whereas too large clearances make drilling more difficult and cause strains, for instance, on the rock drill shank. The clearance should be maintained equal under each wear piece. ieCHAIN FEED CF 145 H + RH714 Maintenance instruction 7. HOSE GUIDE MOVEMENT TIMING The purpose of the hose guide is to keep the hoses in order and properly tightened throughout the feed travel. Correctly adjusted timing keeps the distances a; and ap equal throughout the feed forward and reverse movements. 7.1. Effects of incorrect timing Incorrectly adjusted hose guide timing may cause two situations that result in unnecessary strain on the equipment. 1. The hose guide reaches its stopper too early at the end of the return movement (distance a; smaller than ag). As the rock drill continues moving, the hose guide drive mechanism and spring will be subjected to unnecessary strains and may even break down. 2. The rock drill catches up with the hose guide during the return movement (distance a2 smaller than a;). The speed of the rock drill is twice the speed of the hose guide and, therefore, the carriage will force the hose guide ahead. The chain and the hose guide drive mechanism will be subjected to unnecessary strains. [>] Incorrect hose guide timing always increases the danger of equipment fel failure. Pal Never use incorrect hose guide timing for any purpose (=A Caner] ao )= ° ea & eas ea essed sees eseaeseeee | eee a = distance from hose guide to rear stopper 2 = distance from hose guide carriage to rock drill carriage © 2008 SANDVIK TAMFOCK CORP, Tampere Plant MANOROCEE “Esler Telefax +358 206 44-120(©.31960-4 en 0904 / JT 1322) CHAIN FEED CF 145 H + RH 714 Maintenance instruction 7.2. Timing adjustment When timing is correctly adjusted, the distances a; and a2 should always be equal. The best position to check the distances is when the rock drill carriage is approx. at the middle of the feed beam. If the distances are not equal, adjust them as follows: 4. Ifthe feed chain is normally tightened, loosen it a little. 2. Remove the slide piece (1) above the hose guide drive wheel and the adjusting plates (2) from between the slide piece and the hose guide body. 3. Move the hose guide so that the distances a; and az become equal; guide the feed chain over the hase guide chainwheel. 4, Install the slide piece and place adjusting shims underneath it to make the clearance between the chainwheel and the slide piece to a minimum value of 2 to 4mm. Tighten the feed chain to normal tightness Recheck the distances a; and ap. 7. Test run the the feed movement and check that: ~ the hose guide reaches the rear stopper at the same moment when the rock drill carriage catches up with the hose guide. Thus the distances a, and a2 should close simultaneously. the hose guide shock absorber is at rest when the movement has stopped. Remember to lock the feed chain adjustments. oe Install the slide piece above the hose guide drive wheel before Itis possible that the chain pitch does not allow exactly equal distances a; and ap. In such cases, the maximum allowable difference between a; and a» is approx. 15 mm. Always adjust timing to give the smallest eeCHAIN FEED CF 145 H + RH 714 Maintenance instruction 8. REPLACING FEED CHAIN 1. Position the feed horizontal to prevent the rock drill carriage from sliding by itself when the chain has been disconnected. Run the rock drill o approx. one metre from the rear stopper. 3. Loosen the feed chain. Several threads should, however, be left in mesh between the adjusting bolt and its connecting piece. 4. Disconnect the rock drill hoses. Plug them and mark their positions. 5. Remove the bolts that fasten the rock drill to the carriage, and liftthe rock drill away onto a bench. Use proper hoist and lifting straps. 6. Disconnect both ends of the chain, and connect the new chain to the end of the old one on the front side of the rock drill carriage. Use a separate chain link for connecting the chains. Improvised connections may cause problems in the next step. 7. Run the combined chains through the feed mechanism while guiding the chain ends. Stop at a point where the ends of the new chain are at the shock absorber ears. Remove the chain link between the chains, and connect the new chain. 8. Adjust the chain to correct tightness » Guide both ends of the chain as necessary. Be careful not to leave your /\\ hands in a pinch. [warns | =a Use new connecting pins with the new chain. CAUTION (© 2008 SANDVIK TAMAOCK CORP, Tampere Plant ae ROCHE “Hie. “lel +385:205 4a 120©.91960- 4 en 0504 / JT 15 (22) CHAIN FEED CF 145 H + RH 714 Maintenance instruction 9, FEED MECHANISM 1. Transmission 19. Lip seal 2. Cover 20. Lock ring 4, Intermediate shaft 21. Lock ring 5. Gear 25. Oil drain plug 6. Drive shaft 27. Lubrication nipple 7. Idler sprocket 28. Feed motor OMR 80 8, Bushing 29. Locking plate 9. Axle 32. Wedge 10. Cover 37. Screw 13. Cover 38. Lock washer 17. Bearing at. SealCHAIN FEED CF 145 H + RH 714 Maintenance instruction 9.1. Feed gear The feed motor is an Orbit type hydraulic motor. The feed gear uses gearwheels that reduce the speed of rotation in two stages. Note! Itis possible to remove the feed gear, replace the front chainwheels and remove the hose guide while the rock drill is mounted to the carriage because the chain can be cut from the ‘connecting link slightly below the rock drill. Disassembling feed mechanism 1. Wash the feed mechanism thoroughly. 2. Disconnect the feed chain. Run the feed chain out of the feed mechanism while guiding the chain carefully. Disconnect the feed motor hoses and plug the connections at once, Drain the oil out of the reduction gear housing through the plug (25). Remove the mechanism from the feed beam and drain the rest of the oil out. Place the mechanism on a suitable work bench, and remove the motor (28), the Covers (2, 10 and 13), and the locks (29, 37, 38) of the idling chainwheels (7). Remove the axle (9); the chainwheel (7), the bushing (8) and the wedge (32) are removed at the same time. 7. The bearings (17) on the side of the cover (2) come off together with the cover. If the bearing remain on the axle, remove them with a puller. 8. Remove the snap ring (21). Then you can remove the gearwheel (5) and the other snap ring (20). 9. Pull the intermediate shaft (4) out. 10. Press the drive shaft (6) out. 11. Remove the bearings (17 and 18) and the sealing ring (19). 12. Wash the parts to remove all impurities. Ifthe gear unitis not reassembled straight away, oil the axles and the gearwheels. ee. P Reassembling feed mechanism 1. Install new bearings and sealing ring. 2. Drive the drive shaft (6) into place. Note! Use a counterpiece that prevents the bearing from being pushed out. (© 2004 SANDVIK TAWROCK CORP, Tampere Plant a TANMUROCH “Soha “Telefax +358 205 44 120(©31960- 4 on 0908 / JT 7@ CHAIN FEED CF 145 H + RH 714 Maintenance instruction The drive shaft (6) must be driven so far that the snap ring groove (20) is completely on the inside of the housing. 10, un. 42. 13. 14. 55 a a rr i Install the snap ring (20) and drive the drive shaft back until the snap ring is against the inner race of the bearing. In this position, the drive shaft chainwheel is in line with the other chainwheels. Reassemble the shafts in reversed disassembly order. Install the cover (2) using sealing compound (41) on the mating surfaces of the cover and the housing. Use chemical thread locking compound on all bolt fastenings. Mount the feed motor (28). Use sealing compound and thread locking compound. Install the idling chainwheels (7) (note the wedges 32) and lubricate their axles (9) through the grease nipples (27). Fill the gearbox with 2,4 litre of transmission oil through the cover (13) (nalf way up the drive shaft (6) when the feed is in vertical position). Use SAE 80W/90 API GL5 or SAE 75W/90 API GLS transmission oil depending on the ambient temperature, Cf. oil recommendations. Close the cover (13). Thread the feed chain through the reduction gear and mount the mechanism to the beam. If necessary, use the opening under the cover (10) to help the chain forwards. Install the cover (10). Connect the chain to the rock drill carriage and adjust the feed chain to correct tightness. Connect the feed motor hoses. Test run the feed cautiously. If the repair was made because of a broken sealing ring (19), check (eh always the feed motor axle seal also. A leaking axle seal of the feed motor causes pressure in the gear housing and can, thus, damage the reduction cavTion | gear sealing ring. ‘CAUTION. As the feed chain is disconnected for the work, checkalso the connecting pins between the chain and the carriage, and replace them if necessary.CHAIN FEED CF 145 H + RH 714 Maintenance instruction 10. SHOCK ABSORBER The main purpose of the shock absorber, located under the rock drill, isto even the stress peaks on the feed chain when the drill carriage is run with fast feed against the rear stopper. The arrangement increases feed chain life. The springis not active during drilling, HL 600, HL 710, HL 800 T * Pretightening 11+1 mm of the free lenath of the spring. 1. Shaft 2. Chain mounting piece 3. Ring 4. Spring The shock absorber is disassembled by unthreading the chain mounting piece (2). In order to achieve the desired effect, the spring bushing must be pretightened, when assembled, to the length shown in the figure above. Lubricate the sliding surfaces of the absorber well. HL 510, HLXS Ci a *80 0 * Rubber bushing tightening: 79-80 mm 1. Rubber bushing 2. Axle 3. Axle © 2004 SANDVIK TAMFOCK CORP, Tampere Plant EOBox 109. FIN-38611 TAMPERE, Fntand ‘Tal 1958 205.44 121 “Telefax +358 205 44-120631960-4 en 0904 / JT 190) CHAIN FEED CF 145 H + RH 714 Maintenance instruction 41. CENTRALIZING PITO 12 H RETAINER When drilling long holes, a front retainer with hydraulically operated jaws is used. The condition of the jaw pieces affects the speed and ease of rod changing. 1 Stinger mounting plate 8. Spring pin 2 Supporting arm 9. Grease nipple 3 Jaws 10. Beam mounting plate 4 Hydraulic cylinder 11. Arm 5 Axle 12, Flange 6 Pin 13. Centralizer body 7 Washer 11.1. Replacing jaw pieces Replacing jaw pieces is a regular maintenance task on the Pito retainer. Open the jaw, remove the jaw piece mounting screws, and knock the jaw pieces loose. Install new jaw pieces and tighten the mounting screws. Check that the jaw pieces correspond to the drill steel! diameter you are using 32 mm (1 %"), 38 mm (1 %4"), 45 mm (1%”), 51 mm (2”). The engine must be stopped during the jaw pieces replacement work.CHAIN FEED CF 145 H + RH 714 Maintenance instruction 11.2. Retainer maintenance 1. Drive the spring pins (part 8) out using a suitable size punch that does not damage the pin. Drive the pins (6) out to remove the hydraulic cylinder (4). Remove the arms (2) from their axles (5). Wash all parts thoroughly. Check the pins and axles, as well as the bearing bushings at the arms and cylinder eyes. 6. Reassemble the retainer. 7. Lubricate the pins and axles through the nipples (9) pen 11.3. Retainer alignment The retainer jaw must be aligned with the rock drill shank, Loosen the four nuts (1) and align the Pito retainer (2) so that the rock drill shank is centered in a sleeve held in the retainer jaw. Tighten the four nuts. ‘2004 SANDVIK TAMROGK CORP, Tampere Plant, - TAIMUROGHE “ESiren Er,©.91060-4 en 0904 / JT 21 (@2) CHAIN FEED CF 145 H + RH 714 Maintenance instruction ne ee 12. ROUTINE MAINTENANCE 12.1. Every day Visually check the condition of the feed: rock drill mounting, sliding clearances, and the Pito retainer. Report any damage at once. Remove any rocks in the chain channel. Lubricate all grease-lubricated items. 4. Front chainwheel 1 pes 2. Idler sprockets of the feed mechanism 2 pes 12.2. Every 50 hours Wash the feed thoroughly, preferably with a high-pressure washer. Check the feed chain for tightness and condition. Adjust if necessary. Check all sliding clearances, and adjust as necessary. Lubricate all grease-lubricated items. 3. Tensioning wheel 1 pes 4, Pito 12 H retainer 4 pos 5. Hose guide chainwheel 1 pes 6. Suction head cylinder 2 pes Check bolts and nuts for tightness. 12.3. Every 200 hours Check the oil level in the feed mechanism (only rigs with feedgear). Check the chainwheel bearings. 12.4. Every 1200 hours Change feed mechanism oll every 1200 hours or at least once a year. Use recommended oil type (only rigs with feedgear). a eaeCHAIN FEED CF 145 H + RH 714 Maintenance instruction Notes: C04 SANOVIK TAMROCK CORP, Taroere Part a Bee WANNEIROCIES sSiaree Sous Telefax +386 205 44 120251249 MRA400D-P2N1V1N1NX1000/51249 Ref Qty type Item Description 00s 5 570808 Gusrizione OR (0 Ring) 0008 6 481221 Cilingro (Cylinder) (0008 5 451222 Pistone(Pieton) ‘0006 5 518121 Dado autobloceante(Nut) ‘0007 5 550512 Anello eastco(Ciecip) ‘0008 5 4432542 _Distanziale per perno di aggancio(Retaining ring) ‘0009 5 429500 Pemo di aggancio(Pin) 010 5 492543 Molle(Spring) ott 5 436759 Disco mola pistone(Retalning Disc) oor 1 451252 Albero eccentrico "P" (Eccentric Shaft "P") 13 5 436248 Disco(Dise) 022 5 451113 Coperchio elindro (Cylinder Head) 0023 5 G_585470 Guamisione OR (0 Ring) 025 1 1550521 Anello lastco(Circip) 026 1 570832. Anello Tenuta (Shaft Seal) ‘0030 1 570808 Guarnizione OR (0 Ring) 0031 1 522668 Cuscinetto (Bearing) 0032 2 43023. Anello ago. cilinro(Cylinder Ret. Ring) 0036 2 451809 Spina cincrica(Parallel pin) 0037 2 550702 Molla a tazza(Rotary valve driving shaft spring) 038 1 551997 _Anelo eastico(Circtip) 039 df 451803 Alberno(Rotary valve driving shaft) 042. 1 448175 _Distrcutore rotane(Rotary valve) 0043 1 1528403 Cuscineto(Bearing) 04a 1 444990 Corpo motore (Motor case) 088, 2» 1950930 Vite TOE! (TCEI Screw) 0046 2» 506050 Rosetta(Washer) ose 1 348880 Gruppo Tappo (Plug) 056 5G 528288 _Guarnizione per clinaro(Cylinder seal) 0070 2G _ 563796 Guarnizione OR (0 Ring) ort 5 563600 Guarniione OR (0 Ring) ‘ore 1 461808 Anello di centraggio(Gentering ring) 076 f 442895 _Piattelodistributore(Rotary valve plate) core 1G 583789. Guamizione OR (0 Ring) 079 1 450912 Fondello(Sealing plug) 0081 1 1552991 Anello elasco(Circip) ‘082 1 480311 Anelioreazione(Reaction ring) 0084 1G 588797 Guarnizone OR (0 Ring) 085 1 G 583798 Guarnzione OR (0 Ring) 087 2 1553640 Spina clinrica(Paralel pin) 088 4 1550785 Molla a tazza(Rotary valve spring) 089 1 483643 Centraggio per molle(Spring centering seal) 0094 1 452653 Coperchio detibutore(Rotary valve housing) 082 2 1348459 Gruppo Teppo (Plug) 0085 7 ‘561875. Vite(Screw) 0086 3 528183 Vite(Screw) 100 1 ‘570751 Chiavetta{Key) ost 5 544208 Vite(Serew) osi2 5 505050 Rosetia (Washer) 901 1 451253 Corpo freno (Brake case) 303 1 451254 Flangla anterore (Brake front cover) 0908 1 451255 _Pistone tteno (Brake piston) 0909 1 451256 _Distanziaefreno (Spacer) oot0 5 551164 Disco freno (Disc) oot 4 451257 Controdisco (Counter disc) oats 1 G 564615 Guamzione OR (0 Ring) oats “ 581287 Guamaione OR (0 Ring) 018. 1 G 551251 Guarnizione OR (0 Ring) 0820 8 450824 Molla fren (Spring) oszt 18 450825 Mola fren (Spring) 0923 1 550520 Anello elestico(Circlip) 824 1 550569 Aneio elastco(Cirlip) 028 10 1531182 Vite(Serew) 0931 1 951104 _Cuscinetto (Bearing) 0982 4 ‘348459 Gruppo Tapp (Plug) 1951249 Serie completa dele tenute (Sealkit)ROD HANDLER RH 714 RANGER, SCOUT CONTENTS 4. GENERAL 3 2. SAFETY INSTRUCTIONS 3 3. TECHNICAL DATA 4 3.1. Type identifier 4 3.2, Technical data . 4 3.2.1. Using 11/4" MF rods ee 6 3.2.2. Using 1 1/4” extension rods . .. 6 3.2.3. Using 2" extension rods .. 6 4, MAIN COMPONENTS . 7 5. OPERATING PRINCIPLE 9 5.1. Taking rod to drilling centre 9 5.2. Taking rod to cassette .. 10 6. HYDRAULICS . - 1" 6.1. components RANGER . n 62. circuit diagram RANGER . 12 6.3. Operation RANGER ... 13 6.4. components SCOUT . 14 65. circuit diagram SCOUT 15 6.6. Operation SCOUT .. 16 7. MECHANICAL FUNCTIONS . 17 7.1. Adjusting pito retainer 17 7.2. Adjusting rod handler 7 8. MAINTENANCE INSTRUCTIONS 18 81. Tools . ee 18 8.2, Periodic maintenance . 18 8.3, Grease nipples ... 18 2006 SANDVIK TAMROGK CORP. Tampere Plant , TAMIROCE fire = 368 205 24 120,(© 95700-6 en 0406 /PIR 120) ROD HANDLER RH 714 RANGER, SCOUT ROD HANDLER RH 714 RANGER, SCOUTROD HANDLER RH 714 RANGER, SCOUT CONTENTS 1. GENERAL on 3 2. SAFETY INSTRUCTIONS .... 3 3. TECHNICAL DATA 4 3.1. Type identifier 4 3.2. Technical data . 4 3.2.1. Using 11/4”MF rods ....... 6 3.2.2. Using 1 1/4" extension rods 6 3.2.3. Using 2” extension rods . 6 4, MAIN COMPONENTS ... 7 5. OPERATING PRINCIPLE 9 5.1. Taking rod to drilling centre 9 5.2. Taking rod to cassette 10 6. HYDRAULICS . n 6.1. Hydraulic components RANGER . 1 6.2. Hydraulic circuit diagram RANGER . 12 6.3. Operation RANGER ... 13 6.4. Hydraulic components SCOUT . 14 6.5. Hydraulic circuit diagram SCOUT . 15 6.6. Operation SCOUT .. 16 7. MECHANICAL FUNCTIONS . 17 7.1, Adjusting pito retainer 7 7.2, Adjusting rod handler 17 8. MAINTENANCE INSTRUCTIONS . 18 8.4. Tools ... 18 8.2. Periodic maintenance . 18 8.3. Grease nipples .. 18 (© 2006 SANDVIK TAMAOCK CORP, Tampere Plant ae TARIROC Core Teleax +356'205 48 120(©.95700-6 en 0406 PIF 329 ROD HANDLER RH 714 RANGER, SCOUT 1. GENERAL ‘These instructions describe the structure, operating principle and adjustments of the RH 714 rod handler. Jamrock Service is always ready to offer advice and help in all service problems. 2. SAFETY INSTRUCTIONS Maintenance and adjustments are only allowed to persons who have received specific training on the device in question. Read the system adjustment instructions before starting adjustment work. WARNING OBSERVE ABSOLUTE CLEANLINESS WHEN DISASSEMBLING AND (C221) ASsemBLING HYDRAULIC EQUIPMENT. Blowall parts clean with compressed air and wipe them using a CLEAN, [_caunon |] non-fluffy cloth before assembling. Pressurized hydraulic hoses must not be touched by hand. The hoses may have unnoticeable needle holes that let out high-pressure oil sprays that may penetrate the skin. Beware of moving machine parts. Do the service and repair work only with the rig stopped. Make also sure that the rig cannot be accidentally started during maintenance or repair work. WARNINGAOD HANDLER RH 714 RANGER, SCOUT 3. TECHNICAL DATA 3.1. Type identifier Rock drill serie Rod length max 14’ 3.2. Technical data Number of rods Rod length Rod size ... - 6 pes in cassette + 1 in rock drill 10, 12 o 14 feed 11/4", 11/2", 13/4" and 2” (*) All cassette functions are electrically controlled, ‘The upper end rod handler has three alternative mounting positions: ~ The upper position is for 14’ extension rods, whereby the upper gripper jaw grips the sleeve ~The middle position is for 14’ MF rods and 12" extension rods. ~The lower position is for 12" MF rods and 10’ extension rods. ~ With 12’ and 14’ MF rods, the upper gripper grips the rod. - With extension rods, the upper jaw grips the sleeve. (© 2006 SANDVIKTAMAOCK CORP. Tampere Plant TAMIROG Sire “eletx +358 205 44 120(©.95700-6 en 0408/ FIR 520) ROD HANDLER RH 714 RANGER, SCOUT (@) The cassette can be used with 1 1/4", 11/2", 13/4” or 2" rods when the lenath of lifting cylinder stroke is adjusted with adjusting screw (A). ‘The spare parts required by different rods are listed in the spare parts manual.ROD HANDLER RH 714 RANGER, SCOUT nee 3.2.1. Using 1 1/4” MF rods ~ replace the jaw (1) of both rod handlers - replace the jaw piece (2) of both rod handlers ~ adjust the rod space of both rod handlers with spacers (3) until suitable 3.2.2. Using 1 1/4” extension rods - replace the jaw (1) of the lower rod handler ~ replace the jaw piece (2) of the lower rod handler ~ adjust the rod space of the lower rod handler with spacers (3) until suitable 3.2.3. Using 2” extension rods - replace the jaw (1) of the upper rod handler ~ replace the jaw piece (2) of the upper rod handler ~ replace the latch (4) of the upper rod handler (© 2006 SANDVIKTAMROGK CORP, Tampere Plant ~\NTROGIE “Salven jelax +958 205 44 120€.95700-6 en 0406; PIR 7 (20) ROD HANDLER RH 714 RANGER, SCOUT MAIN COMPONENTS Rod handler, upper end (The upper end rod handler has three alternative mounting positions.) (1*) Rod handler, lower end The rod handlers perform: rod transfers to drilling centre or to cassette, and gripping of rod with jaws and rod storing into cassette. Lower support The rods rest against the lower support in the cassette. Rod gripping cylinder The cylinder presses the gripper jaws around the rod. . Gripper transfer cylinder The cylinder moves the rods in gripper jaws to drilling centre or to cassette. . Top cover The top cover prevents the rods from falling out of the cassette during tramming or transport. . Rod feed cylinder The cylinder keeps the rods in a position where rod handling can take place. . Slide gate Prevents rods from rolling out and falling from the cassette. . Valve block The valves control the rod handler, Pito retainer, and movable suction head. . Flow divider valve The valve divides the oil flow so that both grippers (upper and lower end) move simultaneously to drilling centre or to cassette.ROD HANDLER RH 714 RANGER, SCOUT (© 2006 SANDVIK TAMMROCK CORP, Tampere Plant P.O.Box 100 FN 3361) TAMPERE, Flan 7 88 208. Tea 00 28(©.95700-6 on 0408 /PIR se ROD HANDLER RH 714 RANGER, SCOUT 5. OPERATING PRINCIPLE 5.1, Taking rod to drilling centre When arodis added, the gripper jaw (1) presses the slide gate (2) so thatthe rod can move over the slide gate with the gripper to the drilling centre. ‘When the gripper is in the driling centre, the rods in the cassette are retained behind the slide gate (2) and under the surface (8), preventing the rods from falling out.AOD HANDLER RH 714 RANGER, SCOUT 5.2. Taking rod to cassette When disassembling is started, the inclined edge (4) of the gripper body first presses the rods downwards in the cassette, and then the slide gate under surface (3). When a rod is taken from the drilling centre to the cassette, the gripper jaw and the rod together push the slide gate (2) and the rods (5) in the cassette downwards, making room for the rod coming from the drilling centre, When the jaws open, the slide gate (2) closes, preventing the rods from escaping from the cassette. © 2006 SANDVIKTAMROOK CORP, Tampere Plant ES THAMUROCIE “Sree me “Telefax +355 205 48 1206.1. 50. 173. 199. 200. 201. 202. 203. 204. 205. 206. 207. 208. 209. 210. att. 212 213. 214 215. 216. 217. 218. 219. 236. 237. 243. 268. (© 95700-6 6n 0406 / PIR 1 @0) ROD HANDLER RH 714 RANGER, SCOUT HYDRAULICS Hydraulic components RANGER Variable displacement pump; output to rotation, rod handler, winch, boom and oscillation, Pressure relief valve of LS line for cassette and oscillation circuits Double overcenter valve Rod handler control valve block; the valve block is used for controlling the movements of rod handler, Pito retainer and movable suction head. Control vaive for gripper transfer cylinders Control valve for lower gripper jaw Control vaive for upper gripper jaw Control valve for movable suction head Pito control valve Lis-valve; the valve is activated every time any other valve in the valve block 200 ig activated, The function of the valve is to direct the LS signal to pump 50. The other port is used for directing oil to valve 209. Cylinder lock-up valves, 6 pos Flow divider valve for the gripper transfer cylinders; keeps the speed of cylinder movements equal by regulating the oil flow in and out. Relief valve for warming up the oil Rod feed cylinders Pito cylinder Movable suction head cylinder Cylinder of the upper gripper jaw Cylinder of the lower gripper jaw Gripper transfer cylinder Gripper transfer cylinder Control valve for the rod feed cylinders; directs the oil from the feed cylinders into the receiver when rods are taken into the cassette Shuttle valve; controls LS signal Valve for releasing the lower gripper Front centralizer cylinder Front centralizer cylinder Directional valve of rod centralizer Pressure relief valve for rod lifting cylindersAOD HANDLER RH 714 RANGER, SCOUT 6.2. Hydraulic circuit diagram RANGER 2. 212) 23 | 24) as ae] 20 ny pa a ee en np anh che che - B % 208 207 201) | | Stir Psa ae il wt 05 hkO]SCPSS:«CQ’SCS 1 I L ee a eae wa et lg x! iT. _ Jus 2006 SANDVIK TAMBOCK CORP, Tampere Pant ~ a TANMUROGIE “Fairer Sie “Telex +388:205 49 120(©.95700-6 en 0408 PIF, 1320) ROD HANDLER RH 714 RANGER, SCOUT 6.3. Operation RANGER The rod handlers controlled using levers located in the cabin. They control the directional valves in the rod handler valve block (200) with the purpose of directing the output oll from the variable displacement pump (0) to the cylinders. Rod handler valve block (200) is mounted to the side of the feed. The valve block (200) consists of eight on/off -type control valves (201-205, 217, 219, 249). in addition, the LS valve (206) is provided for pressurizing the pump (60). Valves (201), (202), and (203) control rod handling functions. Control valve (201) directs oll flow tothe gripper transfer cylinders, moving the rod from cassette to driling centre and from driling centre to cassette. Control valve (202) moves the jaw of the lower gripper {openiclosed). Control vaive (203) moves the jaw of the upper gripper (open/closed). When the upper aw is opened, valve 219 releases pressure from the lower jaw cylinder into the receiver thus releasing the grip in the rod; the lower jaw continues to guide the rod during threading. Control valve (204) moves the suction head (up/down), and control valve (205) moves the Pito jaws (open/closed). The double overcenter valve (199) at the Pito directional valve (205) has the purpose of preventing damage to the Pito arms when threads are being loosened in Pito. All other cylinders controlled by directional valves have their own lock-up valve (207) that ensures the remaining pressure in the cylinder while the valve spool is in the middle position. The rod transfer cylinders (215, 216) are provided with an additional flow distribution valve (208) whose purpose is to distribute an equal cil flow to both cylinders in both directions. When the rod string is being disassembled and a rod is taken to cassette, the coll Y217 of the control valve (217) for the rod lifting cylinders (210) becomes aotivated and directs the return oil flow from he cylinders into the tank, This decreases the force used for pushing a rod into the cassette. When the rod is in the cassette and the control lever is released, the coil Y217 becomes dead and pressure enters through the pressure regulator (263) to the piston head side of cylinders (210) and tightens the rods in the cassette. The set value of the pressure regulator (263) is 30-40 bar. The directional valve (243) is used for controlling the rod centralizer cylinders (option). Oil flows from variable displacement pump (60) to port P2 of rod changer valve block (200). From there, oil flows to the desired cylinders as directed by the control valves. The coil Y206a of the LS valve (206) is activated whenever any coil of the directional valves (201-205, 217, 219, 243) in the valve block (200) is activated. The valve (206) is Used for directing the L'S signal to the variable displacement pump (50) as long as any of the directional valve coils is activated. The LS signal line also has a pressure relief valve (173) that restricts the maximum pressure of the pump for cassette movernents to 280 bar.ROD HANDLER RH 714 RANGER, SCOUT 6.4. 80. 85. 86. 199. 200. 201. 202. 203. 204. 205. 207. 208. 210. ant. 212, 213, 214, 215. 216. 217. 219. 236. 237. 243, 263. Hydraulic components SCOUT Gear pump; output for dust collector, cassette, and oscillation. Pressure relief valve of pump 80 Pressurizing valve for pump 80 Double overcenter valve of Pito Rod handler control valve block; the valve block is used for controlling the Movements of rod handler, Pito retainer and movable suction head. Control valve for gripper transfer cylinders Control valve for lower gripper jaw Control valve for upper gripper jaw Control valve for movable suction head Pito control valve Cylinder lock-up valves, 6 pes Flow divider valve for the gripper transfer cylinders; keeps the speed of cylinder movements equal by regulating the oil flow in and out, Rod feed cylinders Pito cylinder Movable suction head cylinder Cylinder of the upper gripper jaw Cylinder of the lower gripper jaw Gripper transfer cylinder Gripper transfer cylinder Control valve for the rod feed cylinders; directs the oll from the feed cylinders into the receiver when rods are taken into the cassette, Valve for releasing the lower gripper Front centralizer cylinder Front centralizer cylinder Directional valve of rod centralizer Pressure reducing valve for rod lifting cylinders (© 2006 SANDVIK TAMROCK CORP, Tampere Plant ZAM OCT eee “Telefax -358 205 44 12015 20) ROD HANDLER RH 714 RANGER, SCOUT (©.95700-6 en 0406 /PIR 6.5. Hydraulic circuit diagram SCOUT fe | [eatinROD HANDLER RH 714 RANGER, SCOUT 6.6. Operation SCOUT The rod handler is controlled using the levers on the control panel. They affect the directional valves in the rod handler valve block (200) that have the purpose of directing the output of the gear pump (80) to the cylinders. Rod handler valve block (200) is mounted to the side of the feed. The valve block (200) consists of eight on/off -type control valves (201-205, 217, 219, 243), Valves (201), (202), and (203) control rod handling functions. Control valve (201), directs oil flow to the gripper transfer cylinders, moving the rod from cassette to drilling Centre and from drilling centre to cassette. Control valve (202) moves the jaw of the lower Gripper (open/closed). Control valve (203) moves the jaw of the upper gripper (open/closed). When the upper jaw is opened, valve 219 releases pressure from the lower jaw cylinder into the receiver thus releasing the grip in the rod; the lower jaw continues to Quide the rod during threading. Control valve (204) moves the suction head (up/down), and control valve (205) moves the Pito jaws (open/closed). The double overcenter valve (199) at the Pito directional valve (205) has the purpose of Preventing damage to the Pito arms when threads are being loosened in Pito. All other cylinders controlled by directional valves have their own lock-up valve (207) that ensures the remaining pressure in the cylinder while the valve spool is in the middle position. The rod transfer cylinders (215, 216) are provided with an additional flow distribution valve (208) whose purpose is to distribute an equal oil flow to both cylinders in both directions. When the rod string is being disassembled and a rod is taken to cassette, the coil Y330 Of the control valve (217) for the rod lifting cylinders (210) becomes activated and directs the return oil flow from he cylinders into the tank. This decreases the force used for Pushing a rod into the cassette. When the rod is in the cassette and the control lever is released, the coll Y330 becomes dead and pressure enters through the pressure regulator (268) to the piston head side of cylinders (210) and tightens the rods in the cassette. The set value of the pressure regulator (263) is 30-40 bar. ‘The directional valve (243) is used for controlling the rod centralizer cylinders (option). From the gear pump (80) oil flows to the port P1 of the rod handler valve block (200) and, Controlled by the directional valves, continues to the desired cylinders. Tne coll Y124 of the pressurizing valve (86) of the pump (80) is unactivated whenever any Coil of the directional valves (201-205, 217, 219, 243) in the valve blockis activated. The valve (86) is used for directing the output of the pump (80) against the plug (A1), whereby ol flow either to an actuator of the cassette or, ifthe actuator is at its extreme position, through the pressure limit valve (85) to the tank. © 2006 SANDVIKTAMROCK CORP, Tampere Plant TRAIMIROCIE “Siren Telefax +956-205 48 1207A. 72. ¢ 95700-6 on 0406 /FIF 1720) ROD HANDLER RH 714 RANGER, SCOUT MECHANICAL FUNCTIONS Adjusting pito retainer Loosen the bolts between the feed and the Pito retainer. Mount a shank to the rock drill and an extension sleeve to the Pito retainer jaws. Drive the shank into the sleeve by using the rock drill. Tighten the bolts, and run the rock drill to the upper position. Adjusting rod handler Move a rod with the gripper transfer cylinders between the extension sleeve and the rock drill shank, Loosen the bolts (1) between the rod handlers and the feed. Loosen the locking nuts of the adjusting screws (2, 3, 4). Centralize the rod to the drilling centre using the adjusting screws (2, 3). Lock the adjustment. Move the rod back to the cassette, and adjust the screw (4) so that the rod is far enough in the cassette (behind the slide gate) and that the gripper jaw pushes the tod against the inclined surface of the gripper. Lock the adjustments. Test all the movements.AOD HANDLER RH 714 RANGER, SCOUT 8. MAINTENANCE INSTRUCTIONS 8.1. Tools No special tools required. 8.2. Periodic maintenance Each shift: - Check possible oil leaks. ~ Tighten all loosened nuts and screws. ~ Lubricate the sliding body (4) grease nipples (2 pcs). Once a week: - Wash the rod handler. - Lubricate all grease nipples. - Check the condition of the gripper and Pito jaws. 8.3. Grease nipples In both rod handlers (upper and lower end): 1. Latch. +. 2pes Gripper jaw cylinder ..... 2 pes Gripper transfer cylinder . 1 pc Sliding body... 2 pes Sliding surface ......... 4 pe geen (© 2006 SANDVIKTAMAOCK CORP. Tampere Part ae TAN OGiIWE ature Telefax +358:205 48 120(©.95700-6 en 0406,/PIR 19.20) ROD HANDLER RH 714 RANGER, SCOUT OoROD RAN HANDLER RH 714 IGER, SCOUT Notes: “DANN ROCLES {© 2008 SANDVIKTANROOK CORP, Tampere Part PO.eex 100 FIN-83311 TAMPERE, Fintand Ta. 4958 20 44 121 Telefax +858 205 44 120,1 (16) © 48060- 8 en 1204/ PIR BOOM DB 800 RANGER, SCOUT BOOM DB 800 RANGER, SCOUT800 RANGER, SCOUT San REEERE ERIN peer CONTENTS GENERAL . SAFETY . MAIN COMPONENTS . BOOM HYDRAULICS ............... 4.1. Hydraulic components RANGER Hydraulic circuit diagram RANGER Operation RANGER . Hydraulic component: .5. Hydraulic circuit diagram SCOUT 4.6. Operation SCOUT ............ 5. REPLACING CYLINDERS . 6. CYLINDER MOUNTING PINS 6.1. Removing the pins . TURNING FEED TO HORIZONTAL DRILLING POSITION . 8. MAINTENANCE . Peps 2008 SANDVIK TAMAOGK CORP, Tampere Plant ~ TDA es MUROCGKK “faire fle ‘Telia +008 205 44(©.45660-8 en 1208/ PIR 3(16) BOOM DB 800 RANGER, SCOUT i 1. GENERAL ‘These instructions describe the structure, operating principle, and the adjustments of the DB 800 boom. There are three alternative mounting places for feed swing cylinder in the boom cross piece. The mounting place in the middle is meant for normal vertical drilling, the ones on both sides for horizontal drilling to the right or to the left. By following these maintenance instructions, itis possible to increase the life, operational reliability, and safety considerably. Tamrock Service is always ready to offer advice and help in all service problems. 2. SAFETY <—~, Never repair a boom or boom components or cylinders by welding (Special materials are used in booms that cannot be welded using normal methods). A repair-welded boom will break, and when it falls or tips over, it can cause personal damage. [ay | Maintenance, adjustments or repairs are only allowed to persons with 4) specific training to service the rig. Read the instructions before servicing, adjusting or repairing the rig. Pressurized hydraulic hoses must not be touched by hand. The hoses may have unnoticeable needle holes that let out high-pressure oil sprays that may penetrate the skin. [warwne | Beware of moving machine parts. Do the service and repair work only én with the rig stopped. Make also sure that the rig cannot be accidentally [Wwanwne_] started during maintenance or repair work. Do not go under an unsupported rig. Do not disconnect hydraulic hoses or valves unless you are certain that the system has no static load. Remove all static load always before starting repair work by a mechanical support or by driving a cylinder to its extreme position. OBSERVE ABSOLUTE CLEANNESS WHEN DISMANTLING AND REASSEMBLING HYDRAULIC EQUIPMENT. Whenever a cylinder has been removed, the hydraulic circuit must be vented and flushed. This is to prevent dirt and air in the cylinder from causing functional disturbances.BOOM DB 800 RANGER, SCOUT 3. MAIN COMPONENTS Cradle Boom arm |. Rear boom . Cross piece Feed swing cylinder Feed transfer cylinder Feed tilt cylinder Boom knee cylinder . Boom lift cylinder PENSAR ONYS (© 2004 SANDVIK TAMROCK CORP, Tampere Plant FO.Bax i = TAUIROCIE “Beier Telefax +058 205 44 120,(©.48660- 8 en 1204/ PIR 5016) BOOM DB 800 RANGER, SCOUT ES 4. BOOM HYDRAULICS 4,1, Hydraulic components RANGER 50. Variable displacement pump 170. Overcenter valves of cylinders (5 pes) 171. Boom control valve; the valve is used for controlling the movements of the boom, feed and upper structure swing. 172, Control valves for boom movement speed (6 pcs); the valves are used for restricting the maximum speed of the boom, feed and upper structure swing movements. 175. Feed transfer cylinder lock valve with a pressure-relief cartridge at the rod side 176. Feed transfer control valve, 30 l/min 177. Boom lift control valve, 35 Ymin 178. Boom arm control valve, 35 \/min 179, Feed swing control valve, 15 min 180. Feed tilt control valve, 25 min 181. Control valve for upper structure swing, 40 \/min 182. Upper structure swing cylinder 183. Feed tilt cylinder 184, Feed swing cylinder 185. Boom knee cylinder 186. Boom lift cylinder 188. Feed transfer cylinder 193. One-way restrictor; regulates the speed of upper carriage swing 194, Double pressure-relief valve of upper carriage swing cylinder 300. Feed swing double pressure-relief valveRANGER, SCOUT SRR Se 4.2. Hydraulic circuit diagram RANGER AgeGee. s eee] ete et eo ta (re || ie “J af al | at le alte] || | oe | aa TWANIMOROCHE #28 FIN-88811 TAMPERE, Frland ‘Tel 958 206 44 121, “Telefax 4956-205 46 120(©.45660- 8 en 1204/ PIR 7 (16) BOOM DB 800 RANGER, SCOUT EE 4.3. Operation RANGER The boom movement speed depends on the positions of the control levers. The movement speed remains constant because of the boom valve's load-sensing feature. Each control valve spool of the valve block has its own flow restrictor (172). They are used for setting the maximum movement speeds for the boom. The boom valve is located in the cabin. The valve block comprises six control valves (176-181). The control vaive levers are of cross-lever type which means that each lever controls two cylinders. The pressure-relief cartridge of the lock valve (175) restricts the pressure at the rod side of the feed transfer cylinder. The double pressure-relief valve (300) restricts the feed swing cylinder pressure. Boom circuit maximum pressure is restricted by the pressure controller of the pump (50). NOTE! The pressure of the whole system is restricted by the pressure reli (85) at the rotation valve. valveBOOM DB 800 RANGER, SCOUT a 4.4. Hydraulic components SCOUT 50. Variable displacement pump 64. Pressure regulator; reduces pilot control pressure to Danfoss PVG directional valve 65. Pressure relief valve; restricts pilot control pressure (safety valve) to Danfoss PVG directional valve 175. Feed transfer cylinder lock valve with a pressure-relief cartridge at the rod side 176. Feed transfer control valve 177. Boom lift control valve 178. Boom arm control valve 179. Feed swing control valve 180. Feed tilt control valve 181. Control valve for upper structure swing 182. Upper structure swing cylinder 183. Feed tit cylinder 184. Feed swing cylinder 185. Boom knee cylinder 186. Boom lift cylinder 188. Feed transfer cylinder 190. Pressure compensator; maintains constant oil flow irrespective of load pressure or pump inlet pressure 191. Shuttle valve; controls LS signal of pump 194. Double pressure-relief valve of upper carriage swing cylinder 300. Feed swing double pressure-relief valve (© 2004 SANDVIK TAMROCK CORP, Tampere Plant ANUTROGK “Esire “Telofax +356 205 48 120909 BOOM DB 800 RANGER, SCOUT (©-45660- 8 en 1204/ PIR 4.5. Hydraulic circuit diagram SCOUT CT |e i L | [1] fale (i fe WEI IA | ct, ge Be ee * teat 7 iL as ma | [rem “NT QBOOM DB 800 RANGER, SCOUT Ln nREenemmaeee eae 4.6. Operation SCOUT The speed of boom actuator movement depends on the position of the electric control levers of the boom (2 levers). The levers are located on the control panel. Deviating a control lever from the middle position affects the control voltage of the electric controller of the actuator block in question. A change in the control voltage proportionally moves the spool the desired amount in the desired direction, and this determines the speed and direction of the actuator movement. The speed of movement remains constant due to the load-sensing properties of the valve. Each actuator block of the boom valve assembly has two screws restricting the maximum position of the spool, and they are used for limiting the maximum speed of the actuator movements. The boom valve assembly is located on the upper carriage. The valve assembly consists of seven actuator blocks (spools §3, 176-181). In addition to the boom and upper carriage swing actuator blocks the valve assembly includes the rock drill rotation actuator block. When one boom movement is run, the variable displacement pump (50) receives information of the load pressure level through the set of shuttle valves (63 and 191), whereby the variable displacement pump (50) adjusts itself to the required pressure level and the position of the spool in the actuator block adjust the required volume of oil flow. The actuator’s speed remains constant irrespective of load variations. |f two or more boom movements are run at the same time, the pressure level of the variable displacement pump (50) adjusts according to the highest load level. The pressure ‘compensator (190) in each actuator block caters for the adjustment of oil flow for the lower level actuators, which keeps the speeds of the actuators operating at lower pressure levels constant as long as the maximum output of the variable displacement pump (50) is not exceeded. Overcenter valves located at the cylinders ensure the positional stability of actuators. The feed transfer cylinder (188) is locked in position by the lock valve valve (175). The pressure-relief cartridge of the lock valve (176) restricts the pressure at the rod side of the feed transfer cylinder. The double pressure-relief valve (300) restricts the feed swing cylinder pressure. The maximum pressure of the boom circuit is adjusted by the pressure controller of the variable displacement pump (50). 2004 SANDVIK'TAMROOK CORP, Tampere Plant - = TANMIROCE “fSive— Telefax +388 205 4¢ 120©45060- 8 en 1204/ PIR 11 (16) BOOM DB 800 RANGER, SCOUT 5. REPLACING CYLINDERS 1. Before starting to remove a cylinder, always securely support the component moved by the cylinder. 2. Inch the cylinder with the hydraulics in order to find the position where the cylinder pins are not under load. 3. Open the overcenter valves enough to remove any cylinder load. 4. Disconnect the hydraulic hoses, plug them, and mark the connections, 5. Support the cylinder and remove the pins. When a cylinder is removed, make sure that no part of the boom is left /\ unsupported. Feed swing cylinder Feed transfer cylinder Feed tit cylinder Boom knee cylinder Boom lift cylinder gPeNsBOOM DB 800 RANGER, SCOUT 6. CYLINDER MOUNTING PINS. The cylinder pins are expandable pins that are tightened clearance-free to the cylinder ears. aN - Check the tightening torque. The correct value is 290 Nm. Check the position of the expanding slot in the pins. The slot must be at right angle (90° degrees) to the cylinder’s direction of movement, and in transport position downwards, if possible. Expanding slot 6.1, Removing the pins Remove the screws (7) and the washers (6). Remove the sleeves (5) using an M24 screw as an extractor. Pull the pin (4) out. ‘© 2004 SANDViK TANROGK CORP, Taper Pan POBox 00 TRAY AC N-S38it TAMPERE, land ‘esoeb anos tat aca 300 205120(©.45600- 8 en 1204/ PIR 13(18 BOOM DB 800 RANGER, SCOUT 7. TURNING FEED TO HORIZONTAL DRILLING POSITION 1. Tum the upper carriage in line with the tracks. 2. Run the rock drill and the feed to the extreme forward position. 3. Move the boom forwards to the position shown below. j Make sure that the centre of gravity is forward of the point x. ’ EE i 5 \ S Keep the feed stinger against the ground to make sure that the feed J\\ cannot move.BOOM DB 800 RANGER, SCOUT 4. Move the feed swing cylinder so that there is no load on the pin. 5. Remove the screw (1) and the washer (2) from the upper end of the pin atthe piston rod end of the swing cylinder. 6. Remove the sleeve (3) using an M24 screw as a puller. Pull the pin (4) out from below and drive the sleeve (5) off upwards from below, 3. 4 5 2 | 1 7 oo 7. Drive the piston rod forwards up to the ear (a) for horizontal drilling, and insert the pin. Tighten to the specified torque of 290 Nm. 8. Lift the stinger up from the ground. 9. Turn the feed to the horizontal drilling position by driving the swing cylinder inwards. (© 2004 SANDVIK TAMAOCK CORP, Tampere Plant ae TAIMOROCIE Sele ‘Teltax +358:205 44 120(©.45660-8 en 1204/ PIR 15 (16) BOOM DB 800 RANGER, SCOUT 8. MAINTENANCE Each shift: © Lubricate the 17 boom greasing nipples: - cylinders = joints @ Visually check the condition of the boom. Each week: © Wash the boom. © Tighten all bolts and nuts. © Check all adjustable cylinder pins and their correct tightness (290 Nm). Every 600 hours: © Check the weldings of the boom.BOOM DB 800 RANGER, SCOUT Notes: ‘© 2004 SANDVIK TAMROCK CORP, Tampere Plant Po Be 100 On CIKS EN S510 TAMPERE, Friend ‘aa aon aa tat “Telefax 4358 205 44 120(©.47150 - 3 en 0206 / JKn 1) HYDRAULIC CYLINDERS REPAIR AND ADJUSTMENT CONTENTS 1, GENERAL .... 1.4, Structure . 2. SAFETY .. 3. OVERCENTER VALVE 3.1. Operation . 4, COMPONENTS 5, DISMANTLING 8.1. Cylinder 5.2. Piston .. 5.3. Inspection 5.4. Replacing of bearings bushing 6. ASSEMBLING ... 6.1. Assembling of cylinder 7. TESTING OF CYLINDER . 7.4, Line A, inspection - 7.2. Line B, inspection . won OO unGAG sO NNNHYDRAULIC CYLINDERS -_eeoeoeoo 1. GENERAL 1.4. Structure The main structural differences between hydraulic cylinders are: © single and double acting © cylinder bore @ stroke © overcenter vaive equipment Stroke can be limited with a spacer mounted either to the piston side or the piston rod side. Correct type of spacer is given in the spare parts list. 2. SAFETY Acquaint yourself with the service and user instructions before starting to work on a cylinder. Learn to know all the components that you will be working on. ‘CAUTION, [— ] Follow the installation instructions issued by Tamrock (CAUTION, Installation, adjustment and repair work can only be carried out by a (1 Person who has the necessary qualifications and knows the equipment. Proper use and service guarantee longer life of the hydraulic cylinder. (CAUTION Use all necessary safety devices and check their condition. (CAUTION Before starting the rig, make sure that nobody is working close to, or /\\ under the rig Never disconnect any hydraulic hoses or valves before making sure that /\ there is no static load in the syster m. [warnana | [ {© 2005 SANDVIK TAMROCK CORP, Tanpors Pam, PO.bex 100, TD OG FIN-S3311 TAMPERE, Finland Tal 358 208 a0 121 Telelx +958 205 4 1203. 3.1. (©-47160-3 en 0205 / JKn 3@ HYDRAULIC CYLINDERS OVERCENTER VALVE Operation Most hydraulic cylinders are equipped with an overcenter valve. They are efther built-in ‘or connected to the hydraulic circuit via hydraulic hoses. Overcenter valves are one-piece components and they cannot be readjusted. Sets of seal rings (1) are provided. The four tasks of an overcenter valve are: Ifa hose connected to the hydraulic cylinder breaks, the overcenter valve acts as a safely valve. During drilling, the overcenter valve prevents oil flow from the cylinder to the oil tank. The boom maintains accurately the position to which itwas moved to by using the boom control valves. When the boom is moved, the overcenter valve does not allow cil to flow from the return side until the pressure on the pressured side rises high enough. Boom movements are smoother and more accurate, and the boom’s own weight cannot accelerate the speed movement. ifan external force raises the pressure in the cylinder higher than the set value of the overcenter valve, the valve opens and lets oil out of the cylinder. This enables the boom to yield under external force, and mechanical damage to the boom can be avoided. The set value of the overcenter valves for different purposes are different. Therefore, you must replace an overcenter valve with one from a other cylinder. the set value of the valve is punched on the top of the valve.HYDRAULIC CYLINDERS 4. COMPONENTS Components of a cylinder 1. [Socket screw (6._ [Locking plate 2.__[Cylinder cover 7__|Rod nut 3._ [Piston 8._ [Piston rod 4. [Overcenter valves 9._ [Spacer 5._ [Cylinder tubes 10. [Bearing bushing Components of a cylinder (threaded cylinder cover) THANTIROCIEE © 2005 SANDVIK TAMROGK CORP, Tarps Box FIN-30311 TAMPERE, Finland Tel. 4858 205.48 121, “Telefax +358 205 4a 120047150-3 en 0205 / JKn se HYDRAULIC CYLINDERS nn 5. DISMANTLING Before starting to remove the cylinder, make sure that the boom is properly supported, and any static loads of the cylinder are removed. Disconnect the hydraulic hoses to the cylinder and plug the open hose ends and cylinder adapters. Remove the locking rings of the cylinder pins, support and secure the oylinder so that it cannot fall down. Tap the pins out. Wash the cylinder externally before starting to dismantie it. Mount the cylinder firmly at the lug in the cylinder tube end. 5.1. Cylinder Hryou can use hydraulic pressure, connect the hoses to the cylinder and run the piston rod (8) out, remove the overcenter valves (4). Unscrew the socket screws off of the cover (2) or, if the cover is thread mounted, open the cover with a suitable tool. Screw the overcenter valves (4) back, and run the piston rod (8) and the cylinder cover (2) out. When pressing out, support the piston rod (8) properly to get it out smoothly. 5.2, Piston Mount the piston rod firmly from the eye end, and tap out the locking washer lug from the groove of the nut, and remove the nut (7). Remove the piston (3) together with the seals. Pull the cylinder cover (2) off the piston rod and remove the cylinder cover seals and the wiper and replace them. Unscrew the overcenter valves (4) from the cylinder tube and visually check their condition. Wash all components. 5.3. Inspection Replace all seals and wipers. Check all sliding surfaces. If scratches, big enough to feel with afingemailare found, should the components be replaced because the sealing ability of the surfaces is no longer good. Also check the piston rod for straightness. If the rod is distorted, check that it is not caused by a incorrect spacer. Check the condition of the bearing bushings (10), and replace them if there are any marks of wear. 5.4. Replacing of bearings bushing If the cylinder already has been removed from the rig, support the cylinder well and tap the old bearing bushings out using a suitable drift and a copper hammer. The new bearing bushings are easier to install if they are cooled in a freezer, and the cylinder eye is warmed up with a torch.HYDRAULIC CYLINDERS 6. ASSEMBLING If the stroke of the cylinder is limited with a spacer and it is left out, the (4) cylinder can be damaged in use. Check that you install the correct type spacer. ‘CAUTION. 6.1. Assembling of cylinder Grease the seal grooves and install the O-rings, the lip seal and the guide rings on the cylinder cover (2). Install the cover of the piston rod (8). Ifa spacer (9) is used to limit the maximum stroke of the cylinder, install the bushing on the piston rod before installing the piston. Grease the seal grooves and install the piston seal (10). When installing the piston's O-ring (11), be careful not to damage it in the piston rod thread. Install the locking plate (6) and the locking nut (7). Tighten the nut and lock it in a place by tuming a tang of the locking plate into its groove, The piston rod and the cover assembly (© 2005 SANDVIK TAMROCK CORP. Tampere Pant, POBox 100 any, OG FIN-83611 TAMPERE, Fntand ‘Tel 358 208 44 121, “Telex +358 205 48 120(©4710 - 3 en 0205 / JKn 70) HYDRAULIC CYLINDERS eee Check if the minimum stroke of the oylinder is limited. If itis, the spacer must be inserted into the cylinder first. Push the piston assembly into the cylinder. Remember to lubricate the seals before assembling! Push the cylinder cover (2) in and insert the socket screws (1) through the cover and tighten them. If the cylinder cover is thread-mounted, use a special tool for tightening. Install the overcenter valves (4) and the adapters, and test the cylinder. A assembled cylinderHYDRAULIC CYLINDERS 7. TESTING OF CYLINDER Testing of cylinder 7.1. Line A, inspection Run the piston rod completely out. Disconnect line A, and pressurize line B. Check line Afor leaking oil. If oil leaks out, one of the seals (10, 11 or 12) or overcenter valve is faulty. 7.2. Line B, inspection Run the piston rod completely in. Disconnect line B, and pressurize line A. Check line B for leaking, Ifoil leaks out, one of the seals (10, 11 or 12) or the overcenter valve is faulty. Ifoil comes out from between the cylinder cover and the cylinder tube, the cylinder cover O-ring (19) is faulty, If oil comes out from between the cylinder cover and the piston rod, the cylinder cover O-ring (14) is faulty. {© 20085 SANDVIK TAMROGK CORP, Tampere Pian, aE TAMIROGK Sire Telotax +356 205 44 120© 13051-1 en 0306, FF 104) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 789 Dw:CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 CONTENTS 2. LOCATION OF COMPONENTS 3. ENGINE AND COMPRESSOR 3.1. Engine Ranger 500, 680, 700, 780... 3.1.1. Engine oil, oil filter and crankcase breather . 3.1.2. Fan and alternator belt . 3.1.3. High pressure fuel pipes . 3.1.4. Bleeding the fuel system 3.1.5. Water separatorffiter 3.1.6. Engine cooling system 3.1.7. Radiator core ............4.. 3.2. Engine and compressor air filters 3.2.1. Service and replacement of air filters . 3.3. Checking and changing oil of Stiebel transfer gear 3.3.1. Oil recommendation of Stiebel transfer gear 4. UPPER FRAME. 4.1. Receivers . 4.1.1. Hydraulic oil receiver 4.1.2. Fuelreceiver ...... 4.2. Upper frame swing cylinder 4.2.1, Adjusting the double pressure-relief valve (194 4.2.2. Removing the cylinder . 4.3. Upper frame extra swing cylinder (optional) 4.3.1. Removing the cylinder . : 4.4. Upper frame swing joint 4.4.1. Removal of upper frame from lower frame 5. TRAMMING HYDRAULICS .. 24 5.1. Components of tramming hydraulics . 24 5.2. Operation ... 26 5.2.1. Tramming from cabin .. 26 5.2.2. Slowspeed........ eae i Teer tibe 5.2.3. Fast speed .. 26 5.2.4. Stopping .. 27 5.2.5. Remote control . 27 ‘© 2008 SANDVIK TAMAOCK CORP, Tampere Pant FO. Box 100 TTA\ TRO) FIN-33811 TAMPERE finland “ToL 058 205 44 121 “Telefax +358 205 44 120© 12061-1 on 0506/P1R 304) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 6. OSCILLATION. 28 6.1. Components of oscillation 28 6.2. Operation ... 30 6.2.1. Operation of oscillation hydraulics 30 6.3. Oscillation cylinders .. 30 6.3.1. Removing the cylinders 30 7. TRACKS AND DRIVE GEAR . 31 7.1. Adjusting tracks .. 31 7.2, Checking and adding final drive oll . 32 7.2.1. Draining final drive oll 32 7.3, Removing and assembling of the track chain . 33 7.4. Removing the final drive . ta 34CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 L SAFETY Always follow safety instructions and be careful in your work. ‘ATTENTION, [ATTENTION Servicing, adjusting, or repairing the rig is only allowed to persons with special service training for the rig in question. Read the instructions carefully before servicing, adjusting, or repairing the rig. Pressurized hydraulic hoses must no be touched by hand. The hoses may have unnoticeable hairline cracks that let out high-pressure oil sprays that may penetrate the skin. Watch out for rotating parts of the rig. Service or repair the rig only with the engine stopped. Make sure that the rig cannot be started without cause during the service. Do not stay under a rig that has not been supported properly. Do not disconnect hydraulic hoses or valves before having supported the rig. Before service, support the rig mechanically or by running a cylinder into its extreme position. OBSERVE ABSOLUTE CLEANNESS WHEN DISMANTLING AND REASSEMBLING HYDRAULIC EQUIPMENT. Whenever a cylinder has been removed, the hydraulic circuit must be vented and flushed. This is done to prevent dirt and air in the cylinder from causing functional disturbances. (© 2006 SANDVIK TAMROGK CORP. Tarnpere Plant \ P20. Box 100, INTRO FIN-33611 TAMPERE Finland "I Sie Telefax +858 205 44 120,© 19951-1 en 0506 FIR 5000 CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 2, LOCATION OF COMPONENTS Fuel receiver Compressor oil / air receiver Engine cooler Engine air filter Compressor air filter Compressor . Hydraulic pumps Side pump . Transfer gear . Hydraulic oil receiver SeenogeoneCRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 3. ENGINE AND COMPRESSOR 3.1. Engine Ranger 500, 680, 700, 780 Refer to your engine operation and maintenance manual to get the detailed instructions. . Dipstick Oil drain plug Oil filter . Oil filing plug Crankcase breather element Fuel filter . Water separator / filter NOOPONe 108 SANDVIK TAMROCK CORP, Tampere Plant ‘m0 F:0. Box 100 FIN-83311 TAMPERE Finland ‘TeL 358.205 46 121, Telefax +258 206 44-120(© 13951-1 en 0506/FIR 7034) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 3.1.1. Engine oil, oil filter and crankcase breather Check engine oil level daily with the dipstick. The oil level must be between “add” and “full” marks. Change both engine oil and oil filter every 200 operating hours. The crankcase breather element (5) must be replaced every 600 operating hours. 3.1.2. Fan and alternator belt ‘Check the condition and tightness of the fan and alternator belt daily. The belt must be replaced after every 600 hours of operation.CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 3.1.3. High pressure fuel pipes There are high pressure fuel pipes in the engine, Never open the joints of the high pressure pipes! For more detailed instructions, see the user and maintenance manual of the engine. hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may {Wwannina| cause personal injury or death. Contact with high pressure fuel may cause fluid penetration and burn The pipes (1-6) and (8) are high pressure pipes, (7) is a high pressure manifold for fuel. 3.1.4. Bleeding the fuel system The fuel system can be bled with a pump (1). Refer to your engine operation and maintenance manual to get the detailed instructions. 72008 SANDVIK TAMROGK CORP, Tampere Plant ; TARMROCH fe irme— Car© 19981-1 en 0306 (PIF 9604) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 3.1.5. Water separatorffilter Frequency of water draining is determined by the amount of impurities in the fuel. Water is heavier than fuel and will settie to the bottom of the bow! (D). The bow! must be drained before the water level reaches the bottom of the filter element (E). Check the water amount in the bowl every day; drain the bow! of water by opening the drain valve (F). Asthe filter element slowly gets blocked by impurities, the fuel flow to the engine becomes restricted, resulting in noticeable power loss and/or troubles in starting the engine. Vacuum gauge (H) monitors the condition of the filter. When the reading of the gauge is between 7 and 8, the filter must be replaced. Check the reading of the gauge every day; note that the engine must be running at full speed during the checking. (a Never let the engine run when the gauge reading is over 9! (=D Replace the filter element every 200 engine hours or if you notice any power loss in the engine. 1. Drain off some fuel from the bowl by opening drain valve (F). Spin element (E) and bow! (D) off together. Remove the bow! from the element and replace o-ring (G) Apply a coating of clean fuel or engine oil to the o-ring and element seal. Spin the bowl onto the new element and spin them onto the filter head manually. Do not use any tools for the tightening! gaep Do not pre-fill the filter with fuel!CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 Water separator/fuel filter ~ check the reading of the gauge when the engine is running at full speed ~ replace the filter element when the needle is between 7 and 8 (inHG) - never let the engine run when the reading is over 9! ‘© 2008 SANDVIK TAMAOOK CORP, Tampere Plant WOROGHK “Fale “Telefax +358 205 44120(© 19951-1 en 0306/PIR 11084) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 3.1.6. Engine cooling system Atthe upper part of the engine there is an inlet air intercooler and at the lower part a water cooler. Expansion vessel is located beside the cooler. Always use antifreeze solution or cooling system conditioner to protectthe cooling system from corrosion. Check the proper concentration from engine instruction booklet. Check the amount of cooling liquid daily when the engine is cold. The amount of cooling liquid is correct when the liquid level reaches the bottom of the expansion vessel filling pipe. Engine revolution speed drops first to idle and stops after a delay ifthe amount of cooling liquid drops too low. At the same time the control display displays a notice.CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 Hot fluid and steam can cause severe injuries. Never open the radiator le cap when the engine is hot or running. head. Never add cold coolant to hot engine as this may damage the cylinder ‘Change antifreeze solution every 1800 operating hours. Drain both engine and radiator. Mix the antifreeze solution and refill cooling system slowly to avoid air pockets. Start the engine with expansion vessel cap off and let the coolant level stabilize. Add coolant if necessary. Check the cooling system for leaks at the same time. 3.1.7. Radiator core Clean the radiator core every 50 hours for impurities. Always inspect/clean the radiator core with the engine stopped. Ifyou use a high pressure washer for the cleaning, be careful not to damage the radiator core. Normal impurities, such as dust, can also be removed with pressurized air. Do not use a higher air pressure than 4 bar. The engine is equipped with a suction fan. Blow the radiator clean from the fan side. {© 2006 SANDVIKTAMROGK CORP, Tampere Plat P.O. Box 100, ROGES BIN-83011 TAMPERE Firiand ‘a oase 20844 1, Telefax +88 205 44 120© 19951-1 en 0306 /PIR 13.64) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 3.2. Engine and compressor air filters The engine and the compressor have separate air filters that are located in the rear of the rig on top of the engine. The air filter unit includes a pre-separator and a filter element. 34 Airis drawn in the filter through the hole (1). The intake air gets into a whirling motion which separates the heavier particles from the air. The engine exhaust gases create suction that draws the particles out through the ejector tube (2). The pre-cleaned air is then drawn through the air filter (3) and the safety filter (4) into the engine and the compressor.CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 3 / oo Intake holes Ejector tube Filter element Safety filter element Service indicator BPR ‘The purpose of the safety filter element is to prevent impurities from entering the intake holes while the filter element is removed or in case the filter element breaks down. 3.2.1. Service and replacement of air filters The air filter units are equipped with a service indicator (5). When the engine or compressor air supply is disturbed because the air filter is blocked, the service indicator shows red colour. The function of the service indicator is must be checked daily by pressing the button at the end of the indicator. The red float should move freely. The filter element must be cleaned or replaced when the service indicator shows red. The filter element must be replaced at least every 600 hours or every 6 months. The filter element can be cleaned max. six times. Note that the filtering (L222) | capacity and structure of the element are weakened after every cleaning. [caumon | When the filter element is cleaned or changed the safety filter element [£22] must be kept in place. ‘CAUTION (ZN (CAUTION. The safety filter element must not be cleaned. ‘© 2005 SANDVIK TAMROCK CORP, Tampere Pent Soa ANNTIROC co a "1 eines Tokar +358 205 44 120,© 19951-1 en 0306/PIR 1504) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 The safety filter element must be replaced when the filter element has been replaced three times, or at least every 1200 hours. Cleaning the filter element Outwards from the clean side. With pressurized air: max 6 bar from over 5 om distance. With water without a nozzle: max 2.5 bar. The filter element can also be cleaned with a washing agent recommended by the producer, see instructions of the producer Dry the element after having cleaned it with water. The drying temperature must be below 82°C. After cleaning, put a bright light inside the filter element to check any possible damage. Turn the filter around slowly; if you notice any ‘CAUTION (CAUTION luminous points or other damage, replace the filter immediately. When changing the ilters, always check the seals and the sealing (L22]}| surfaces. Carefully install the seals in their correct places. When changing the filters, also check the engine and the compressor intake lines and their connections.CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 3.3. Checking and changing oil of Stiebel transfer gear Check the transfer gear oil level (1) daily. Change the transfer gear oil after first 200 engine hours and then after every 1200 engine hours. Oil capacity is about 3,2 litres. Always check the oil level by the dipstick. Drain plug (2) and filing plug (3). Open air plug (4) to help oil filing. Clean the breather (5) during every oil change by compressed air. Only use the oils according to the oil recommendation next page. ‘© 2006 SANDVIK TANROCK CORP, Tampere Plant a OGRE ee feiee Telotax +388 205 44 120© 19951-1 en 0306/PIR 1704) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 3.3.1. Oil recommendation of Stiebel transfer gear ‘Synthetic olf PAO Lubricant type Kine. viscosity (mm2js) 40°C Ambient temperature ARAL ‘Alphasyn 1220 T 100 Reductett ‘Synthese 220 Tntor HCLP 220 ‘Spartan Synthetic EP 220 Fenolin Unisyn | Renolin Unisyn CLPHC 220 | CLPHC 100 Mobilgear Mobilgear SHC XMP 220} SHC XMP 100 ikiabersyrth EG-4-220 KLUBER Agip Blasia SX 220 | Blasia SX 100 Tugra Synthetic Gear Lubricant 220 Shell Omala Oil HD 220 ‘Synthetic A220 A100 Factory filling: Shell Gear HDS 150 Synthetic gear oilCRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 4. UPPER FRAME 4.1. Receivers 4 Hydraulic oil receiver Hydraulic oil receiver is located on the left side of the rig. Breather filter Oil level sight glass Hydraulic oil return filter 4. Collecting piece Hydraulic oll level is checked in the level indicator on the left side of the receiver. The oil level should be half way up the sight glass. A hand pump is used for filling the hydraulic and the compressor oll receivers. Choose the receiver to be filled with a 3-way valve on the top of the hand pump. The hydraulic oil receiver breather filter is located on the top of the receiver (changing interval 600 h). ees The hydraulic oil return filter is inside the receiver. To change the returm filter the cover on top of the receiver must be opened. Before the cover is removed, the top of the receiver must be carefully cleaned to prevent dirt from entering the receiver. The sealing surfaces of the filter element must always be checked and carefully pressed into the grooves. The hydraulic system pressure filter is located at the rear of the control panel. The filter is equipped with an electric device that indicates when the filter element should be replaced. The filter indicator light may go on for a while when the engine is started and the hydraulic oil is still cold. This does not, however, mean that the filter is clogged. ‘© 2006 SANDVIK TAMROCK CORP, Tampere Pant EE TARIROCGE (Sire “Telefax +358 205 46 120© 13951-1 en 0308 /PIR 1964) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 4.1.2. Fuel receiver Fuel receiver is located in the front right-hand corner. 1. Breather fiter 2. Drainage plug 3. Filling cap Fill the tank with clean fuel only; it is extremely important to keep the fuel storage tank clean and also to drain the water and clean it regularly. Clean the area around the filing tube carefully before opening the fuel receiver filling cap. This prevents dust and other impurities from entering the receiver. Keep the filling pump valve clean; when using a hand pump take care that the pump inlet hose and the fuel container intake hole are clean. Clean the electric filling pump valve and protect it from impurities before filling the tank. 7 =r =CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 Do not keep the tank filling cap open when using the electric pump. Drain water from the fuel tank regularly (every 50 hours or once a week). Clean the tank every 1200 engine hours. Replace the breather every 600 engine hours or if it is moistened by fuel (overfilled). Fill the fuel tank at the end of each day of operation to drive out moist air and to prevent condensation. Do not fill the tank to the top. Fuel expands as it gets warm and may overflow. 4.2. Upper frame swing cylinder The upper frame swing cylinder is equipped with end-position damping and a manifold-mounted double overcenter valve. The manifold must not be replaced with hydraulic hoses. Double pressure-relief valve 194 of the cylinder. (© 2006 SANDVIK TAWROCK CORP. Tampere Plant MUROCHE “ESire- “elo +356'205 44 120© 13951-1 en 0306/PIR 21 (08) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 4.2.1. Adjusting the double pressure-relief valve (194) 1. Plug the hoses leading to the swing cylinder (valve ports A2 and B2). 2. Connect a pressure gauge to the measuring point (MA) at the port (A1). 3. While the engine is running at full speed, pressurise the port (A2) by turning the upper carriage to the left. 4. Adjust the pressure to 130 bar. 5. Connect the pressure gauge to the measuring point (MB) at the port (B1). 6. While the engine is running at full speed, pressurise the port (B2) by turning the upper carriage to the right. 7. Adjust the pressure to 180 bar. 8. Lock the adjustments.CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 ——————— eee eee 4.2.2, Removing the cylinder 1. Drive the rig onto level ground. 2. Support the upper frame immovable in relation to the lower frame by, for instance, pressing the feed stinger firmly against the ground 3. Operate the cylinder hydraulically to find the point where the cylinder pins are not under load. 4. Loosen the overcenter valves just enough to release the cylinder pressures. 5. Disconnect the hydraulic hoses of the cylinder. Plug and mark the connections. 6. Support the cylinder and remove the pins. 4.3. Upper frame extra swing cylinder (optional) The upper frame extra swing cylinder is equipped with a manifold-mounted double overcenter valve. The manifold must not be replaced with hydraulic hoses. 4.3.1. Removing the cylinder 1. Drive the rig onto level ground. 2. Support the upper frame immovable in relation to the lower frame by, for instance, pressing the feed stinger firmly against the ground. 3. Operate the cylinder hydraulically to find the point where the cylinder pins are not under load. 4. Loosen the overcenter valves just enough to release the cylinder pressures. Disconnect the hydraulic hoses of the cylinder. Plug and mark the connections. 6. Support the cylinder and remove the pins. a 1. Upper frame swing cylinder 2. Upper frame extra swing cylinder ‘© 2006 SANDVIK TAMROCK CORP, Tampere Plant “TDANIMTIRO CIAL Bi Biiaprernns “Telefax +368-205 44 120© 19951-1 en 0306 /PIR 23 (08) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 4.4. Upper frame swing joint ‘Two radial bearings and one axial bearing are used at the swing joint between the upper frame and the lower frame. Regular lubrication of the bearings significantly lengthens their operational life. 4.4.1. Removal of upper frame from lower frame 1. With the boom in the transport position, move the rig onto level ground. 2. Connect the lifting hooks (Cf. Fig.) and lift the upper frame enough to keep it steady. Lifting points on the rig; 1,2 and 3 3. Remove the upper frame swing cylinder (don't remove the upper frame extra swing cylinder). 4. Disconnect the hydraulic hoses between the upper frame and lower frame. Plug and mark the connections. 5. Remove the swing joint locking cover. Lift the upper frame off the lower frame as straight as possible. Lower the upper frame onto a strong and steady base for repairs. xo j Never stay under a load that is hanging from lifting ropes.CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 TRAMMING HYDRAULICS 5.1. Components of tramming hydraulics 1. Variable displacement pump. 130. Pilot control valve for the tramming valve 135; the valve is used for controlling the right and left track of the rig. 131. Remote control tramming valve (optional); the valve is used for controlling the left track of the rig 182, Remote control speed adjusting valve; the valve is used for selecting desired ramming speed. 133, Tramming mode selector vaive (optional); the valve is used for selecting either tramming from cabin or using remote control for tramming. 134. Remote control ramming valve (optional); the valve is used for controlling the right track of the rig. 135. Tramming valve; divides oil flow to the left and the right tramming motor. The valve includes main pressure relief valve 138 and pressure compensators 139 and 140, flow regulators 141 and 142, and inlet valves 152 and 153. 136. Right tramming valve spool; determines the volume of the oil flow to the right tramming motor. 137. Left tramming valve spool; determines the volume of the oil flow to the left tramming motor. 138. Main pressure relief valve for the operation of pump 1. 139. and 140. Tramming spool pressure compensators. A pressure compensator ensures that the tramming speed remains unchanged despite changes in load, 141. and 142. Flow regulators; used for adjusting the oil flow to the tramming motors so that the rig runs straight. 143, Right tramming brake valve; acts as a hydrostatic brake preventing the motor from rotating by keeping the return line closed. Also prevents the rig from rushing when tramming downhill. 144. Left tramming brake valve; acts as a hydrostatic brake preventing the motor from rotating by keeping the return line closed. Also prevents the rig from rushing when tramming downhill 145. Right brake. 146. Left brake. 147. Right tramming motor. 148. Left ramming motor. 149. Tramming speed selector valve; used for selecting slow/fast tramming speed, The valve is controlled by the selector switch in the cabin. 150. Control cylinder for swash plate angle (RH). 151. Control cylinder for swash plate angle (LH). 152. and 153. inlet valves; prevent motor cavitation. 154. Pressure switch; switches on back-up alarm when reversing. (© 2006 SANDVIK TAMROCK CORP, Tampere Plant RES TANMROGE “Esire Telefax «386-205 44 12025 (34) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 (€ 13951-1 en 0308 /PIRCRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 ——————— eee 5.2. Operation The rig is equipped with piston motors (hub gear). Two tramming speed ranges are available. Max. tramming speed is 3.5 km/h 5.2.1. Tramming from cabin The pilot control valve (130) levers are used for moving the tramming valve (135) spools hydraulically. Pilot pressure comes from the energized tramming mode selector valve (133) The idling pressure of the pump (1) affects the spools through the pressure compensators of the tramming valve (135). When the pilot control levers are moved, control pressure moves the spools accordingly. When the spools are deviated from neutral position, the load sensing line to the pump regulator is opened. The pump is adjusted to an output corresponding the load of the tramming motor. Oil flows through the tramming valve into the tramming motor and opens the tramming brake valves (143 and 144) in the return line. At the same time oil pressure opens the tramming motor brakes (145 and 146) through the shuttle valve. The return oil from the tramming motor flows through the tramming brake valve and the tramming vaive into the receiver. 5.2.2. Slow speed When the tramming speed selector valve (149) is without voltage, the control cylinders (150 and 151) move the tramming motor swash plate to maximum angle to gain slow ‘tramming speed and high torque. 5.2.3. Fast speed When the tramming speed selector valve (149) gets voltage, tramming cirouit pressure affects the piston side of the control cylinders (150 and 151) moving them against the spring to extreme positions. This, in turn, gives a smaller angle to the tramming motor swash plate and results in high tramming speed and less torque. ‘© 2006 SANDVIK TAMAOCK CORP, Tampere Plant TANIROCH €Sire— “elo +358 205 48 120© 19851-1 en 0806 /PIA 27 (88) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 5.2.4. Stopping The rig is stopped by returning the pilot control levers to neutral position. The pilot pressure is released through the control valve into the receiver; the tramming valve spools (136 and 137) return to neutral position. The tramming circuit pressure is released through the tramming valve spools into the receiver. The springs now push the tramming motor brakes on. When the rig is stopped, or when the tramming speed gets too high (e.g. when tramming downhill), the tramming motor tends to act as a pump due to external load. Since the pressure in the line to the tramming motors drops, the control pressure in the tramming brake valves (143 and 144) drops as well. The valve moves towards neutral position restricting the return flow and that way the motor speed. Thus the valve operates as a hydraulic brake preventing the rig from rushing downhill. When the rig has stopped, the spools of the tramming brake valves return in neutral position. Together with the mechanical brakes this ensures that the rig stands still. 5.2.5. Remote control Pilot control pressure comes from the drilling block through the unenergized tramming mode selector valve (133). The remote control vaive block contains electrical remote control tramming valves (131 and 134) for both tramming motors. The block also includes a pressure reducing valve (132), which is used for selecting maximum tramming speed. Control pressure affects the Position of the spools and the oil flow to the tramming motors through the shuttle valve.CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 6. OSCILLATION 6.1. Components of oscillation 50. Variable displacement pump. 159. Control valve for left oscillation lock-up valves 162 and 168. The valve is used for locking and unlocking the left oscillation cylinder. It is operated electrically by switch $25 in the cabin (not shown here). A light in the panel indicates the valve being energized (oscillation unlocked). 160. Control valve for right oscillation lock-up valves 161 and 167. The valve is used for locking and unlocking the right oscillation cylinder. It is operated electrically by ‘switch S25 in the cabin (not shown here). A light in the panel indicates the valve being energized (oscillation unlocked) 161. Lock-up valve of the right oscillation cylinder; when closed, the valve prevents oil from flowing from the piston side of the oscillation cylinder. When needed, the valve locks the right-side cylinder together with the valve 167. 162. Lock-up valve of the left oscillation cylinder; when closed, prevents oil from flowing from the piston side of the oscillation cylinder. When needed, the valve locks the left-side cylinder together with the valve 168. 163. Right oscillation cylinder. 164. Left oscillation cylinder. 165. Oscillation control valve; the valve is used for oscillating the rig. It is operated electrically by switch $26 in the cabin (not shown here). 166. Oscillation cylinder main lock-up valve; closes the oscillation circuit during tramming when the lock-up valves 161,162 167 and 168 are open 167. Lock-up valve of the right oscillation cylinder; when closed, prevents oil from flowing from the piston-rod side. When needed, the valve locks the right-side cylinder together with the valve 161. 168. Lock-up valve of the left oscillation cylinder; when closed, prevents oil from flowing from the piston-rod side. When needed, the valve locks the left-side cylinder together with the valve 162. 169. Flow control valves for the oscillation cylinders; the valves are used for adjusting oscillation speed. 246. Shuttle valve (© 2006 SANDVIK TAIAROCK CORP, Tampere Plant AMIROCHE “FEE “Telefax +358 205 44 12029 (34) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 © 13051-1 en 0306/PIR pocn-----------------. 90 ; 3 i 3CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 6.2. Operation During tramming the track oscillation must be open; the cylinders are then connected to each other through cylinder lock-up valves. Free movement of the tracks ensures good maneuverability and reduces stress in the frame structures. After tramming oscillation is locked. This gives good support to chain feed during alignment and drilling. 6.2.1. Operation of oscillation hydraulics When the rig is oscillated, the hydraulically operated lock-up valves (161, 162, 167 and 468) are open, provided that the control valves (159 and 160) are open (energized) The oscillation valve 165 is used for directing oil either to the piston-rod side or the piston side of the cylinders, depending on the desired oscillation angle. In case only one track is oscillated, choose first the desired track with an oscillation lock-up control valve (159 or 160) by using switch S25. The oscillation valve (165) is used for directing oil either to the piston side or the piston-rod side of the cylinder. Oil flowis restricted with one way restrictor (169) during oscillation. The movement will be smooth regardless of the position of the boom and the feed. Pilot controlled non-return valve (166) ensures that the oscillation will not creep. 6.3. Oscillation cylinders 6.3.1. Removing the cylinders When removing the cylinders, make sure that the rig is properly /\\ supported. Run the rig onto level ground. Support the rig immovable by, for instance, pressing the feed stinger firmly against the ground as far to the front as possible. Support the rear end of the upper frame firmly against the ground. 4. By operating the cylinder hydraulically, search the point where the cylinder pins are not under load. j Do not disconnect hydraulic hoses or valves before having supported 1. 2, 2 the ri 5. Disconnect the hydraulic hoses and plug and mark the connections. 6. Support the cylinder and remove the pins (see instructions in boom section). (© 2006 SANDVIK TAMROCK CORP, Tampere Plant INL Pea “TDAN INI Sear “Telex +358 205 44 120© 13051-1 en 0306 /IR 31089 CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 7. TRACKS AND DRIVE GEAR 7.1. Adjusting tracks Both of the tracks are equipped with a grease-filled tensioning cylinder (1). To tension the track, grease is pressed into the cylinder with the grease press provided for this purpose. The track is correctly adjusted when the upper stretch slack is 15 - 35 mm. If the track needs to be slackened, open the grease nipple (2) cautiously 2-3 turns, whereby grease will squeeze out of the cylinder along the groove in the thread of the nipple.CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 7.2. Checking and adding final drive oil 1. Oil filing plug 2. Oil checking and drainage plug Check oil level every 200 operating hours, and change oil every 600 operating hours. When oil evel is checked, or oll is added, the gear must be in such a position that the drain plug is upwards and below the gear centre line (ref. fig.). When you are adding oil, open both plugs. Oil filling capacity is 2,0 |. Ref. Oil recommendation for the quality of oil If the amount of oil in the drive gear has increased, it is probable that the shaft seal of the hydraulic motor is damaged. 7.2.1. Draining final drive oil 1. Oilfilling plug 2. Oil checking and drainage plug Drive the gear in a position in which the drain plug points downwards. Open both plugs. $$$ $$$ © 2006 SANDVIK TAMROCK CORP, Tapers Piant, ee TAMIROCHK "Siva “Telex +958 205 48 1206 19961-1 en 0906/PIR 2369) CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 7.3. Removing and assembling of the track chain 1. Drive track chain so that the masterpin is in center line of the idler wheel. The masterpin is marked with a 10 mm drilling in the center of the pin. 2. Slacken the track chain by loosening the adapter in end of the track tensioning cylinder. Hit the masterpin out from the chain link. 4. Drive the rig backwards so that the chain straightens on the ground. Take care that ‘the chain will not stick to the track frame. Note the need of space when driving the rig. 2 Assembling: 1. Liftthe end of the chain on the drive wheel. Drive the rig forwards and at the same time pull the chain e.g. with iron bar so it comes tight enough on the track frame. 2. Drive the chain to the center line of the idler wheel. Support the under end of the chain with e.g. plank. 3. Install the washers and hit the masterpin back to the chain link.CRAWLER BASE Ranger Rock Pilot 500, 680, 700, 780 ————— eee Removing the final drive Turn the upper frame to lateral position. Cut the track. Jack up the track from oscillation axle so that the drive sprocket is free. Clean the final drive and the hose connections carefully. Remove cover of the final drive. Disconnect the hoses of tramming, pilot pressure and drain case lines. Dismantle also the flange connections of the tramming hoses from the drive gear. Mark and plug the hoses and connections. 7. Support the final drive unit. parenak 8. Loosen final drive mounting bolts inside the track frame. 9. Pull the final drive out. See separate instructions on how to change the tramming motor shaft seal. ‘© 2006 SANDVIK TAMROCK CORP, Tampere Pant ee TANUROCH fire Telefax +956 205 44 120,(© 169001 GB 0198 / MAH 110) FINAL DRIVE ree 1. FINAL DRIVE 1.1. Parts of final drive PLANET GEAR HYDRAULIC MOTOR MOTOR ADJUSTMENToOMANNESMANN REXROTH Brueninghaus Hydromatik Reparaturanleitung Repair Instructions A10VEC Baureihe 52 / Series 52 NenngréBe 45 Size 45 RDE 91 710-10-R 03.97ee Notes Repair Instructions A 10 VEC Series 52 HINWEIS Teilgepratte und vormontierte Original Brueninghaue Hydromatik, Werk Horb- Baugruppen erméglichen bel karzestem Zeitautwand ertolgreiche Reparaturen. Besonders rasch erhalten Sie die richtigen Er- satztelle, wenn Sie uns bel der Bestellung Typ- und Fabrikaummer mit angeben. (Far den A 10- Ersatzteilservice wurde ein Schneliversand eingefahrt, bitte got. RD 90124 anfordern.) Die Reparaturarbeiten sing eintach, trotzdem soliten Sie unser Angebot zur Schulung nut- zen und sich bei uns das notwendige Spezial- wissen ansignen. EINLEITUNG Der Schaltmotor A 10 VE BR 52 mit seinen in dio AnschluGplatte integrierten Ventilen ist autgeteilt in 4 Ventilgruppen. Diese Gruppen sind einzein besehriaben, indem die Gruppen zerlagt und Hinweise far den Zusammenbau gegeben werden. Diese Vorgshensweise erleichtert das Verstandnis for den Umgang mit der gesamten Funktionsweise. Sollte eine Kemplett-Demontage vorgenom- men werden, so sind alle Ventiigruppen zu demontieren. Auf diese Weise kann dann eine Reinigung der AnschluGplatte erfolgen. um die Ventile erneut einzubauen. sone INHALT Bags Inhaltsverzeichnis/Hinweise 2 Sehnittbile 3 Ventiibaugruppen/Saugruppen/Dichtsatze 45 Vorbereltung der AnschluBplatte zur 67 Ventilmontage Definition der Ventilgruppe 1. Bremsventil, 8 Rackschiagventil-, Nachsaugeventilkombination, Drosselventile (nicht demontierbar) Demontage, Montage Ventligruppe 1 O15 Definition der Ventilgruppe 2. 16 Druckausgleichs- und Bremsiaftvent Demontage, Montage der Ventilgruppe 217-19 Definition der Ventiigruppe 3, 20 Druckbegrenzungsventil Demontage. Montage der VentilgruppeS 21-28 Definition der Ventiigruppe 4, 24 Hochdruckwechselventil, Steuerdruckplatte Demontage, Montage der Ventilgruppe 425-28 ‘Triebwerksdemontage des Hydromotors, , 29-95 Hinweise zur Montage Montage-Abstimmung 36 Sinstellhinweise und Pratung 36, 37 Werkzeuge und Anziehdrehmomente 38, 39 2 — Brueninghaus Hydromatik NOTE Pretested and preassembled Original Brueninghaus Hydromatik, plant Horb- subassemblies make quick and successful repairs possible. Delivery of the correct spare parts will be especially quick if you state the type and the serial number when ordering. (We created an A 10-spare part-quick shipping-service, order RE 90 124 if necessary.) Although repairs are simple, you are encouraged to enroll in the repair training classes offered by Brueninghaus Hydromatik, plant Horb. This will give you the proper experience and specialized knowledge to make your own repairs. INRODUCTION ‘The 2-speed motor A1OVE - series 52 with its auxiliary valves mounted in the port plate is divided into 4 groups of valves. Instructions how to disassemble and reassemble again are given for ‘each group. This method facilitates the understanding of the valves" total funetic 7. In case of a complete disassembly of the unit, all valve groups must be taken apart. Pr vr to re-aesembly the port plate housing must »6 thoroughly cleaned and washed. CONTENTS Index / Instructions Sectional view Valve modules / Modules / Seal kits Preparation of port block prior to disassembly Detinition of valve goup 1: Brake valve check vaive-, Anti-cav.valve combination, flow contro! (cannot be disassembled) Disassembly, assombly valve group 1 Definition of valve group 2, pressure balancing- and brake release valve Disassembly, assembly valve group 2 Definition of valve group 3 Pressure relief valves Dicassembly, assembly of valve group 3 Definition of valve group 4 high pressure shuttle valve, control pressure plate Disassembly, assembly of valve group 4 Disassembly of rotary group, instructions for assembly Shims for re-assembly Instructions for adjustments and test Tools and tightening torquesROE 91 710-10-R 09.97 Sehnitbild Reparaturanleitung A 10 VEC BR 52 Section Repair Instructions A 10 VEC Series 52 SCHNITTBILD cross-sectional diagram Achtung: Einstellung des Qmin- Anschlages siehe S. 36 Adjustment of min. displacement stop see page 36 Attentio:Repair Instructions A 10 VEC Series 52 Geofineter Schaltmotor: links Motorengenause mit Triebwerk, rechts AnschluGplatte mit zentrisch fixierter Verteilerplatte. View on open motor: Left shows motorhousing with rotary group, right shows port plate with distributor plate located in centre. AnschluGplatte mit Befestigungsschrauben. Port plate with mounting screws. AnschluBplatte mit Venti!-Gruppe 1: Bremsventile, Nachsauge-Ruckschlagv: ntil- Kombinationen. Port plate with parts of valve group 1: £ ake valve, anti-cav./check vaive-combinatio -s. AnschluBplatte mit Gruppe 2: Druckausgleichs- und Bremstiaftventil Port plate with group 2 - valve parts: Pressure balancing and brake release valve. AnschluBplatte mit Gruppe 3: Druckbegrenzungsventile. Port plate with parts of valve group Pressure relief valves. Brueninghaus HydromatikADE 91 710-10-R 08.87 Reparaturanieitung A 10 VEC BR 52 Repair Instructions A 10 VEC Series 62 ean vo c 11 ie, \o i Ks oo oO 0 = Ventilgruppe 4 (Bild K6 und K7): Steuer- druckplatte mit montierter HZ-Patrone. Valve group 4 (pictures K6 and K7): Control pressure plate with integrated HZ-cartridge. Noch Ventilgruppe 4: Wechselventil in der Anschlufplatte. Continued valve group 4: Shuttle valve taken out of the port plate. Kompletter Dichtsatz: Dichtsatze sind typenbezogen festgelegt. Hier Wellendichtring aus FPM, dbrige Dicht- elemente aus NBR. Hinzu kommt der Metall-Dichtring fur den Verstellkolben (far Schwenkwiegenverstellung). Complete seal kit: Contents of seal kits vary with motor type. Shown are FPM-shaft seal and other seal types in BUNA-N. In addition also the metal seal ring for the contro! piston. ‘Triebwerk bestehend aus: 9 Kolben (komplett), Zylinder (komplett montiert), Motor-Verteiler- platten und ROckzugkugel und Rackzugplatte. Rotary group completely with 9 piston assemblies, cylinder assembled with pre-load spring, motor-valve plate, retaining ball and retaining plate. Swash plate (cradle).Preparation of port block for disassembly Repair Instructions A 10 VEC Series 52 Markieren der AnschluBplatte und des Gehauses. Put mark on port block and housing to prevent mistake when re-assembling. Lésen der Zylinderschrauben. Loosen belts in port block. Demontage der Zylinderschrauben. Remove cylinder screws all the way. Beim Abheben der AnschluSplatte ist darauf zu achten, daG ein Herunterfallen der Verteiler- platte sicher verhindert wird. When lifting port block from the motor housing make sure that distributor plate does not drop. Abheben der Verteilerplatte von der AnschluB- Platte. Carefully lift the distributor plate from the port block. 6 Brueninghaus HydromatikRDE 91 710-10-R 03.97 \Vorbereitung der Anschiufplatte zur Venti-Demontage Reparaturanieitung 10 VEC BR 52 Preparation of port block for disassembly Repair Instructions A 10 VEC Series 52 Abheben des O-Ringes. Remove O-ring. 7 Mit handelsdblicher Abziehvorrichtung last sich der AuGenring des rackwartigen Kegel- rollenlagers abziehen. Outer bearing ring can be removed with standard pulling device. 8 Vor dem Zusammenbau ist ut ein exakte, ebene Aniage der Ver- telerplatt an der AnschuGplate zu achten, Der Fisieratit eit in is! den -Ausbruct 2utFinirung de Lage in syrmetischer Mitelte- dinweis tung der Paton zsrander,Verwenen Sia eas Feta Al ben" der Verallrplate une mentlren Sle bei Platten gomelnsam. Vina ro-asseing make sure ctor plate ad por late are Note! perfect plane, witout any piel between the mating suraces Hake sre cove! pin po Olek matchoe op weet hsrbuor patel" lok wth re Fixierung der Verteilerplatte durch den Fixier- stift. S. auch Hinweise S. 35, Abb. 128...130. Locating the distributor plate by means of the dowel pin. See also instructions page 35 with pictures 128...130. Montage der Anschluplatte durch Unter- greifen und dadurch Festhalten der Verteiler- plate an der Anschlusplatte. Mounting of port block on motor housing while firmly holding the distributor plate against the port block.Definition of valve group 1 Repair Instructions A 10 VEC Series 52 Drosselventil Control orifice Bremsventil Brake valve spool Nachsaugeventil Anti cavitation valve Rickschlagventil Check valve 8 Brueninghaus HydromatikDE 91 710-10-A 03.97 Ventlgruppe 1: Brems-, Rickschlagventilo u.a, Reparaturanleitung A 10 VEC BR 52 Valve group 1: Brake valve, check valve, etc. Repair Instructions A 10 VEC Series 52 eee a VerschluBschraube am Bremsventil lésen. Loosen plug of brake valve spool. VerschluBschraube demontieren. Remove plug completely. (O-Ring an der VerschluBschraube entfernen. Remove O-ring from plug. Anschiag innerhalb der VerschluSschraube demontieren. Remove stop from inside of plug. Feder demontieren Remove spring.Valve group 1: Brake valve, check valve, et Repair instructions A 10 VEC Series 52 10 Brueninghaus Hydromatik VerschluBschraube (gegendberliegend) lésen und demontieren. AnschlieBend werden aut dieser Seite die oben beschriebenen Schritte Abb. 12...15 (S. 9) durchgefanrt. Loosen plug on opposite end and remove. Also on this side follow the same steps as described in pictures 12...15 (page 9). Oberprufung der Laufeigenschatt des Bremskolbens in der Anschlu@platte. Check movement of brake valve spool in port plate. Beim Herausziehen des Bremsventilkolbens ist auf der gegendberliegenden Seite auf das Herausfallen des einen Federtellers zu achten. When pulling the brake valve spool out of its bore, make sure to catch the spring washer from the opposite end. Abziehen des 2. Federtellers am ausgebauten Bremsventilkolben. Remove also the other spring washer from the brake valve spool. Bremsventil komplett mit Kolben, 2 Feder- teller, Federn, Anschlagen, 2 Verschius- schrauben und den O-Ringen. Brake valve complete with spool, 2 spring washers, springs, stops, 2 plugs and O-rings.\Ventilgruppe 1: Brems-, Rickschlagventil u.a. Valve group 1: Brake valve, check valve, etc. ADE 91 710-10-8 03.97 Reparaturanieitung A10VEC BR 52 Repair instructions A 10 VEC Series 52 Hinweis! Note! 24 Zusammenbau des Bremsventils erfolgt in umgekehrter Reihenfolge. Auf die folgenden Hinweise ist zu achten. Rie-assembly of the brake valve takes place in the reverse sequence of steps. The following instructions and hints are important. ‘Vor dem eigentlichen Zus: bau sind die Bauteile grindlich auszuwaschen, inigungsrdckstande sind zu beseitigen durch entsprechendes Ausblasen. Aut ober- fléchliche Beschadigungen ist zu achten. Nur Teile mit guten Laufeigenschatten sind eingedlt wieder zu verwenden. Before assembly, all parts must be thoroughly washed and cl All dirt particles must be removed, if necessary with air nozzle. Make sure all surfaces are smooth, without scratches, and move freely in their cavities. Wet surfaces with oll when assembling.27 28 iia 2S Verschlufschraube der Rackschlagventil/ Nachsaugeventilkombination sen. Loosen plug screw of check valve-/anti cavitation valve combination. Demontieren der Verschlu@schraube. Remove plug screw. Entfernen des O-Ringes Remove O-ring. Feder demontieren. Remove spring. Rackschlagventil-Kegelsitz demontieren. Remove the check valve seat. 12. Brueninghaus Hydromatik\Ventilgruppe 1: Brems-, Rackschlagventile ua. Valve group 1: Brake valve, check valve, etc. RDE 91 710-10-R 03.97 Reparaturanieitung A 10VECBR 52 Repair Instructions 10 VEC Series 52 Lésen der Nachsaugeventilkegelfanrung: Hier wird ein 3-Zapfenschlassel verwendet, der einfach aus einer langen 17er StecknuB herge- stellt werden kann (siehe auch Abb. 38, S. 14). Loosen and unscrew the anti-cavitation valve stem guide. This can be done with a 3-pronged spanner which can fairly simple be made out of a long wrench socket - 17 mm (see also fig. 38 - following). Demontage der Nachsaugeventilkegelfahrung. Remove anti-cavitation valve stem guide. Demontage der Nachsaugeventi Feder. Remove valve spring. Demontage des Nachsaugeventilkegels. Remove anti-cavitation valve poppet. Lésen der VerschluBschraube far die 2. Seite der Rackschlagventil/Nachsaugeventil- kombination. Alle oben beschriebenen Arbeiten (S. 12...13, Abb. 27...34) sind zu wiederholen. Loosen and unserew the plug on the opposite side for the check-/anti-cavitation valve combination. All steps in accordance with instructions (p. 12...18, pictures 27...34) must be repeated.sl ae Valve group 1: Brake valve, check valve, etc. Repair instructions A 10 VEC Series 52 Or -— fs, be ree fOr die Hochdruckanschlisse A und B komplett mit O-Ringen. ae” as Cieneds atune Coe cee complete with O-rings. 37 Hinweis! Zusammenbau Assembly. Note! Die Nachsaugeventilke -elfahrung wi: 4 mit einer speziell zugeschli fenen 17er N 8 montiert. Achten Sie au das erforder che Anzugsmoment (s. auc? Abb. S. 8). The anti-cavitation valv2 stem guide an be mounted again, with a: 3eclally grou d #17 mm wrench socke (also see fig page 8). 450 Nm ESSER DP BARR 150 Nr. . AY Le = 4 i SZ le 5 Z Fahrung kann mit Sechskantschlssel < Valve stem guide can be screwed in leicht angezogen werden. Das erforder-_ with a regular allen-wrench. The liche Drehmoment wird mit 0.2. SchlGs- _ tightening torque of 40 Nm has to be sel s. Abb. 38 aufgebracht: 40 Nm. applied with the special wrench socket. 14 Brueninghaus HydromatikDE 91710-10-R08.87 © Venilgruppe 1: Brems-, Rdckschiagventle ua. Reparaturaniotung 10 VEC BA 52 Valve group 1: Brake valve, check valve, et Repair Insiructions A 10 VEC Series 52 Lage der Drosselventile in der Anschlusplatte. Position of shuttle-orifi in port plate. beiden Drosselventile sind in der AnschluBplatte eingebérdelt. Sie sind nicht aus der Platte demontierbar. Both shuttle-orifi are flared into the port plate. They cannot be removed. Stopfen S entfernen, um bei kompletter Demontage die Anschlugplatte komplett 2u durehspalen (Reinigung). Also remove plug ,S"; this enables a thorough and complete flushing and cleaning after a total disassembly.Definition of valve group 2 Druckausgleichsventil Pressure balancing valve 5 Bas a TE BN NS Ere NV ee HIT ee Zi NYA SNae as CKNE EZ, SS SAS “4 Bremsliftventil Brake release valve 16 Brueninghaus Hydromatik Repair Instructions A 10 VEC St jeries S20\Ventiigruppe 2: Druckausgleichs-, Bremsidftventi Valve group 2: Pressure balance-, Brake release valve RDE 91 710-10-R 03.97 Reparaturanieitung A 10 VEC BR 52 Repair Instructions 10 VEC Series 52 46 VerschluSschraube am Druckausgleichsventil lésen. Hinweis far die Montage: Die Verschius- schraube wird mit dem erforderlichen Anzugs- moment von 20 Nm angezogen. Loosen plug at pressure balancing valve cavity. Instruction for re-assembly: Required tightening torque for this plug amounts to 20.Nm. VerschluSschraube demontieren. Remove plug. Lésen des Druckausgleichsventils. Hinweis: ses Ventil wird eingeklebt mit Loctite 601 bei der Montage (s. auch S. 19, Abb. 58). Loosen pressure balancing valve. Note: This valve is mounted with Loctite 601 (see also fig. 58 / page 19). Bei gedrehter AnschiuGplatte: Demontage des Druckausgleichsventils. Removal of pressure balancing valve, with port plate turned around. Einzeltelle des Druckausgleichsventils. Individual parts of pressure balancing valve.EE K&KG« Valve group 2: Pressure balance-, Brake release valve Repair instructions A 10 VEC Series 52 Lésen des Stopfens am Bremsluftventil. Hinweis fir die Montage: Erforderliches Anzugsdrehmoment 30 Nm. Loosen plug at brake release valve. Instruction for assembly: Plug has to be tightened with 30 Nm torque. Demontage des Stopfens. Remove plug. Demontage der Feder. Remove spring. Demontage des Bremsiaftventilkolbens. Removal of brake release valve spool. Bauteile des Bremsidftventils (die eingepreBte Laufbichse des Ventils in der AnschluGplatte ist nicht demontierbar). Individual parts of brake release valve. The valve sleeve is pressed into the port plate and cannot be removed. 18 Brueninghaus HydromatikVentilgruppe 2: Druckausgleichs-, Bremsliftventi Valve group 2: Pressure balance-, Brake release valve ROE 91 710-10-R 03.97 Reparaturanleitung A 10 VEC BR 52 Repair Instructions 4 10 VEC Series 52 56 VerschluBstopfen Br lésen, entfernen. Erforderliches Anzugsmoment bei der Montage far diesen Stopfen Br = 20 Nm. Loosen plug Br and remove. Required tightening torque for assembly amounts to 20 Nm. 87 Note! Der Zusammenbau der Ventile erfolgt in umgekehrter Reihenfolge. Achten Sie auf folgenden Hinweise, s. Abb. 58 und 59. Re-assembly of valves takes place in reverse sequence of steps. Please note the following instructions, see fig. 58 and 59. Achtung: Die hier verwendete Loctite-Sorte entspricht nicht der dblichen Loctite-Sorte. Loctite Nr. 601 verwenden. Erforderliches Drehmoment: 15 Nm. Note: Please use Loctite 601. This is not the regular type of Loctite. Required tightening torque: 15 Nm. Funktionsprifung nach Loctite-Klebung und dem vorgeschriebenen Drehmoment erforder- lich: Mit Imbusschldssel prifen, ob das Venti! schaltet. Functional check after assembly with Loctite: Verify that valve can be shifted.Definition der Ventilgruppe 3 Druckbegrenzungsventile Reparaturanieitung A 10 VEC BR 52 Definition of valve group 3 - Pressure relief valves Repair Instructions A 10 VEC Ser 12 MB OSS za. \y BQ Ay 40 Nm Ws SSRN 145Nm 40.Nm MA 20 Brueninghaus HydromatiicVentilgruppe 3: Druckbegrenzungsventile Valve group 3 - Pressure relief valves ADE 91 710-10-8 03.97 Reparaturanieitung A 10 VEC BR 52 Repair Instructions A 10 VEC Series 52 Lésen und Entfernen des MeGstopfens MA. Loosen and remove plug in pressure gauging port MA. Lésen des VerschluBstopfens an der Druck- begrenzung A. Leosen plug at pressure relief valve ,A“-side. Demontage des Stoptens. Remove plug. O-Ring am VerschluBstopfen. Remove O-ring. Feder entnehmen. Remove spring.ee rere | ttt eee | Valve group 3 - Pressure relief valves Repair Instructions A 10 VEC Series 52 22 Brueninghaus Hydromatik Demontage der Druckbegrenzungsventil- patrone: Mit Durchschlag vorsichtiges Heraustreiben. Remove the relief valve cartridge carefully with hammer and punch. Weitere Zerlegung der Druckbegrenzungs- patrone: Abziehen des Dampfungskolbens. Further disassembly of relief valve cartridge. Removal of dampening spool. Druckbegrenzungsventil mit Dichtelementen (eigentliche Patrone nicht komplett zerlegbar). Pressure relief valve with sealing elements (the actual cartridge cannot be completely disassembled). Stopfen MB Iésen. Loosen plug in gauging port MB. Zweite Druckbegrenzungspatrone: Vorgehen wie bei Abb. 62...68, S. 21 und 22. Disassemble second pressure relief valve on opposite side. Repeat steps as per tig. 62...68, page 21 and 22.Ventigruppe 3: Druckbegrenzungsventile Valve group 3 - Pressure relief valves ADE 91 710-10-R 03.97 Reparaturanieitung A 10 VEC BR 52 Repair Instructions A 10 VEC Series 52 o So Hawi Bos @ oO 71 Druckbegrenzungspatronensatz komplett: Es ist darauf zu achten, da@ die Einzelteile der Ventile nicht verwechselt werden. Complete sets of pressure relief valve cartridge parts. Do not mix parts from one cartridge into the other one. Hinweis! Note! 72 Zusammenbau in umgekehrter Reihenfolge: Siehe dazu S. 21 bis 23 die Abb. 61...71. Assembly takes place in reverse sequence of steps. See pages 21 through 23, fig. 61...71. 73 Die Lage des Dampfungskolbens aut der Ven- tilpatrone dart nicht verdndert werden (eine Planseite mit 5°-Schrage fdr Dichtfunktion) The position of the dampening spool in the cartridge assembly may not be changed (one face has 5° angle for sealing function).24 Brueninghaus Hydromatik EAS =H yo ws NG HZ-Steuerdruck-Pl. ‘Steuerdruck-Platte Control pressure plate Wechselventil Shuttle valveRDE 91 710-10-8 03.97 Ventilgruppe 4: Hochdruckwechselventil, Stelldruckplatta Reparaturanieitung A 10 VEC BR 62 Valve group 4: Shuttle valve, control pressure valve 76 Repair Instructions A 10 VEC Series 52 ‘Stopfen (13) am Wechselventil lésen. Loosen plug in shuttle valve cavity. Demontage des Wechselventilstopfens. Remove shuttle vaive plug. Lésen des Wechselventils. Loosen shuttle valve. Ausbau des Wechselventils. Remove shuttle valve. Einzelteile des Wechselventils: Beim Zusam- menbau ist auf die gereinigten Teile zu achten, ebenso ist das erforderliche Anzugs- drehmoment des Ventils zu beachten (s. auch S. 24) Parts of shuttle valve; assemble only thoroughly cleaned parts, and note the correct tightening torque for the valve and plug (see page 24)SEE eee CeCe EEC O EERE EEE eEeeEe rere Valve group 4: Shuttle valve, control pressure valve Repair instructions A 10 VEC Series 62 26 Brueninghaus Hydromatik et 82 83 a4 85 Lésen der Befestigungsschrauben der HZ-Stelldruck-Platte. Loosen mounting bolts of HZ-control pressure plate. Demontage der Befestigungsschrauben an der Steuerdruckplatte. Remove bolts of control pressure plate. Abschrauben der Steuerdruckplatte: 1 jefesti- gungsschraube wird unterlegt mit Unte 1eg- scheibe. Auf die richtige Anordnung de Scheibe ist zu achten. Remove the contro! pressure plate. Or > of the mounting bolts has keen mounted ith a washer; please note the correct positic 7 of the washe! Entfernen des Verschlu@stopfens am Eingang X der HZ-Steuerdruck-Platte. Remove endplug at entry port .X" in Hz-control pressure plate. Demontage der HZ-Patrone. Unscrew and remove Hz-cartridge.FUE v1 UU 03.97 Ventlgruppe 4: Hochdruckwechselventie, Stelldruciplatte Reparaturanleltung A 10 VEC BR 2 Valve group 4: Shuttle valve, control pressure valve cry HZ-Patrone komplett. Complete HZ-cartridge. 87 HZ-Patrone zerlest. Hz-cartridge, disassembled. ea Lésen der Dase. Loosen orifice. 89 Herausschrauben der Dase. Unscrew and remove orifice. 20 Repair instructions A 10 VEC Series 52 Hinweis Note! Beim Zusammenbau der Ventile in umgekehr- ter Reihenfolge ist insbesondere aut die offene Blende zu achten (s. auch Hinweis S. 28). When re-assembling the valves in reverse sequence of steps, make sure orifice is clean and open (see also instruction on page 28).Valve group 4: Shuttle valve, control pressure valve Repair instructions A 10 VEC Series 52 1 Kontrolle der Dasendurchlassigkeit. Check the opening of the orifice. 28 Brueninghaus Hydromatik‘Motorgehause demontieren (komplett) Disassembly of hydraulic motor Reparaturanieitung A 10 VEC BR 52 Repair Instructions A 10 VEC Series 52 Vor dem Beginn der Demontage ist die AnschluBplatte gemeinsam mit dem Motoren- gehause zu kennzeichnen (s. auch S. 6, Abb. 1). Before disassembly put mark on port plate and housing (see also page 6, tig. 1). Lésen der Befestigungsschrauben und demontieren. Loosen and remove mounting bolts. Abheben der AnschiuGplatte: s. auch Hinweise auf S. 6, Abb. 4. Carefully lift off the port plate; also note the instructions on page 6, fig. 4. inge entfernen. : Die folgenden Abbildungen sind nicht mit dem Originalge- hause aufgenommen, die Abweichungen sind jedoch unbedeutend. Im wesentlichen wird der Ablaut der Komplettdemontage gezeigt. Remove O-ring. Note: The following pictures show a different motor housing; the disassembly procedure however is identical, and the difference in housing can be neglected. Abheben des Kegelrolleniagers (anschluBpiattenseitig). Disassemble the taper roller bearing (near by port plate).——————— Disassembly of hydraulic motor Repair Instructions A 10 VEC Series 62 102] Entfernen der Abstimmscheibe. Remove the adjustment shim. Lésen und Entfernen der Hutmutter far Anschlag Qmin (Ringschlussel far die Konter- mutter leicht nachgeschliffen). Unscrew the cap nut of stopper min. displacement and remove-it (ring wrench is ground a little bit). 103 Mutter zur Fixierung der Anschlagschr .ube Qmin lésen und entfernen. Loosen the lock nut of the stopper mir displacement and disassemble it. 108 Anschlagschraube Qmin entfernen. Unscrew stopper min. displacement and remove it. Einzelt des Qmin-Anschlages. Loose parts of min. displacement stop.Motorgehause demontieren (komplett) Disassembly of hydraulic motor ADE 91 710-10-R 03.97 Reparaturanieitung A 10 VEC BR 52 Repair Instructions A 10 VEC Series 52 Triebwerk in horizontaler Lage herausziehen Disassemble the rotary group In horizontal position. Lésen der VerschluBschraube. Loosen the plug. Entfernen der VerschluBschraube. Remove the plug. Verstellkolben entnehmen (mit Schwenkwiege ber Kolbenstange nachhelfen). Disassemble the contro! piston while moving the swash plate. Kolbenstange entnehmen (Schwenkwiege zum Ausbau in leichte Schraglage bringen). The swash plate must be lifted a little bit to disassemble the piston rod.ee Disassembly of hydraulic motor 32 Brueninghaus Hydromatik Repair Instructions A 10 VEC Series 52 Ausbau der Schwenkwiege. Disassembly of the swash plate. Beide Lagerschalen herausnehmen. Remove both bearing shells. Antriebswelle herausnehmen. Remove the drive shaft. Sicherungsring ausbauen. Disassemble the snap ring. Wellendichtring austreiben. Disassemble the sealing ring.Motorgehause demontieren (komplett) Disassembly of hydraulic motor DE 91 710-10-R 03.97 Reparaturanieitung A 10 VEC BR 52 Repair Instructions A 10 VEC Series 52 Abziehen des LagerauBenrings im Motorge- hause. ZweckmaBige Unterlage benutzen zur Vermeidung von Motorbeschadigungen (s. auch Hinweis Abb. 118). The external front bearing ring is pulled out of the motor housing (too! and surface infos see picture 118, too). Hinweis! Note! Die folgenden Abbildungen 118...121 zeigen das weitere Zerlegen von Bautellen bzw. Baugruppen, 2.8. Anschlupplatte, Zylinder. The following pictures nrs. 118...121 show how to disassemble parts or sub assembles e.g. port plate, cylinder. Abziehen des LagerauBenrings mit serien- maBiger Abziehvorrichtung. Beschadigung der Anschlusplatte durch Kunststoffunterlagen vermeiden. A usual commercial bearing puller is used to disassemble the external bearing ring of the taper roller bearing inside the port plate. Take care of the surface of the port plate. Zylinder: Demontage der 3 Druckstifte bei vorgespannter Feder. Cylinder: The spring has pretention while you disassemble the three pressure pins inside the cylinder. Zusatzliche Vorspannung der Feder far den Ausbau der Hakenstifte: durch Zylinder- schraube und Scheiben (s. Skizze). Disassembly of the three special pins by additional spring pretention: Use a screw and shims (see picture).SS eee eee eee Disassembly of hydraulic motor Repair Instructions A 10 VEC Series 52 321 Verstellkolben mit Dichtring. Control piston with sealing ring. Hinweis! Note! Zusammenbau des Verstellmotors in umgekehr- ter Reihenfolge. Dabel ist auf folgende Punkte zu achten: siehe die folgenden Abb. Nr. 123-130. Assemble the variable displacement motor In reverse order and note-the following: see pictures 123-130. 124] 125] 34 Brueninghaus Hydromatik Nach der Demontage des gelaufenen Wellen- dichtrings, einfetten des neuen WDR. (Kontrolle der Laufflache, Welle und Gehause). Before assembly of the new shaft seal put grease on mating surfaces. (Also check condition of mating surfaces in housing and on drive shaft). ‘Soll'im Ausnahmefall bei Reparaturen eine Montage des Wellendichtrings von auBen erfolgen, so ist vor der Montage des Wellendichtrings eine Einfahrhdlse zu ver- wenden. (Diese Halse wird auch verwendet bei serien- maBiger Montage des Wellendichtrings von innen her). In exceptional repair conditions, you can also mount the shaft seal from the outside. Use a special sleeve for mounting the sealing ring. (The same sleeve is also used in our standard production assembly for mounting the seal from the inside). Montage des Wellendichtrings mit geeignetem Rohr nur so tief, da Sicherungsring montier- bar ist. (Zu tlefes Montieren fahrt zum Ausfall: BerGhrung mit dem Wellenlager!). Einrasten des Sicherungsrings o. Abb. Push sealing ring with suitable sleeve just deep enough to mount snap ring. (If seal is pushed against bearing ring sealing function might be damaged). Assembly of snap ring without picture.Motorgehause demontieren (komplett) Disassembly of hydraulic motor 126 127 FUE 81 U1 0.97 Reparaturanieitung A 10 VEC BR 62 Repair Instructions A 10 VEC Series 52 Ausmessen der Kegelrolleniager-Vorspannung (s. auch S. 36). Measurement of the taper roller bearing pretention (see page 36, too). Beim Einbau ist auf den richtigen Sitz der Kolbenstange in der Schwenkwiege zu achten. Note that there is a correct connection of the piston rod and the swash plate. Positionsstift zur Fixierung der Verteilerplatte. Pin to tix the valve plate. Positionsstift ragt in die Fixiernut der Verteiler- plate. Pin holds the valve plate in position by a groove in the valve plate. Bei Motoren mit wechseinden Abtriebsdreh- richtungen wird die Verteilerplatte mittig posi- tioniert. Eine Abweichung der Geometr zwischen Verteiler- und Anschlu@platte ist nicht erkennbar, s. auch Pfeil Abb. links. Motors with both output-directions of rotation must have centered position of the vaive plate. There Is no difference between the geometry of the valve- and port plate (see arrow at the control area, picture left!).