ZR 20 / 32 P BOOM

C 44120--2 en 0507/LH 1 (33)

ZR 20 / 32 P BOOM

2 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. BOOM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. ADJUSTING THE BOOM CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1. Adjusting the clearance between the boom’s inner and outer
tubes and replacing the wear pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2. Adjusting the clearance between the cradle and
the drilling module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3. Checking / replacing the gear ring seal . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. REMOVING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1. Replacing the boom side tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2. Replacing the boom tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3. Replacing the extension cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4. Replacing the rear stinger cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. ADJUSTING THE ROTATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.1. Flushing the boom side tilt circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.2. Flushing the boom zoom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.3. Flushing the boom forward tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . 17
8.4. Flushing and bleeding the feed turning gear . . . . . . . . . . . . . . . . . . . . 18
8.5. Flushing the drilling module extension cylinders . . . . . . . . . . . . . . . . 18
9. BOOM LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10. ROTATION MECHANISM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11. CHECKING AND REPLACING BEARING BUSHINGS . . . . . . . . . . . . . . . . . . . 21
11.1. Checking bearing bushings and axle pins . . . . . . . . . . . . . . . . . . . . . . . 21
11.2. Replacing bearing bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.3. Checking the cylinder pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
11.4. Removing cylinder pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12.1. All hydraulic functions slow or not working at all . . . . . . . . . . . . . . . . 24
12.2. Boom rotation does not function properly. . . . . . . . . . . . . . . . . . . . . . . 24
12.3. Boom does not hold its position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.4. Feed moves backward during drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
13. FEED TURNING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13.1. Adjusting the rotation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13.2. Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13.3. Breaking in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13.4. Disassembly/assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
14. BOOM LIFTING AND LIFTING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
15. REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

C 44120--2 en 0507/LH 3 (33)

ZR 20 / 32 P BOOM

1. GENERAL
This manual covers the most important maintenance and service instructions for the ZR
20 / 32 P boom.

2. SAFETY INSTRUCTIONS
Before maintenance or repairs, ensure that the equipment cannot be accidentally
switched on.

Do not use the equipment unless you have been given proper training.
Read the operating and maintenance instructions before using or
servicing the equipment.
WARNING

Make sure that there is no static pressure in the system before you
remove the hydraulic hoses or valves. Before starting any repair work,
always release the static load by running the boom to rest against a
WARNING suitable mechanical support or to the extreme position.

If you need to remove any cylinders during the maintenance, you will
have to flush and bleed the system according to the instructions in
“Flushing and bleeding the boom hydraulic circuit”. This is to prevent
WARNING malfunctions caused by dirt or air trapped in the cylinders.

Do not go under the boom without a good reason.

WARNING

Ensure that the equipment cannot be accidentally switched on during

the maintenance or repairs.

WARNING

When lifting heavy parts, use only appropriate hoists.

WARNING

4 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

3. BOOM COMPONENTS
ZR 32 P

2 4

7
P
3

C 44120--2 en 0507/LH 5 (33)

ZR 20 / 32 P BOOM

ZR 20

4
5

7
P
3

6 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

P [mm] A_ B_
Type P 3200 45 30
Type C 2100 45 30
Type F 2100 20 45

1. Rotation mechanism, 2 pcs . . . . . . . . . 360_ rotation

2. Cradle, 1 pcs . . . . . . . . . . . . . . . . . . . . . . .
3. Boom zoom cylinder, 1 pcs . . . . . . . . . I 100/50, percussion 485 mm
4. Forward tilt cylinder, 2 pcs           I 125/50, percussion 547 mm
5. Side tilt cylinder, 2 pcs . . . . . . . . . . . . . . I 125/50, percussion 435 mm
6. Feed extension cylinder, 1 pcs . . . . . . I 100/50, percussion 1,200 mm (LF 706)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 100/50, percussion 1050 mm (LF 705)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 100/50, percussion 985 mm (LF 704)
7. Rear stinger cylinder, 1 pcs . . . . . . . . . I 80/50, percussion 1,500 mm
8. Feed turning gear (only in the P--model)

C 44120--2 en 0507/LH 7 (33)

ZR 20 / 32 P BOOM

4. HYDRAULIC DIAGRAM

CARRIER BLOCK 3

8 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

5. ADJUSTING THE BOOM CLEARANCES

5.1. Adjusting the clearance between the boom’s inner and outer
tubes and replacing the wear pieces

Items Z and Y

30 Inner tube
21
Z
60
Outer tube
22

M 80x2
Socket wrench,
19 mm

Y 30
21

x) Replace the wear pieces (21) if distance x is about 5 mm.

Adjusting and replacing the wear pieces in point Z:
-- There are 8 wear pieces.
-- Turn the boom to a vertical position.
-- Remove the locking nut (30).
-- Install a new wear piece (21).
-- Turn the screw (22) until it touches the inner tube. Then turn it backwards for 1/4
of a turn.
-- Install and tighten the locking nut (30).

Adjusting the wear pieces in point Y (4 pcs):

-- Turn the boom to a vertical position.
-- Move the drillling module against the ground so that the clearance between the
inner and outer tubes is in the middle position.
-- Adjust the clearances in the aforementioned way.

C 44120--2 en 0507/LH 9 (33)

ZR 20 / 32 P BOOM

5.2. Adjusting the clearance between the cradle and the drilling
module
Turn the boom and the drilling module to a horizontal position.

Fastening screws 1.0 mm

Adjusting screws
3 pcs/side
LF 700 Feed beam

Cradle
Fastening screws

-- Open the fastening screws.

-- Turn the adjusting screws counterclockwise. The pieces will move toward the
beam and the clearance will grow smaller.
-- Tighten the fastening screws.

10 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

5.3. Checking / replacing the gear ring seal

2
3

The seal (1) should prevent cuttings and dirt from getting on the gear ring.
If you can see cuttings or dirt through the inspection hole (4), you have to replace the seal.
Replacing the seal:
-- Remove the tightening collar (2).
-- Remove the steel spring band on top of the seal (3).
-- Remove the seal (1).
-- Clean the surfaces of the seal groove and lubricate it lightly with grease.
-- Install a new seal (1) and a new spring band (3).
-- Install the tightening collar (2).
-- Tighten the tightening collar (2) until the seal (1) is firmly pressed against the
surface.
-- Check that the seal is in its groove for the whole of its length.
Note! Install the seal extension below the boom.

C 44120--2 en 0507/LH 11 (33)

ZR 20 / 32 P BOOM

6. REMOVING CYLINDERS
Ensure that the equipment cannot be accidentally switched on during
maintenance.

WARNING

6.1. Replacing the boom side tilt cylinders

Replacing the side tilt cylinder number 1:

-- Position the rig horizontally and lower the jack beam to the ground.
-- Run the boom side tilt cylinders to a vertical position.
-- Detach the cylinder hoses and connections for the cylinder that you wish to
replace, and plug them.
-- Open the overcentre valve cartridges a little to release the pressure from the
cylinders.
-- Detach the cylinder pins and lift the boom side tilt cylinder to remove it.
-- Install the new cylinder and connect the hoses.
-- Run the piston rod out so that you can install the pins.
-- Bleed the cylinders according to section 8.
-- Replace cylinder 2 in a similar way.

12 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

6.2. Replacing the boom tilt cylinders

Replacing the boom tilt cylinder number 1:

1 2

-- Position the rig horizontally and lower the jack beam to the ground.
-- Run the tilt cylinders to a vertical position.
-- Detach the cylinder hoses and connections for the cylinder that you wish to
replace, and plug them.
-- Open the overcentre valve cartridges a little to release the pressure from the
cylinders.
-- Detach the cylinder pins and lift the tilt cylinder to remove it.
-- Install the new cylinder and attach the lower end pin.
-- Attach the hoses to the cylinder and run the cylinder so that you can attach the
upper end pin.
-- Bleed the cylinders according to section 8.
-- Replace cylinder 2 in a similar way.

C 44120--2 en 0507/LH 13 (33)

ZR 20 / 32 P BOOM

6.3. Replacing the extension cylinder

2 1

3
-- Position the rig horizontally with the jacks and the jack beam.
-- Turn the drilling module to a horizontal position.
-- Run the boom upright with the tilt cylinders.
-- Run the extension cylinder (1) to the maximum extension.
-- Detach the cylinder piston rod side end joint pin (2).
-- Run the cylinder to the minimum extension (= piston rod in).
-- Disconnect the cylinder hoses and plug them.
-- Detach the cylinder hydraulic nipples (3).
-- Support the cylinder and detach the other joint pin (4).
-- Lift the cylinder away.
-- Install the new cylinder.
-- Attach the joint pin in the cylinder hydraulic connections end.
-- Attach the hoses to the cylinder.
-- Run the cylinder to the maximum and attach the joint pin.
-- Bleed the cylinder according to section 8.

14 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

6.4. Replacing the rear stinger cylinder

2 1

4
-- Position the rig horizontally with the jacks and the jack beam.
-- Turn the drilling module to a horizontal position.
-- Run the boom upright with the tilt cylinders.
-- Run the rear stinger cylinder (1) to the maximum.
-- Detach the cylinder piston rod side end joint pin (2).
-- Run the cylinder to the minimum extension (= piston rod in).
-- Remove the rear stinger inner tube (3) by pulling it out.
-- Disconnect the cylinder hoses and plug them.
-- Detach the cylinder hydraulic nipples (4).
-- Support the cylinder and detach the other joint pin.
-- Lift the cylinder away.
-- Install the new cylinder.
-- Attach the joint pin in the cylinder hydraulic connections end.
-- Attach the hoses to the cylinder.
-- Run the cylinder to the maximum. Push the rear stinger inner tube (3) in and attach
the joint pin (2).
-- Bleed the cylinder according to section 8.

C 44120--2 en 0507/LH 15 (33)

ZR 20 / 32 P BOOM

7. ADJUSTING THE ROTATION SENSOR

The sensor (S11) gives a signal before the rotation movement ends. After the signal the
rotation continues at a slow speed before it stops to the mechanical limiter.

4 mm
S11

Adjust the distance between the sensor (S11) and the surface of the identifier piece to 4
mm and lock the sensor with a locking nut.

16 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

8. FLUSHING AND BLEEDING THE BOOM HYDRAULIC CIRCUIT

Flushing and bleeding the boom hydraulic circuit prevents the malfunctions caused by air
in the cylinders or dirt in the hydraulic circuit. This is necessary if the cylinders or hoses
have been detached for any reason.

8.1. Flushing the boom side tilt circuit

1. Turn the boom to the right extreme position by moving the joystick to 3 o’clock and
holding the turning movement on for about 10 seconds. The pressure in the left
side tilt cylinder piston rod side and in the right side tilt cylinder piston side will
release to the tank through the overcentre valve.
2. Turn the boom to the left extreme position by moving the joystick to 9 o’clock and
holding the turning movement on for about 10 seconds. The pressure in the right
side tilt cylinder piston rod side and in the left side tilt cylinder piston side will
release to the tank through the overcentre valve.
3. Repeat the tilt movement from one extreme to the other at least twice..

8.2. Flushing the boom zoom cylinder

1. Run the zoom cylinder completely out by pressing the joystick button and pushing
the joystick to 12 o’clock. Hold the movement for about 10 seconds. The pressure
in the zoom cylinder piston rod side releases to the tank through the overcentre
valve.
2. Run the zoom cylinder completely in by pressing the joystick button and pulling the
joystick to 6 o’clock. Hold the movement for about 10 seconds. The pressure in the
zoom cylinder piston side releases to the tank through the overcentre valve.
3. Repeat the movement from one extreme to the other at least twice or until the
movement runs smoothly.

8.3. Flushing the boom forward tilt cylinders

1. Run the boom forward tilt completely forward by pulling the joystick to 6 o’clock.
Hold the movement for about 10 seconds. The pressure in the forward tilt cylinder
piston side releases to the tank through the overcentre valve.
2. Run the boom forward tilt completely back by pushing the joystick to 12 o’clock.
Hold the movement for about 10 seconds. The pressure in the forward tilt cylinder
piston rod side releases to the tank through the overcentre valve.
3. Repeat the movement from one extreme to the other at least twice or until the
movement runs smoothly.

C 44120--2 en 0507/LH 17 (33)

ZR 20 / 32 P BOOM

8.4. Flushing and bleeding the feed turning gear

1. Turn the boom to one extreme and hold the movement for about 10 seconds. Open
the bleeder screw carefully and release the possible air. Close the screw and turn
the boom to the other extreme. Hold the movement for about 10 seconds. Bleed
in the aforementioned way.
2. Repeat the movement from one extreme to the other at least twice or until the
movement runs smoothly.

8.5. Flushing the drilling module extension cylinders

1. Turn the long hole unit into a horizontal position.
2. Move the long hole unit completely forward by pushing the boom joystick forward
and right (about 1.30 o’clock). Hold the movement for about 10 seconds. The
pressure in the extension cylinder piston side releases to the tank through the
overcentre valves.
3. Move the long hole unit completely back by pulling the boom joystick back and left
(about 7.30 o’clock). Hold the movement for about 10 seconds.
4. Repeat the movement from one extreme to the other at least twice or until the
movement runs smoothly.

The return filter has to be replaced after flushing the cylinders!

CAUTION

18 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

9. BOOM LUBRICATION POINTS

Centralized lubrication (optional)
The rig can be equipped with a cetralized lubrication system which takes care of boom
lubrication. See separate instructions.
Manual lubrication:
4, 7
10

2
3

5
10

6 9
1
Lubricate the following points daily:
1. Boom side tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . 4 nipples
2. Boom forward tilt cylinders . . . . . . . . . . . . . . . 4 nipples
3. Feed extension cylinder . . . . . . . . . . . . . . . . . 2 nipples
4. Zoom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 nipples
5. Zoom tube wear pieces . . . . . . . . . . . . . . . . . . . . . . . . 16 nipples
6. Boom joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 nipples
7. Rotation mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 2 nipples
8. Feed rotation limiter . . . . . . . . . . . . . . . . . . . . . 1 nipple
9. Stinger cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 nipples
10. Cradle and turning gear (only in P model) . . . . . . . . 4 nipples
There are 39 lubrication points in total.

C 44120--2 en 0507/LH 19 (33)

ZR 20 / 32 P BOOM

10. ROTATION MECHANISM MAINTENANCE

The most important maintenance procedure in the rotation mechanism is checking and
changing the oil regularly using the recommended oil grade.

Oil filler plug Oil filler plug

Brake Gear

Oil level check plugs

B1 A1
Oil draining Oil draining

Part Oil grade Volume

Brake RF 5/65 SHELL DONAX TD 0.6 litres
Gear RR 500/70 SHELL SPIRAX HD 80W/90 1.4 litres

Change the oil in the rotation mechanism regularly to ensure the best possible profit and
a long service life.
If the oil is of a wrong grade, the brake discs will glaze and braking power
will decrease.
CAUTION

Oil changes:
-- After the first 50--60 operating hours.
-- After every 1000 operating hours or once a year.
Bleeding:
You will have to bleed the brake and the rotation mechanism gear after maintenance or
service operations (e.g. replacing seals).
Bleed the brake and the rotation mechanism from the hose connectors when the rotation
mechanism has stopped.
Use goggles and beware of possible oil splashes when bleeding!

WARNING

Rotate the rotation mechanism back and forth. Stop the mechanism, open the hose
connector carefully, and release the air. Repeate the bleeding until there is no air in the oil.

20 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

11. CHECKING AND REPLACING BEARING BUSHINGS

The boom joints and the hydraulic cylinder mounting ears are equipped with bearing
bushings and axle pins. All the sliding surfaces are lubricated with lubricating grease
through the grease nipple installed specifically for the purpose.

11.1. Checking bearing bushings and axle pins

In order to check the bearing bushing and its axle pin on the boom joint or the hydraulic
cylinder mounting ear, you will have to move the part into a position where the weight of
the boom or one of its components does not rest on the cylinder to be checked. Move the
boom or its part back and forth by hand in the working direction of the hydraulic cylinder.
You can easily see the possible play between the bearing bushing and the axle pin by
watching the movement of the boom or its part and the cylinder in question.

11.2. Replacing bearing bushings

You can remove the bearing bushings in the hydraulic cylinder mounting ear and its body
with a suitable punch.
When you install a new bearing bushing, the temperature difference between the bearing
bushing and the hydraulic cylinder mounting ear or mounting hole in the body should be
40_ -- 50_C.
When installing a bearing bushing to a mounting hole, you can heat the metal around the
hole with a blowtorch in order to get the temperature of the hole 40_ -- 50_C higher than the
temperature of the bearing bushing.
When installing a bearing bushing to a hydraulic cylinder mounting ear, it is recommended
to cool down the bearing bushing in order to reach the required temperature difference.
This way the hydraulic cylinder seals will not be damaged due to the heat from the
blowtorch.

C 44120--2 en 0507/LH 21 (33)

ZR 20 / 32 P BOOM

11.3. Checking the cylinder pins

The cylinder pins are conical and they are installed to their ear without any clearance.

D
-- Check the tightening torque according to the table below.
-- Check the position of each adapter sleeve’s groove. The groove has to be
perpendicular to the cylinder movement direction, and downward if possible.

Size D of the Tightening torque with a Tightening torque with a

cylinder pins torque wrench [Nm] pneumatic wrench [Nm]
[mm]
55 150 130

Groove

22 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

11.4. Removing cylinder pins

-- Support the cylinder so that it has no tensile or compression stress.

-- Detach the M20 bolts (1) and lock washers (2) from both ends of the pin.
-- Thread a M24 bolt (5) into the the adapter sleeve thread (3) and tighten the bolt
against the axle end until you can remove the adapter sleeve (4). Remove both
sleeves.
-- Now you can detach the pin by pushing it.

2
5 1

3
4

C 44120--2 en 0507/LH 23 (33)

ZR 20 / 32 P BOOM

12. TROUBLESHOOTING
12.1. All hydraulic functions slow or not working at all
1. Not enough hydraulic oil, or its viscosity is too high.
D Check the oil level. Check the correct viscosity from the oil
recommendation table.
2. The hydraulic circuit leaks, or a hose is clogged.
D Check the hoses and connections.
3. Not enough pressure or output from the oil pump.
D The pressure limit is incorrectly adjusted, or the pump has an internal
leak. Check and repair.
D The switch between the motor and the pump is faulty. Check and repair.
4. The pump intake line is clogged.
D Drain and clean the tank. Check the intake line.
5. There are leaks between the carrier block and the boom hydraulics.
D Check the carrier block and repair if necessary.

12.2. Boom rotation does not function properly.

1. External leaks.
D Check the hoses and connections.
2. Internal leaks.
D Check the condition of the rotation motor and gear, and replace seals if
necessary.
3. Faulty overcentre valve.
D Impurities, a broken O--ring, or a broken seal in the overcentre valve.
Check and repair if necessary.
4. Faulty shuttle valve.
D Impurities, a broken O--ring, or a broken seal in the shuttle valve. Check
and repair if necessary.
5. Rotation control valve control faulty.
D Check the control of the reels Y18 and Y19.
6. Rotation mechanism brake trails.
D Check the shuttle valves, hoses, and connections.
7. Impurities on the gear ring, or a damaged gear ring.
D Check the seal condition, and replace if necessary.
D Clean the gear ring.

24 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

12.3. Boom does not hold its position.

1. Leaking overcentre valve in the boom side tilt, zoom, or tilt cylinder.
D Impurities, a broken O--ring, or a broken seal in the shuttle valve. Check
and repair if necessary.
D The overcentre valve socket is worn. Check and repair if necessary.
2.Dirt in the hydraulic circuit.
D Flush the hydraulic circuit according to instructions.
3. Air is trapped in the cylinder.
D Vent the cylinders according to the instructions in Chapter 8.
4. Cylinder seals worn.
D Replace the cylinder seals.

12.4. Feed moves backward during drilling

1. The non--return valve between the feed extension cylinder and control valve is
leaking.
D Clean the valve and replace any faulty or worn parts.
2. The feed extension cylinder piston seals are leaking, or some other external
leaking occurs.
D Replace the piston seals.

C 44120--2 en 0507/LH 25 (33)

ZR 20 / 32 P BOOM

13. FEED TURNING GEAR

13.1. Adjusting the rotation angle
You cannot adjust the rotation angle of this rotation motor.

13.2. Leak
The rotation motor can be compared to well--sealed linear cylinders due to its round seals.
Therefore all the intermediate positions can also be used with full load.

13.3. Breaking in
The rotation motor has to be started several times in both directions without load and with
a small pressure. This way the air possibly trapped in the hydraulic hoses starts to flow
toward the rotation motor. Open both bleeder screws (1) one at a time and bleed the
discharge chambers by making more rotation movements.

26 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

13.4. Disassembly/assembly
Note! Because the work procedures related to the assembly and disassembly of the
rotation motor are very complicated, you are advised to send the rotation motor to the
manufacturer for seal replacements as well as maintenance and repairs.
Disassembly
The rotation motor may be disassembled and assembled only by persons or experts
trained in the procedures.
You can replace the spare parts completely only after the rotation motor has been
removed. You always have to take care that the surroundings are absolutely clean when
disassembling and assembling the rotation motor and replacing the seals. You can only
remove the seals with appropriate tools (seal remover), and you have to be careful not
to damage the seal surfaces.

1. Unscrew the main bearing (1).

2. Remove the intermediate shaft (2) from the piston (3) by turning it anti--clockwise.
If this is difficult, use a clamp.
3. You can detach the piston (3) from the housing (4) with a clamp.

The rotation motor is now fully disassembled.

Assembling the rotation motor
You assemble the rotation motor in the reverse order. When assembling, you have to
check that the teeth touch their marked points.
If necessary, polish the operation and seal surfaces. When you have cleaned the rotation
motor thoroughly, you can replace all the seals. You will have to be very careful not to
damage the rotation motor prematurely when installing the seals. The seals and guiding
tapes have to be lubricated with an acidless lubricant.
If you have disassembled the whole rotation motor, start it according to the instructions
in the chapter Breaking in.

C 44120--2 en 0507/LH 27 (33)

ZR 20 / 32 P BOOM

Replacing the piston seal

1. Remove the old seal.
2. Remove all impurities and clean all components.
Installing the piston seals:
When you install the piston seal, widen the outer ring slowly and fit the piston seal in its
place with the help of installation tools (expanding sleeve and an expanding mandrel). If
the seal installation is performed without tools, the following issues must be considered:
-- It is easier to install the seal if it is warmed to about 80_C to 100_C with water, oil,
or a blowtorch. The warming expands the seal, and when the seal cools down, it
will shrink to its original size.
-- The seal is easier to install if oil or grease is applied to it. Make sure that the seal
material and the lubricant are compatible. Use only grease with no solid additives,
such as molybdenum sulphide or zinc sulphide.
Before you install the piston seal, make a groove to the seal outer ring according to the
picture.

O--ring

Spring wire
Pison seal Groove
A--A
Piston rod seal

A
Wiper seal ring

Guiding tape

28 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

You should use a calibration tool if a stretched ring makes it difficult to install the piston.
Calibration of the seal can be performed with a separate calibration sleeve or cylinder.

Installing the piston rod seal

Piston rod seal

1. Squeeze the seal into a form depicted in the picture below (you cannot bend the
seal in sharp angles) and place the squeezed seal into the groove.

2. Form the seal into a round shape with your hands.

C 44120--2 en 0507/LH 29 (33)

ZR 20 / 32 P BOOM

14. BOOM LIFTING AND LIFTING POINTS

2166
2228

m=2190 kg

m=2840 kg

1098
ZR 20

ZR 32 P
1280
1280

2031

Always follow the laws on lifting safety and the applicable local safety
regulations.

WARNING

D Only use a lifting device of the appropriate type and sufficient lifting capacity. You
may not lift the boom with anything else than a device designed for lifting.
D You must know the weight of the boom, because you may not exceed the capacity
of the lifting device specified by the manufacturer.
D Choose the lifting routes so that you do not need to lift the boom above people or
above areas where there might be people.
D Check that the lifting device is in good condition.
D The lifting cables and chains must be checked regularly. Material failing the checks
must be clearly marked and discarded immediately.

30 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

D Make sure that the boom is properly attached and balanced. You can check the
fastenings and balance by lifting the boom just a few centimetres at first. Do not
lift the boom higher unless you are absolutely sure that the fastenings and balance
are in order.
D Lifting cables consisting of many parts may not be twisted. Lifting cables must be
fastened according to the manufacturer’s instructions.
WRONG RIGHT

C 44120--2 en 0507/LH 31 (33)

ZR 20 / 32 P BOOM

15. REGULAR MAINTENANCE

Service chart

CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
WASH REPLACE
S SERVICE

PERCUSSION HOURS
AT THIS INTERVAL (hours)
50 / 200 / 500 / 1000 /
ZR 20 / 32 P BOOM DAILY
WEEKLY ONCE A
MONTH
EVERY 6
MONTHS
ONCE A YEAR

Check the tightness of bolts and nuts.

Adjust if necessary.
Check for possible oil leaks.

Lubricate the boom grease nipples.

Check the condition and functioning
of the boom. Report possible faults to
the persons in charge.
Wash the boom
Check the condition of the cylinder
pins and sleeves.
Check the fastening and functioning
of the rotation sensor (S11).
Lubricate the rotation ring.
Check the condition of the hoses. Re-
place, if necessary.
Check the tightening of the adjust-
able cylinder pins.
Check the condition of the rotation
mechanism seal.
Check the operation of the rotation
mechanism brake.
Check the mechanical structure of
the boom. Pay special attention to
the fastenings, breaks, and the
condition of the welds. Repair the
faults immediately.

32 (33) C 44120--2 en 0507/LH

 ZR 20 / 32 P BOOM

CHECK / CLEAN AND CHANGE /

TEST
LUBRICATE
WASH REPLACE
S SERVICE

PERCUSSION HOURS
AT THIS INTERVAL (hours)
50 / 200 / 500 / 1000 /
ZR 20 / 32 P BOOM DAILY
WEEKLY ONCE A
MONTH
EVERY 6
MONTHS
ONCE A YEAR

Check the clearings of the boom

wear pieces. Adjust it if necessary.
Check the cradle and feed
clearances Adjust it if necessary.
Check the fastening and condition of
the rotation mechanism gears.
Check the fastening and condition of
the rotation mechanism gear ring.
Check that the rotation mechanism
gear ring is clean.
Check the condition of the rotation
mechanism gear ring seals.
Change the rotation mechanism
brake oil.
Change the rotation mechanism gear
oil.
Replace the cradle wear pieces

C 44120--2 en 0507/LH 33 (33)

 CILINDROS HIDRÁULICOS

REPARACIÓN Y AJUSTES

CONTENIDO

1. GENERALIDADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1. Estructura . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. SEGURIDAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. VALVULAS DE RETENCIÓN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1. Operación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. COMPONENTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. DESMONTAJE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1. Cilindro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2. Pistón . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3. Inspección . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.4. Reemplazo de los casquillos del cojinete . . . . . . . . . . . . . . . . . . . . . . . 5
6. ENSAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1. Ensamble del cilindro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. PRUEBA DEL CILINDRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.1. Línea A, inspección . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.2. Línea B, inspección . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

C 47150--4 es 0507 / MS 1 (8)

CILINDROS HIDRÁULICOS

1. GENERALIDADES
1.1. Estructura
La principal diferencia en las estructuras de los cilindros hidráulicos son accionamiento
simple o accionamiento doble, diametro del cilindro, desplazamiento y, si son equipados
con válvulas de retención.
El desplazamiento puede ser limitado con un espaciador montado en cualquiera de los
dos lados del embolo ya sea del pistón o del mango del embolo.

2. SEGURIDAD

Familiarízate con las instrucciones de uso y servicio antes de comenzar

a trabajar en un cilindro. Aprende a identificar todos los componentes
con los que ud. va a trabajar.
ATENCIÓN

Siga las instrucciones emitidas por Sandvik.

ATENCIÓN

Ajustes y trabajos de reparación pueden ser conducidos solamente por

personal cualificado y que conozca el equipo.
ATENCIÓN

El uso adecuado y servicio garantizan larga vida de los cilindros

hidráulicos.
ATENCIÓN

Use todas las herramientas de seguridad y chequee su condición.

ATENCIÓN

Antes de arrancar, esté seguro de que nadie esta trabajando cerca de, o
debajo de la perforadora.

PRECAUCIÓN

Jamás desconecte ninguna manguera hidráulica o válvulas antes de

estar seguro de que no tenemos carga estática en el sistema.

PRECAUCIÓN

2 (8) C 47150--4 es 0507 / MS

 CILINDROS HIDRÁULICOS

3. VÁLVULAS DE RETENCIÓN
3.1. Operación
La mayoria de los cilindros hidráulicos es son equipados con válvulas de retención. Ellas
están o fabricadas en el cilindro o conectadas en el circuito hidráulico via mangueras
hidráulicas.

Las válvulas de retención son componentes de una sola pieza, y no pueden ser
reajustados. Juegos de sellos con añillos O (1) pueden ser proporcionados.
Las cuatro funciones de las válvulas de retención son:

-- Si alguna manguera conectada al cilindro hidráulico se rompe, la válvula de

retención actua como una válvula de seguridad.
-- Durante la perforación, la válvula de retención previene que el aceite fluja del
cilindro al tanque reservorio. El brazo mantiene su posición precisa a la que fue
movido usando las válvulas de control de los brazos.
-- Cuando se mueve el brazo,la válvula de retención no permite que el aceite fluja
del lado del retorno hasta que la presión en el lado presurizado suba lo
suficientemente alto. Los movimientos de los brazos son suaves y precisos, y el
mismo peso del brazo, no puede acelerar la velocidad de movimiento del brazo.
-- Si una fuerza externa sube la presión en el cilindro más alta que la que tenemos
como valor en la válvula de retorno, la válvula se abre y deja el aceite salir del
cilindro. Esto permite al brazo ceder ante fuerzas externas, pero eliminamos la
posibilidad de daños mecánicos en el brazo.

El ajuste de estas válvulas es fijo, pero son diferentes de acuerdo al uso

que se le va a dar. Pero ud. jamás debe de reemplazar una válvula de
retención con una de otro cilindro. El valor del ajuste de la válvula de
ATENCIÓN
retención está marcada en el tope de la válvula.

C 47150--4 es 0507 / MS 3 (8)

CILINDROS HIDRÁULICOS

4. COMPONENTES
10
1
2
9
8
5
3
6
7
4

10

Componentes del cilindro

1. Perno Allen 6. Placa de cerradura

2. Cubierta del cilindro 7. Tuerca del eje
3. Pistón 8. Embolo
4. Válvula de retención 9. Espaciador
5. Cilindro 10. Casquillo del cojinete

10
2
9
8
5
3
6
7
4

10

Componentes del cilindro (tapa del cilindro con rosca)

4 (8) C 47150--4 es 0507 / MS

 CILINDROS HIDRÁULICOS

5. DESMONTAJE
Antes de comenzar a desmontar el cilindro, esté seguro de que el brazo (boom) esté
firmemente apoyado, y que el cilindro no tenga ninguna carga estática. Desacoplar las
mangueras hidráulicas del cilindro y tapar los adaptadores del cilindro como las
mangueras.
Sacar los anillos de cerradura del pasador del eje del cilindro y golpear los pasadores
hacia afuera, asegura el cilindro para evitar la caida de este.
Lava la superficie externa del cilindro antes del desmontaje. Fija el cilindro firmemente
desde la orejera del cuerpo del cilindro.

5.1. Cilindro
Si ud. puede usar presion hidráulica, conecte las mangueras hidráulicas al cilindro y con
la presión empuja el embolo del pistón (8) hacia afuera, saca las válvula de retención.
Destornilla los pernos Allen de la tapa (2) o, si la tapa es del tipo montada en hilo, abrela
con una llave conveniente. Instala las válvulas de retención (4) y empuja el embolo del
pistón (8) con la tapa del cilindro (2) hacia afuera. Cuando lo estés sacando hacia afue
ra, apoya el embolo del pistón (8) para que salga suavemente.

5.2. Pistón
Fija el embolo del cilindro firmemente desde la orejera del embolo del pistón, y golpea
suavemente hacia afuera el anillo de seguridad de la ranura de la tuerca, remueve la
tuerca (7). Remueve el piston (3) con sus sellos. Saca la tapa del cilindro (2) afuera del
embolo del pistón y remueve los limpiadores y sellos de la tapa del cilindro.
Reemplázalos. Destornilla las valvulas de retención (4) del tubo del cilindro y visualmente
chequea su condición. Lava todos sus componentes.

5.3. Inspección
Reemplaza todos los sellos y los limpiadores. Chequea todas las superficies de
deslizamiento. Si se encuentran araños sensitivos a uña, se debe reemplazar los
componentes porque la capacidad de sellado de superficie ya no está buena. Chequea
también de que el embolo está directo. Si el embolo está torcido, chequea que no será
causado por un espaciador de tipo incorrecto. Chequea el estado de los casquillos del
cojinete (10) y reemplázalos si tienen marcas de desgaste.

5.4. Reemplazando los casquillos de los cojinetes

Si el cilindro ha sido removido de la máquina, asegura el cilindro bien y golpea
suavemente hacia afuera los viejos caquillos de cojinete usando un botador conveniente
y un martillo de cobre.
Los nuevos casquillos de cojinete son fáciles de instalar si es que ellos son enfriados en
un congelador, y la oreja del cilindro calentada con una antorcha.

C 47150--4 es 0507 / MS 5 (8)

CILINDROS HIDRÁULICOS

6. ENSAMBLE
Si el recorrido del cilindro está limitado con un espaciador y este es
dejado afuera, el cilindro puede ser dañado cuando lo use. Chequea de
que ud. instala el espaciador de tipo correcto.
ATENCIÓN

6.1. Ensamble del cilindro

2 Engrase todas las ranuras de los sellos e

9 instale los anillos O, los sellos y los anillos
guias en la tapa del cilindro (2). Instale la
tapa en el embolo del piston (8). Si un
espaciador (9) es usado para limitar el
recorrido del cilindro, instale el cojinete en
8 el embolo del pistón antes de la instalación
del pistón.

11 Engrase todos las ranuras de los sellos, e

6
instale el sello del pistón (10). Cuando
7 instale el anillo O (11) del embolo del
pistón, tenga cuidado de no dañarlo con el
hilo del mismo (embolo del pistón). Instale
la placa de cerradura (6) y la tuerca de
10 seguridad (7). Ajuste la tuerca y asegurala
en su sitio girando una de las espigas en
una de sus ranuras.

Ensamble del embolo del pistón y la tapa del cilindro

6 (8) C 47150--4 es 0507 / MS

 CILINDROS HIDRÁULICOS

Chequea si el mínimo recorrido del cilindro es limitado. Si lo es, el espaciador debe de

ser instalado primero dentro del cilindro. Empuja el embolo del pistón adentro del cilindro
(lubrica los sellos antes de ensamblarlos).

Empuja la cubierta del cilindro (2) hacia adentro e instala los pernos Allen (1) a traves de
la tapa y ajustalos. Si la tapa del cilindro esta montada con hilos, usa una herramienta
especial para el ajuste.

Instala las válvulas de retención (4) y los adaptadores, y prueba el cilindro.

2 1

Cilindro ensamblado

C 47150--4 es 0507 / MS 7 (8)

CILINDROS HIDRÁULICOS

7. PRUEBA DEL CILINDRO

11
12
10

13
14

Prueba del cilindro

7.1. Línea A, inspección

Saca el embolo del pistón completamente afuera. Desconecta la línea A, y presuriza la
línea B. Chequea la línea A por perdida de aceite. Si bota hacia afuera el aceite, uno de
los sellos (10,11 o 12), o la válvula de retención está defectuosa.

7.2. Línea B, inspección

Saca el embolo del pistón completamente afuera. Desconecta la línea B, y presuriza la
línea A. Chequea la línea B por perdida de aceite. Si bota aceite hacia afuera, uno de los
sellos (10,11 o 12), o la válvula de retención está defectuosa. Si el aceite sale afuera entre
del cilindro y la tapa del cilindro, uno de los anillos O (13) de la tapa del cilindro está
defectuoso. Si el aceite sale afuera entre la tapa del cilindro y el embolo, uno de los anillos
O (14) de la tapa del cilindro está defectuoso.

8 (8) C 47150--4 es 0507 / MS