RD314 REBUILD PROCESS

NOTICE!
These instructions contain supplementary information for maintenance and
repair of a component.
Before performing maintenance or repair procedures for the component
described in these instructions,
read and understand the information in the technical instructions of the component.
Pay special attention to the safety information.

2
 Lifting instructions

• Fasten the lifting eye bolt to the tapped hole. Screw the lifting eye bolt to
the object to be lifted, use washer if necessary.
• If there is no thread in the lift hole, use nut to fasten the lifting eye. Use
suitable washers.

3
 Lifting instructions
Lifting RD314 rock drill

• Tie lifting straps to the rock drill as shown in figure.

• Rock drill weight: D45 120kg, D38 125kg

4
 Removing the rock drill from the carriage

• 1. Open and remove the mounting bolts (1) and (2).

• 2. Lift the rock drill from the carriage.
• Because the hub is sealed against water and drilling mud, the rock drill
might resist the lifting slightly. The vacuum created between the rock drill
• and the carriage will fill through the hole in the hub in a short time, making the lifting easier.

5
 Fastening the rock drill to the assembly stand

• 1. Remove the O-ring (5) from the hub wear bushing.

• 2. Attach the assembly stand table (T22) to the assembly stand (A) with the bolts (4).
• 3. Attach the rock drill (3) to the assembly stand table (T22) with the bolts (1) and (2).

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 Dismantle flushing housing

Removing the flushing housing, D45

• 1. Open the bolts (1).
• 2. Remove the flushing housing (2).
• 3. Remove the the O-ring (3) and the gasket plate (4).
• 4. Remove the shank (5).
• 5. Remove the coupling (6).
• 6. Remove the rotation bushing (7).

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 Dismantle flushing housing

Removing the flushing housing, D45

• 1. Open and remove the bolts (1).
• 2. Remove the guard (2).
• 3. Remove the cover (3).
• 4. Remove the O-ring (4).
• 5. Remove the seal (5) from the cover (3).
• Changing the flushing housing bushings, D45
• 1. Remove the seals (1) from the seal housing and from the shank bushing.

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 Changing the flushing housing bushings D45

• 2. Remove the front bearing (2), the seal housing (3), and the shank
bushing (4) from the flushing housing.
• Use a hydraulic press, the special tools (T1) and (T2), and a suitable sleeve (A).
• 3. Remove the O-rings (5) and (6) from the seal housing (3) and from the
shank bushing (4).
• 4. Remove the front bearing (2) from the seal housing (3).

• Use a hydraulic press, the special tools (T2) and (T26), and a suitable
sleeve (B).
• 5. Clean the flushing housing and the seal housing.

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 Changing the flushing housing bushings D45

• 6. Install the front bearing (2) to the seal housing (3).

• Use a hydraulic press and the special tool (T1).
• The front bearing must be aligned correctly with the seal housing. Use
the lubrication hole (C) in the bearing and the groove in the seal housing
to align the components correctly.
• 7. Install the seals (1) and the O-rings (5) to the seal housing.

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 Changing the flushing housing bushings D45

• 10. Install the shank bushing (4) into the flushing housing.
• Use a hydraulic press, the special tool (T8), and a suitable sleeve (D).
• Note that the shank bushing has to be in the correct position during
installing, so that the locking surface (E) meets the corresponding shape in the flushing housing.

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 Assembling the flushing housing, D45

• Check the condition of the flushing housing mounting surfaces before

assembling. Clean the surfaces gently. Do not polish or grind them.
• 1. Install the seal (5) and the O-ring (4) to the flushing housing cover (3).
• 2. Install the shank (7) into the flushing housing (6).
• 3. Install the cover (3), the guard (2), and the bolts (1) to the flushing
housing (6). Use the shank (7) to align the cover correctly.
• 4. Tighten the bolts (1).
 Pre-Tighten to 100Nm (10kpm.)
 Tighten to 200 Nm (20kpm.)

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 Removing the flushing housing, D38

• 1. Open the bolts (1).

• 2. Remove the flushing housing (2).
• 3. Remove the the O-ring (3) and the gasket plate (4).
• 4. Remove the shank (5).
• 5. Remove the coupling (6).
• 6. Remove the rotation bushing (7).

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 Disassembling the flushing housing, D38

• 1. Open and remove the fitting flange mounting bolts (1).

• 2. Remove the fitting flange (2) and the gasket plate (3).
• 3. Remove the fitting flange O-rings (4).

• 4. Check the condition of the hose fitting.

• Replace the fitting if needed.
• 5. Open and remove the front cover mounting bolts (5).

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 Disassembling the flushing housing, D38

• 6. Remove the front cover (7) and the seal housing (6) by using the special
tool (T25) and a copper hammer.
• The rearmost seal comes out with the front cover and the seal housing.

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 Changing the flushing housing bushings, D38

• 1. Remove the front bearing (1).

• Use a hydraulic press, the special tool (T2) and a suitable sleeve (E).
• 2. Remove the shank bushing (2).
• Use a hydraulic press, the special tools (T1) and (T2), and a suitable
sleeve (F).
• 3. Remove the O-ring from the shank bushing.
• 4. Clean the parts.

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 Changing the flushing housing bushings, D38

• 5. Install a new O-ring (3) and a new seal (4) to the new shank bushing (2).
• Make sure that the seal is installed in the right direction.
• 6. Install the shank bushing (2) to the flushing housing.
• Use a hydraulic press and a suitable punch (A).

• 7. Install the front bearing (1) to the front cover.

• Use a hydraulic press and the special tool (T1).

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 Assembling the flushing housing, D38

• Check the condition of the flushing housing mounting surfaces before

assembling. Clean the surfaces gently. Do not polish or grind them.
• 1. Install the O-rings (11) and the seals (10) to the seal housing (6).
• 2. Install the seal housing to the flushing housing.
• Use the special tools (T1) and (T2), and a rubber hammer.
• Ensure that the flushing water port of the seal housing points at the same
direction than the flushing water port of the flushing housing.
• 3. Use the special tool (T25) to turn the flushing water port of the seal
housing to the correct direction.

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 Assembling the flushing housing, D38

• 4. Install the O-ring (9) and the seals (8) to the front cover.
• 5. Install the front cover to the flushing housing.
• Use a new gasket plate.

• 6. Tighten the front cover bolts (5).

 Pre-tighten to 100Nm (10kpm.)
 Tighten to 200 Nm (20kpm.)

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 Assembling the flushing housing, D38

• 7. Install new O-rings (4) to the fitting flange (2).

• 8. Install the fitting flange (2) to the flushing housing.

• Use a new gasket plate (3).
• 9. Tighten the fitting flange mounting bolts (1).
 Pre-tighten to 100Nm (10kpm.)
 Tighten to 200Nm (20kpm.)

20
 Replacing the chuck

• 1. Press the chuck (1) out from the rotation bushing (2).
• Use a hydraulic press and the special tool (T15).
• 2. Clean the parts.
• 3. Lubricate the parts with hydraulic oil.
• 4. Install a new chuck to the rotation bushing.
• Use a hydraulic press and the special tool (T15).
• Note! Make sure that the chuck is installed in the right direction.

21
 Removing pressure accumulators

1. Make sure that the accumulators pressures has been released by opening
the filling valves.
2. Remove filling valves.
3. Open the accumulator mounting bolts.
4. Detach the accumulators.
5. Remove the O-rings.
6. Remove the gasket plates.
7. Check the condition of the accumulators.
 NOTE! Filling pressures
 HP 40bar
 LP 4bar

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 Removing the rotation motor

• 1. Open and remove the mounting bolts (1).

• 2. Remove the hydraulic motor assembly (2) from the rock drill body.
• 3. Remove the O-rings (3), (4), (5) and (7), and the seal (6).

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 Removing the rotation motor

• 4. If necessary, open the bolts (8) and pull out the motor (9) from the flange (10).
• Open the bolts only if the motor needs to be serviced.
• Note! When the bolts have been opened, do not turn the motor such that
the flange surface faces downward, because the parts are loose and
could fall out. The parts could become damaged if hitting a hard surface.

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 Removing the balance plate

• If the O-rings are holding the balance plate (11) tight, it can be released
using grease (A), and the spacer pin (12).
• 1. Punch the spacer pin with a hammer so that the grease will loosen the
balance plate. Add more grease and continue punching until the balance plate comes out.
• Note! Cover the motor case with a cloth or similar to prevent the high
pressure grease from shooting upwards.
• 2. Remove the ring spring (13) under the balance plate.

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 Assembling the rotation motor

• 1. Lift the motor flange (1) onto the top of the assembly base (2), with the O-ring groove facing upward.
• The height of the assembly base should be approx. 37 mm. (A used
rotation bushing front bearing can be used as an assembly base.)
• 2. Install the O-ring (3) on the motor flange (1).
• 3. Install the axle shaft (4) in the motor flange (1) hole.
• 4. Lift the gerotor plate (5) onto the top of the motor flange (1), with the Oring-
groove facing upward.
• 5. Install the O-ring (6) on the gerotor plate (5).
• 6. Install the valve drive shaft (7) on the gerotor plate (5).
Install the valve drive shaft (7) so that the narrower ring gear faces downward.
• 7. Install the channel plate (8) on top of the gerotor plate (5), with the O-ring groove facing upward.
Install the channel plate (8) so that the oil channel (C) is parallel with the oil channel (B) of the gerotor plate (5).
• 8. Install the O-ring (9) on the channel plate (8).

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 Assembling the rotation motor

• 9. Install the balls (10) in the channel plate (8) notches.

• The channels are not in use, so it is not necessary to install the balls (10).
• 10. Attach the valve plate (11) on top of the channel plate (8).
• Install the thin sector of the gerotor plate (5) wheel and the valve plate
• (11) so that they are parallel, as shown in the figure. This ensures that
the motor rotates in the correct direction.
• 11. Install the spring plate (17), the cylindrical pin (14), and the balance
• plate (15) with the two O-rings (16) and a pin (18) in the valve housing.
• 12. Attach the valve housing (12) on top of the channel plate (8).
• 13. Install the bolts (13) and tighten them.

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 Removing the primary gear and bearings

• 1. Pull the primary gear (3) out of the gear housing.

• Use the special tools (T3) and (T9).
• 2. Remove the bearing (2) from the primary gear (3).
• Use a puller.
• 3. Remove the bearing (5).
• Use a puller.
• 4. Remove the shim (4).
• 5. Remove the spacer pin (1).

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 Removing the rear cover

• 1. Open and remove the bolts (1) and washers (2).

• 2. Remove the rear cover (3).
• 3. Remove the O-rings (4), (5), and (6).

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 Removing the percussion cartridge

• 1. Remove the percussion cartridge (1).

• Use a copper hammer and the special tool (T7).
• Support the percussion cartridge components when they come out of the
rock drill body, so that they will not hit anything and get damaged.

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 Disassembling the percussion cartridge

• 1. Pull the piston (4) out of the percussion cartridge.

• 2. Pull the piston (4) from the rear cylinder (5).
• 3. Pull the distributor (3) out of the pilot cylinder (2).
• 4. Insert the special tool (T7) into the percussion cartridge.
• 5. Insert the bolt of the special tool (T7) through the holes in the pilot
cylinder (2) and the special tool (T7).
• 6. Remove the pilot cylinder (2) from the front cylinder (1).
• Use a hammer and the special tool (T7).
• 7. Remove the seals from the percussion cartridge components.

31
 Checking the percussion cartridge components

• 1. Check the distributor (1).

• Remove the light scratches by polishing them with a cloth wheel.
• If the distributor has deep scratches that can't be polished off, replace the distributor.
• 2. Check the piston (2).
• Replace the piston if:
• the bevel (A) at the percussion end has worn off
• the piston has cracks
• the piston has seizure marks on it.
• If necessary, the piston may be polished with a cloth wheel. (no grinding)
• Replacing the front and rear cylinders
• The recommended replacement interval for the front cylinder (1) and the
rear cylinder (2) is 2000 percussion hours.

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 Removing the rotation bushing front bearing

• 1. Method A: Remove the rotation bushing front bearing (1) from the rock drill body.
• a) Remove the rock drill from the assembly stand table. Use a hoist.
• b) Use a hydraulic press and the special tools (T8) and (T17) to press out the bearing.

• 2. Method B: Remove the rotation bushing front bearing (1) from the rock
drill body.
• a) Use the slide hammer (T9) and the special tools (T8) and (T11) to
pull out the bearing.

33
 Removing the rotation bushing rear bearing

• 1. Remove the rock drill from the assembly stand table.

• Use a hoist.
• 2. Remove the rotation bushing rear bearing (1).
• Use a hydraulic press and the special tools (T5) and (T17).
• Removing the hub wear bushing
• The hub wear bushing (1) must be replaced if the indicator groove (A) has
worn off at any point.
• 1. Remove the hub wear bushing (1).
• Use the special tools (T9) and (T28).

34
 Installing the hub wear bushing

• 1. Install the hub wear bushing.

• Make sure that the grooves on the bushing are aligned with the grooves
on the rock drill body.
• Use a hydraulic press and a suitable punch.

• Installing the rotation bushing rear bearing

• 1. Install the new rotation bushing rear bearing (1) into the body cylinder.
• Use a hydraulic press and the special tools (T2) and (T6).

35
 Installing the rotation bushing front bearing

• 1. Install the rotation bushing front bearing (1) into the body cylinder.
• Use a hydraulic press and the special tool (T4).

• Preparing the percussion cartridge

• 1. Install the seals (1) and (2).
• 2. Install the piston seals (7).
• When installing the new seals, make sure they are installed in the right
direction.
• 3. Install the seals (4), (5) and (6).

36
 Preparing the percussion cartridge

• 4. Install the piston seals (10).

• When installing the new seals, make sure they are installed in the right
direction.
• 5. Install the seals (8) and (9).
• Assembling the percussion cartridge
• 1. Push the piston (2) through the rear bearing (1).
• 2. Install the distributor (3) over the piston (2).
• Make sure that the distributor is installed in the right direction.
• 3. Install the front cylinder (5) on the pilot cylinder (4).
• Use a hammer and the special tool (T10).

37
 Preparing the percussion cartridge

• 4. Install the pilot cylinder (4) and the front cylider (5) together over the
• piston (2), distributor (3), and the rear cylinder (1).
• Use a hammer and the special tool (T10).

38
 Installing the percussion cartridge

• 1. Lift and attach the rock drill body to the assembly stand table.
• Use a hoist.
• 2. Turn the assembly stand table to the vertical position.
• Use a hoist.
• 3. Install the percussion cartridge (1) to the rock drill.
• Use a hammer and the special tool (T10).

39
 Installing the rear cover

• 1. Turn the assembly stand table to the horizontal position.

• Use a hoist.
• 2. Lock the assembly stand table to the horizontal position.
• 3. Install the O-rings (4, 5, and 6) on the rear cover.
• Use grease to keep the O-rings in place.
• 4. Lubricate the bolt (1) threads with thread grease.
• 5. Put the new lockwashers (2) onto the bolts.
• 6. Attach the rear cover (3) to the rock drill with the bolts (1).
• 7. Cross-tighten the bolts (1).
 Pre-tighten 100Nm (10kpm)
 Tighten the rear cover bolts to 200Nm (20kpm)

40
 Assembling the primary gear bearings

• 1. Install the ball bearing (1) on the gear (2) shaft.

• Use a hydraulic press and the special tool (T16).
• 2. Turn the gear assembly over.
• 3. Install a shim (4) on the gear (2) shaft.
• 4. Install the spherical roller bearing (3) on the gear shaft.
• Use a hydraulic press. Use the old roller bearing (A) as a punch to guide
the bearing to its place.

41
 Installing the primary gear and bearings

• 1. Install the pin (1) into the primary gear assembly (2).

• 2. Install the special tool (T27) onto the shim, between the roller bearing
and the gear wheel.
• The special tool (T27) keeps the outer ring of the roller bearing correctly
aligned.
• 3. Start installing the primary gear assembly (2), with the special tool (T27),
into the gear housing. Stop when the outer surface of the ball bearing is
at the same level with the hydraulic motor mounting surface.
• Use a copper hammer and the special tools (T17) and (T24).

42
 Installing the primary gear and bearings

• 4. Remove the special tool (T27).

• 5. Install the primary gear assembly (2) to the bottom of the gear housing.
• Use a hammer and the special tools (T17) and (T24).

43
 Installing the hub wear bushing O-rings

• 1. Remove the rock drill from the assembly stand table (T22).
• 2. Place the rock drill temporarily on a table so that you have access to both
of the hub wear bushings.
• Support the rock drill so that it can not move unintentionally.
• 3. Clean the hub wear bushings.
• 4. Install new O-rings (1) to both hub wear bushings.
• Do not apply grease on the hub wear bushing.

44
 Installing the rotation motor

• 1. Install the seal (6) and the O-rings (3), (4), (5) and (7) to the motor flange.
• Use grease to keep the O-rings in place.
• 2. Install the rotation motor assembly (2) to the gear housing.
• 3. Install and tighten the bolts (1).
 Pre-tighten the bolts to 40 Nm (4 kpm).
 Tighten the bolts to 80 Nm (8 kpm).

45
 Installing the pressure accumulators

• 1. Remove the protective plugs (7).

• 2. Lubricate the bolt (6) threads with thread grease.
• 3. Install the gasket plates (2) and the O-rings (1) and (3) in their place on
the pressure accumulators (4).
• Use two of the bolts to position the gasket plate correctly when installing
an accumulator.
• 4. Install the accumulators (4) to the rock drill.
• Install the high pressure accumulator to the rear end of the rock drill and
the low-pressure accumulator to the front end.
• 5. Install and tighten the bolts (6).
 Pre-tighten the bolts to 100 Nm (10 kpm).
 Tighten the bolts to 200 Nm (20 kpm).

46
 Installing the flushing housing

• 1. Install the new O-ring (3) to the flushing housing (2).

• 2. Install the rotation bushing (7) and the coupling (6) into the rock drill
body.
• 3. Install the shank (5) into the flushing housing (2) (if not already installed).
• 4. Install the flushing housing (2) to the rock drill body.
• Use a new gasket plate (4).
• Adjust the position of the shank during the install, so that its inner end
goes inside the coupling.
• 5. Install and tighten the flushing housing mounting bolts (1).
 Pre-tighten the bolts to 200 Nm (20 kpm).
 Tighten the bolts to 400 Nm (40 kpm).

47
 Tightening torques

• Accumulator bolts

• RISK OF DAMAGING THE ACCUMULATOR!

• The four-bolt accumulator must be tightened by using a
crosstightening method.
• 1. Lubricate the bolt threads with grease.
• 2. Pre-tighten the bolts to 100 Nm (10 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.
• 3. Tighten the bolts to 200 Nm (20 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.

48
 Tightening torques

• Flushing housing mounting bolts

• 1. Lubricate the bolts threads with grease.

• 2. Install the bolts.
• Use new lockwashers.
• 3. Pre-tighten the bolts to 200 Nm (20 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.
• 4. Tighten the bolts to 400 Nm (40 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.

49
 Tightening torques

• Flushing housing front cover bolts

• 1. Lubricate the bolt threads with grease.

• 2. Install the bolts.
• Use new lockwashers.
• 3. Pre-tighten the bolts to 100 Nm (10 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.
• 4. Tighten the bolts to 200 Nm (20 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.

50
 Tightening torques

• Flushing line fitting flange bolts

• 1. Lubricate the bolt threads with grease.

• 2. Install the bolts.
• Use new lockwashers.
• 3. Tighten the bolts to 85 Nm (8.5 kpm).
• Use a torque wrench.

51
 Tightening torques

• Rotation motor bolts

• 1. Lubricate the bolt threads with grease.

• 2. Pre-tighten the bolts to 40 Nm (4 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.
• 3. Tighten the bolts to 80 Nm (8 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.

52
 Tightening torques

• Rotation motor flange bolts

• 1. Lubricate the bolt threads with grease.

• 2. Pre-tighten the bolts to 60 Nm (6 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.
• 3. Tighten the bolts to 120 Nm (12 kpm).
• Use a torque wrench. Use the tightening sequence A → B → C → D.

53
 Tightening torques

• Rear cover bolts

• 1. Lubricate the bolt threads with grease.

• 2. Install the bolts.
• Use new lockwashers.
• 3. Pre-tighten the bolts to 100 Nm (10 kpm).
• Use a torque wrench.
• Use the tightening sequence A → B → C → D → E → F → G → H.
• 4. Tighten the bolts to 200 Nm (20 kpm).
• Use a torque wrench.
• Use the tightening sequence A → B → C → D → E → F → G → H.

54
 Tightening torques

• Rock drill mounting bolts

• 1. Lubricate the bolt threads with grease.

• 2. Install the bolts.
• Use new lockwashers.
• 3. Pre-tighten the bolts to 200 Nm (20 kpm).
• Use a torque wrench.
• Use the tightening sequence A → B → C → D.
• 4. Tighten the bolts to 400 Nm (40 kpm).
• Use a torque wrench.
• Use the tightening sequence A → B → C → D.

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 Wear limits

56
 Special tools

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