Df540l-blt Maintenance Manual 2017 En

DOOFOR DF540L-BLT HYDRAULIC ROCK DRILL INSTRUCTION MANUAL 2017

CONTENTS 1. SAFETY INFORMATION 7 1.1 SYMBOLS 7 1.2 GENERAL SAFETY INSTRUCTIONS 8 2. IMPORTANT INFORMATION 10 2.1 WARRANTY 10 2.2 MANUALS 10 3. INTRODUCTION 12 4. PRODUCT INFORMATION 13 5. CONNECTIONS 15 6. ACCUMULATORS 16 6.1 ACCUMULATOR IDENTIFICATION 16 6.2 ACCUMULATOR PRESSURE AND MAINTENANCE 16 6.3 MEASURING THE ACCUMULATOR PRESSURE 17 7. OIL RECOMMENDATIONS 18 7.1 OIL CHOICE 18 7.2 OIL SPECIFICATIONS FOR DOOFOR ROCK DRILLS 20 7.3 HYDRAULIC OIL SUGGESTIONS FOR DOOFOR ROCK DRILLS 21 8. LUBRICATION REQUIREMENTS 23 8.1 LUBRICATION OF THE SHANK AND THE GEARING 23 9. PERCUSSION AND ROTATION SYSTEMS 24 9.1 PERCUSSION SYSTEM 24 9.2 ROTATION SYSTEM 24 10. FLUSHING SYSTEM 26 10.1 AIR FLUSHING 26 10.2 WATER FLUSHING 26 11. INSTALLING THE ROCK DRILL 27 11.1 INSTALLATION AND DESIGN 27 11.2 RETAINING MECHANISMS 29 11.3 DRILL TOOLS 29 11.4 COMMISSIONING 30 11.5 COMMISSIONING CHECK LIST 31 12. OPERATIONAL HINTS 32 13. DESIGN NOTES 34 14. MAINTENANCE OF THE ROCK DRILL 36 14.1 TOOLS AND TOOL KITS 36 14.2 SPARE PARTS 37 14.3 MAINTENANCE TIPS AND PROCEDURES 38 14.4 STORING AND DECOMMISSIONING THE ROCK DRILL 38 14.5 MAINTENANCE INTERVAL TABLE 39 15. TROUBLESHOOTING 41 15.1 HIGH ROTATION PRESSURE 41 15.2 ROTATION SYSTEM FAULTS 42 15.3 VIBRATION 42 15.4 PERCUSSION FAULTS 43 15.5 DRILLING PROBLEMS 43 15.6 BREAKAGES 44

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CONTENTS 15.7 CAVITATION AND CORROSION 15.8 LEAKAGES 16. ACCUMULATOR MAINTENANCE 16.1 ACCUMULATORS 16.2 ACCUMULATOR TYPE AND SERIAL NUMBER 16.3 TOOL KITS 16.4 ACCUMULATOR ASSEMBLY 16.5 ACCUMULATOR MAINTENANCE 16.6 ACCUMULATOR MAINTENANCE PROCEDURE 17. DF540L-BLT ASSEMBLY DRAWINGS 17.1 MAIN ASSEMBLY DRAWING 17.2 FRONT SECTION ASSEMBLY DRAWING 17.3 GEAR BOX ASSEMBLY DRAWING 17.4 BODY CYLINDER ASSEMBLY DRAWING 18. REPLACING THE SHANK ADAPTER 18.1 REASSEMBLY 19. FRONT SECTION MAINTENANCE 19.1 DISASSEMBLY 19.2 REPLACING THE FLUSHING SEALS 19.3 REPLACING THE BRONZE BUSHING 19.4 REPLACING THE BEARING COLLAR SEALS 19.5 REASSEMBLY OF THE FRONT SECTION 20. GEAR BOX MAINTENANCE 20.1 DISASSEMBLY 20.2 MAINTENANCE OF THE SECTION FLANGE 20.3 GEAR BOX DISASSEMBLY 20.4 ROTATION BUSHING MAINTENANCE 21. BODY CYLINDER MAINTENANCE 21.1 DISASSEMBLY 21.2 VALVE PACKAGE DISASSEMBLY 21.3 REPLACING THE FLANGES’ SEALS AND O-RINGS 21.4 REASSEMBLY OF THE VALVE PACKAGE 21.5 REASSEMBLY OF THE BODY CYLINDER 22. ROCK DRILL REASSEMBLY 23. TECHNICAL INFORMATION 23.1 DIMENSIONS 23.2 BOLT TORQUES 23.3 TECHNICAL DATA ANNEX A: REMAINING RISKS

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47 48 49 49 49 49 49 50 51 57 57 57 58 58 59 60 61 61 65 66 67 68 72 72 75 78 80 82 82 85 87 88 90 93 97 97 98 99

CONTENTS

© 2015–2016 Doofor Oy The contents of this manual may not be reproduced, published or translated in any form or by any means without prior permission from Doofor Oy. The contents of this manual may be changed by the manufacturer without any prior notice. Original instructions. V3R1

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GENERAL SAFETY INSTRUCTIONS

© 2015–2017 Doofor Oy The contents of this manual may not be reproduced, published or translated in any form or by any means without prior permission from Doofor Oy. The contents of this manual may be changed by the manufacturer without any prior notice. Original instructions. General safety instructions, version I1DC

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1. SAFETY INFORMATION Dear Customer, Thank you for choosing Doofor product. This manual contains general safety instructions and other important information. Please read the manual carefully and follow the instructions when using or servicing the product. Keep the manual available to all operators and maintenance personnel, and make sure that the instructions are understood and followed. Attention! In countries and regions where EC regulations and directives apply, the Doofor hydraulic rock drill must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of the machinery directive (2006/42/EC). Any EC declaration of conformity is not resposibility of Doofor, Inc but must be made by the party or person placing the final product on the market or putting it into service. In the regions where the machinery directive (2006/42/EC) does not apply, Doofor Inc, does not claim any responsibility beyond what is listed in the General Terms of Sale.

1.1 SYMBOLS The symbols used in the manuals are explained below. Warning symbol is used to mark very important safety information if there is a danger of injury or a possiblity of serious damage to the equipment or to the environment. Attention symbol is used to mark safety information when there is a danger of damage, wrong installation or wrong kind of operation. Note symbol is used to mark useful information and hints or tips regarding the use, maintenance or repair. Operation symbol is sometimes used to mark maintenance procedures or other procedures. Cause symbol is used to mark sections where possible reasons for malfunction are explained.

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1. SAFETY INFORMATION Work safety must be first priority in all quarrying, mining and maintenance work. Always obey all local workplace safety instructions, local laws and local regulations. Quarries can have different safety instructions regarding the use of drill wagons, drill rigs or other drilling machines. It is very important to obey these instructions. The most important instructions of the hydraulic rock drill are listed here.

1.2 GENERAL SAFETY INSTRUCTIONS Always use a hard hat, steel-toe boots, safety glasses and earmuffs.

Always keep as far away as possible from the rock drill while it is operating. Rock chips, metal scraps from the drill steel and other materials may fly away from the drill hole or from the drill itself when it is in operation. Never touch a moving drill steel. Never put your hand, foot or any other body part under the drill bit or the drill steel. Always be alert to the possibility that the drilling machine may suddenly move due to mechanical failure of the feeding mechanism. Never open the accumulator of the rock drill! Opening the accumulator may cause serious danger. Only properly authorised maintenance personnel may carry out the maintenance of the accumulator, when there is no hydraulic pressure. Keep non-workers away from the working area. Make sure that the drilling operations cannot accidentally harm anyone or anything. Check that the operational environment is safe before drilling. Make sure that all cables, hoses, tools etc are out of the way. Make sure you can’t drill into power lines, piping or other objects. Remove all lifting hooks from the rock drilling machine before operation. Lifting hooks may detach during operation and cause serious danger. Rock drills use high hydraulic pressure. Users and maintenance personnel must be trained to use the hydraulic equipment properly. The drill is designed for drilling rock material. Drilling any hazardous materials is forbidden. Safe working procedures, with extra caution, must be followed when handling drilling waste or removing stuck materials. Loose rock is considerable risk in tunnel work. Bolting, injection and drilling can temporarily increase the risk of collapsing parts of the roof. Expertise in bolting, grouting and other mining safety methods is required.

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1. SAFETY INFORMATION Always check the condition of the rock drill before using it. Check the drill for signs of leaks or damage. Check all hoses and fittings. Make sure that the lubrication system is working. Contact the manufacturer before using the rock drill to anything other than its specified purpose. If there is a danger of fire, prevent it with necessary measures. The drill does not have fire safety features. Always shut down the hydraulic system before any maintenance and make sure there is no pressure in the system. High hydraulic pressure may cause serious injuries or death. Do not modify the rock drill, accessories or spare parts without explicit permission from the manufacturer. Use only authentic spare parts. If you have received a spare part and it doesn’t look similar to the original or it is otherwise suspicious, contact the manufacturer before using it. Installation, maintenance and repair may only be carried out by properly trained personnel. The rock drill must be stopped before any drill tools are manually changed and accidental start or any movement must be prevented, for example by locking controls. Protect the workers from the drilling dust. Use sufficient and safe dust removal methods, such as drilling dust removal machine. Drilling dust is dangerous and can in short time cause severe health problems or diseases leading to death. Shields, fences, safety valves and other safety features should be installed to the drill rig or other system to which the rock drill will be installed. The design and choice of these systems is the responsibility of the party designing or modifying the drill rig or the system, and must be done according to the local laws and regulations. Before drilling, inspect the drill, drill tools, drill rig, and environment to make sure that drilling can proceed safely. Make sure everyone in the area is wearing safety equipment. Old drill holes may contain remnants from blasting operations. Make sure there is no risk of explosion before drilling by inspecting the holes. Contact blasting experts if there is any risk of explosion. Mines and quarries may have explosive gases and easily igniting dust. Check that the area is safe for drilling before starting to work. Remove any dangerous equipment.

AT MINIMUM, ALWAYS USE THE FOLLOWING SAFETY EQUIPMENT: // Hard hat // Protective earmuffs // Safety glasses

// Steel-toe boots // Protective clothing

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2. IMPORTANT INFORMATION 2.1 WARRANTY Warranty of the drill is subject to the terms and conditions of the drill at the time of the purchase. When making a warranty claim, gather necessary information such as the serial number of the drill, total operating hours, make and model of the drill rig, drilling conditions (local temperature, rock material type, drilling depth etc.) Provide this information with the warranty claim. Contact the supplier to obtain a warranty claim form. 2.1.1 WARRANTY AND SPARE PARTS Please note that the warranty does not cover a rock drill or authentic parts that have been modified in any way without explicit permission from the manufacturer. Any damage caused by non-standard or non-authentic part or parts will not be covered by the warranty. Substandard third-party parts may damage the drill and cause extra costs.

2.2 MANUALS Rock drill manual set consists of two manuals: the instruction manual and spare part manual. The assembly instructions of the rock drill comprise of these two manuals. Contact the supplier if you need another copy of a manual. Keep the manuals available for operators and maintenance personnel. Latest versions of manuals may be made available when requested. Contact the supplier for the latest version. 2.2.1 ERRORS AND MISSING INFORMATION If you feel that a manual has an error or it is missing some information, please contact the manufacturer. 2.2.2 CONTACT INFORMATION You can contact the manufacturer from our website www.doofor.com or by email: [email protected].

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INSTALLATION AND OPERATING INSTRUCTIONS

3. INTRODUCTION Dear Customer, Thank you for choosing Doofor DF540L-BLT hydraulic rock drill. This manual contains important and useful information about the product. Please read the manual carefully and follow the instructions when using or servicing the rock drill. Keep the manual available to all operators and maintenance personnel. This manual is designed for DF540L-BLT type 14280. Please note that the installation and maintenance of the rock drill or any equipment may only be carried out by properly trained and authorised personnel.

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4. PRODUCT INFORMATION Doofor DF540L-BLT is a hydraulic rock drill designed for bolting, general excavations and underground production drilling. The rock drill is equipped with multiple sealing and hermetic rotation mechanism for demanding underground conditions. Flushing can be done with water or with air. The optimal maximum drill hole diameter for Doofor DF540L is 64 mm [2 ½”]. The rock drill can be equipped with female shank adapters FR28 and FR32 or male shank adapter R32.

Doofor DF540L-BLT type 14280 hydraulic rock drill.

Doofor DF540L-BLT type 14280 main assembly.

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4. PRODUCT INFORMATION Seven digit serial number of the rock drill has been punched to the side of the cylinder body. The serial number of the accumulator is punched next to the gas valve of the accumulator.

DF540L hydraulic rock drill serial number is located on the body cylinder.

Accumulator type (LP = low pressure, HP = high pressure), prefilling pressure, and serial number can be found next to the gas valve. 14

5. CONNECTIONS

A. G1/2 hydraulic pressure line of the rotation motor, where hydraulic oil enters the system (drilling direction). B. G1/2 hydraulic oil return line of the rotation motor, from which oil returns to the tank. C1. G1/4 shank adapter lubrication line, where pressurised air-oil mixture is fed to the rock drill. C2. G1/4 alternative shank adapter lubrication line, plugged. D. Two flushing leak indicator orifices, from which flushing water flows out if sealing breaks. E1. Shank adapter lubrication exit line, from which air-oil mixture flows out of the rock drill. Recommended for use when bolting, helps keep the front seal intact. E2. G1/4 alternative lubrication exit line, plugged by default. Can be used as alternative exit. By removing the BLT flushing box, lubrication feed line from the bearing collar to the E1 can be plugged, if necessary. F. G1/2 flushing line, where flushing air/water flows into the system. G1. G3/4 percussion pressure line, where percussion oil enters the system. G2. Two alternative G3/4 percussion pressure lines. H1. G3/4 main percussion return line, from which percussion oil returns to the tank. H2. Two alternative G3/4 percussion return lines. Attention! If the hydraulic circuit is equipped with quick snap-on type connectors, make sure the connectors remain closed and cannot be forced open during operation. 15

6. ACCUMULATORS Doofor rock drills utilize accumulators to accumulate hydraulic energy and prevent shock loads. Accumulators are an important component and it is necessary to keep them functional. Accumulators contain high pressure nitrogen gas N2. Due to transportation regulations, the accumulators may have been delivered empty. Check the pressure of the accumulators before use and fill them if necessary.

6.1 ACCUMULATOR IDENTIFICATION The serial number of the accumulator can be found next to the accumulator gas valve. ”HP” signifies high pressure and ”LP” signifies low pressure. Doofor DF540L rock drill has one high pressure accumulator and one low pressure accumulator. Attention! Do not mix the accumulators. Using an accumulator with a wrong

pressure may damage the drill. Accumulators may have been delivered without pressure, and may need filling before the rock drill is used.

6.2 ACCUMULATOR PRESSURE AND MAINTENANCE It is possible to remove the accumulator from the rock drill for replacement or maintenance. Accumulators should be serviced every 500 hours. Check the pressure of the accumulators regularly. Accumulator pressure can be measured using a suitable pressure gauge. It is not necessary to remove the accumulator from the rock drill for measurement. Accumulators can be refilled while they are on the drill or they can be removed for refilling. Note: You can find more information on the removal, replacement and maintenance of the accumulators in the maintenance instructions. 16

6. ACCUMULATORS 6.3 MEASURING THE ACCUMULATOR PRESSURE Check the pressure of the accumulators regularly. The following procedure shows how to measure the pressure using tools from the accumulator refilling kit.

// HP accumulators: 55 bar [798 psi] N₂ // LP accumulators: 4 bar [58 psi] N₂

Prefill pressures:

1. Make sure that the hydraulic system is depressurised before measurement. 2. Connect the adapter to the pressure gauge. 3. Connect the pressure gauge to the accumulator gas valve (H).

4. Open the accumulator gas valve (H). Note! Pressure may drop slightly when the gas valve is opened. 5. Check the pressure value. 6. Close the accumulator gas valve (H). 7. Remove the pressure gauge.

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7. OIL RECOMMENDATIONS It is important to select suitable hydraulic oil for the rock drill. Oil quality and type can have a great impact on the lifetime of the components. Unsuitable or low quality oil may lead to problems such as excessive wear, breakages, high energy use and increased operation costs. The rock drill’s percussion system is lubricated with the hydraulic system’s high pressure oil. It is important to choose hydraulic oil that is capable of preventing contact between the rapidly moving piston and cylinder. Shank adapter and gearing are lubricated through the lubrication input port with an external lubricator using pressurised air-oil mixture. Hydraulic oils are typically not suitable for gearing air-oil mist lubrication and specialized rock drill oil should be used instead. When choosing the hydraulic oil for Doofor rock drill both the requirements of the rock drill and the requirements of the drill rig should be considered. Consult your hydraulic system’s instructions for more information on suitable oils. Oil choice should always depend on the environmental conditions, such as temperature. Consult your oil supplier for information about oil viscosity in given temperatures. Attention! In addition to choosing hydraulic system oil, make sure that the shank

and gearing lubrication is sufficient. Shank and gearing are lubricated separately from the percussion system.

7.1 OIL CHOICE Following features must be considered when choosing the oil: »» Viscosity »»Cold start viscosity »»Operating temperature viscosity »»Highest temperature viscosity »» Additives »» Oil aging »» Impurities »» Oil ability to prevent wear 7.1.1 OIL VISCOSITY Using oil with too high viscosity during cold start up prevents the oil from flowing properly and causes wear due to insufficient lubrication. Oil with too low viscosity in maximum operating temperature does not lubricate properly, causing contact between moving components, which will lead to wear and seizures. Low viscosity may also cause leakage. Wrong viscosity oil may increase the power consumption of the entire hydraulic system. Temperature of the oil in the hydraulic system can be lowered with sufficient oil cooling. 18

7. OIL RECOMMENDATIONS

Example diagram of the properties of selected oils in different temperatures. Some oils have better cold start viscosity while others operate better in higher temperatures. 7.1.2 ADDITIVES Hydraulic oils may contain additives, such as extreme pressure (EP) additives. Mixing two oils with different additives can have a harmful effect on the rock drill components. The benefits and detrimental effects of oil additives should be carefully considered when choosing the oil. Oil suppliers can provide more information. 7.1.3 OIL AGING Oil aging is a result of chemical reactions in the oil. Some additives improve the aging behaviour of the oil and in some cases a special filters helping to prevent aging may be installed to the hydraulic system. Oil aging produces varnish, which is encountered as oil sludge in the system. Varnish may have a negative effect on seals and o-rings. The quality and condition of the hydraulic system’s oil filters should be checked regularly. 19

7. OIL RECOMMENDATIONS 7.1.4 PURITY Over time, oil may collect impurities such as water and various particles. Water can exist in the oil in dissolved, emulsified or as free water. Too high water content in the oil may lead to various problems, such as rust and oxidation, reduced lubrication and cavitation. Particles in the oil can accumulate to the surfaces, causing increased friction and wear. Oil purity should be measured and observed regularly to prevent problems. Attention! Check regularly that the oil does not contain impurities. Impurities in the oil are one of the most common causes of leaks or breakages. Prevent repair costs, downtime, and low production by using only clean oil.

7.1.5 OIL ABILITY TO PREVENT WEAR While Doofor rock drills do not use extreme hydraulic pressures, it is still very important to choose an oil that is able to maintain a constant oil film between the piston and cylinder. Some oils may be unsuitable for the task. Check that the oil is designed to prevent wear in hydraulic systems in the rock drill pressure range and operating temperatures. 7.1.6 OIL TEMPERATURE Oil temperature has two important aspects: overheated oil will lose viscosity, leading to leaks, wear or seizures, and overheated oil will also damage seals, which leads to power loss and leaks. Use sufficient oil cooling and do not allow the drill to run idle.

7.2 OIL SPECIFICATIONS FOR DOOFOR ROCK DRILLS Attention! Temperature affects viscosity. Choose oil accoding to the operating,

maximum and cold start-up temperatures. Using an oil which has unsuitable viscosity will cause wear, high costs and problems with seized components.

Use the values below to choose a suitable oil with the correct viscosity in operating and start-up temperatures. Maximum viscosity at cold start up: Optimum operating viscosity: Maximum operating oil temperature: Lowest temporary viscosity:

2000 cSt 30‑60 cSt 70 °C / 158 °F 20 cSt

Note that the viscosity of all oils changes due to impurities and aging. Change the oil according to the environmental conditions and oil durability. 20

7. OIL RECOMMENDATIONS 7.3 HYDRAULIC OIL SUGGESTIONS FOR DOOFOR ROCK DRILLS Attention! Always consider the requirements of the entire hydraulic system when

choosing the oil. Doofor does not accept responsibility if the oil recommendations and/or graphs are outdated, misleading or wrong.

Shell Tellus S4 VX 32, S3 V 68 and S2 V 100 calculated kinematic viscosity graph.

Mobil SHC 524, 526 and 527 calculated kinematic viscosity graph.

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7. OIL RECOMMENDATIONS Working temperature

Maximum temporary temperature ***)

53–70°C 127–158°F 43–62°C 109–143°F 21–44°C 70-–111°F 54–70°C 129–158°F 43–60°C 109–140°F 25–40°C 77–104°F

70°C 158°F 70°C 158°F 60°C 140°F 70°C 158°F 70°C 158°F 50°C 122°F

Motor oil

Shell Tellus S2 V 100 Shell Tellus S3 V 68 Shell Tellus S4 VX 32 Mobil SHC 527 Mobil SHC 526 Mobil SHC 524

The lowest recommended starting temperature

- 2°C **) 28°F **) - 12°C 10°F - 45°C *) - 49°F *) - 8°C 18°F - 12°C 10°F - 24°C *) -11°F *)

*) The highest working temperature may bee too low in hot conditions. **) Estimated. ***) Recommended for very short periods only.

Attention! Measure and observe the quality of the hydraulic oil. Do not use oil

that contains impurities or excessive water. Water and impurities cause wear and damage in the rock drill components.

Oil and lubrication hints: Do: »»Check that the oil is suitable for the rock drill and the hydraulic system. »»Check the environmental temperatures and oil operating ranges. »»Use oil cooling if necessary. »»Check the purity of the oil regularly. »»Lubricate the shank and gearing with sufficient lubrication. Don’t: »»Don’t use an impure oil. »»Don’t allow the oil to heat up excessively. »»Don’t use an pressureless oil drip for the shank and gearing lubrication. 22

8. LUBRICATION REQUIREMENTS 8.1 LUBRICATION OF THE SHANK AND THE GEARING 8.1.1 OIL MIST LUBRICATION It is essential that oil lubrication is in constant use when operating the rock drill. An oil mist lubricates the shank and gears. Only use lubricants suitable or meant for hydraulic drills. The manufacturer recommends ARDEE ROCK DRILLING OIL GRADE 68 (produced by Petro Canada), Shell Torcula oils, or equivalent to reduce wear and tear and to prolong the lifetime of the product. Recommended air pressure for lubrication is 6–7 bar (87–101.5 psi). Recommended oil consumption is 200–300 g/hour or approximately 2.3–3.5 dl/hour (7.8–11.7 fl oz/hour) . Attention! Lubricate the shank and the gearing with sufficient pressurised air-oil

mixture. Lack of pressurised air in the lubrication will lead to internal damage in the system. It may be necessary to adjust lubrication rate and pressure.

Lubrication line

Lubrication line (non-return valve)

Default lubrication exit Alternative lubrication exit, plugged by default Default setup. Lubrication air-oil mist exits normally through a hole in the flushing box, lubricating the flushing seals and shank adapter. Alternatively, a hole in the bearing collar can be used. In this case the lubrication line should be plugged. Attention! Flushing seals require extra lubrication during grouting or other heavy use.

8.1.2 GREASE FITTING LUBRICATION In special cases, as an alternative to the oil mist lubrication, the shank and gearing lubrication can be arraged through grease fittings. The manufacturer recommends Mobilgrease XHP Mine-series grease or similar product. Apply sizeable amount of grease every 1–2 hours of operation. Gears must not run dry. Observe the temperature of the gearing and adjust the amount of grease if it is hot. Attention! The manufacturer recommends using air-oil mist lubrication. Always contact the manufacturer before using any other method.

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9. PERCUSSION AND ROTATION SYSTEMS 9.1 PERCUSSION SYSTEM DF540L percussion system has maximum recommended percussion pressure of 150 bar [2176 PSI]. The recommended return pressure is 6–10 bar [87–145 psi]. Higher percussion pressure requires higher return pressure. Measure the return pressure of the system before active use. Measurement should be done both when starting a drill hole (collaring) and when continuously drilling. Attention! Measure the return pressure in all drilling situations before

continuous use. Too low return pressure may cause cavitation damage in short time inside the body cylinder or in the components.

9.1.1 PERCUSSION SYSTEM COMPONENTS

9.2 ROTATION SYSTEM DF540L is equipped with an independent orbit-type gear motor. The gear ratio between the motor output shaft and the rotation bushing (shank adapter) is 1.625: 1. Motor 80 cm³, 125 cm³ or 160 cm³ can be placed to the side of the drill, either to the left hand side or the right hand side. Normal operating pressure of the rotation varies inside the range of 40–80 bar. Rotation pressure is affected by rock structure and hardness, feeding pressure, flushing pressure and drill hole size. Danfoss OMS -motors tolerate continuous pressure of 210 bar and temporary pressure of 275 bar (allowed value may be reached for 10% of time during one minute) and maximum pressure of 295 bar. Return line pressure should be kept as low as possible to prolong the lifetime of the shaft seal of the motor. The maximum pressure in the return line is 20 bar, for a short time only. The bypass flow line of the hydraulic motor can be connected to the percussion return line. 24

9. PERCUSSION AND ROTATION SYSTEMS 9.2.1 ROTATION SYSTEM COMPONENTS

9.3 ROTATION SPEED CHART

Rotation speed chart with continuous pressure, single motor. 25

10. FLUSHING SYSTEM DF540L-BLT hydraulic rock drill can use either water or air as flushing media to remove chips of rock from the drill hole. Sufficient flushing means better production and rock drill life time.

10.1 AIR FLUSHING The optimum velocity for the air is 15m/sec. Air-water mist or foams can be used in a DF540L rock drill within the normal setup. Using air-water mist can add to the shank adapter and drill tool cooling effect of the flushing. Warning! When using air flushing it is very important to properly protect the

workers and nearby personnel to minimize the inhalation of exhausting flushing air from the drill hole. The flushing air contains dangerous dust, particles from the rock drill, and other impurities, which are harmful to the human respiratory system. Flushing air particles may cause severe health problems, including diseases that may lead to death.

10.2 WATER FLUSHING

When water flushing is used, the sealing of the rock drill is under a lot of stress. The saline and acid water used in underground mines corrode the shank adapter in a short time thus leading to rapid wear of the flushing seals of the rock drill. Therefore it is important to monitor the rock drill during drilling for water leakages. If the rock drill is used when the flushing seal is broken, the flushing water can enter the rock drill and cause corrosive damage to the rock drill. The DF540L is equipped with an indicator hole, which helps to determine if the seal between the flushing box and the gear box need to be replaced. If water is leaking out of the indicator hole, the drilling should be stopped and new flushing seals should be installed. Acceptable temperature for the flushing water is 3–30°C [37–86°F]. When water flushing is used, the shank oil-air mist lubrication should always be on to prevent corrosion. Shank lubrication should also be left on for at least 1 minute after drilling in order to clean the possible flushing water from the gear and bearings. Attention! Flushing water quality has a great effect on the durability of the flushing seals. Using an acidic, saline or impure water quickly damages the seals leading to leaks and corrosion damage.

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11. INSTALLING THE ROCK DRILL 11.1 INSTALLATION AND DESIGN Doofor rock drills are designed to operate as a part of a drilling rig or other drilling unit. To reach full capacity and maximum lifetime of the drill, certain requirements must be met. This chapter lists the basic requirements for the combination of Doofor hydraulic rock drill and a drilling rig/platform. Required values can be found in the specifications of the drill. 11.1.1 FEEDING AND DRILLING SYSTEMS »» Feeding beam, mast or boom must be capable of supporting the weight of the drill and other equipment in all possible positions. »» Beam needs to have a rod guide at the end of the beam. »» Feeding force must be limited so that it never exceeds the maximum allowed value. Feeding force can be limited, for example, with a pressure limiter. »» Feeding force must be adjustable by the operator. »» Maximum feeding speed should be restricted. The drifter should not fall freely in any situation, for example, when there is no resistance caused by drilling. When drill moves down the beam fast accidentally, it can cause serious risk of injury to the operators. A feeding motor with a brake and suitable counterbalance valve is recommended. »» Drilling line must be straight in all directions, from the drill all the way to the drill bit. Excessive feeding force can cause drilling rod or steel to bend, which must not be allowed. »» Hydraulic hoses, other hoses and other equipment should allow full range of movement for the drifter in all positions and situations, without possibility of accidental damage to the drilling rig components. »» Hydraulic hoses must be of high quality. Connectors/fittings should require tools to open and hoses should be secured with safety cables and protected with sleeves, if possible. Follow all appliciable regulations, directives and standards. 11.1.2 CARRIAGE PLATE »» Carriage plate must be able to bear the load caused by drilling or retracting the drill. Make sure it does not bend. »» Operator should be able to regularly check the tightness of the drifter bolts, carriage plate bolts and hose connections. »» Use the mounting method displayed in the following picture. Bolts of sufficient size and highest durability should be used.

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11. INSTALLING THE ROCK DRILL

Drawing displays the location of the mounting holes. 3D models are available from the manufacturer. Doofor recommends using M16 12.9 bolts and M20 12.9 bolt and NordLock washers. The dimensions can be found in the dimension drawing. Four side bolts should extend at least 35 mm into the carriage plate threads. 11.1.3 HYDRAULICS AND CONTROL SYSTEM DESIGN »» Percussion pressure must be limited so that it never exceeds the maximum allowed value. The operator must be able to adjust the percussion pressure. »» Rotation pressure must be limited so that it never exceeds maximum allowed value. »» The operator must be able to adjust the rotation oil flow. Oil flow must be limited to the maximum value. »» Percussion return pressure must be within specified limits. The pressure must be measured to be correct when starting to drill a hole and when continuously drilling. Too low return pressure may cause serious cavitation damage in a short time. »» Hydraulic oil must be according to the specifications and suitable for use in the operating conditions. »» When retracting (pulling out) the drill rod, percussion must not be on. Percussion can be used when retracting only if the drill has an extractor (back hammer). »» Percussion must not strike empty. When the piston strikes empty, energy of the percussion is converted to heat and cavitation may occur. Overheating will cause leaks and the percussion system may seize. »» Antijamming system is recommended (Feed is reversed if the rotation pressure is too high). »» It is recommended to display all relevant pressure values (feeding, rotation and percussion) to the operator during operation. 28

11. INSTALLING THE ROCK DRILL 11.1.4 FLUSHING AND DUST CONTROL »» Pressurised air, water or foam flushing is required. (Foam and water flushing may not be suitable for all models, see flushing specifications). »» Dust control method is highly recommended for air flushing. Drilling dust contains harmful substances. 11.1.5 LUBRICATION »» Pressurised air-oil mist lubrication is required. Air pressure and oil quantity must be within specified limits. Oil must be suitable for the system and water resistant. »» Pressure of air-oil mist lubrication should be left on for one minute after using water flushing. »» Grease fitting lubrication can be used with specific permission from the manufacturer. »» Grease fitting lubrication is suitable for air flushing only. 11.1.6 SAFETY SYSTEMS »» The rock drill does not contain safety switches, external protective covers or other safety devices. The design and installation of the safety devices is the responsibility of the designer of the drilling rig/platform or the party putting the product on market. »» The manufacturer recommends using safety shields/fences to prevent users from accidentally getting in contact with the drill tools, hexagon chuck or shank adapter. »» The manufacturer recommends designing the control system so that accidental start during drill steel replacement / other maintenance is prevented. »» Safety should be first priority in design. Safety system and machine desing must be done according to machinery directive 2006/42/EC and other EC regulations and standards, where appliciable. Risk of injury should be minimized no matter where the finised drill rig is put on the market or into use.

11.2 RETAINING MECHANISMS Drill rod removal system can be designed to remove the rods from the shank adapter by holding the drill rod with a retaining mechanism. At the same time, the system can rotate the drill to the opening direction while the feed system is used to carefully pull the shank adapter out.

11.3 DRILL TOOLS The optimal maximum drill hole diameter for Doofor DF540L is 64 mm [2 ½”]. The rock drill can be equipped with female shank adapter FR32 or male shank adapters R32 or T38. 29

11. INSTALLING THE ROCK DRILL 11.4 COMMISSIONING 11.4.1 FEEDING SPEED Feeding speed of the carriage and the drill must be correct. Too low feeding speed may lead to overheating and issues with cavitation. Excessive feeding speed may bend drill steels and internal damage to the rock drill components. Suitable drilling speed depends on rotation speed, percussion power and drilling tools. It is recommended to start drilling with lower feeding force and gradually increase the feeding force until the rock drill stops vibrating. Wrong feeding speed may lead to various problems, such as damaged components due to bending, shifting of piston hitting point, or even cavitation inside the body cylinder. Do not attempt to increase drilling rate with excessive feeding speed or force. Generally speaking, feeding force should be adjusted instead of feeding rate or speed. Maximum recommended feeding force is 15 kN (3372 lbf). 11.4.2 GEARING AND SHANK ADAPTER LUBRICATION Gearing and shank adapter pressurised air-oil lubrication must be on whenever the rock drill is used. If water flushing is used, the lubrication must be left on for 1 minute after drilling to remove water from the bearings and gears. Make sure that the lubrication exit port is not blocked. Blocked exit may lead to overheating. For more information, see chapter ”Shank and gearing lubrication.” 11.4.3 RETURN PRESSURE MEASUREMENT Too low percussion return pressure is major contributor to cavitation and other problems. Percussion return pressure must be measured before any continuous drilling. Measure the pressure when starting the hole and when continuosly drilling. Check the pressure periodically. Make sure that the hydraulic system filters are not clogged and are cleaned regularly. If necessary, adjust percussion pressure or install spring-loaded check valve. Check also the rotation return pressure. For more information, see chapter ”Percussion and rotation systems.”

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11. INSTALLING THE ROCK DRILL 11.5 COMMISSIONING CHECKUP Go through this list step by step before using the drill. 1. Measure the air pressure of the shank/gearing lubrication system. Check the lubrication oil type and quantity. 2. Start the lubrication system and check that oil is coming out of the oil exit. This may take a moment. 3. Check the hydraulic oil type, quality, quantity, temperature and cleanliness. Check filters. 4. Measure, using the maximum oil flow, that the rotation system pressure cannot exceed the maximum value. 5. Make sure that the rotation oil flow is limited to the maximum value. 6. Rotation flow shoud be adjustable by the user, depending on the drill bit type and hole size. 7. Measure, using the maximum oil flow, that the percussion system pressure cannot exceed the maximum value. 8. Check that the feed force is easily adjustable by the user and independent from the feeding speed. 9. Measure that the drilling line is straight from the drill rod guide to the rock drill, in all directions. 10. Check that the rock drill can traverse safely without hitting anything. Make sure that the feeding system prevents rapid movement of the drill when there is no drilling load. 11. Check that all hoses, fittings etc are securely connected and all lifting hooks are removed. 12. Measure that the accumulators have correct pressure. 13. Test the rotation to both directions, and check that the drill rotates to the correct direction when drilling. 14. Start the percussion system for a short time without drill tools. Measure the percussion return line pressure during idle operation and make sure it is within allowed range. 15. Test the actual drilling: Install drilling tools and adjust the feed force to the minimum value. Start lubrication, flushing, rotation and percussion systems. Increase the feed force until the rock drill is stable. If the drill rod bends or feed beam is slipping before the requested feed force is reached, then the percussion pressure should be reduced until the rock drill is stable. Adjust the rotation speed to achieve the optimal drilling speed. When optimal drilling speed is reached, measure the percussion return line pressure and make sure that it is within allowed range. Note: Accumulator gas filling device should always be available. It is recommeded to keep spare parts readily available for maintenance. 31

12. OPERATIONAL INSTRUCTIONS Broken drill steel or bit:

In many cases the problem is solved by solving issues in the flushing system. The function of the flushing system becomes more and more critical when drilling with high penetration speed. If the rock cuttings stay under the bit, the compression wave is reflected back to the steel causing temperature increase in the contact surfaces. Check drill bit buttons or cutters. Also check the rotation speed of the drill steel, as rotation speed should be adjusted according to the size of the drilling hole. Lower the percussion pressure when drilling small hole. This prevents the overheating of the drilling equipment.

Overheating of the drill tools:

Empty accumulators:

Too low penetration speed:

Lower the percussion pressure when drilling small holes to prevent overheating of drilling tools and shank adapter! Remember to check the prefilling pressure of the accumulators before any use. The rock drill and the accumulator are sometimes delivered empty due to many safety restrictions in the transportation. Do not exceed the maximum feeding force. Instead, adjust rotation speed, and make sure that the flushing is sufficient. Check the condition of the drill bit. Check also the percussion.

Lubrication oil is not exiting:

It may take a while after starting. Check that the oil exit port is not blocked. Make sure you have sufficient lubrication air pressure and oil amount.

Flushing seals wear out fast (shank adapter models):

Impure flushing water can quickly wear seals. Special seals may be available. Seals may require lubrication. 32

12. OPERATIONAL INSTRUCTIONS Attention! Do not allow the percussion to strike empty! Striking empty will cause severe problems!

To avoid problems, always follow the instructions below: »» Do not allow the rock drill to strike empty (run idle). When percussion strikes empty, its energy transfers to the oil, causing problems: cavitation, seal failure, seizures and overheating. These issues may happen in short time. »» When removing the drill rod from the hole, stop the percussion system. »» When starting to drill a hole, start with 1/2 pressure. Then increase the pressure to optimal drilling pressure. »» Never exceed the maximum allowed feed force. Drill tools must not bend. »» Never exceed maximum allowed pressure / flow values. »» Use sufficient flushing to remove the drill cuttings. Insufficient flushing decreases penetration and may lead to jamming. »» Check lubrication after 1-2 drilling hours. When using pressurised air-oil mist lubrication system, check that the oil exit port is not blocked. »» Check the tightness of all external bolts and fittings regularly. »» Measure accumulator pressures regularly. Loss of accumulator pressure leads to decreased drilling capability. »» Measure the return pressure. If it is too low, adjust it with a valve or some other method. »» Adjust percussion and rotation according to varying rock hardness and integrity.

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13. DESIGN NOTES Issues to consider during design:

Doofor hydraulic rock drills require a suitable control system to operate. You can find more information about the requirements for the control system in the installation instructions. A feeding system with rod retainers and rod guides is required. Pressurised air-oil mist lubrication system is required. Flushing system is required. Safety devices must be installed by the party manufacturing the drill rig/boom. When designing a new system and its automated flushing-on function, please take the impulse for the flushing-on from the rotation line instead of the percussion line. This ensures that the operator does not need to drill air if he likes to keep flushing on during retracting the steel from the hole. Drilling into air or without sufficient feed force heats up the oil and shank adapter and is harmful to the rock drill. Consider using automated oil-air mist lubrication instead of using user-activated system. Automatic system prevents user from forgetting to use lubrication. Automated system may be designed to leave the oil-air mist lubrication on for 1 minute after drilling with water flushing. Remember to limit maximum percussion and rotation pressure. Make it possible to measure the return pressure, percussion pressure and rotation pressure.

Safety should be first priority in the design process.

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MAINTENANCE INSTRUCTIONS

14. MAINTENANCE OF THE ROCK DRILL Doofor rock drill should undergo maintenance every 500 hours, even when it operates well. Failure to maintain the rock drill properly may lead to breakages or lowered efficiency of the rock drill. O-rings, seals, gaskets and accumulator diaphragms should be replaced with new ones every 500 hours, minimum. Other wearing parts should be checked for wear or damage and replaced when necessary. »» Check the pressure of the accumulators regularly. »» Inspect the rock drill body for signs of hydraulic oil leaks regularly. »» Check that all the bolts are tight. »» During operation, check that water is not leaking out of the indicator hole. Warning! Installation, maintenance and repair may only be carried out by properly trained personnel. Warning! Always shut down the hydraulic system before maintenance and make sure there is no pressure in the system. High hydraulic pressure may cause serious injuries or death. Note! Please contact the supplier if you need more assistance in the maintenance.

14.1 TOOLS AND TOOL KITS Use only suitable tools in good condition when servicing the drill. Do not use tools which may damage the drill components. Special tools and tool kits, containing mandrel tools, extractors etc may be available for the rock drill. Contact the supplier for more information.

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14. MAINTENANCE OF THE ROCK DRILL 14.2 SPARE PARTS Spare parts can be ordered from the supplier. Use only original spare parts to prevent damage to the drill. Consult the spare part book for part codes. If you do not have the spare part book, contact the supplier to obtain a copy. Please provide necessary details such as rock drill model and serial number. Use a spare part code when ordering spare parts. ID number is used in the maintenance manual only: do not use it to order spare parts.

Spare part listing from the spare part manual.

Note! Always use the spare part codes from the spare part book when ordering parts. 14.2.1 SPARE PART KITS Following kits are available from the manufacturer: »» Seal kit, containing seals and wipers for the rock drill. »» 500 hour maintenance kit »» 1000 hour maintenance kit »» 1500 hour maintenance kit »» 2000 hour maintenance kit »» Overhaul kit for restoring the rock drill may be also available. 500–2000 hour maintenance kits contain all parts considered necessary for each maintenance. Kits do not contain parts for necessary for earlier maintenances. If you wish to prepare for all four maintenances, you will need all four kits. Seal kits are included. Note! Some wearing parts, like shank adapters etc, are not included. Contact the manufacturer for more information. Note! Depending on the drilling conditions etc, some parts may wear out early. You can help to design better and cheper kits by providing information on what parts were worn out early and what were the drilling conditions. Sending feedback benefits everyone. 37

14. MAINTENANCE OF THE ROCK DRILL 14.3 MAINTENANCE TIPS AND PROCEDURES Always read the entire procedure on the manual before proceeding with maintenance. Make sure you have necessary parts, tools and lubricants available. Use only high quality lubricants and other chemicals. The maintenance procedures in this manual contain some advice on what lubricants and chemicals you should use. In addition to these instructions, you should follow the instructions below: »» Always apply some lubricating oil spray to the o-rings. »» Always use either anti-seizing thread lubricant, sealing silicone or locking glue on threads depending on the instructions. After maintenance, test the drill. Check that the pressure required to operate the drill is not excessive. Also check that there are no leaks. Check that all bolts, hydraulic hoses and connectors are tight.

The picture above shows some general examples of seals and wipers which must be installed with the correct facing.

Correct installation direction is important with some seals and wipers. Follow the installation instructions.

14.4 STORING AND DECOMMISSIONING THE ROCK DRILL When removing the rock drill for storage or transport, the drill should be emptied of excessive lubrication and hydraulic oil to prevent leaks and environmental damage. Accumulators can be emptied. The rock drill and its components should be protected from corrosion using suitable anticorrosion lubricants during transport or storage. When the drill is removed from use permanently it’s components should be recycled, if possible. Contact the manufacturer for best replacement options and offers.

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14. MAINTENANCE OF THE ROCK DRILL 14.5 MAINTENANCE INTERVAL TABLE The table shows estimated lifetime for wearing parts. Seals, diaphragms and needle bearings should be replaced every 500 hours. Other parts can be inspected and replaced when necessary. ● = Replacement recommendation for the part. ○ = The part should be checked for signs of wear or damage. Part Seals, o-rings and wipers Accumulator diaphragms Thrust plates Drive shaft pin Bolts and motor nuts Nord-Lock washers Small needle bearings Accumulator gaskets Bronze bushing Gearing box plane gasket Thrust bearing Slide bearing 100/120 Main assembly headless screws Hat nuts Accumulator gas valves Clutch sleeve Anvil Valve

ID All D 24, 30 27 All All 26, 29 G 8 22 34 23 113 77 H 31 16 58

Location Entire drill Accumulators Gear box Gear box Entire drill Entire drill Gear box Body cylinder Front section Gear box Gear box Gear box Entire drill Entire drill Accumulators Gear box Front sction Body cylinder

500h ● ● ● ● ● ● ● ● ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Spring plates Sping plate Anvil ring Piston Seal flange Middle gear Drive shaft Rotation bushing Flange 100 Flange 90

14 61 32 54 47 28 25 33 15 13

Front section Body cylinder Gear box Body cylinder Body cylinder Gear box Gear box Gear box Front section Front section

○ ○ ○ ○ ○ ○ ○ ○ ○ ○

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1000h ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

1500h ● ● ● ● ● ● ● ● ○ ○ ○ ○ ○ ○ ○ ○ ● ● ● ● ● ○ ○ ○ ○ ○ ○ ○

2000h ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ○ ○ ○ ○ ○ ● ● ● ● ● ● ●

14. MAINTENANCE OF THE ROCK DRILL Part Flushing collar, internal surfaces Bearing collar, internal surfaces Gear box, internal surfaces Section flange, internal surfaces Body cylinder, internal surfaces Shank adapter Inner cylinder Front and rear housing Front and rear flange Locking screw Rotation motor

ID 123 120 78 36 51 9 53 57, 59 56, 60 35 38

Location Front section Front section Gear box Gear box Body cylinder Front section Body cylinder Body cylinder Rear cover Gear box Gear box

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500h ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

1000h ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

1500h ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

2000h ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

15. TROUBLESHOOTING 15.1 HIGH ROTATION PRESSURE Increase the amount of lubrication oil in the mist. Rotation gears and bearings are starting to seize, causing the need for high rotation pressure:

Lack of lubrication oil.

Broken or worn bearings. High rotation pressure, no faults detected:

Check that the air flow is sufficient. Check that the lubrication exit is open. Check the quality of the oil: use the recommended types. Check suitability for the operating temperature. Inspect and replace the bearings.

Fissured rock Sharpen the buttons.

Drill bit buttons are flat.

Replace the drill bit. Use high-quality drill bits.

A worn or broken drill bit causes the need for high rotation pressure:

Rotation motor return pressure is too high, causing the need for higher rotation pressure.

Drill bit buttons break often.

Switch the drill bit. Check that the feeding pressure is not too high.

Drill bit is worn.

Switch the drill bit. Check that the feeding pressure is not too high.

Fault in the hydraulic system.

Check return line hose, fittings and filters.

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15. TROUBLESHOOTING 15.2 ROTATION SYSTEM FAULTS Broken bearings in the gearbox of the rock drill. Uneven rotation:

Loss of rotation:

Replace the bearings.

Too low or reduced amount of flushing.

Check the flushing pressure and possible cloggings in the rock drill.

Rotation motor malfunction.

Replace the rotation motor.

Reduced hydraulic pressure in the rotation motor.

Check the rotation pressure.

Rotation motor malfunction. Impurities in the gearing.

Replace the rotation motor. Clean and lubricate gearing. Check the condition of parts.

Seizure in rotation bushing or bearings.

Service the bearings and anvils. Check the shank adapter lubrication. Check the flushing sealings.

Loss of pressure in the accumulators.

Check the accumulator pressure.

Excessive tension in hydraulic hoses.

Slacken hydraulic hoses slightly.

15.3 VIBRATION Excessive vibration of hydraulic hoses:

Excessive vibration of the rock drill:

Bolts are loose. 42

Check all bolt tightnesses and tighten with correct torque.

15. TROUBLESHOOTING 15.4 PERCUSSION FAULTS

The percussive mechanism stops:

Sudden drop of the percussion pressure:

Check the hydraulic pump and the valve block of the percussion line.

Loss of the hydraulic pressure. Jammed piston or valve.

Take the drill for maintenance.

Reduced oil flow to the rock drill.

Check the hydraulic pump and rock drill function controls.

Malfunction in the accumulators.

Check the pressure in the accumulators and refill them or remove them for maintenance.

15.5 DRILLING PROBLEMS

Uneven drilling speed:

Malfunction in the feeding motor. Carriage plate sticking.

The hydraulic pump cannot maintain pressure. A gradual loss of the drilling capability:

Malfunction in the accumulators. Broken drill steel or bit. 43

Replace feeding motor. Check carriage plate attaching and tightnesses. Clean and grease carriage plate sliding surfaces or replace wear parts. Check the hydraulic pump controls and output capacity. Check the accumulators and take them for maintenance, if an accumulator cannot maintain necessary pressure. Use new or equivalent drill bits, do not drill using too high pressure and control the amount of flushing.

15. TROUBLESHOOTING

Increased need of feeding force and low speed of drilling:

Broken or wornout valve in the rock drill.

Take the rock drill to the maintenance.

Loss of pressure in accumulators.

Refill accumulators.

Too high return pressure in the drill rig.

Measure return pressure of the rock drill. Return pressure should not exceed 10 bar.

Wrong torque settings.

Check the correct torque settings from this manual.

15.6 BREAKAGES

Rock drill side bolts break:

Body cylinder / seal flange / seal cover seals break too often:

Wrong tightening of bolts.

Check correct bolt tightening procedure. Replace bolts. Only use authentic parts.

LP accumulator diaphragm broken and/or pressure lost.

Replace the diaphragm and refill the accumulator

Damaged piston.

Check and replace the piston.

Wrong direction of seals.

Check and reinstall seals.

Too low return pressure from the rock drill.

Measure return pressure of the rock drill. Adjust percussion pressure or install spring-loaded check valve.

Displacement during installation.

Install with extra care or contact manufacturer for advice.

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15. TROUBLESHOOTING

(Models with Shank adapter) Flushing seals break too often:

Excessive wear or breakage of the shank adapter:

Regular breakage of the drill steel or shank adapter:

Too saline, acidic or impure flushing water.

Use pure water.

Near-freezing flushing water.

Use warmer water.

Corroded shank adapter

Replace the shank adapter.

Worn bronze bushing.

Replace the bronze bushing.

Loss of pressure in accumulators. Worn-out or broken drill bit buttons.

Check accumulator pressure. If accumulator cannot keep up pressure, take it for servicing. Use good condition buttons. Adjust rock drill power according to the size of the drill bit. Control flushing flow and pressure.

Drill steel bends because of excessive feeding force.

Check for correct input pressure.

Drill steel bends because of it being nonaligned.

Maintain feeding bar or drill carriage restraints and check feeding alignment.

Shank adapter thread breaks because of too low feeding force.

Check for correct feeding force.

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15. TROUBLESHOOTING

Piston breaks too often:

Rear flange or seal cover seals are broken or wrong.

Replace the seals. Use only original spare parts.

Rear flange or seal cover seals have wrong direction.

Check installation direction and replace the seals.

Inner cylinder is damaged. Drill rod is damaged or uneven. Hydraulic oil problems cause seizure.

Check oil purity and suitability. Particles or wrong oil can cause seizures.

Chuck or rotation bushing installation.

Check that the chuck/ rotation bushing assembly is correct and has right facing.

Drill or carriage is misaligned.

Hexagon chuck models: Chuck breaks too often:

Check the cylinder inner surfaces and replace if worn or scratched. Replace the rod. Uneven rod end causes sideways impact forces, breaking the piston.

Excessive feed force. Worn bronze bushing, rotation bushing, and/or bearing. Drill rod is damaged or uneven. Misaligned rotation bushing and bearing. 46

Adjust the carriage. Drill line should be straight in all directions. Misaligned line can cause bending forces inside the drill. Adjust the feed force. Bending drill tools can cause damage to the drill. Check and replace components. Replace the rod. Uneven rod end causes sideways impact forces, causing damage. Check the installation and check that the components are not worn.

15. TROUBLESHOOTING 15.7 CAVITATION AND CORROSION

Too low return pressure. Cavitation in body cylinder or components:

LP accumulator pressure loss. Too low feeding speed. Drill is striking empty. Impurities in the oil.

Corrosion in the shank adapter and/or gearing.

Adjust percussion pressure or install a spring-loadad check valve. Measure the return pressure. Check that the hydraulic system’s oil filters are not clogged. Refill LP accumulator. Also check the diaphragm. Check and adjust the feeding speed. Do not use percussion when removing the drill from the hole. Do not let drill run idle. Replace the hydraulic oil according to the recommendations. Check other possible reasons.

Insufficient oil in oil-air mist lubrication.

Increase the amount of oil in the mist.

Insufficient air flow in the lubrication.

Increase the air flow or pressure.

Lubrication shuts down too quickly.

Leave the oil-air mist lubrication on for 1 minute after drilling with water flushing.

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15. TROUBLESHOOTING 15.8 LEAKAGES Oil leaking from lubrication oil exit Broken or damaged seal cover seals Wrong installation of seals Overheated hydraulic oil Hydraulic oil leaks:

Too high percussion pressure Percussion striking empty Faulty seal cover

Oil leaks between the rear cover and body cylinder

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Make sure that this is not lubrication system oil. Then proceed with checking. Replace the seals. Check installation direction and replace the seals. Temperature max 70 °C. Use suitable oil and oil cooling if necessary. Do not allow percussion to strike empty. Use a valve to limit pressure to max value. Turn percussion off when removing the drill from the hole. Do not allow empty striking at all. Check and replace the seal cover. Some models may have updated versions. Make sure that the o-rings are in place and that sealant is used correctly on the rear cover.

16. ACCUMULATOR MAINTENANCE 16.1 ACCUMULATORS Accumulators are an important component in a rock drill. The accumulators are filled with nitrogen gas N₂. It is important to maintain correct pressure in the accumulators. Wrong pressure may increase wear of the rock drill components. Maintenance interval should be same as the rock drill. Note that it is not necessary to remove the accumulator to measure pressure or refill it.

16.2 ACCUMULATOR TYPE AND SERIAL NUMBER The serial number of the accumulator can be found next to the accumulator gas valve. ”HP” signifies high pressure and ”LP” signifies low pressure. Typically there is one high pressure accumulator and one low pressure accumulator, or two high pressure accumulators and one low pressure accumulator. Attention! Do not mix the accumulators. Using an accumulator with a wrong

pressure may damage the drill. Accumulators may have been delivered without pressure.

16.3 TOOL KITS Special tools needed for rock drill and accumulator maintenance are available. Specialized charging unit kit is also available. Spare parts of the accumulator are listed on the spare part manual. Please contact the supplier for kits and spare parts.

16.4 ACCUMULATOR ASSEMBLY Note: Accumulator cover and bottom are always replaced together.

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16. ACCUMULATOR MAINTENANCE 16.5 ACCUMULATOR MAINTENANCE Warning! Always shut down the hydraulic system before removing the

accumulator. Removing the accumulator releases the high pressure hydraulic oil from inside the drill. High pressure may cause severe injuries or death.

Warning! Never try to remove the accumulator when the gas valve is attached.

Never assume that there is no pressure in the accumulator. Never penetrate or poke the accumulator diaphragm with any object.

Warning! Pressurised gas may cause severe injuries or death! Only authorised and

properly trained maintenance personnel may service or maintain the accumulators.

Follow the procedure below to remove the accumulator: 1. Switch off the power from the operating machinery, like a drilling rig, an excavator or other platform. 2. Remove the red protective plastic (if there is one) from the gas valve (H) and turn open the yellow safety nut. 3. Undo the gas valve (H) by two full turns of the nut valve. You may hear sizzle when possible gas pressure is released from the accumulator. 4. Remove the gas valve (H) from the accumulator. 5. Remove the bolts (E) and washers (F) from the accumulator. 6. Remove the accumulator for maintenance.

Warning! Nitrogen gas replaces oxygen in the air and may cause suffocation. Only fill with industrial nitrogen gas N₂. Other gases may cause an explosion. Correct fill pressure of the high pressure accumulators depends on the operating pressure of the hydraulic percussion line. If the operating pressure of the hydraulic percussion line is lower than the accumulator fill pressure the diaphragm of the accumulator may break. Correct prefilling pressure of the high pressure accumulators (HP) is 55 bar [798 psi] or 50% of the hydraulic percussion line pressure. Correct prefilling pressure of the low pressure accumulator (LP) is 4 bar [58 psi]. 50

16. ACCUMULATOR MAINTENANCE 16.6 ACCUMULATOR MAINTENANCE PROCEDURE 1. Follow the instructions given on the previous page and remove the accumulator. Warning! Make sure to remove the gas valve so that there is no pressure in the accumulator.

2. Open the bottom part (B) of the accumulator with an accumulator tool.

3. Oil the groove on the bottom of the accumulator cover (A). Replace the accumulator diaphragm (D). Oil the diaphragm (D).

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16. ACCUMULATOR MAINTENANCE 4. Make sure that the diaphragm (D) fits to the cover (A) edges.

5. Spray anti-seizure grease on to the thread of the bottom part (B).

6. Install the accumulator bottom part (B) to the cover (A).

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16. ACCUMULATOR MAINTENANCE 7. Tighten the accumulator bottom part (B). Punched dots on the bottom part (B) and on the cover part (A) should match. If this is not the case, the thread may be too worn.

8. Connect the gas valve (H) to the accumulator. Use medium hard thread glue on thread.

9. Replace the o-ring (C).

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16. ACCUMULATOR MAINTENANCE 10. Steps 11–13 assume that the accumulator is charged using charging unit kit provided by the supplier. Attention! Always follow the instructions given in the charging unit user’s guide. Instructions may vary.

11. Connect the adapter and and the hose to the accumulator gas valve (H).

12. Open the gas valve (H) by two full rounds before filling.

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16. ACCUMULATOR MAINTENANCE 13. Open the nitrogen gas bottle valve to fill the accumulator. Use the charging unit discharge valve to release excessive pressure if necessary. Attention! Ambient temperature affects the nitrogen pressure. The manufacturer has set the prefill pressure in the temperature of 20 °C [68 °F].

14. Close the accumulator gas valve (H). Tightening torque is 12 Nm [9 lbf·ft]. Remove the adapter and the hose.

15. Spread band of silicone sealant on the surface of the accumulator position on the body cylinder or install the gasket (G).

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16. ACCUMULATOR MAINTENANCE 16. Apply anti-seizure grease on the bolt (E) threads. 17. Install the accumulators. Correct tightening order 1–3–2–4 and tightening torque is 160 Nm [118 lbf·ft]. Attention! Remember to install high pressure accumulators and low pressure accumulators to the correct positions. Keep the original installation direction.

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17. DF540L-BLT ASSEMBLY DRAWINGS 17.1 MAIN ASSEMBLY DRAWING

17.2 FRONT SECTION ASSEMBLY DRAWING

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17. DF540L-BLT ASSEMBLY DRAWINGS 17.3 GEAR BOX ASSEMBLY DRAWING

17.4 BODY CYLINDER ASSEMBLY DRAWING

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18. REPLACING THE SHANK ADAPTER 1. Open two bolts (126).

2. Pull out the shank adapter (9) and the front section assembly.

3. Detach the shank adapter (9).

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18. REPLACING THE SHANK ADAPTER 18.1 REASSEMBLY Before reassembly ensure that the parts are clean. Use high quality lubricants/oils in the parts. Correct lubrication of parts significantly improves the lifetime of the rock drill. 1. Install the shank adapter (9).

2. Install the front section assembly.

3. Attach two bolts (126) and NordLock washers (127). Tighten with torque of 500 Nm [368 lbft].

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19. FRONT SECTION MAINTENANCE When performing maintenance to the front section check the condition of all components before reassembly. Replace worn parts. All seals, wipers and o-rings should be replaced during scheduled maintenance (every 500 operating hours).

19.1 DISASSEMBLY 1. Open two bolts (126).

2. Pull out the shank adapter (9) and the front section assembly.

3. Detach the shank adapter (9).

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19. FRONT SECTION MAINTENANCE 4. Remove four bolts (121) and Nord-Lock washers (122) from the flushing collar (123).

5. Pull out the flushing collar (123).

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19. FRONT SECTION MAINTENANCE 6. Remove the lock ring (17).

7. Remove the anvil (16) and anvil ring holder (181).

8. Remove the flange 100 (15), two spring plates (14) and flange 90 (13).

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19. FRONT SECTION MAINTENANCE

9. Remove the o-ring (7) from the rear side of the bearing collar (120).

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19. FRONT SECTION MAINTENANCE 19.2 REPLACING THE FLUSHING SEALS 1. Remove three flushing seals (124) from the flushing collar (123).

2. Install new flushing seals (124) to the flushing box (123). Attention! The flushing seals must have the correct direction! Wrong direction may damage the seals. See next picture for correct direction. Parts: 3 pcs Seal 1113688 NBR 1113690 PU 65

19. FRONT SECTION MAINTENANCE 19.3 REPLACING THE BEARING BUSHING 1. Check the condition of the bearing bushing (8) inside the bearing collar (120). Remove it if necessary.

2. First remove two flushing seals (124) from the bearing collar (120). Then remove the bearing bushing with a mandrel tool.

3. Lubricate new bearing bushing (8). Install it with a mandrel tool. Install also new flushing seals (124). Attention! Seals must have correct facing. Check next chapter for instructions. Parts: 1 pc Bearing bushing 2567820 2 pcs Seal 1113688

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19. FRONT SECTION MAINTENANCE 19.4 REPLACING THE BEARING COLLAR SEALS 1. Replace two seals (124) inside the bearing collar (120). Attention! Seals must have the correct direction. See the next picture. Parts: 2 pcs Seal 1113688

2. Seal (124) directions inside the bearing collar (124).

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19. FRONT SECTION MAINTENANCE 19.5 REASSEMBLY OF THE FRONT SECTION Before reassembly ensure that the parts are clean. Use high quality lubricants/oils in the parts. Correct lubrication of parts significantly improves the lifetime of the rock drill. 1. Install new flange 90 (13), two spring plates (14) and flange 100 (15) to the bearing collar (120). Attention! Spring plates must have correct facing: convex side towards the gear box. Parts: 1 pc Flange 90 1594874 2 pcs Spring plate 1366602 1 pc Flange 100 1594873 2. Install the anvil (16) to bearing collar (120). Attention! Make sure that the anvil stays straight. Misaligned anvil can cause insufficent rotation. Parts: 1 pc Anvil 721395

2. Install the anvil ring holder (181) between the anvil (16) and the lock ring groove. Parts: 1 pc Anvil ring holder 1646845 68

19. FRONT SECTION MAINTENANCE 3. Install the lock ring (17) to bearing collar (120). Parts: 1 pc Lock ring 1646997

4. Install new o-ring (7) to the rear side of the bearing collar (120). Parts: 1 pc O-ring 2036849

5. Inspect and clean the check valve (166). If possible, use a special tool to install or remove the valve. Note! Tighten the valve until it reaches the bottom.

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19. FRONT SECTION MAINTENANCE 6. Install the flushing collar (123) to bearing collar (120).

7. Install four bolts (121) and NordLocks (122). Tighten diagonally with torque of 80 Nm [59 lbf·ft]. Parts: 4 pc Bolt 1507111 4 pc Washer 1630989

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20. GEAR BOX MAINTENANCE

When performing maintenance to the gear box check the condition of all components before reassembly. Replace worn parts. All seals, wipers and o-rings should be replaced during scheduled maintenance (every 500 operating hours).

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20. GEAR BOX MAINTENANCE 20.1 DISASSEMBLY 1. Open 4 rotation motor attachment bolts (20).

2. Pull the bolts (20), 4 washers (21), 4 washers (40) and nuts (39) out.

3. Pull the motor (38) out.

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20. GEAR BOX MAINTENANCE 4. Remove 2 bolts (18) and washers (19).

5. Remove 4 hat nuts (77) and washers (114) in order 1-3-2-4. Attention! Leave the headless screws (113) in place so that the gear box does not fall by accident.

6. Remove the clutch sleeve (31). Note! Removing the shank adapter may have already removed the clutch bushing too.

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20. GEAR BOX MAINTENANCE 7. Pull the gear box (78) out.

8. Remove the gasket (22).

9. Pull the section flange (36) out.

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20. GEAR BOX MAINTENANCE 20.2 SECTION FLANGE MAINTENANCE 1. Remove the locking screw (35) from the section flange (36).

2. Use an accumulator opener tool to replace the worn thrust bearing (34) from the section flange (36). Tighten with torque of 250 Nm [184 lbf·ft]. Parts: 1 pc Thrust bearing 2153683

3. Install the locking screw (35) to the section flange (36). Use medium hard thread glue on the thread. Parts: 1 pc Locking screw 5006695

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20. GEAR BOX MAINTENANCE 4. Remove the worn thrust plate (30).

5. Remove needle bearing (29) using an extractor. Note! The ring of the needle bearing may have to be broken before it can be removed.

6. Install new needle bearing (29) using an mandrel tool and a plastic hammer. Parts: 1 pc Needle bearing 1871191

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20. GEAR BOX MAINTENANCE 7. Install new thrust plate (30). Parts: 1 pc Thrust plate 2153684

8. Replace the o-ring (37) of the rotation motor on the section flange. Parts: 1 pc O-ring 2036847

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20. GEAR BOX MAINTENANCE 20.3 GEAR BOX SECTION DISASSEMBLY 1. Remove the drive shaft (25).

2. Check the pin (27) inside the drive shaft (25). Replace if it is worn. Parts: 1 pc Pin 2439790

3. Remove the middle gear (28)from the gear box (78).

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20. GEAR BOX MAINTENANCE 4. Remove the rotation bushing (33) from the gear box (78).

5. Remove the worn bearing (23) from the gear box (78) using a hydraulic press and a mandrel tool.

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20. GEAR BOX MAINTENANCE 20.4 ROTATION BUSHING MAINTENANCE 1. Remove worn anvil ring (32) using a plastic hammer and a mandrel tool.

2. Install new anvil ring (32) into the rotation bushing (33) with a mandrel tool and a plastic hammer. Parts: 1 pc Anvil 2965406 1 pc Rotation bushing 2409298

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20. GEAR BOX MAINTENANCE 4. Install the rotation bushing (33).

5. Install the drive shaft (25) and the middle gear (28) to the gear box (78). Lubricate the gear teeth. Check that the pin (27) is inside the drive shaft. Parts: 1 pc Middle gear 2961215 1 pc Drive shaft 2921488

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21. BODY CYLINDER MAINTENANCE

When performing maintenance to the body cylinder check the condition of all components before reassembly. Replace worn parts. All seals, wipers and o-rings should be replaced during scheduled maintenance (every 500 operating hours).

21.1 BODY CYLINDER DISASSEMBLY 1. Remove the seal flange (47).

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21. BODY CYLINDER MAINTENANCE 2. Remove the rear plug (52).

3. Strike out the inner cylinder (53), piston (54) and valve package (79) with a mandrel tool and a hammer. Attention! Try to keep constant force to keep parts together while removing them.

4. Remove the inner cylinder (53) and the piston (54).

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21. BODY CYLINDER MAINTENANCE 5. Remove the front valve assembly (56+57+58). Note! Valve package may come out as whole or in parts.

6. Remove the rear valve assembly (59+60).

7. Remove the spring plate (61).

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21. BODY CYLINDER MAINTENANCE 8. Remove 6 o-rings (50) from inside the body cylinder (51).

21.2 VALVE PACKAGE DISASSEMBLY 1. Remove the valve (58).

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21. BODY CYLINDER MAINTENANCE 2. Separate the rear flange (60) from the rear housing (59).

3. Separate the front flange (56) from the front housing (57).

4. Remove the seal (55) from the front flange (56).

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21. BODY CYLINDER MAINTENANCE 21.3 REPLACING FLANGES’ SEALS AND O-RINGS 1. Replace 2 o-rings (41 and 49) from the seal flange (47). Parts: 1 pc O-ring 2036840 1 pc O-ring 2036847 1 pc Seal flange 2684301

2. Replace 2 seals (46 and 48) from the seal flange (47). First install the o-ring part of the seal, then the seal part. Attention! Seal grooves must face away from each other, as shown in the picture. Parts: 2 pcs Seal 544664

3. Replace seal (55) from the front flange. Install the o-ring part first, then the seal part. Attention! Seal groove must face to the right direction, as shown in the picture. Parts:

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1 pc Seal 2572676 1 pc Front flange 705010

21. BODY CYLINDER MAINTENANCE 21.4 REASSEMBLY OF THE VALVE PACKAGE Before reassembly ensure that the parts are clean. Use high quality lubricants/oils in the parts. Correct lubrication of parts significantly improves the lifetime of the rock drill.

1. Install the valve (58) into the rear housing (59). Attention! Lubricate thoroughly before installing. Parts: 1 pc Valve 2932050 1 pc Rear housing 705150

2. Install the front housing (57) on the valve (58). Attention! Lubricate thoroughly before installing. Parts: 1 pc Front housing 705140

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21. BODY CYLINDER MAINTENANCE 3. Install the assembled front flange (56) to the front housing (57). Attention! Lubricate thoroughly before installing.

4. Install the rear flange (60) to the rear housing (59). Attention! Lubricate thoroughly before installing. Parts: 1 pc Rear flange 705050

5. Install the spring plate (61) to the rear flange (60).

Attention! Use thick grease to make sure the spring plate stays on the center. Parts: 1 pc Spring plate 1366594

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21. BODY CYLINDER MAINTENANCE 21.5 REASSEMBLY OF THE BODY CYLINDER 1. Reinstall the rear plug (52). Parts: 1 pc Plug 3/4” 2708298

2. Install 3 of the body cylinder o-rings (50) to the rear grooves of the body cylinder (51). Parts: 3 pcs O-ring 2036899

3. Install the valve package (79) into the body cylinder (51). Check the next picture for more instructions. Attention! Lubricate the parts well before installing. Be careful not to scratch the parts. Make sure that the spring plate stays on the valve package.

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21. BODY CYLINDER MAINTENANCE 4. Use the piston or a mandrel tool to install the valve package. Then pull out the piston or tool. Attention! Be careful not to scratch the parts. Check that the spring plate stays on the valve package.

5. Install remaining 3 body cylinder o-rings (50) to the front grooves of the body cylinder (51). Parts: 3 pcs O-ring 2036899

6. Install the piston (54). Attention! Lubricate the cylinder and the piston well before installing. Be careful not to scratch the piston. Parts:

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1 pc Piston 1727840

21. BODY CYLINDER MAINTENANCE 7. Install the inner cylinder (53). Attention! Lubricate the cylinder well before installing. Be careful not to scratch the part. Parts: 1 pc Inner cylinder 2586054

8. Install the assembled seal flange (47).

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22. ROCK DRILL REASSEMBLY Before reassembly ensure that the parts are clean. Use high quality lubricants/oils in the parts. Correct lubrication of parts significantly improves the lifetime of the rock drill.

1. Install the assembled section flange (36).

2. Install new gasket (22). Parts: 1 pc Gasket 2676890

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22. ROCK DRILL REASSEMBLY 3. Install the assembled gear box front.

4. Install 4 hat nuts (77) and 4 washers (114). Use anti-seize lubricant on the threads. Tighten in order 1-3-2-4. Tightening torque 500 Nm [369 lbf·ft].

5. Install the clutch sleeve (31). Parts: 1 pc Clutch sleeve (bronze) 1480779

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22. ROCK DRILL REASSEMBLY 6. Install the rotation motor (38). Parts: 1 pc Rotation motor 80 cm3 2024546 125 cm3 2024547 160 cm3 2024550

7. Install 4 rotation motor attachment bolts (20), washers (21), washers (40) and nuts (39). Tighten diagonally in order 1-3-2-4. Tightening torque 80 Nm [59 lbf·ft]. Parts: 4 pcs Bolt 1507117 8 pcs Washer 1630989 4 pcs Nut 1494047

8. Install 2 bolts (18) and washers (19). Tighten with torque of 200 Nm [148 lbf·ft]. Parts: 2 pcs Bolt 1507096 2 pcs Washer 164945

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22. ROCK DRILL REASSEMBLY 9. Replace the shank adapter (9).

10. Put back the front section assembly.

11. Reinstall two bolts (126) and Nord-Lock washers (127). Tightening with torque of 500 Nm [369 lbf·ft]. Parts: 2 pcs Bolt 1507202 2 pcs Washer 164947

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23. TECHNICAL INFORMATION 23.1 DIMENSIONS

Dimensions (mm). 1 inch equals 25.4 mm. 97

23. TECHNICAL INFORMATION 23.2 BOLT TIGHTENING TORQUES AND ACCUMULATOR PRESSURES

Warning! Fill with industrial nitrogen gas N₂ only. Other gases may explode.

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23. TECHNICAL INFORMATION 23.3 DF540L-BLT TECHNICAL DATA Nominal percussion power

14 kW

Percussion pressure

115–140 bar 1668–2030 psi

(Percussion oil flow)

(90–100 litres / min) (23.8–26.4 GPM)

Percussion return pressure

6–10 bar 87–145 psi 200–300 litres / min 52.8–79.3 US gpm

Lubrication air flow Lubrication air pressure

6–7 bar 87-101 psi

Lubrication oil flow

200–300 g/h 7.8–11.7 fl oz/h (2.3–3.5 dl/h)

Flushing air pressure

5–7 bar 73–174 psi

Flushing air flow

4000 litres / min (4 Nm3/min) 1056.7 US gpm

Flushing water flow

150 litres / min 39.6 US gpm

Recommended maximum feed force

15 kN 3372 lbf

Weight

132 kg 291 lb

Rotation motor size

80 cm3

125 cm3

160 cm3

Rotation torque

504 Nm 372 lbf·ft

796 Nm 587 lbf·ft

975 Nm 719 lbf·ft

Rotation speed max

250 rpm

250 rpm

250 rpm

Rotation oil flow max (for single motor)

80 litres / min 21.1 US gpm

90 litres / min 23.8 US gpm

90 litres / min 23.8 US gpm

Gear ratio

65/40

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Doofor Inc. Talttakatu 8 FI-37150 Nokia Tel. +358 3 343 0747 [email protected]

www.doofor.fi