D 20118 – 1 en 0405 / MAH 1 (1)

HYDRAULIC ROCK DRILL HL 650, HL 650 S

LIFTING INSTRUCTIONS

CORRECT INCORRECT

Max.
55_

HL 650, HL 650 S . . . . . . . . . . . . . 245 kg

E 2004 SANDVIK TAMROCK CORP., Tampere Plant

P:O. Box 100
FIN–33311 TAMPERE,Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
B 22250 - 1 en 0405 / MAH 1 (22)

HL 650, HL 650S
Operation and maintenance

E 2005 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
2 (22) B 22250 - 1 en 0405 / MAH

HL 650, HL 650S
Operation and maintenance

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. TAKING A NEW ROCK DRILL INTO USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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
6.5. Rotation bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.6. Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.7. Front bearing of gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.8. Chuck and lock ring pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.9. Wear limits of shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7. CHECKING AND TIGHTENING BOLTS AND TIE RODS . . . . . . . . . . . . . . . . . . 15
7.1. Tie rod tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2. Pressure accumulator bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3. Idle gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.4. Assembly of rotation motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.5. Rotation motor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.6. Flushing device bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.2. Maintenance tools and -- parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.3. Daily, after work shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.4. Every week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.5. Basic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.6. After rock drill service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.7. Service card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.8. Service follow-- up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E 2005 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
EXIT
 B 22250 - 1 en 0405 / MAH 3 (22)

HL 650, HL 650S
Operation and maintenance

1. GENERAL
These instructions describe in brief the main maintenance procedures for HL 650 series
hydraulic rock drills.
Tamrock 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.
CAUTION

1. Pressurize the accumulators according to the instructions. See “Pressure

accumulator reparation instructions”.
2. Before a new rock drill is 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;

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 retighten in correct order.
E 2005 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
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4 (22) B 22250 - 1 en 0405 / MAH

HL 650, HL 650S
Operation and maintenance

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
CAUTION
type of ”idling drilling” is the most critical while drilling upwards or
cleaning the holes with pumping motion.

3. HOSE CONNECTIONS

6 7
4 8

1 2

5 3

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 (L.P.) (Ø 8 mm) 8. Rotation, pressure (H.P.)
4. Flushing
5. Shank lubrication collector

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P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
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 B 22250 - 1 en 0405 / MAH 5 (22)

HL 650, HL 650S
Operation and maintenance

4. LUBRICATION SYSTEM
The rock drill percussion mechanism and the rotation motor are lubricated by the hydraulic
oil flowing through them.
The rotation mechanism and the shank have oil 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 underground version (fig. 3) the continue lubrication airflow is conducted out via the
canal (3), to the drain hole.
In the surface version (fig. 4) the excess oil is conducted out via the canal (2), to the drain
hole.

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.

Never connect the used oil mist to the hydraulic system’s return line.

CAUTION

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P.O.Box 100
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HL 650, HL 650S
Operation and maintenance

4.1. Lubrication system, underground model

Fig 3. Lubrication system; underground model, HL 650 S

E 2005 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN--33311 TAMPERE, Finland
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 B 22250 - 1 en 0405 / MAH 7 (22)

HL 650, HL 650S
Operation and maintenance

4.2. Lubrication system, surface model

Fig 4. Lubrication system; surface model, HL 650

E 2005 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
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HL 650, HL 650S
Operation and maintenance

2
1

Air

Fig 5. Shank lubrication (surface model)

1. Rock drill 3. Drain valve

2. SLU 1/2/3 4. Filling cap

1. The oil consumption of the shank lub is adjustable. **

2. If the 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

E 2005 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN--33311 TAMPERE, Finland
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 B 22250 - 1 en 0405 / MAH 9 (22)

HL 650, HL 650S
Operation and maintenance

7
4
Air

6 1

3
2

5
Fig 6. Shank lubrication (Underground -- model)

1. Rock drill 5. Connection nipple

2. Oiler 6. Sight glass
3. Drain valve 7. Regulating valve
4. Filling cap

1. 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 oil
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.
4. Only the oils mentioned in the oil recommendation are allowed.
5. 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.

E 2005 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
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10 (22) B 22250 - 1 en 0405 / MAH

HL 650, HL 650S
Operation and maintenance

5. FLUSHING

5 1

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

1. Flushing housing
2. Water pressure gauge
3. Pilot--controlled flushing valve.
4. 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.
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, if the 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
CAUTION
drilling breaks. If this isn’t possible, blow the flushing housing dry
before taking a break.

E 2005 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN--33311 TAMPERE, Finland
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 B 22250 - 1 en 0405 / MAH 11 (22)

HL 650, HL 650S
Operation and maintenance

6. INSPECTION AND MAINTENANCE OF FRONT END WITH ROCK

DRILL IN CARRIAGE
In order to replace the shank, the rock drill has to be tilted as much as
possible in a horizontal position. This way you eliminate that the rotation
bushing and coupling won’t drop.
WARNING

If the lubrication clogges up, (no air coming from the shank lubrication)
turn off the motor, slowly let the pressurized air escape via the locking
bolt before loosening the bolts of the flushing housing. Otherwise the
WARNING flushing housing can burst out due to the pressure and cause damages.
You can also detach the flushing housing without having to remove the rock drill from the
carriage by opening the bolts (1) and the nuts. The coupling and the shank will also detach,
as well as the rotation bushing and the chuck opening the lock bolt (2). Always check
these items when replacing the shank.

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 (3) and the
connector flange (2) before removing the seal housing.

2
3

Fig 9. Dismantle of tube--version flushing housing

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12 (22) B 22250 - 1 en 0405 / MAH

HL 650, HL 650S
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.

90_

1
Drain holes Drain holes
A

1 2 3

1 2 3
B
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 housing 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.

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 B 22250 - 1 en 0405 / MAH 13 (22)

HL 650, HL 650S
Operation and maintenance

6.3. Assembling the flushing housing

Lubricate the o-- ring with vaseline before assembly.

CAUTION

Place the connector flanges’ holes of the flushing housing and the seal housing in line and
press the flushing housing in. Assemble the connector 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 B 90_

8
7

Fig 11. Assembly of the tube flushing housing lock rings

6.4. Coupling
Pull the coupling out from the rotation bushing. Check and
replace, if the edges of the inner teeth are worn sharp.

6.5. Rotation bushing

Check the teeth and the bearing surface for wear.

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HL 650, HL 650S
Operation and maintenance

6.6. Chuck
The chuck inside the rotation bushing must be replaced if the
surface has worn down 1 mm (see picture), it has cracks or if the
shoulder has worn down to the surface. Use a hydraulic press
and a 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.

6.8. Chuck and lock ring pair

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

max 1 mm max 1 mm 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.

Manufacture. 2 mm
Reject 1mm

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

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P.O.Box 100
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 B 22250 - 1 en 0405 / MAH 15 (22)

HL 650, HL 650S
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.
If the 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.
Use only an inspected, high-- quality torque wrench.

CAUTION

3 7 400 Nm
5 (200 Nm)
4
6 (200 Nm)

3 1 2
3 1

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

Circle means that new lock washer pair must be used for locking after
every opening of the bolts.
CAUTION

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16 (22) B 22250 - 1 en 0405 / MAH

HL 650, HL 650S
Operation and maintenance

7.1. Tie rod tightening

The tools required:
-- torque wrench
-- 24 mm socket

1. Lubricate the threads and the nut faces with grease.

2. Tighten first slightly the rear nuts (A) to bottom.
3. Pre--tighten the front nuts (B) to 200 Nm (20 kpm). Correct tightening order is
1--2--3--4.
4. Final tightening torque is 400 Nm (40 kpm). Same tightening order (1--2--3--4)
should be used.

24
(100 Nm) 200 Nm 3 2
3

4 1
3

4
B 1

A
(200 Nm) 400 Nm

Fig 13. Tie rod tightening

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HL 650, HL 650S
Operation and maintenance

7.2. Pressure accumulator 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 200 Nm (20 kpm). Same tightening order (1--2--3--4)
should be used.

7.3. Idle gear shaft

Required tools:
-- torque wrench
-- 24 mm socket

1. Lubricate the threads and the nut faces with grease.

2. 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)

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HL 650, HL 650S
Operation and maintenance

7.4. Assembly of rotation motor

Detach the flushing housing (1) and the gear housing before assembling
the motor.
CAUTION

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--2--3--4)
should be used.

150 Nm 3
2

1 4

Fig 15. Rotation motor bolts

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HL 650, HL 650S
Operation and maintenance

7.6. Flushing device bolts

The tools required:
-- torque wrench
-- 36 mm socket
1. Lubricate the bolt and nut threads with grease.
2. Pre--tighten all four bolts to 300 Nm (30 kpm). Correct tightening order is 1--2--3--4.
3. Final tightening torque is 600 Nm (60 kpm). Same tightening order (1--2--3--4)
should be used.

3 1
3

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.
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HL 650, HL 650S
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.

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 bolt tightness.
2. Check seal tightness during drilling by observing the check holes (1) and (3), Fig.
3.
3. Check possible oil leaks.
4. 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.

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P.O.Box 100
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 B 22250 - 1 en 0405 / MAH 21 (22)

HL 650, HL 650S
Operation and maintenance

8.4. Every week

1. Check hour meter reading.
2. Check accumulator filling valves and their protective caps and the accumulator
bolt tightness.
3. Check accumulator pressures.
4. Check rotation motor and rear cover bolts tightness.
5. Check idler gear shaft bolts for tightness.
6. 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.

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 drill is clearly displayed, and by comparing
the cards the effect of different circumstances and measures can be determined.
-- The cards help in determining maintenance required to prevent major damage.
-- Properly filled cards show the complete maintenance history of the rock drill.
-- The cards help to determine the point when the rock drill should be scrapped.

8.8. Service follow--up

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

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22 (22) B 22250 - 1 en 0405 / MAH

HL 650, HL 650S
Operation and maintenance

ROCK DRILL SERVICE CARD No

Equipment S/n
Rock drill S/n
Since previous service percusion hours
drill. shifts/rounds
drilled meters
SERVICE INFORMATION
Purpose of the service Serviceman
Arr.date Prev.service Prev.perc.hours Working Dism. Insp.
hours
Dep.date Prev.service card No Rep. Ass. Total

REPLACED PARTS/ PART INSPECTION

Repaired Replaced Remarks
Qty Part No Description / Batch / Batch OK
Piston
Front cylinder
Fron bushing
Rear cylinder
Rear bushing

Distributor

LP accumulator
HP accumulator
Spacer
Gear housing
Rotation bushing

Rot.bush.bearing
Chuck
Connecting piece
Rotation motor
Rotation shaft
Rot. shaft bearings
Front cover/ body

Flus. seal housing

Shank bearings

Idle gear
Idle gear bearing
Idle gear pin

Percussion Rotation
Remarks mechanism tested mechanism tested

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D 22250 – 1 en 0405 / MAH 1 (32)

HL 650, HL 650S
Repair instructions

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 2 (32) D 22250 – 1 en 0405 / MAH

HL 650, HL 650S
Repair instructions

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 D 22250 – 1 en 0405 / MAH 3 (32)

HL 650, HL 650S
Repair instructions

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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 percussion mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
6.4. Percussion mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.5. 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. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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 4 (32) D 22250 – 1 en 0405 / MAH

HL 650, HL 650S
Repair instructions

1. GENERAL
These instructions are intended for persons who have to service and repair the
650–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.

CAUTION

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 parts, too, may be
dirty (a bottle brush is a useful aid for the cleaning of the drill’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:

2 4 Features of a good repair place are:

– good lighting
– good washing facilities
1 5 6
10 – compressed air available
– dustless
7 8 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

CAUTION It’s forbidden to use the drill bit grinder in the repair place.
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 D 22250 – 1 en 0405 / MAH 5 (32)

HL 650, HL 650S
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 2. Tools for the rock drill disassembly and assembly

Fig 3. Tools used with the hydraulic press

Fig 4. Tools for the disassembly, assembly and testing of the pressure accumulator
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HL 650, HL 650S
Repair instructions

Fig 5. Special tools

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D 22250 – 1 en 0405 / MAH 7 (32)

HL 650, HL 650S
Repair instructions

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HL 650, HL 650S
Repair 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 removing:

Be careful not to scratch the drill’s interior parts and sealing

grooves.

Fig 6. Removing of seals

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 so 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
a 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

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HL 650, HL 650S
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.

Note the correct position of the seal lip.

CAUTION

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HL 650, HL 650S
Repair instructions

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 650 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.

3
2

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).
CAUTION

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 D 22250 – 1 en 0405 / MAH 11 (32)

HL 650, HL 650S
Repair instructions

Í ÍÍ
ÍÍÍ

ÍÍ
ÍÍ ÍÍ
ÍÍ

Fig 12. Hydraulic rock drill HL 650

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12 (32) D 22250 – 1 en 0405 / MAH

HL 650, HL 650S
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

Before removing the accumulators from the drill release the pressure by
opening the filling valves
CAUTION

Fit immediately a cover plug to the opening in the body.

CAUTION

See instructions ”Pressure Accumulators”.

CAUTION

Fig 14. Removal of pressure accumulators

Required tools:
– Torque wrench
– 24 mm socket
Open the fastening bolts of the accumulator (fig 14). Dismount the accumulator and the
gasket.
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HL 650, HL 650S
Repair instructions

5.3. Hydraulic motor

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)

16 4 3
8 5
12
6 12
11
10
15
ÂÂ 6

7
14 ÂÂ
ÂÂ
ÂÂ 13

2
Fig 16. Parts of the hydraulic motor

2. Housing 10. Rotation shaft

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

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HL 650, HL 650S
Repair instructions

Hydraulic motor assy

15

4 3
10 7 12 5 2

Fig 17. Hydraulic motor assy

Use the assembling punch (1) from the tool set when you pull rotation
shaft through the cover so seals do not damaged.

CAUTION

Assembling order (fig 17):

1. Bearings inner track (15) on shaft (10)
2. Seals. Assemble the cover seals (12) by using a punch (152 537 28) and the
circles.
3. Assemble the cover (7) with it seals on the shaft by using the punch (1)
4. Assemble the bearing (5) onto the shaft (10), tighten the nut (3) and secure it with
the locking washer and some glue.
5. Assemble the shaft sassy. into the bearing housing (2).
6. Cross–tighten the cover–bolts (8)
– pre–tightening 10 Nm
– final tightening 32 Nm

Observe the locking of locking washers and threads with glue.

CAUTION

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HL 650, HL 650S
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.
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HL 650, HL 650S
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:

D the striking head is worn as deep as the bevel is
D there are fractures and seizing marks on the piston.
When necessary, piston can be polished with a buffing wheel. Piston must not be ground.
Examine the distributor if:
– If there are burrs in the distributor, remove them by polishing with a buffing wheel
(light scratches)
– If there are seizing marks in the distributor, change a new part.

Rear cylinder must not be ground.

CAUTION

Examine the rear cylinder if:

– If there 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.

CAUTION

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HL 650, HL 650S
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

Replace the bearing bushing of the

front cylinder only, if it is damaged.
Press the bolts on the special tool (1)
against each other and fit the tool into the
bearing (2) groove of the front cylinder.
Press the bearing out by using a punch (3)
3 and a thrust (4).

2
1

ÇÇ Ç
4
ÇÇ
ÇÇ Ç
Ç
ÇÇ Ç
ÇÇ Ç
Fig 22. Removal of the front cylinder bearing

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HL 650, HL 650S
Repair instructions

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

A
3

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.

B C
2 Align long groove B of the
bearing with spacer marking
C. Pay attention to locking
surface.

Fig 24. Installing the bearing

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HL 650, HL 650S
Repair instructions

Seal housing must be replaced if the seal groove in the spacer is wider than 4,35 mm. Use
the tool 150 746 48 to check the width.

1 4
2
6
5

3 A B

Fig 25. Removal and installation of the spacer seal housing. Use a hydraulic press.

1. Disassembly
2. Assembly
3. Locking rings 550 055 28
4. Punch for removing 550 055 27
5. O–ring
6. 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.

Clean the spacer and the seal bushing carefully before installation.

CAUTION

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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
(2pcs) 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.

Make sure the thicker edge of the needle bearing points outwards and
comes flush with the surface of the idler gear.
CAUTION

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HL 650, HL 650S
Repair instructions

Disassembly and assembly of the gear housing

Check the wear limits of the gear housing (see page 31).

ÂÂ
10 1 7

ÂÂ
5
9

9 10

10 12
2
4
11
9

12

Don't glue the o-rings

until you mount the rock
8 drill to the carriage
3

Fig 28. Parts of the gear housing

1. 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

ÉÉÉ
ÉÉÉ
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
ÉÉ
ÉÉÉÉÉ
É ÉÉÉÉ picture. Assembly the bushings with a
punch.

ÉÉ
ÉÉÉÉÉ
É ÉÉÉÉ
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HL 650, HL 650S
Repair instructions

Front bushing of the gear housing

ÇÇÇÇ
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.

ÇÇÇ
ÇÇÇ
Detachment of front bushing

When using a screwdriver, be sure not to scratch the inner surface of the
gear housing.
CAUTION

The gear housing rear bushing

The bearings must be changed by using a punch and a hydraulic

press, if the wear indication groove has worn out as shown in the
picture .

Cylindrical roller bearing

Cylindrical roller bearing

ÉÉ ÉÉ
Remove the plugs, circlip and bushing. Remove the bearing by
using punches and hydraulic press as shown in the picture
Mounting
ÉÉ ÉÉ Mount the bearing by using punch and hydraulic press . The riv-
ets of the bearing pin housing must be point to back of the rock
drill . Mount the inner ring of the bearing with shaft assy . The
bearing must be changed after every 500 drilling hours.

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HL 650, HL 650S
Repair instructions

6. ASSEMBLY
Exercise particular care when assembling the rock drill. Check that all parts are absolutely
clean.
Before assembling the drill check all the wear parts, such as bearings and pressure
accumulator diaphragms (See ”Pressure Accumulators”), and replace with new ones
when necessary. All wear limits of the parts are indicated in the ”Wear limit chart” (See
Section 7). Before the assembly the parts should be lubricated for example with motor
oil.
All joint surfaces must be absolutely dry and clean.

CAUTION

Assembly stand
The assembly of the drill is started with the assembly stand in the horizontal position. Make
sure that the fastening bolts (2 pcs) and the locking latch are secured and closed.
Mount the gear housing assembly onto the assembly stand. Tighten the bolts.

6.1. Assembly of the idler gear and the spacer

Assembly of the idler gear

Required tools:
200 Nm – Torque wrench
– 24 mm socket
Fit the slide ring and the idler gear into the
gear box. Push the shaft in by hand to
o–ring. Knock the shaft carefully in with
rubber hammer. Make sure the rings stay in
place during the assembly. Tighten the
screws to the torque of 200 Nm (20 kpm).
Use new locking washer pairs
Fig 29. Assembly of the idler gear and shaft

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24 (32) D 22250 – 1 en 0405 / MAH

HL 650, HL 650S
Repair instructions

Assemble the spacer assy into gear house

Use grease for the support plate to help the assembly.

CAUTION

Be sure that the seals of the spacer and the gear housing are in right
places
CAUTION

Assembly stand
Turn the assembly table to upright position

6.2. Assembly of the front cylinder and the body cylinder

Lower the body cylinder carefully down . Tighten slightly the assembly table rear mounting
bolts.

Fig 30. Assembly of the front cylinder and the body cylinder
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 D 22250 – 1 en 0405 / MAH 25 (32)

HL 650, HL 650S
Repair instructions

6.3. Tightening the tie rods

Turn the assembly table to horizontal position using a hoist. Lock the mounting plate with
bolts (2pcs) and the latch located in the rear end of plate.
Required tools:
– Torque wrench
– 24 mm socket
1. Lubricate the threads and the nut faces with grease.
2. 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.
3. Tighten the body cylinders rear to the assembly table.
4. Final tightening torque is 400 Nm (40 kpm). Same tightening order should be
used.

24

4 1
3

A
400 Nm (200 Nm)

Fig 31. Tightening the tie rods

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26 (32) D 22250 – 1 en 0405 / MAH

HL 650, HL 650S
Repair instructions

6.4. Percussion mechanism

Use a lot of oil inside surface of the body cylinder.

CAUTION

Check the chapter ”Seals” to make sure the seals are fitted correctly.
Check also that the components are not installed wrong way.

CAUTION

Lift the assembly plate to a vertical position with a hoist. Assemble the front cylinder into
the body cylinder. Assemble the rear bearing deep enough into the rear cylinder. Check
the edges. Assemble the distributor, rear cylinder assy. onto the shaft.
Lift the shaft assy. into the body cylinder. Use the same special tool as used for lifting the
percussion mechanism.

Fig 32. Percussion mechanism

6.5. Rear cover
Required tools:
– Torque wrench
– 30 mm socket
Install the rear cover and the bolts in the body cylinder. Before the installation, place the
O–ring in the groove of the rear cover. Use new lock washer pairs .The surfaces should
be clean and dry.

Fig 33. The rear cover

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 D 22250 – 1 en 0405 / MAH 27 (32)

HL 650, HL 650S
Repair instructions

Tightening the rear cover bolts

400 Nm (200 Nm)

Fig 34. Tightening the rear cover bolts

Tightening torques
– pre–tightening torques 200 Nm (20 kpm)
– final tightening torque 400 Nm (40 kpm)
– use a cross–tightening order

6.6. Assembly of hydraulic motor

Carefully assemble the hydraulic motor

into the gear housing and tighten the bolts.
4
Required tools:
– Torque wrench
150 Nm 1 – 24 mm socket
2
Grease the bolts. Pre–tighten all four bolts,
3 with a torque wrench to 100 Nm (10 kpm).
Use a tightening order 1–2–3–4 .The final
tightening torque is 150 Nm (15 kpm). Use
the same tightening order 1–2–3–4.

Fig 35. Tightening of the hydraulic motor bolts

Use grease on hydraulic motor o–ring and pole.

CAUTION

All joint surfaces must be absolutely dry and clean.

CAUTION

Always assemble the the motor before the rotation bushing and the
flushing housing.
CAUTION

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 28 (32) D 22250 – 1 en 0405 / MAH

HL 650, HL 650S
Repair instructions

6.7. Assembly of the pressure accumulators

Grease the O–ring and the bolts.

Install the pressure accumulators using a
rubber mallet. See Repair instructions
”Pressure Accumulators”.
3 2 Required tools:
– Torque wrench
– 24 mm socket
200Nm(100Nm) Pre–tighten all four bolts, with a torque
44
1 wrench to 100 Nm (10 kpm). Use a
tightening order 1–2–3–4.The final
tightening torque is 200 Nm (20 kpm). Use
the same tightening order 1–2–3–4.

Fig 36. Tightening the pressure accumulator bolts

Looking from the back of the drill the high-pressure accumulators (H.P.)
are on the right side and the low-pressure accumulators (L.P.)

CAUTION

The types and pressures of the accumulators

Type of accumulator Pressure [bar]
High pressure 80 (max)
Low pressure 4

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 D 22250 – 1 en 0405 / MAH 29 (32)

HL 650, HL 650S
Repair instructions

6.8. Assembly of the front end

Fig 37. Assembly of the coupling piece , rotation bushing and the flushing housing. Use
new gasket (1). Flushing housing ssembly; See operation and maintenance

Assembly of the setscrew Tilt the mounting stand into horizontal

position using a suitable hoist. Secure the
stand on with a latch and locking screw.
Assembly of the setscrew
Required tools:
– 19 mm socket
– torque wrench
Lubricate the bolt threads with grease. Use
new bonded seal. Tighten the bolt to 120
Nm (12 kpm).

Fig 38. Tightening the setscrew

Tightening of flushing housing bolts:

Required tools:
24 – Torque wrench
– 36 mm socket
Lubricate the bolt and nut threads with
3
grease.
Pre–tighten all four nuts to 300 Nm (30
kpm). Correct tightening order is 1–2–3–4.
4 Tighten the bolts up to 600 Nm (60 kpm).
1 Use the cross–tightening method. Use new
lockwashers
Fig 39. Tightening the flushing housing bolts
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30 (32) D 22250 – 1 en 0405 / MAH

HL 650, HL 650S
Repair instructions

ÇÇÇÇ ÉÉÉÉ
G

ÇÇÇÇ ÉÉÉÉ
ÇÇÇ
G ÉÉÉÉ
ÇÇÇA
ÇÇ N

K E

ÇÇÇ
ÇÇÇ
C
D

ÇÇ B

ÍÍÍ
ÍÍÍ

M
ÍÍ
F Í ÍÍ
L Í

Fig 40. Wear limits

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 D 22250 – 1 en 0405 / MAH 31 (32)

HL 650, HL 650S
Repair instructions

7. WEAR LIMITS

PART NAME WEAR LIMIT

A. Bearings of the shank Must be changed, if the oil groove is worn

flush with the bearing surface in any place.
B. Gear housing Manufacturing 271 mm / Reject 270 mm
C. Front bearing of the gear housing Must be changed if the ”oil pockets” are worn
out on some places on the bearing
surface.
D. Rear bearing of the gear housing Must be changed if the oil groove is worn out
on some places on the bearing surface.
E. The shaft of the idler gear Must be changed if the shaft/bushing is worn
loose or the surface of the shaft is damaged.
F. Piston Must be changed if the bevel of the piston
head is worn out.
G. Chuck / Lock ring pair Must be changed if the pair depression is 1
mm / if there are cracks on the surface.
H. Coupling Must be changed when the teeth are worn
halfway.
K. Shank See Operation and Maintenance.
L. Spacer bearing The bearing must be replaced when the wear
indicator groove has worn down to the level of
the surface at any point.
M. Seal housing of the spacer Change the seal housing if the width of the
seal groove is more than 4,35 mm.
N. Rotation bushing Check the wearness of the bearing surfaces
and the rotation bushing teeth.

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32 (32) D 22250 – 1 en 0405 / MAH

HL 650, HL 650S
Repair instructions

Checking the percussion cartridge fit between the spacer and the rear cover

B
A

1 2

Fig 41. Measuring points

Wash the percussion cartridge (1) parts. Before measuring and assembling check that
the parts are clean and without oil films.
Measure the dimensions (A), (B) and (C).
The difference of the measurements (A) and (B) must be larger than the measurement
(C). If it is not, discard the parts (3) and (4).

8. TEST RUN
Do the test–run for the Rock drill to check the ordinary functions.
Observe during the test:
– that there is no oil leak at the front of the rock drill or at the connections between
the different components
– operation of the shank lubrication
– operation of the flushing
– pressures and temperature

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 D 28160-- 8 en 0905 / PIR 1 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. CHECKING THE FILLING GAS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. REMOVING THE PRESSURE ACCUMULATOR FROM THE ROCK DRILL . 3
4. DISMANTLING THE PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . 4
5. CHECKING THE PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.1. Filling device of pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . 7
7.2. Filling instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.3. Filling pressures of accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3.1. Low pressure accumulator (LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3.2. High pressure accumulator (HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3.3. Pressure of stabilizer accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8. MOUNTING THE PRESSURE ACCUMULATOR ON THE ROCK DRILL . . . . 11

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2 (12) D 28160-- 8 en 0905 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

1. GENERAL
As in all hydraulic machinery so also in hydraulic drill rigs cleanness is the most important
consideration if trouble--free operation is to be ensured. We therefore recommend that all
maintenance work of the accumulators is done in a clean and dustless room.
The condition of pressure accumulator should be checked always when the accumulator
is dismantled and when the rock drill is overhauled. The rock drill special tool set includes
all the tools needed in maintenance and checking the accumulators.
Experiences have shown that the first (originally fitted) accumulator diaphragm does not
reach the normal service life, particularly if the time interval between the pressurization
and taking into use is long. For this reason the accumulators supplied as spares are
unpressurized. There is a note of this on the accumulator.
The accumulator bottom and cover should always be kept as a pair. Tamrock supplies
covers and bottoms only as a pair; other parts such as diaphragms and filling valves can
be obtained separately.

Only qualified service personnel may service the pressure

accumulators. The following instructions must be strictly observed;
failure to do so may cause a danger of accident.
WARNING

Before removing the accumulator from the rock drill, discharge the
accumulator pressure by opening the filling valve.

WARNING

Repair of a pressure accumulator by welding or by other means is strictly

forbidden.

WARNING

While using the gauge, the pressure relief hole must always be pointed
to the opposite direction from any persons close by to avoid personal
injures in case the sudden pressure discharge.
WARNING

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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.

a b

1. Remove the cap (a).

2. Screw the pressure gauge to the filling valve.
3. Undo the lock nut (b).
4. Wait until the needle of the gauge stops and then read the gauge indication.
5. Close the lock nut (b).
6. Unscrew the gauge from the filling valve and fit the cap (a) in place.

3. REMOVING THE PRESSURE ACCUMULATOR FROM THE ROCK

DRILL
Pressure accumulator can be changed without demounting the rock drill from the feed.
If you for some reason cannot immediately install a new accumulator, must the open oil
channels be covered thoroughly with eg. plastic plugs.

1. Discharge the accumulator pressure by opening the filling valve!

2. Undo the accumulator bolts (wrench size 24 mm).

Do not start the hydraulic power pack if an accumulator is not in place in

the rock drill.

WARNING

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

4. DISMANTLING THE PRESSURE ACCUMULATOR

Before dismantling the accumulator, be sure it has no pressure.

WARNING

1. Fasten the assembly stand (1) in the vice, and place the accumulator in the stand
with the bottom upwards.
2. The same number appears both on the accumulators cover as well as on the
bottom. The cover and the bottom must remain paired.
3. Make sure that the filling valve is open!
4. Open the accumulator bottom with the opener (2).

5. CHECKING THE PRESSURE ACCUMULATOR

1. Check the accumulator visually for wear, damage, corrosion, etc.

2. Clean and check the threads carefully.

If the threads are badly corroded or worn, the accumulator must be

scrapped!

WARNING

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

6. ASSEMBLY

b
10 Nm
40 Nm secure with glue
20 Nm
b

1. Fit a new or inspected diaphragm in the cover. Make sure that the diaphragm is
in the groove and fitted the right way down.
2. Lubricate the surface (a) with vaseline or lanolin.

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

Check that the number on the cover and the bottom is the same.

WARNING

D The high pressure accumulator is marked with uneven numbers and the low
pressure accumulator with even numbers.

HP LP

3. Lubricate the threads of the bottom with vaseline or lanolin.

4. Screw the bottom all the way in and tighten it with the special tool to a torque of
150 Nm.
D When the pressure accumulator diaphragm is changed, the O--rings (b) should
also be changed.

Check the wear limit marks of the threads always after tightening (150 Nm) of the bottom.
If the mark (I) in the bottom remains after the tightening between the dot (S) and the mark
(R) in the cover, the thread is in order.
If the mark (I) in the bottom goes beyond the mark (R), are the threads of the accumulator
cover and bottom too much worn. Replace the accumulator and discard the old one.
A worn--out or damaged pressure accumulator must be discarded
immediately.

WARNING

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

7. FILLING
The only allowable filling gas is nitrogen (N2).

WARNING

Do not fill an unchecked or a too worn accumulator.

WARNING

D You can refill the accumulator while mounted to the rock drill.

7.1. Pressure accumulator filling device

12 9 8 7 6 5 3 2

N2
11 10 13,14 15 4 1

1. Accumulator body
2. Filling valve
3. Locking nut
4. Cap
5. Quick coupling stem
6. Quick coupling sleeve
7. Hose
8. Accumulator pressure gauge
9. Gas bottle pressure gauge
10. Pressure reducing valve
11. Pressure regulating valve
12. Shut--off valve
13. Adapter
14. Seal
15. Elbow adapter

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

7.2. Filling instruction

1. Remove the cap (4).

2. Screw the elbow adapter (15) to the filling valve (2).
3. Push the quick coupling sleeve (6) onto the stem (5).
4. Undo the locking nut (3).
5. Turn the pressure regulating valve (11) open.
6. Open the nitrogen bottle valve (12). The gauge (9) indicates the pressure in the
bottle.
7. Adjust the pressure in the low pressure accumulator to 5 -- 10 bar by turning the
regulating valve (11). Gauge (8) indicates the pressure in the accumulator.
8. Adjust the pressure in the H.P. accumulator with the pressure control valve (11),
according to the instructions. Gauge (8) indicates the pressure in the accumulator.
Max. pressure is marked on the accumulator.
9. Adjust the pressure of the stabilizer accumulator with the pressure control valve,
according to the instructions. Gauge (8) indicates the pressure in the accumulator.
10. Close the filling valve (2) by turning the locking nut (3).
11. Close the nitrogen bottle valve (12).
12. Turn the pressure regulating valve (11) open.
13. Disconnect the quick couplings (5) and (6).
14. Release the elbow adapter (15) from the filling valve (2).
15. Mount the checking gauge (0--10 bar) in to the low pressure accumulator filling
valve (2) and by opening the locking nut (3) let the pressure flow out until the gauge
shows 3 -- 5 bar.
16. Tighten the locking nut (3) to 20 Nm.
17. Refit the cap (4).
18. Assure the tightness of the accumulator by immersing it in water. Dry the
accumulator carefully for example with compressed air.
19. If the accumulator is not taken into use directly, release the pressure and store it
in a dry place protected from dirt.

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 D 28160-- 8 en 0905 / PIR 9 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

7.3. Filling pressures of accumulators

7.3.1. Low pressure accumulator (LP)

Low pressure accumulator damps hydraulic vibrations in the return line. It also prevents
cavitation in return lines and channels. To get the optimum result of LP--accumulator, gas
pressure should be half of the return line pressure. Normally it is from 3 to 5 bars.

7.3.2. High pressure accumulator (HP)

The main function of high pressure accumulator is to store pressurised oil during the
return stroke of the piston. This stored pressure can be utilized during the next piston
stroke. Another vital function is to dampen vibrations. HP--accumulator gas pressure
should be related to the set max. percussion pressure according to graph below.

Stem-- type diaphragm

100

90

80

70
Filling pressure

60

50

40

30

20

10

0
100 120 140 160 180 200 220
Percussion pressure
Upper limit
Lower limit

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PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

Normal (stemless) diaphragm

100

90

80
Filling pressure

70

60

50

40

30

20

10

0
100 120 140 160 180 200 220

Upper limit Percussion pressure

Lower limit

7.3.3. Pressure of stabilizer accumulator

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

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 D 28160-- 8 en 0905 / PIR 11 (12)

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

8. MOUNTING THE PRESSURE ACCUMULATOR ON THE ROCK

DRILL

D See “Hydraulic rock drill, repair instructions“.

1. Before mounting the accumulator on the rock drill, remove the cover plugs from
the accumulator connection port, and clean the joint surfaces both in the
accumulator and in the rock drill.
2. Check that the bolts move easily in their threads in the drill body. Lubricate the
threads of the bolts.
3. Fit the O--ring and the gasket.
4. Tighten the pressure accumulator bolts in two phases:
pretightening 100 Nm, final tightening 200 Nm.

1 2

4 3

Tightening of the four--bolt accumulator

The four-- bolt accumulator must be tighten by using a cross-- tightening

method 1--3--2--4.
CAUTION

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 12 (12) D 28160-- 8 en 0905 / PIR

PRESSURE ACCUMULATOR FOR HYDRAULIC ROCK DRILL

Repair instructions

Notes:

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 D 28400 ---2 GB 0997TTi 1 (6)

HYDRAULIC MOTORS OMT, OMSU

Repair Instructions

OMSU

100 Nm secure with glue

OMT

24 Nm secure with glue

190 Nm

CONTENTS
1. Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Timing the motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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2 ( 6) D 28400 ---2 GB 0997TTi

1. SPECIFICATION

MOTOR MOUNTED ON ROCK DRILL HL 500/ HL 550

OMSU 80 OMSU 100 OMSU 125

Motor . . . . . . . . . . . . . . . . . Orbit type
Rotation rate . . . . . . . . . . . 0...250 rpm 0...250 rpm 0...200 rpm
Torque, max 175 bar
(max continuos) . . . . . . . . 400Nm 490Nm . . . . 630 Nm
Oil flow l / 1/min . . . . . . . . 46 / 250 58 / 250 58 / 200

MOTOR MOUNTED ON ROCK DRILL HL 600

OMT160 OMT 200 OMT 250 OMT 315

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

MOTOR MOUNTED ON ROCK DRILL HL 700

OMT160 OMT 200 OMT 250 OMT 315

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

MOTOR MOUNTED ON ROCK DRILL HL 1000

OMT 250 OMT 315 OMT 500

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

E 1997 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100
FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
EXIT
 D 28400 ---2 GB 0997TTi 3 (6)

HYDRAULIC MOTORS OMT, OMSU

Repair Instructions

2. REPAIR

In all hydraulic machinery the cleanness is the most important

consideration to ensure the trouble---free operation. We therefore
recommend that all maintenance work of the hydraulic motors is done
in a clean and dustless room.
When dismantling the hydraulic motor, always change all seals.
Change the worn---parts for new ones in time to avoid more serious
damage.

1 45 Nm 60 Nm secure with glue

2 190 Nm
3
Use cross
24 Nm secure with glue 5---10 Nm tightening
method

Fig. 1 Hydraulic motor OMT

The spacer ring (2) has to be always changed with the roller bearings
(1) . After you have pressed the bearings onto the shaft, tighten the lock
nut (3) up to 60 Nm and secure with glue and by pressing the locking
nut collar to the groove of the shaft .

E 1997 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100
FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
EXIT
4 ( 6) D 28400 ---2 GB 0997TTi

2
3
4
5
3
6
7
8 6

9
10
11
12 13
14 15 16 17 18
19
20 21
22 23 24

5---10 Nm 80 Nm
Use cross
tightening
method

Fig. 2 Hydraulic motor OMSU

2. O --- RING 10. CHANNEL PLATE 18. PLUG
3. SCREW 11. DISC VALVE 19. HOUSING
4. PLATE 12. PLATE 20. BALL
5. SHAFT 13. PIN 21. SPRING
6. O --- RING 14. O --- RING 22. WASHER
7. GEAR WHEEL SET 15. O --- RING 23. PLUG
8. PIN 16. SPACER 24. BOLT
9. SHAFT 17. SPRING WASHER

Never rotate the motor without the shaft, this will damage
! the disc.

E 1997 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100
FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
EXIT
 D 28400 ---2 GB 0997TTi 5 (6)

HYDRAULIC MOTORS OMT, OMSU

Repair Instructions

CHECKING THE MOTORS

2 1
5---10 Nm

Fig.3 Non ---return valve

Non---return valve

Check the condition of ball (1) and valve surfaces (2), if they are
damaged the valve leaks and the motor must be changed.

Gearwheel set

If there are fractures, seizing marks or georotor is worn the motor has to
be changed.
The gearwheel set must be used as a pair.

E 1997 TAMROCK OY, SERVICE TAMPERE PLANT

P.O.Box 100
FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
EXIT
6 ( 6) D 28400 ---2 GB 0997TTi

3 Nm
1 2 4
Fig.4 Hydraulic motor OMSU
Push the cover (2) firmly in place. Make sure the cap is
! even between the cover and body before tightening the
bolts (1). If the cap is not even the shaft (4) might be
jammed behind the corner (3) and while tightening the
mounting bolts the bearing (5) will damange the rear cover
of the motor.
If the motor is not used immediatly, fill with oil and close the oil supply
parts so that it stays full of oil until it is put into operation. Oil prevents
rust and provides lubrication for all moving parts when the motor is
started.

3. TIMING THE MOTORS

4

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

of the of the holes (A) which goes thru 3
the valve, is located on the center line.
2. Fit the shaft (2) into the disc valve. B
3. The drain hole (B) in the channel plate
2
(3) must be located on the same center
line .
4. The tooth of the gear (4) must be set on
the right side of the center line . 1

Fig.5 Timing the motors

A
E 1997 TAMROCK OY, SERVICE TAMPERE PLANT
P.O.Box 100
FIN--- 33311 TAMPERE, FINLAND
Tel. +358 205 44 121 , Telex 22335 parts fi
Telefax +358 205 44 4771
EXIT
 C 00640-1 en 0198

ROCK DRILL SERVICE CARD N:o

Equipment S/n
Rock drill S/n
Percussion hours since last
service
drill. shifts/rounds
drilled meters

SERVICE INFORMATION
Purpose of the service Service man

Arrival date Previous service Edell. iskutunnit Work. hours Dism. Insp.

Departure date Previous service card n:r Rep. Ass. Total

REPLACED PARTS / PART INSPECTION

Qty Part no. Description Repaired Replaced OK Remarks
Piston
Front cylinder
Front bearing
Rear cylinder
Rear bearing
Distributor
LP. accumulator
HP. accumulator
Spacer
Gear housing
Rotation bushing
Rot. bush. bearing
Chuck
Connecting piece
Rotation motor
Rotation shaft
Rot. shaft bearings
Front cover / body
Flushing seal housing
Shank bearings

Perc.mechanism Rot.mechanism
Remarks tested tested

Cont.

© 2000 SANDVIK TAMROCK CORP., Tampere Plant

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

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