Boom

HYDRAULIC TB BOOM

Table of Contents

1. SAFETY . 32. GENERAL .............................................................................................................................. 53. TECHNICAL DATA ................................................................................................................ 64. MAIN PARTS ......................................................................................................................... 85. CHECKING BOOM CLEARANCES ...................................................................................... 9

5.1. Adjusting clearance between boom inner and outer tube ............................................................ 10

5.2. Replacing the wipers ............................................................................................................................... 11

5.3. Checking the slide plates and slide pieces ....................................................................................... 12

5.4. Replacing the slide plates and pieces ................................................................................................ 13

5.5. Checking the slide piece clearances (TB120- and TB150-booms) ............................................. 14

5.5.1. Inner tube slide pieces (TB150) .................................................................................................... 15

6. CRADLE TO FEED CLEARANCE ........................................................................................ 176.1. Checking the slide pieces of the cradle ............................................................................................. 18

6.2. Replacing the slide pieces of the cradle ............................................................................................ 19

7. BEARING BUSHINGS AND AXLE PINS .............................................................................. 207.1. Checking bearing bushings and axle pins ........................................................................................ 20

7.2. Replacing bearing bushings ................................................................................................................. 20

8. CHECKING CYLINDER PINS ............................................................................................... 218.1. Mechanical taper pin ............................................................................................................................... 22

8.2. Tightening torques for cradle tightening bolts ................................................................................ 22

9. CHECKING OF THE ANGLE RESTRICTION FUNCTION ................................................... 2310. TESTING THE LIFT/SWING CYLINDER SEALS ............................................................... 24

10.1. Testing the boom lift cylinder seals .................................................................................................. 25

10.2. Testing the boom swing cylinder seals ........................................................................................... 25

11. ROTARY ACTUATOR ......................................................................................................... 2611.1. Operating principle of the rotary actuator ....................................................................................... 29

11.2. Mounting ................... 29

11.3. Taking into use ....... 29

11.4. Bleeding .................... 29

11.5. Disassembly of rotary actuator .......................................................................................................... 30

11.6. Assembly of rotary actuator ............................................................................................................... 30

12. FLUSHING AND BLEEDING THE BOOM HYDRAULIC CIRCUIT .................................... 3112.1. Lift circuit ................. 31

12.1.1. Flushing and bleeding (left/right) ................................................................................................ 3112.1.2. Bleeding (boom in normal position) ........................................................................................... 32

12.2. Boom swing circuit 32

12.2.1. Flushing and bleeding (right boom) ........................................................................................... 3212.2.2. Bleeding (right boom, boom in normal position) ...................................................................... 3212.2.3. Flushing and bleeding (left boom) .............................................................................................. 3312.2.4. Bleeding (left boom, boom in normal position) ......................................................................... 33

12.3. Rotary actuator ....... 33

Copyright © Sandvik Mining and Construction 1 (57)ID: 271 1 en 2009-01-29

12.4. Feed tilt and feed swing cylinders ..................................................................................................... 33

12.5. Other cylinders ....... 34

13. PERIODIC MAINTENANCE ................................................................................................ 3513.1. Greasing points ...... 35

13.2. Checking the zoom tube wiper ........................................................................................................... 35

13.3. Washing the boom . 35

13.4. Checking the condition of hoses and connections ...................................................................... 35

13.5. Checking the condition of electrical cables ................................................................................... 35

13.6. Tightness of bolts and nuts ................................................................................................................ 36

13.7. Checking the sensor boxes ................................................................................................................. 36

13.8. Lubricating the electric box connections ........................................................................................ 36

14. BOOM LIFT AND SWING CYLINDERS .............................................................................. 3714.1. Boom lift and swing cylinder repair .................................................................................................. 37

15. TROUBLESHOOTING ......................................................................................................... 3815.1. All hydraulic functions slowly or not working at all ..................................................................... 38

15.2. Feed moves backwards during drilling ............................................................................................ 38

15.3. Automatic parallelism not working properly .................................................................................. 39

15.4. Feed extension movement unsteady ................................................................................................ 39

15.5. Boom rotation mechanism not working .......................................................................................... 39

15.6. Boom creeping ....... 39

15.7. Boom doesn't turn sideways .............................................................................................................. 40

15.8. Lifting and lifting points ....................................................................................................................... 40

16. BOOM LIFTING AND LOWERING ...................................................................................... 4116.1. Lifting movement ... 41

16.2. Lowering movement .............................................................................................................................. 43

16.3. Operation of block (2) valves .............................................................................................................. 44

16.4. Angle restriction function .................................................................................................................... 45

17. BOOM CONTROL (THC) ..................................................................................................... 4717.1. Hydraulic diagram (THC) ...................................................................................................................... 47

17.2. Boom control block ............................................................................................................................... 49

17.2.1. Adjusting boom circuit max. LS pressure .................................................................................. 5017.2.2. Adjusting boom circuit max. pressure ........................................................................................ 5117.2.3. Adjusting max. speed of boom movements .............................................................................. 5217.2.4. Boom movement not working ..................................................................................................... 5217.2.5. Boom working pressure too low ................................................................................................. 53

18. BOOM CONTROL (TPC) ..................................................................................................... 5418.1. Hydraulic diagram (TPC) ...................................................................................................................... 54

19. BOOM CONTROL (TPC 561 DATA) ................................................................................... 5619.1. Hydraulic diagram (DATA) ................................................................................................................... 56

2 (57) Copyright © Sandvik Mining and ConstructionID: 271 1 en 2009-01-29

SAFETY ID: 28714

Follow always the safety instructions. Do your work carefully.

Never go under the boom if they are not securely braced.

Risk of personal injury or material damage: Incorrect connec-tion in the hydraulic system of boom swing compensation sys-tem can cause personal injury and damages to mechanicalcomponents. Check and test hydraulic connections of the boomswing compensation before using the rig.

Do not remove hydraulic hoses or valves before you are surethat the system is not statically loaded. High-pressure hydraulicoil can cause severe injury. Before removing any hydrauliccomponent or disassembling a cylinder, always ensure that thecomponent in question is not pressurised. This situation is pos-sible even if the rig is stopped and the components are suppor-ted so that static pressure is not generated. These componentsinclude the overcentre and non-return valves in the boom rota-tion mechanism, cylinders, and some valve blocks, hoses, andpipes. The pressure can be released with, e.g., a bleeder screw,if so equipped; otherwise, the component must be removed withextreme caution when the oil temperature is sufficiently low. Inremoving the component, it is recommended that the compo-nent be covered with, e.g., a cloth in order to prevent the spray-ing of high-pressure oil.

Do not touch pressurized hydraulic hoses. Theymay have un-noticeable pin-holes to let out a thin oil spray which may pene-trate through the skin.

The operator must acquaint himself with the instruction man-uals provided by the manufacturer, and follow the instructionstherein. Plan your work in advance with the prevention of acci-dents, damage, and injuries in mind. The operator must knowthe performance characteristics of the rig.

Observe absolute cleanliness when disassembling or assem-bling hydraulic equipments. Blow all parts clean with pressur-ized air and wipe them with clean, non cluffy cloth before as-sembling. This is to avoid operating disturbances caused by dirtand air in the cylinders.

The BOOM MAY FALL UNCONTROLLED! This could cause se-rious personal injury or death, if a person is located within thedanger area of the boom.

1.

HYDRAULIC TB BOOM


The boom may fall uncontrolled, if the boom lift cylinder innerseals are failed and simultaneously the Y-port hose is damagedor loosened.Automatic parallelism not working as intended may indicate thecylinder seal failure. In the models not using hydraulic parallel-ism system (full Data jumbos and Cabolt), the automatic paral-lelism doesn’t indicate the possible seal failure and the cylinderseals must be tested according to updated instructions (attach-ed).

If any of booms function doesn’t work properly, there is a failurein the system and working with this unit must be stopped im-mediately. It is very important that the reason of the failure willbe investigated and properly repaired before continuing towork.

HYDRAULIC TB BOOM


GENERAL ID: 28666

This user manual gives to the user instructions for maintenance and dismantling of TB hydraulicuniversal booms. By following these instructions the length of life and reliability of operation of hy-draulic universal booms can be increased.TB boom series are hydraulic universal roll-over booms for mechanized tunneling, drifting, cross-cutting and bolt hole drilling. They can also be used for production drilling with cut-and-fill and room-and-pillar methods.

2.

HYDRAULIC TB BOOM


TECHNICAL DATA ID: 24103

1

2

3

4

5

6

7

8

a

a

L

ID: 24250

TB 40 TB 60 TB 90 TB 120 TB 1501. Height [mm] 1051 1118 1118 1268 12692. Zoom [mm] 1050 1200 1800 1900 32003. Width [mm] 818 884 935 951 9514. Length [mm] 5414 5545 6670 7493 74935. Boom swing α 40°/40° 45°/45° 45°/45° 45°/45° 45°/45°6. Boom head swing 40°/40° 45°/45° 45°/45° 45°/45° 45°/45°7. Boom lowering 30° 25° 24° 30° 30°8. Feed extensionstandard[mm]

1350 1650 1650 1650 1650

9. Weigth, boom withinternal hosing [kg]

1850 2250 2650 3100 3350

Unspecified turning degrees are the same on all of the booms.

3.

HYDRAULIC TB BOOM


TB 150 A = 159,0 m²TB 120 A = 120,0 m²TB 90 A = 95,0 m²TB 60 A = 56,5 m²TB 40 A = 44,5 m²

ID: 24251

TB 40 TB 60 TB 90 TB 120 TB 150Coverage with parallel holding [m²] 44,5 56,5 95,0 120,0 159,0Coverage in parallel roof bolting [m²] 5,1 7,5 15,2 18,8 34,5Coverage in parallel cross-cutting [m²] 5,3 6,5 13,5 16,6 31,0

HYDRAULIC TB BOOM


MAIN PARTS ID: 24104

712 3 9 1

45

10

13

112

68

ID: 24256

1 Feed extension cyliner 2 Bolting cylinder3 Feed tilt cylinder 4 Feed swing cylinder5 Boom swing cylinder 6 Rotation mechanism7 Boom extension cylinder 8 Boom lift cylinder9 Feed cradle 10 Boom outer tube

11 Boom inner tube 12 Turn arm13 Fastening

4.

HYDRAULIC TB BOOM


CHECKING BOOM CLEARANCES ID: 24105

To check the clearances,move the boom into different positions and separately follow the movements at eachjoint and sliding surface during the movements. Check especially the hydraulic cylinders and their mountings.Replace worn bushings between cylinder pins and cylinder mounting brackets as necessary. A new bushingis easier to install if the body and the cylinder bracket is warmed up with a blowtorch before installation.

5.

HYDRAULIC TB BOOM


Adjusting clearance between boom inner and outer tube ID: 24108

1. To adjust the clearance between the boom'sinner (14) and outer (13) tube, run the innertube (14) fully into the outer tube (13) usingthe boom extension cylinder.

13

14

ID: 24284

2. Place a suitable stand(s) under the boom head/rollover/feed rail assy. Slowly lower the boom untilthe head/rollover/feed rail weight is taken by the stand(s). Now the inner tube is no longer pressingupwards against the rear top wear pieces or downwards against the front bottom wear pieces.

3. Remove the wiper flanges (17) and the wipers(16) by removing the bolts (18).

16 18

17

ID: 24285

4. Remove the locking screws (21).

21

2121

ID: 24286

5. No clearance should be left between the inner tube (14) and the slide pieces (19). The slide pieces(19) should be tightened against the inner tube (14) with moderate torque by using adjusting screw(20), after which the locking screw (21) must be screwed back into place.

6. Install the wiper (16) and the wiper flanges (17), and tighten the bolts.7. Finally, check that the inner tube slides freely out from the outer tube and back in to verify the

complete extension movement.

5.1.

HYDRAULIC TB BOOM


21

21

21 20 19

20

19

2019

24

14

16

1714

ID: 24287

Replacing the wipers ID: 28665

The wiper (16) prevent drill cuttings and soil from getting in between the boom’s inner and outer tube.Damaged wiper can be replaced without removing the inner tube from the outer tube. In this case,the new wiper must be cut at the bottom section, as shown, to make installation possible.The wipers should also be replaced when new slide plates (24, 6) or slide pieces (19) are installed.

5.2.

HYDRAULIC TB BOOM


Checking the slide plates and slide pieces ID: 24322

Wear of the slide plates (24) and slide pieces (19) can be checked by measuring the distance (C)between the inner (14) and the outer (13) tube. If the value of C is below 2 mm, the slide plates (24)must be replaced. Or if the value of D (top/side) is more than 7 mm, the slide pieces (19) must bereplaced.

13

19

2414

19

14

24

ID: 24327

5.3.

HYDRAULIC TB BOOM


Replacing the slide plates and pieces ID: 2798

21 2019

13

19

20

21

24

16

14

17

18

ID: 24303

1. Remove the wiper flanges (17) and the wiper (16) from the outer tube (13) by removing the bolts(18) and pull them away from the mounting surface.

2. Remove the locking screws (21), the adjustment screws (20) and the slide pieces (19).3. Remove the slide plate (24) by running the inner tube (14) slowly outwards. If the rear slide plate

must be replaced, the inner tube must be removed.

After installing the inner tube, the clearance between the inner and outer tube is adjusted as instructedin chapter "Adjusting clearance between boom inner and outer tube"

NOTE! Wiper and its flanges must be installed onto the inner tube be-fore it is inserted into the outer tube.

5.4.

HYDRAULIC TB BOOM


Checking the slide piece clearances (TB120- and TB150-booms) ID: 24110

The slide piece clearance checking procedure for the TB120 TB150 booms differs from that for otherTB booms. The distance between the inner and outer tube can bemeasured through measuring holesin the boom, and the alignment can then be adjusted with screws.Measuring holes (A1, A2, B1, and B2) are provided for checking that the inner tube is parallel withthe outer tube. This can be done with, for example, Vernier callipers. Remove the screw plugs fromthe measuring points (A1, A2, B1, and B2) and perform the measurement. The values measured frompoints A1 and B1 must be equal. This applies also to the values measured from the other side of theboom from points A2 and B2. The measuring point (C) below the boom is provided for checking thewear of the lower front slide piece, located between the outer and inner tube. Remove the screw plugand measure the distance between the outer and inner tube. Allowable values: maximum of 19 mmand minimum of 14 mm.

A1

B1

C

A2

B2

max 19mmmin 14mm

ID: 24361

5.5.

HYDRAULIC TB BOOM


Inner tube slide pieces (TB150) ID: 24111

123

4

4

4

4

A

A

ID: 24386

1 Outer tube2 Middle tube3 Inner tube4 Inner tube slide pieces

5.5.1.

HYDRAULIC TB BOOM


ID: 24387

Figure: Location of Inner tube slide pieces

HYDRAULIC TB BOOM


CRADLE TO FEED CLEARANCE ID: 24112

The feed beam is mounted to the cradle with wear pieces and moved with the feed extension cylinder.Each slide piece is mounted to the cradle with bolts through the slide piece body. The bolts securethe slide piece lengthwise. Securing in the crosswise direction is achieved by the form of the slidepieces and the slide piece body.The slide pieces must be changed, they are not adjustable. Correct clearances and positioning inrelation to the beam centre line is achieved with the aid of the mounting shoulders on the cradle.

1

2

4

3

ID: 24388

1 Steel strip2 Slide piece3 Slide piece body4 Mounting shoulder

6.

HYDRAULIC TB BOOM


Checking the slide pieces of the cradle ID: 24113

1. Check the clearance between the steel strip(1) and the slide piece (2).If the pieces are so worn that the clearance isover 2 mm, the slide pieces should bereplaced.

1

2

1

2

ID: 24394

6.1.

HYDRAULIC TB BOOM


Replacing the slide pieces of the cradle ID: 24114

1. Turn the feed horizontal so that the rock drill is at the top side.2. Support the feed beam on to the stands or by crane.3. Remove the mounting bolts of the slide piece body (3) and replace the worn slide piece (2) with

the new ones.4. Refit the slide piece bodies (3) back and tighten the bolts to 200 Nm.5. Check the clearances between the steel strips (1) and the slide pieces (2) once more.6. Test the extension movement. Observe especially that no seazure occurs at any point of the travel.

1

2

3

13

2

ID: 24395

6.2.

HYDRAULIC TB BOOM


BEARING BUSHINGS AND AXLE PINS ID: 24115

The boom joints and the hydraulic cylinder mounting brackets have bearing bushings and axle pins.Each sliding surface between them is grease lubricated and provided with grease nipples for thatpurpose.

Checking bearing bushings and axle pins ID: 644

Check the condition of bearing bushings and its axle pin in the boom joints or the hydraulic cylindereye. Any play between bearing bushings and axle pins is easy to notice by observing the excessivefree movement of the boom, or its component, and the hydraulic movement.

Replacing bearing bushings ID: 2800

Observe all safety matters before doing the replacement.

The bearing bushings in the hydraulic cylinder eye and in the body can be removed by driving it outwith a suitable punch.When a new bushing is installed, the temperature difference between the bushing and the hydrauliccylinder eye, or the hole in the frame, must be 40-50 °C.When a bearing bushing is to be installed into an eye of a hydraulic cylinder, we recommend that thebushing is cooled down to reach the required temperature difference. In this way, the danger ofdamaging the hydraulic cylinder sealings with the open flame can be avoided.

7.

7.1.

7.2.

HYDRAULIC TB BOOM


CHECKING CYLINDER PINS ID: 1277

The cylinder pins are adjustable conical pins that are tightened clearance-free to the bracket.

A Cylinder eyeB BracketX There must not be any clearance

AB B

X

ID: 27860

Check the tightening torque. The correct values are as follows:

Size of cylinder pin Using torque wrench Using pneumatic toolM12 60 Nm 55 NmM16 150 Nm 135 NmM20 290 Nm 270 NmM24 530 Nm 490 Nm

Table: Tightening torques of the cylinder pins

Check the position of the cut (A) in the pins. Thecut must be at right angle to the cylinder’s direc-tion of movement, and downwards if possible.Lubricate pins carefully before installing, see lu-bricate recommendations in “Lubricant and cool-ant recommendations”.

A

ID: 27861

When a cylinder is removed,make sure that boom is correctlysupported. Observe safety procedure.

8.

HYDRAULIC TB BOOM


Mechanical taper pin ID: 24116

The mechanical taper pin must be removed fromthe TB-boom when bolting with the TCAD or DA-TA versions.

ID: 24422

Tightening torques for cradle tightening bolts ID: 2801

A

B

C

ID: 24420

The cones of the cone bolts (A) must be lubricates before installation.Standard bolts (B) are tightened using the torque of 520 Nm, while cone bolts require the tighteningtorque of 545 Nm.Special bolts (C) used in TB 40 -booms are tightened using the torque of 450 Nm.

8.1.

8.2.

HYDRAULIC TB BOOM


CHECKING OF THE ANGLE RESTRICTION FUNCTION ID: 24117

The angle restriction function should be checked every 6 monthor if the hydraulic connections of the boom has been opened.

Use about two-meter length of sturdy pipe (or similar) for depressing the plunger (1).

1. Move the boom to a parallel and horizontal position to the rig.2. Move the lift cylinder upwards and simultaneously push the knob (1) on the plunger valve (2) at

the point shown by the arrow. The boom should turn in the same direction as the knob is pressed.3. Move the lift cylinder downwards and simultaneously push the knob (1) on the plunger valve (2)

at the point shown by the arrow. The boom should turn in the same direction as the knob ispressed.

4. Repeat the same functions on the the plunger valve (2) situated on the other side of the boom.5. Turn the boom to the right and simultaneously press the knob (1) on the right side. The boom

should turn to the left.6. Turn the boom to the left and simultaneously press the knob (1) on the left side. The boom should

turn to the right.

1

2

ID: 24436

9.

HYDRAULIC TB BOOM


TESTING THE LIFT/SWING CYLINDER SEALS ID: 24566

A

ID: 24574

A Seals

Faulty seals may cause the boom unexpected lowering in casewhere the PUMP line hose is leaking, removed or broken. Thisis possible because cylinder piston side chamber and PUMPline will combine.

Before starting to test the seals, thoroughly read the hydraulicboom safety instructions.

The BOOM MAY FALL UNCONTROLLED! This could cause se-rious personal injury or death, if a person is located within thedanger area of the boom

The boom may fall uncontrolled, if the boom lift cylinder innerseals are failed and simultaneously the Y-port hose is damagedor loosened.Automatic parallelism not working as intended may indicate thecylinder seal failure. In the models not using hydraulic parallel-ism system, the automatic parallelism doesn’t indicate the pos-sible seal failure and the cylinder seals must be tested accord-ing to updated instructions (attached).

10.

HYDRAULIC TB BOOM


If any of booms function doesn’t work properly, there is a failurein the system and working with this unit must be stopped im-mediately. It is very important that the reason of the failure willbe investigated and properly repaired before continuing towork.

The third chamber seals must be tested every 1000 percussionhours or every 12 months. When the seals have failed, cylindermust be properly repaired before continuing work.

Testing the boom lift cylinder seals ID: 24563

1. Drive the boom to the horizontal position and brace it securely.2. Carefully and slowly undo the hose from Y-port of the boom lift cylinder and plug the hydraulic

hose end with a steel cap.3. Carefully and slowly undo the hose hose from B-port of the boom lift cylinder and plug the hydraulic

hose end and the B-port of the cylinder with a steel cap.4. With powerpack or diesel engine running, carefully apply pressure to the boom lift cylinder A-port

(boom lift) and observe if any oil continues to come out from the cylinder Y-port.

Be careful of the oil spray from the cylinder Y-port!Don’t place your body parts in the cylinder Y-port area!Feed tilt will possibly operate when applying pressure to boomlift!

5. If oil is coming out, it means that the inner piston seals are leaking. This cylinder must beoverhauled or replaced immediately before continuing to work.

Testing the boom swing cylinder seals ID: 24564

1. Drive the boom to the vertical position and brace it securely.2. Carefully and slowly undo the hose from Y-port of the boom swing cylinder and and plug the

hydraulic hose end with a steel cap.3. Carefully and slowly undo the hose from B-port of the boom swing cylinder and plug the hydraulic

hose end and the B-port of the cylinder with a steel cap.4. With powerpack or diesel engine running, carefully apply pressure to the boom swing cylinder A-

port (boom swing) and observe if any oil continues to come out from the cylinder Y-port.

Be careful of the oil spray from the cylinder Y-port!Don’t place your body parts in the cylinder Y-port area!Feed swing will possibly operate when applying pressure toboom swing!

5. If oil is coming out, it means that the inner piston seals are leaking. This cylinder must beoverhauled or replaced immediately before continuing to work.

10.1.

10.2.

HYDRAULIC TB BOOM


ROTARY ACTUATOR ID: 24126

1

2

7

12

18

19

20

21

24

25

50

51

5253

55

56

57

6061

62

6566

70

80

8182

90

91

95

50

52

56

96

G2

G1

A1

B1

A1

B1

100

ID: 28696

Figure: Torque motor

11.

HYDRAULIC TB BOOM


1 Housing 2 Bottom7 Piston 12 Gear shaft

18 Guiding shatf 19 Outer gear ring20 Lock nut 21 Clamp washer24 Pin 25 Sliding thrust washer50 Piston seal 51 Guiding tape52 Rod seal 53 Guiding tape55 Rod seal 56 Guiding tape57 Wiper ring 60 Rod seal61 Guiding tape 62 Wiper ring65 O-ring 66 O-ring70 Cylindrial roller thrust bearing 80 Hexagon socket head cap screw81 Hexagon socket head cap screw 82 Spring washer90 Bleed screw 91 Sealing ring95 Pressure relief valve 96 Grease nipple

100 Bleeding screw

NOTE! Sandvik only delivers the seal and bearing set as spare parts.

HYDRAULIC TB BOOM


ID: 28697

Figure: Exploded view of the torque motor

HYDRAULIC TB BOOM


Operating principle of the rotary actuator ID: 24127

The axial movement of the piston (7) is translated into a rotary movement through the set of left-handhelical gears G2. This rotary movement is transferred onto the second set of gears G1 with a right-hand pitch therefore causing a further rotary movement straight onto the gear shaft (12). The sum ofthe two rotary movements equals the total rotation of the gear shaft (12). Positive lubrication andnitriding of gear surfaces ensure a long service life.

Mounting ID: 24129

Remove paint or other foreign particles from the joint flange surfaces. Make sure that the hydraulic lines areclean before connection.

Taking into use ID: 24130

After reaching the operation temperature, check all the connections and screw joints etc.

Bleeding ID: 24132

When opening the bleeding screw or lowering valve when therotary actuator is mounted on the boom, prevent the rotary ac-tuator from rotating freely and beware of spraying oil in orderto prevent accidents.

NOTE! Bleed the system if the unit has been opened.

1. Bleed the hoses (connect the hose A1 to the hose B1 and circulate the oil).2. Place the rotary actuator on the floor so that the lowering valves are upwards. Connect the hoses

to the rotary actuator.3. Run the motor from one extreme position to the other and stop it in themid position.4. Open one of the bleeding screws (in the cylinder chamber) and close the screw when no air or

oil with air bubbles comes out.5. Repeat the procedure with the other bleeding screw.6. Repeat the run and stop procedure (step 3) and bleed procedure (steps 4 and 5) until no air or

oil with air bubbles comes from the bleeding screws.7. Then, check the operation of the machinery by rotating it from one extreme position to the other

two times. This completes the bleeding procedure.8. Mount the rotary actuator on the boom and ensure that no air enters into the rotary actuator during

the following stages.9. Do not open the screw chamber bleeding screw during bleeding.

11.1.

11.2.

11.3.

11.4.

HYDRAULIC TB BOOM


Disassembly of rotary actuator ID: 24133

The rotary actuator should only be dismantled and reassembled by persons who have been trainedhow to do this or by experts.A complete change of spare parts can only be carried out after the rotary actuator has been removedfrom the part to which it is connected.Attention must be paid to absolute cleanliness at all times when dismantling and reassembling therotary actuator and also when changing seals. the seals should be removed only with appropriatetools (seal lifters) whereby care must be taken that the sealing surfaces are not damaged.

1. Remove the bottom (2) by loosen the hexagon socket head cap screws (80).2. The piston (7) can be separated from the housing (1) by turning it anti-clockwise. If this proves

difficult, use a pressing-off device.After the rotary actuator has been thoroughly cleaned, all seals can be changed easily. polish therunning and sealing surfaces. if the rod seal (55), the wiper ring (57) or the guide tape (56) mustbe changed (only by leakage!) the following procedure is necessary:

3. Remove the outer gear ring (19), from the housing (1) with help of the three threads. Beforeremoving make a mark on the outer gear ring (10) and on the housing (1) in order to be able toget the gear ring in appromaximately the same position at reassembly.

4. Slack the hexagon socket head cap screws (81). Remove the clamp washer (21) with help of thethreads. Here also make a mark to find the same position at reassembly.

5. Screw out the lock nut (20).6. Remove the gear shaft (7).

The rotary actuator has now been fully dismantled.

Assembly of rotary actuator ID: 24134

Polish the running and sealing surface if necessary. After the rotary actuator has been thoroughlycleaned, all the seals can be changed. The seals must be assembled very careful to avoid earlydamages. by assembly the seals and the guiding tapes must be greased with an acid-free grease.By assembly of the piston seal (50) should be this one slowly expanded and fitted with an assemblytool (expanding jacket and expanding mandrel).The use of a burnishing shell is recommended when the assembly of a piston is made difficult by anoverstretched ring.

1. Insert the sliding thrust washer (25) with the pins (24) and the gear shaft (12) in the housing (1).2. Put in the cylindrical thrust roller bearing (70).3. Tighten the lock nut (20) until the gear shaft (12) is not moveable, then turn back the lock nut (25)

and move the gear shaft (12) to displace the grease on the sliding thrust washer (25). Tighten thelock nut (20) again until the gear shaft (12) has an axial back lash ( ca. 2/100 mm to 5/100 mm).

4. Positioning the clamp washer (21) (note the correct position). Tighten up the hexagon socket headcap screws (81) with new spring washers (82) crosswise to an initial torque of 38 Nm using atorque spanner. Then repeat the tightening up process, tightening up this time a final torque of115 Nm.

5. Put in the outer gear ring (19) (note correct position).6. Insert the piston (7) in the gear shaft (12) and the outer gear ring (19). Care must be taken in

course of this that the teeth engage in the tooth spaces with punch marks.7. Put the bottom (2) carefully. Tighten up the cylinder screws (80) crosswise to initial torque of 105

Nm using a torque spanner. Then repeat the tightening up process, tightening up this time to afinal torque of 315 Nm.

8. Fill the chamber with grease by the grease nipple (96).

11.5.

11.6.

HYDRAULIC TB BOOM


FLUSHING AND BLEEDING THE BOOM HYDRAULIC CIRCUIT ID: 24580

Flushing and bleeding the boom hydraulic circuit is used to help prevent themalfunctions caused bythe air in the cylinders or the dirt in the hydraulic lines if the cylinders or the hoses are removed forvarious reasons.

Check that an extra tank hose is properly connected to lift- andswing cylinder throttle valve (A) before bleeding (see picturebelow).

A

ID: 24581

Lift circuit ID: 28682

Flushing and bleeding (left/right) ID: 24144

1. With the boom fully down, move the feed tilt cylinder completely in. Keep still the boom controljoystick in boom down position next 10 seconds.

2. Lift the boom fully up and after that still keep the liftmovement on approx. 10more seconds.3. Move the boom to the down position (-30 or -24 degrees) and repeat previous lifting movement

at least twice.4. With the boom completely down position, move the feed tilt-cylinder in.5. Stop the powerpack.6. Connect an extra hose from the throttle valve to the unpressured side of the tank.7. Start all powerpacks.8. Open the throttle valve.9. Hold the joystick in the tilt-cylinder in -position 90 seconds.10. Close the throttle valve.11. Stop the powerpack(s).12. Remove the extra hose from the throttle valve to the tank and fit the plug to the throttle valve.

Cover the throttle valve with some cloth before opening to pre-vent oil spray which may cause personal injury.

12.

12.1.

12.1.1.

HYDRAULIC TB BOOM


Bleeding (boom in normal position) ID: 24145

1. Turn roll-over about 90 degrees so that the feed becomes alongside the boom. Drive the tiltcylinder from end to end two times.

2. After that drive the tilt-cylinder totally out. Lift the boom totally up and keep the movement on 10more seconds.

3. On this boom position drive the tilt-cylinder completely in and after that lower the boom fully downposition (-30 or -24 degrees). Keep the feed tilt cylinder (cylinder in) pressurized and open thethrottle valve.Note! Cover the throttle valve with some cloth before opening it. Close the throttlevalve.

4. Repeat point 3 two times.

Boom swing circuit ID: 24146

Flushing and bleeding (right boom) ID: 24147

1. Swing the boom completely to the left (45 degrees) and simultaneously move the feed swingcylinder fully in.

2. Swing the boom fully to the right and keep the movement on approx. 10 more seconds.3. Repeat the complete swing from end to end at least two times.4. With the boom completely left position, move the feed swing cylinder in.5. Stop the powerpack.6. Connect an extra hose from throttle valve to the unpressurized side of the tank.7. Start all powerpacks.8. Open the throttle valve.9. Hold the joystick in the swing cylinder in -position 90 seconds.10. Close the throttle valve.11. Stop the powerpack(s).12. Remove the extra hose from throttle valve to the tank and fit the plug to the throttle valve.


Bleeding (right boom, boom in normal position) ID: 24149

1. Drive the feed swing cylinder from end to end 2 times.2. Drive the feed cylinder totally out. Swing the boom totally right and keep the movement on 10

more seconds. (In case of need you have a possibility to compensate the feed swing movementby moving the bolting cylinder).

3. In this boom position move the feed swing cylinder completely in and swing the boom totally left.Keep the boom swing cylinder pressurized (cylinder in) and open the throttle valve. Note! Coverthe throttle valve with some cloth before opening. Close the throttle valve.


12.1.2.

12.2.

12.2.1.

12.2.2.

HYDRAULIC TB BOOM


Flushing and bleeding (left boom) ID: 24150

1. Swing the boom completely to the right (45 degrees) and simultaneouslymove the feed swingcylinder fully in.

2. Swing the boom fully to the left and keep the movement on approx. 10 more seconds.3. Repeat the complete swing from end to end at least two times.4. With the boom completely right position, move the feed swing cylinder in.5. Stop the powerpack.6. Connect an extra hose from (D) throttle valve to the unpressurized side of the tank.7. Start all powerpacks.8. Open the throttle valve.9. Hold the joystick in the swing cylinder in -position 90 seconds.10. Stop the powerpack(s).11. Remove the extra hose from throttle valve to the tank and fit the plug to the throttle valve.


Bleeding (left boom, boom in normal position) ID: 24155

1. Drive the feed swing cylinder from end to end 2 times.2. Drive the feed swing cylinder totally out. Swing the boom totally left and keep the movement on

10 more seconds. (In case of need you have a possibility to compensate the feed swing movementby moving the bolting cylinder.)

3. In this boom position drive the feed swing cylinder completely in and swing the boom totally right.Keep the boom swing cylinder pressurized and open the throttle valve. Note! Cover the throttlevalve with some cloth before opening. Close the throttle valve.


Rotary actuator ID: 24156

Operate the actuator from end to end 5 to 6 times.See instructions in chapter "Rotary actuator" .

Feed tilt and feed swing cylinders ID: 24157

These cylinders are partly connected to hydraulic circuits which are closed by using pump cylinders.When using pump cylinders the bleeding is done according the instructions in chapter "Flushing andbleeding the boom hydraulic circuit" . The feed tilt is connected to boom tilt circuit and feed swing toboom swing circuit.

12.2.3.

12.2.4.

12.3.

12.4.

HYDRAULIC TB BOOM


Other cylinders ID: 24158

The cylinders not mentioned above should be flushed and bled by driving the cylinder in and out threetimes and leaving the movement on for ten seconds at each ends.

After the work is done, don't forget to change the filters!

12.5.

HYDRAULIC TB BOOM


PERIODIC MAINTENANCE ID: 14735

Greasing points ID: 1273

ID: 28683

Checking the zoom tube wiper ID: 28670

Regularly check the condition of the zoom tubewiper. Replace the wiper if its edge is ragged orotherwise worn.

ID: 28675

Washing the boom ID: 28724

Wash the boom.

Checking the condition of hoses and connections ID: 711

Check the condition of hoses and connections.Tighten any loosened connectors and replace broken hoses and connectors.

Checking the condition of electrical cables ID: 1275

Check the condition of electrical cables.

13.

13.1.

13.2.

13.3.

13.4.

13.5.

HYDRAULIC TB BOOM


Tightness of bolts and nuts ID: 619

Check the tightness of bolts and nuts using suitable tools.

Checking the sensor boxes ID: 28722

Check the sensor boxes.

Lubricating the electric box connections ID: 28723

Lubricate the electric box connections.

13.6.

13.7.

13.8.

HYDRAULIC TB BOOM


BOOM LIFT AND SWING CYLINDERS ID: 24162

The boom lift and swing cylinders are triple chamber cylinders. The cylinders have chambers A andB, and a third chamber inside the hollow piston rod. When, for instance, the lift cylinder lengthchanges, the volume of the third chamber changes, and the cylinder gives or takes oil from the tiltcylinder, acting in this way as an essential part of the automatic parallelism system.The connector Y of the hollow rod chamber, or the PUM Pline may never be plugged when the cylinderis in use as the oil in the third chamber is not connected with the chambers A and B of the triplechamber cylinder.

Boom lift and swing cylinder repair ID: 24163

Before opening the piston, heat up the piston thread area (X) toapprox. 150-200 °C.When reassembling the piston, use Loctite271 or similar on the thread area.

X C

ID: 24584

If you have repaired the cylinder or about to change the hy-draulic oils, you have to be sure that no air is left inside the thirdchamber,when filling it up with new hydraulic oil (Dieseling dan-ger). The right method for filling is as follows:

1. Place the cylinder in a vertical position, cylinder rod straight up.2. Open the bleed plug (C).3. Connect the hydraulic oil filling hose to Y-plug.4. Fill the inner cylinder slowly with the hydraulic oil as long as the oil is coming out from the bleed

plug (C).5. Close the bleed plug (C).6. Place the cylinder in a horizontal position (hose connections upwards), so that any oil is coming

out from the cylinder and remove the oil filling hose.

14.

14.1.

HYDRAULIC TB BOOM


TROUBLESHOOTING ID: 24164

If any of the boom functions are not working as intended, it means there has been a failure in thesystem. Even if the failure appears to be only minor and allows quite normal unit operation, there isa possibility of consequential damages in other areas. It is very important that the reason for the failureis investigated immediately and repaired according to instructions given in maintenance and servicemanuals, before continuing to work.

All hydraulic functions slowly or not working at all ID: 24165

1. Hydraulic oil level too low, or oil viscosity too high.• Check oil level. See oil recommendations for correct viscosity.

2. Hydraulic circuit leaking.• Check hoses and connections.

3. The pressure relief valve at the control valve functioning incorrectly and the required 210 barworking pressure is not reached.• To measure the pressure, use a T-fitting to connect a pressure gauge (max. 250 bar) to the

line between the control valve and the hydraulic pump. Disturbances in the pressure relief valveare normally caused by impurities. Dirt may block the cartridge valve. To remedy the condition,remove the cartridge valve and replace its O-rings. Before reinstalling the cartridge, clean itthoroughly using pressurized air. If the fault is not removed, the likely reason is that the valvecartridge is worn; replace the cartridge.

4. Oil pump not working properly.• Check the pump by connecting the output line of the pump to another boom. If that boom is

not working properly either, it is likely that the pump is damaged. A flow meter can also be usedfor checking the pump’s output. If the booms have separate oil tanks, remember that whenbooms are cross-connected the oil level in one tank drops and increases in the other.

5. Intake of pump blocked.• Drain and clean the tank. Check the hose.

6. Shuttle valve between carrier and boom hydraulics leaking.• Check the shuttle valve and replace it if necessary.

Feed moves backwards during drilling ID: 24166

1. Leaking non-return valve between feed transfer cylinder and control valve.• Clean the valve and replace damaged or worn parts.

2. Piston seals of feed transfer cylinder leaking, or other external leak.• Replace the piston seals.

15.

15.1.

15.2.

HYDRAULIC TB BOOM


Automatic parallelism not working properly ID: 24167

1. Faulty seals in the triple chamber of the boom swing or lift cylinder. First indication of seal failureis the loss of parallel holding in lift or swing movement.• To pinpoint the faulty seals, test the seals according to the chapter "Testing the lift/swing

cylinder seals" .2. Faulty O--ring or worn valve seat causing leakage in the pressure relief or overcenter valve of one

of the valve blocks of parallelism automatics.• To pinpoint the leakage, one by one disconnect the hoses between the valve block and the

control valve to determine and locate the malfunction. Replace any damaged and worn parts.3. Air trapped in pump cylinder

• See bleeding instructions on chapter "Flushing and bleeding the boom hydraulic circuit" .

Feed extension movement unsteady ID: 24168

1. Air trapped in extension cylinder.• See bleeding instructions on chapter "Flushing and bleeding the boom hydraulic circuit" .

2. Feed cradle slide pieces too tight or worn.• Replace worn slide pieces.

Boom rotation mechanism not working ID: 24169

1. External leaks.• Check hose connections.

2. Rotation cylinder seals damaged.• Install new sealing. Repair the rotation mechanism according to the instructions in Chapter

"Rotary actuator" .3. Dirt or broken O--rings and seals in overcenter valves.

• Replace damaged parts and clean the valves.

Boom creeping ID: 24170

1. Leaking overcenter valve of boom swing or lift cylinder.Broken O-ring or worn seat surfaces.• Replace damaged or worn parts.

2. Dirt in hydraulic circuit.• Flush the hydraulic circuit according to the instructions in Chapter "Flushing and bleeding the

boom hydraulic circuit" .3. Air trapped in cylinder.

• Bleed the cylinders according to the instructions in Chapter "Flushing and bleeding the boomhydraulic circuit" .

4. Faulty seals in the triple chamber of the boom lift cylinder and PUMP line hose leaking, removedor broken.• Is parallelism working as intended?• Check the PUMP line hose condition, replace if needed.• Test the seals according to the instructions in Chapter "Testing the lift/swing cylinder seals" .

15.3.

15.4.

15.5.

15.6.

HYDRAULIC TB BOOM


Boom doesn't turn sideways ID: 24171

1. Plunger valve on boom swing pillar seized or tank hose from plunger valves blocked.2. Control valves damaged in control block.

• Check the operation of the valves.

Lifting and lifting points ID: 24172

Follow the safety instructions concerning the boom lifting.

Observe the boom's total weight specified in the technical dataof this manual.

ID: 24666

TB 40 TB 60 TB 90 TB 120 TB 150L1 [mm] 2065 2175 2725 2960 2960

15.7.

15.8.

HYDRAULIC TB BOOM


BOOM LIFTING AND LOWERING ID: 24173

Lifting movement ID: 24174

ID: 24704

16.

16.1.

HYDRAULIC TB BOOM


When the boom is lifted, oil flows via block 1(; A9-A) to chamber A of the boom lifting cylinder. Oilflows along line G-G and through valve X1, and continues along line E1-A to chamber A of the tiltcylinder.Block (1) has a pressure regulator (100 bar) that restricts the pressure to chamber A of tilt cylinder.This is to prevent the pressure relief valve (300 bar) of the tilt cylinder from opening.The pressure regulator in block (1) restricts the pressure (6 bar) to block (2) so that the pressure inline T does not rise higher than allowed.Oil flows out of the piston rod side of the lift cylinder along line B-B and through block (1) into the tank.From chamber B of the tilt cylinder, oil flows along the PUMP line (B-F1 and H-Y) to the third chamberof the lift cylinder. The tilt cylinder extends in direct proportion to the extending of the lift cylinder,which is a part of the automatic parallelism system.

HYDRAULIC TB BOOM


Lowering movement ID: 24175

ID: 24705

16.2.

HYDRAULIC TB BOOM


When the boom is lowered, oil flows via block 1(; B9-B) to the piston rod side of the lift cylinder. Fromchamber A of the lift cylinder oil flows through block 1(; A-A9) to the tank. When the boom is lowered,the volume of the third chamber of lift cylinder is reduced. In this situation, oil flows out of the chamberalong line Y-H, through block (2) and into chamber B of tilt cylinder. Tilt cylinder length is reduced indirect proportion to the shortening of lift cylinder length, which is a part of the automatic parallelismsystem. From chamber A of tilt cylinder oil flows along line A-E1-T1-T2-T4 to the tank.

Operation of block (2) valves ID: 24188

The overcenter valve X1 makes the phasing of lift and tilt cylinders more accurate during lowering.When the boom is turned the valve X2 makes the phasing of boom and feed swing cylinders moreaccurate.The overcenter valves S1, S2, S3 and S4 make it possible to use tilt and boom head swing inde-pendently.The pressure--controlled non--return valves make it possible to use the zoom cylinder.If the PUMP LINE (B-Y or H-Y) is not receiving oil from the tilt or the boom head swing cylinder, thevalves AA and AB open and oil flows in from tank line T.When the boom is turned, the valves Y1 and Y2 let oil flow unrestricted to the boom swing cylinderuntil the boom reaches its max. swing angle 45° (TB 40=40°). Then the valves receive control fromthe swing angle restrictor valves (3 or 4).When, for instance, turning the boom 45° to the swing cylinder side (oil flowing to chamber B of swingcylinder) the valve receives control and Y1 changes its status and lets oil flow to chamber A of theswing cylinder.

16.3.

HYDRAULIC TB BOOM


Angle restriction function ID: 24190

ID: 24706

16.4.

HYDRAULIC TB BOOM


The boom swing arm is provided with 1+1 angle restrictor valves (3 and 4) that react when the boomswing angle exceeds 45° (TB 40=40°) and turn the boom back. The correction of swing angle iscarried out by changing the length of boom swing cylinder. The angle restrictor valves react alwayswhen the angle exceeds the allowed limit, and if boom lift or swing is used, or both are used simul-taneously.Example: When the boom is turned to the swing cylinder side, the angle restrictor valve (3) reactsand oil starts flowing from the angle restrictor valve to the valve Y1 in block (2), and through there tochamber A of the swing cylinder causing the boom to turn. When activated, the angle restrictor valvegives a control signal through the flow control valve (5) to line X2 of block (2), where the 3/2 directionalvalve changes its status and closes the line (A8) coming from the boom valve. At the same time, itopens the line L-L to the tank, allowing the oil in chamber B of the swing cylinder to flow unrestrictedto the tank as long as the angle restrictor valve (3) is activated.The control circuit operates similarly when the boom is swung to the other side.For the angle restriction circuit to operate, the angle restrictor valves (3 and 4) always need pressurein line P, when the boom is lifted or swung, or both movements are run simultaneously. This is whyblock (1) has three shuttle valves that allow pressure to enter the angle restrictor valve line P.Due to the mechanical properties of the boom, it swings as it is lifted. In the horizontal position theboom does not turn more than 45° and, thus, the angle restrictor valves are not activated even whenthe boom is swung to the extreme position.

HYDRAULIC TB BOOM


BOOM CONTROL (THC) ID: 24191

Hydraulic diagram (THC) ID: 24199

ID: 24731

17.

17.1.

HYDRAULIC TB BOOM


ID: 24732

HYDRAULIC TB BOOM


Boom control block ID: 24192

2345678 110

11

9

ID: 24718

1 Boom lifting/lowering 2 Boom swing right/left3 Zoom in/out 4 Boom head rotation5 Feed tilt up/down 6 Feed swing right/left7 Feed transfer forwards/backwards 8 Bolting cylinder in/out9 Compensator (tightening torque for the cap

100 Nm)10 Boom circuit pressure relief valve

(tightening torque for the cap 60 Nm)11 Boom circuit LS pressure relief valve

(tightening torque for the cap 60 Nm)

17.2.

HYDRAULIC TB BOOM


Adjusting boom circuit max. LS pressure ID: 24194

The pressure relief valve of the boom circuitmax.LSpressure is located in the boom valve inputblock (Cf. Fig.). It is adjusted in the following way:

ID: 24719

1. Loosen the locking nut of the adjusting screw of pressure relief valve for the max. LS pressure.2. Turn the adjusting screw of themax. LS-pressure pressure relief valve almost fully open

(counterclockwise).3. Install a pressure gauge to the measuring point M1 of the feed and percussion control block.4. Start the carrier engine (diesel).5. Run the zoom cylinder inwards with the engine speed at 1800 rpm, and adjust, at the same time,

the boom circuit max. LS pressure to 210 bar by turning the adjusting screw of the LS-pressurepressure relief valve clockwise. Read the pressure in the pressure gauge installed to themeasuring point M1 of the percussion control block.

6. Stop the diesel engine and lock the adjusting screw of the LS-pressure pressure relief valve.7. Remove the pressure gauge from the measuring point M1 of the feed and percussion block.

Check if the carrier’s hydraulic circuit has a pressure relief valvethat restricts the adjustment of the valve. If such a valve exists,adjust it beforehand to an approx. 10 bar higher value than thepressure setting for the boom circuit max. LS-pressure pres-sure relief valve. Remember to return the carrier’s pressure re-lief valve to its original setting after the adjustment.

17.2.1.

HYDRAULIC TB BOOM


Adjusting boom circuit max. pressure ID: 24195

The boom circuit max. pressure relief valve is lo-cated in the intermediate block (Cf. Fig.). Its pres-sure setting is 240 bar. The valve is provided forremoving all possible pressure peaks when usingboom hydraulics. The max. pressure relief valveat the boom valve is adjusted as follows:

ID: 24720

1. Remove the cap of the pressure regulator (B) for the variable displacement pump (1).2. Loosen the adjusting screw locking nut of the pressure regulator (B) for the variable displacement

pump (1).3. Loosen the adjusting screw locking nut of the boom valve max. pressure relief valve.4. Turn the adjusting screw of the boom valve max. pressure relief valve fully closed (clockwise).5. Install a pressure gauge to the measuring point M1 of the feed and percussion control block.6. Start the powerpack.7. Run, for instance, the zoom cylinder inwards and adjust, at the same time, the system pressure

to 250 bar with the pressure regulator (B) of the variable displacement pump (1).Read the pressurein the pressure gauge at themeasuring point M1.

8. Run, for instance, the zoom cylinder inwards and adjust, next, the boom circuit max. pressure to240 bar. Read the pressure in the pressure gauge at the measuring point M1.

9. Lock the adjusting screw of the boom circuit max. pressure relief valve.10. Run, for instance, the zoom cylinder inwards and adjust the pressure regulator (B) of the variable

displacement pump (1) to 225 bar.11. Lock the adjusting screw of the variable displacement pump pressure regulator (B), and reinstall

the cap.12. Stop the powerpack.13. Remove the pressure gauge from the measuring point M1.

17.2.2.

HYDRAULIC TB BOOM


Adjusting max. speed of boom movements ID: 24196

All boom valve spools are equipped with specificrestrictors. These restrictors can be used for in-dividually adjusting the speed of each movement.The adjustment of movement speeds should bedone with the hydraulic oil in normal drilling tem-perature (40-50 °C).

ID: 24721

Boom movement not working ID: 24197

If a boom movement is not working, it is likely that the shuttle valve of the load sensing line for thecorresponding control block is sticking or the functional unit is faulty. Check the condition of the shuttlevalve as follows:

• Install a pressure gauge to the measuring point M7 of the feed and percussion control block.• Start the powerpack.• Move the control lever of the boom movement that is not working.• If themeasuring pointM7does not receive pressure, it is likely that the load sensing line shuttle valve

of the movement is sticking.• Stop the powerpack.• Remove the boom valve at the top of the control panel.• Disassemble the boom valve and check the shuttle valves of all working blocks.• Reassemble the boom valve after cleaning and inspecting it, and mount it back.

• If the measuring point M7 receives pressure, it is likely that the functional device of the boom isfaulty.• Refer to the maintenance instructions for the boom.

17.2.3.

17.2.4.

HYDRAULIC TB BOOM


Boom working pressure too low ID: 24198

If the boom working pressure is too low, check the operation of the boom’s max. pressure relief valveaccording to Chapter "Adjusting boom circuit max. pressure" . If the pressure limit does not adjustto the set value of 240 bar, proceed as follows:

• Stop the powerpack.• Clean and repair, or replace the boom’s max. pressure relief valve, and adjust it as instructed in

Chapter "Adjusting boom circuit max. pressure" .

17.2.5.

HYDRAULIC TB BOOM


BOOM CONTROL (TPC) ID: 24200

Hydraulic diagram (TPC) ID: 24201

ID: 24734

18.

18.1.

HYDRAULIC TB BOOM


ID: 24735

HYDRAULIC TB BOOM


BOOM CONTROL (TPC 561 DATA) ID: 24202

Hydraulic diagram (DATA) ID: 24203

ID: 24736

19.

19.1.

HYDRAULIC TB BOOM


ID: 24737

HYDRAULIC TB BOOM


HYDRAULIC CYLINDERS

1 (8)C 47150--5 en 1207 / AR

REPAIR AND ADJUSTMENT

CONTENTS

1. GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1. Structure 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. SAFETY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. OVERCENTER VALVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1. Operation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. COMPONENTS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. DISMANTLING 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1. Cylinder 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2. Piston 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3. Inspection 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4. Replacing of bearings bushing 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. ASSEMBLING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1. Assembling of cylinder 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. TESTING OF CYLINDER 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1. Line A, inspection 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2. Line B, inspection 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC CYLINDERS

2 (8) C 47150--5 en 1207 / AR

1. GENERAL

1.1. Structure

The main structural differences between hydraulic cylinders are:D single and double actingD cylinder boreD strokeD overcenter valve equipment

Stroke can be limited with a spacermounted either to the piston side or the piston rod side.Correct type of spacer is given in the spare parts list.

2. SAFETY

Acquaint yourself with the service and user instructions before startingto work on a cylinder. Learn to know all the components that you will beworking on.

Follow the installation instructions issued by Sandvik

Installation, adjustment and repair work can only be carried out by aperson who has the necessary qualifications and knows the equipment.

Proper use and service guarantee longer life of the hydraulic cylinder.

Use all necessary safety devices and check their condition.

Before starting the rig, make sure that nobody is working close to, orunder the rig

Never disconnect any hydraulic hoses or valves beforemaking sure thatthere is no static load in the system.

CAUTION

CAUTION

CAUTION

CAUTION

CAUTION

WARNING

WARNING

HYDRAULIC CYLINDERS

3 (8)C 47150--5 en 1207 / AR

3. OVERCENTER VALVE

3.1. Operation

Most hydraulic cylinders are equipped with an overcenter valve. They are either built--inor connected to the hydraulic circuit via hydraulic hoses.

1

Overcenter valves are one--piece components and they cannot be readjusted. Sets ofseal rings (1) are provided. The four tasks of an overcenter valve are:

-- If a hose connected to the hydraulic cylinder breaks, the overcenter valve acts asa safety valve.

-- During drilling, the overcenter valve prevents oil flow from the cylinder to the oiltank. Theboommaintains accurately the position towhich it wasmoved to by usingthe boom control valves.

-- When the boom is moved, the overcenter valve does not allow oil to flow from thereturn side until the pressure on the pressured side rises high enough. Boommovements are smoother and more accurate, and the boom’s own weight cannotaccelerate the speed movement.

-- If an external force raises the pressure in the cylinder higher than the set value ofthe overcenter valve, the valve opens and lets oil out of the cylinder. This enablesthe boom to yield under external force, and mechanical damage to the boom canbe avoided.

The set value of the overcenter valves for different purposes aredifferent. Therefore, you must not replace an overcenter valve with onefrom a other cylinder. The set value of the valve is punched on the top ofthe valve.CAUTION

HYDRAULIC CYLINDERS

4 (8) C 47150--5 en 1207 / AR

4. COMPONENTS

47635

8

9

2

110

10

Components of a typical cylinder

1. Socket screw 6. Locking plate

2. Cylinder cover 7. Rod nut

3. Piston 8. Piston rod

4. Overcenter valves 9. Spacer

5. Cylinder tubes 10. Bearing bushing

47635

8

9

2

10

10

Components of a typical cylinder (threaded cylinder cover)

HYDRAULIC CYLINDERS

5 (8)C 47150--5 en 1207 / AR

5. DISMANTLING

Before starting to remove the cylinder,make sure that the boom is properly supported, andall static loads of the cylinder are removed. Disconnect the hydraulic hoses to the cylinderand plug the open hose ends and cylinder adapters.

Remove the locking rings of the cylinder pins, support and secure the cylinder so that itcannot fall down. Tap the pins out.

Wash the cylinder externally and mount securely before starting to dismantle it.

5.1. Cylinder

If you can use hydraulic pressure, connect the hoses to the cylinder and run the pistonrod (8) out, remove the overcenter valves (4). Unscrew the socket screws off of the cover(2) or, if the cover is thread mounted, open the cover with a suitable tool. Screw theovercenter valves (4) back, and run the piston rod (8) and the cylinder cover (2) out.Whenpressing out, support the piston rod (8) properly to get it out smoothly.

Be aware of oil spilling

5.2. Piston

Mount the piston rod firmly from the eye end, and tap out the locking washer lug from thegroove of the nut, and remove the nut (7). Remove the piston (3) together with the seals.Pull the cylinder cover (2) off the piston rod and remove the cylinder cover seals and thewiper and replace them. Unscrew the overcenter valves (4) from the cylinder tube andvisually check their condition. Wash all components.

5.3. Inspection

Replace all seals and wipers. Check all sliding surfaces. If scratches, big enough to feelwith a fingernail are found, the components should be replaced because the sealing abilityof the surfaces is no longer good. Also check the piston rod for straightness. If the rod isdistorted, check that it is not caused by a incorrect spacer. Check the condition of thebearing bushings (10), and replace them if there are any marks of wear.

5.4. Replacing of bearings bushing

If the cylinder already has been removed from the rig, support the cylinder well and tapthe old bearing bushings out using a suitable drift and a copper hammer.

The new bearing bushings are easier to install if they are cooled in a freezer, and thecylinder eye is warmed up with a torch.

WARNING

HYDRAULIC CYLINDERS

6 (8) C 47150--5 en 1207 / AR

6. ASSEMBLINGIf the stroke of the cylinder is limited with a spacer and it is left out, thecylinder can be damaged in use. Check that you install the correct typespacer.

6.1. Assembling of cylinder

Grease the seal grooves and install theO--rings, the lip seal and the guide rings onthe cylinder cover (2). Install the cover ofthe piston rod (8). If a spacer (9) is used tolimit the maximum stroke of the cylinder,install the bushing on the piston rod beforeinstalling the piston.

Grease the seal grooves and install thepiston seal (10). When installing thepiston’s O--ring (11), be careful not todamage it in the piston rod thread. Installthe locking plate (6) and the locking nut (7).Tighten the nut and lock it in a place byturning a tang of the locking plate into itsgroove.

The piston rod and the cover assembly

CAUTION

2

8

9

11

7

6

10

HYDRAULIC CYLINDERS

7 (8)C 47150--5 en 1207 / AR

Check if the minimum stroke of the cylinder is limited. If it is, the spacer must be insertedinto the cylinder first. Push the piston assembly into the cylinder. Remember to lubricatethe seals before assembling!

Push the cylinder cover (2) in and insert the socket screws (1) through the cover andtighten them. If the cylinder cover is thread--mounted, use a special tool for tightening.

Install the overcenter valves (4) and the adapters, and test the cylinder.

4

2 1

Assembled cylinder

HYDRAULIC CYLINDERS

8 (8) C 47150--5 en 1207 / AR

7. TESTING OF CYLINDER

1012

11

13

A

B

14

Testing of cylinder

7.1. Line A, inspection

Run the piston rod completely out. Disconnect line A, and pressurize line B. Check lineA for leaking oil. If oil leaks out, one of the seals (10, 11 or 12) or overcenter valve is faulty.

7.2. Line B, inspection

Run the piston rod completely in. Disconnect line B, and pressurize line A. Check line Bfor leaking. If oil leaks out, one of the seals (10, 11 or 12) or the overcenter valve is faulty.If oil comes out from between the cylinder cover and the cylinder tube, the cylinder coverO--ring (13) is faulty. If oil comes out from between the cylinder cover and the piston rod,the cylinder cover O--ring (14) is faulty.

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