NOT FOR EXTERNAL RELEASE OUTSIDE SANDVIK. DO700 [S2500] Telescopic Feed Cylinder Repair & Upgrade Procedure

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1 Internal Bulletin - FLP Drills Sandvik Mining & Construction Tomago ABN PO Box 571 Hunter Region Mail Centre NSW Old Maitland Road NSW 2322 Australia Phone Fax Bulletin Number: IB1002 Date: 20/04/2010 Subject: DO700 [S2500] Telescopic Feed Cylinder Repair & Upgrade Procedure Purpose To provide guidance to Sandvik personnel the repair and upgrade of DO700 (S2500) Telescopic Feed Cylinders. This includes testing and assembly procedures, and recommended Check Sheet. Applicable to All DO700 (S2500) Telescopic Feed Cylinders Cylinder No. Rig Length Retracted Length Extended Length ZB ZC ZD ZE ZG ZJ Z* Telescopic Feed Cylinder shown in this document. * Denotes lengths as shown above. Distribution SMCT Hexham workshop PLM FLP Drill & Bolt VP Underground SMCA Account Management SMCA PLM Mech. Cutting Equip. SMCA Tomago workshop SMCT Documentation SMC UK - Doncaster SMCT Engineering SMCA Procurement SMCT Procurement Description The following information outlines modifications and part replacements made to existing DO700 (S2500) Telescopic Feed Cylinders for upgrade to the latest construction. These instructions assume that all work is being carried out by staff with experience in cylinder repair and assembly. Each workshop is to conduct its own JSEA prior to undertaking the work. IB /04/2010 Page 1 of 13

2 IB /04/2010 Page 2 of 13

3 Major Components 1. Short Feed Barrel (Z*200330) Early versions of this barrel were longer than current builds and used old style shoulder-less steel glands. These glands must be discarded and the barrel must be shortened to current specs and current Cast Iron Glands (part no. H16371) are to be used in all cylinder rebuilds. Cylinder bores should be measured at a number of intervals along it s length to ensure that dimensions, including taper and ovality, fall within tolerence. Particular attention should be paid to pitting and longitudinal scoring in bore. Honing of bore is recommended for removal of light scoring. Make sure bore and thread are concentric. Acceptable wear on brass wear strips is at the discretion of the person quoting. Z* SHORT FEED BARREL RIG LENGTH A LENGTH IB /04/2010 Page 3 of 13

4 2. Short Feed Rod (Z*200320) Early rods were equipped with screwed pistons sealed by O-rings. These are no longer acceptable, and all pistons must be welded in position and the welds tested under hydraulic pressure to ensure no possible bypassing. There are 3 different types of rod currently in use. The earliest type has the internal transfer holes situated close to the end of the threads. This rod uses the shorter, bronze Gland (part no. H15353), and Ported Bung (part no. H15358). The next version has the transfer holes located further inside the bore requiring the use of a longer Gland (part no. H16372), and Non-Ported Bung (part no. H16373). The latest version is similar to the previous but has an additional groove in one end to house an O-ring and Back-up Washer, used to seal a different Gland (part no. H16374). If this rod is used, a different Seal Kit (part no. H60536) is required. Close inspection of bore for scoring is required. Damaged Chrome Sleeves on rod may be replaced by machining through welds on ends of rod. Z* SHORT FEED ROD IB /04/2010 Page 4 of 13

5 3. Long Feed Rod (Z*200310) Early style rods were machined to suit short Pistons and long Stop Tubes (part no. ZP200113). These rods must now be modified to carry the newer Pistons (part no. H15352). The long Stop Tube may be re-used as long as they are the Bronze type. The newer style rod are machined to suit the new shorter bronze Stop Tube (part no. ZP200114), as well as the new Piston. Z* LONG FEED ROD IB /04/2010 Page 5 of 13

6 Minor Components Glands All Outer Barrel Glands should be of the newest Cast Iron Type (part no. H16371). Short style Bronze Glands (part no. H16353), have been upgraded to include a back-up Washer behind the O-ring. Two types of the longer style Bronze Glands are available, one carries an O-ring and back-up Washer (part no. H16372), the other has neither (part no. H16374). Close attention must be paid to the area inside the bore under the O-ring groove as this can weaken due to the small wall thickness. All Glands must be assembled with Loctite 569 Hydraulic Sealant. Bungs Short style Ported Bungs have been upgraded to include a back-up Washer behind the O-ring. Once upgraded, these Bungs should never require replacement. Use Loctite 569 Hydraulic Sealant on thread when assembling. Piston The newest style long Piston (part no. H15352), must be used in all Cylinders. Long Feed Rods that have previously been fitted with old style short Pistons must be modified to suit the new pistons. IB /04/2010 Page 6 of 13

7 Trunnions All Trunnions must be upgraded to the newest style that uses split plain bearings and wiper seal. Old style Trunnions with wear strips must be discarded. Seals Use hydraulic fluid as lubricant for fitting seals and o rings. Information taken from Hallite Fluid Power Seal Catalogue. Seal No. Seal Type SURFACE TOL SURFACE ROUGHNESS H6164 WIPER; TYPE 520 f9 Ra = , Rt = 4 MAX H PISTON; TYPE 730 h9; H10 Ra = , Rt = 4 MAX H PISTON; h9; H10 Ra = , Rt = 4 MAX H PRESSURE; TYPE 621 f9; Js11 Ra = , Rt = 4 MAX H PRESSURE; TYPE 621 f9; Js11 Ra = , Rt = 4 MAX H STATIC; TYPE 155 h9; H10 H WIPER; TYPE 38 f9; H11 Ra = , Rt = 4 MAX Identification It is recommended that all Major Components of these Cylinders be engraved or stamped with the original Serial Number before reassembly. This will aid in historical monitoring of the cylinder and avoid confusion of compatibility. Outer Barrels to be engraved in large numbers on side plate. Short Feed Rods to be engraved on side of piston. Long Feed Rods to be stamped on Rod End Cap. Compatibility Issues Due to the many changes made to these Cylinder components over time, certain combinations are not compatable and would lead to incorrect Open & Closed Centre dimensions. 1. If the Short Feed Rod is of the older style with the transfer holes close to the end of the internal threads, only the short Glands (part no. H16353), and short Bungs (part no. H16358), can be used. This also requires that the Long Feed Rods carry the longer Stop Tube (part no. ZP200113). 2. If the Short Feed Rod is of the newer style it requires the use of the longer Glands & Bungs, and short Stop Tube on the Long Feed Rod. 3. If an old style Short Feed Rod requires replacement it will be replaced by the newer style, this will also require the replacement of the Long Feed Rod to the latest specs as it cannot be modified to take the short Stop Tube. IB /04/2010 Page 7 of 13

8 Assembly & Testing Before disassembling Cylinder, test using bench set at 250 bar checking for leaks and bypass, to determine point of failure. 1. Attach brass wear strips to outer barrel. 2. If Short Feed Rod has undergone any reconstruction, it will require deburring and flushing of transfer passageways. As a suggestion you could use a dial ball gauge for checking concentricity and surface finish tester on surfaces. 3. Screw Seal Guide (TP2506) into Short Feed Barrel on one end as shown. 4. Screw one Gland fitted with seals into Outer Barrel, fit Piston Seals* to Short Feed Rod then fit Rod into Barrel. Remove Seal Guide. Push remaining Gland over Rod and screw into Barrel. * Feel Piston Seal for machining deformity Lip and assemble as shown in image. 5. Assemble Trunnions and push onto Rod. IB /04/2010 Page 8 of 13

9 6. Fit o ring and backup ring into Short Feed Rod using Seal Guide shown below to avoid damage. Screw Seal Guide (TP2505) into Short Feed Rod as shown. Fit 0 ring (SBD ) and Backup Ring (SBD B). 7. Fit Gland with seals, Stop Tube, Piston with seals*, and Nyloc Nut to Long Feed Rod. * Feel Piston Seal for machining deformity Lip and assemble as shown in image (8). IB /04/2010 Page 9 of 13

10 8. Push Long Feed Rod into Short Feed Rod, unscrew and remove Seal Guide, and tighten Gland. 9. Fit Bung (H16373) with O rings (SBS326, HS090051) and screw into other end of Short Feed Rod. 10. Attach test plate to Long Feed Rod End Cap and blanking plate to bung if required. Connect hoses from test bench. 11. Test Cylinder with bench set at 250 bar, checking for external leaks, bypass testing at open & closed centres and midpoint. Measure dimensions. 12. Fill out check sheet. (See Page 12) 13. Care must be taken to avoid damage in packing and transportation. A suggestion would be to carefully place cylinder in individual box and pack tightly with timber blocks ensuring no movement of the cylinder can occur resulting in damage. Do not apply excess force when packing as this may cause bending of rods and damage to cylinder function. IB /04/2010 Page 10 of 13

11 IB /04/2010 Page 11 of 13

12 DO700 (S2500) TELESCOPIC FEED CYLINDER CHECK SHEET CYLINDER LENGTHS LENGTH BYPASS LEAKAGE SIGNED PASSED CLOSED CENTRES mm MID LENGTH mm OPEN CENTRES mm BARREL LENGTH A mm - - DIAMETER TOLERANCES SHORT FEED BARREL REQUIRED SIZE ACTUAL SIZE SURFACE FINISH 0.1 Ra TO 0.4 Ra SIGNED PASSED BORE: POSITION 1 Ø BORE: POSITION 2 Ø BORE: POSITION 3 Ø BORE: POSITION 4 Ø SHORT FEED ROD BORE: POSITION 1 Ø BORE: POSITION 2 Ø BORE: POSITION 3 Ø BORE: POSITION 4 Ø O RING GROOVE DIA Ø O RING GROOVE WIDTH LONG FEED ROD OUTSIDE DIAMETER Ø STOPTUBE SURFACE Ø STOPTUBE SURFACE LENGTH PISTON SURFACE Ø GEOMETRIC TOLERANCES SHORT FEED BARREL TYPE TOLERANCE ACTUAL SIGNED PASSED THREAD END 1 CONCENTRIC Ø 0.05 THREAD END 2 CONCENTRIC Ø 0.05 MOUNT PLATE 1 PARALLELISM 0.25 MOUNT PLATE 2 PARALLELISM 0.25 SHORT FEED ROD THREAD END 1 CONCENTRIC Ø 0.25 THREAD END 2 CONCENTRIC Ø 0.25 HONED BORE CONCENTRIC Ø 0.25 OUTSIDE DIAMETER CONCENTRIC Ø 0.25 END 1 PERPENDICULAR 0.25 END 2 PERPENDICULAR 0.25 LONG FEED ROD STOPTUBE SURFACE CONCENTRIC Ø 0.05 PISTON SURFACE CONCENTRIC Ø 0.10 PRE ASSEMBLY INSPECTION - CYLINDERS PORTS FULLY DEBURRED CYLINDER TUBE FLUSHED AND INSPECTED CYLINDER TUBE GLAND THREADS - NO BURRS CYLINDER ROD CHAMFERED AS PER DRAWING CYLINDER ROD CHROME INSPECTED - NO DAMAGE GLAND AND PISTON FULLY DEBURRED GLAND AND PISTON SEALS FITTED AND INSPECTED LUBRICATE SEALS PRIOR TO ASSEMBLY ASSESSMENT FINDINGS: IB /04/2010 Page 12 of 13

13 Implementation These modifications are to start immediately. These modifications are to be performed on ALL DO700 (S2500) telescopic feed cylinders prior to leaving Sandvik workshops or stores, including rigs that have been returned for servicing and rigs fitted to continuous miners or other host machines. Further Information Please contact your Engineering representative regarding any additional information you may require. IB /04/2010 Page 13 of 13