Atlas CopcoMaintenance instructionRotation unitDHR 6H

No. 9852 2088 01b

Atlas Copco Rock Drills ABrebro, SwedenAtlas Copco Rock Drills AB, 2010, All rights reserved

Copyright 2010, Atlas Copco Rock Drills AB, SwedenAll product names in this publication are trademarks of Atlas Copco.

Any unauthorised use or copying of the contents or any part thereof is prohibited.Illustrations and photos may show equipment with optional extras.

No warrantly is made regarding specifications or otherwise.Specifications and equipment are subject to change without notice.Consult your Atlas Copco Customer Center for specific information

Atlas Copco Rock Drills ABSE-70191 rebro, Sweden

Contents

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Contents1. GENERAL .......................................................................................................... 4

1.1 Environment ........................................................................................................................ 41.2 Safety regulations................................................................................................................ 4

Important reading before starting ........................................................................................ 4

2. SERVICE INTERVAL ......................................................................................... 52.1 Before starting a new or newly overhauled rotation unit ..................................................... 62.2 After each shift when using a new or newly overhauled rotation unit.................................. 62.3 Every week.......................................................................................................................... 62.4 After every 500th percussion-hour ...................................................................................... 62.5 After every 1000th percussion-hour .................................................................................... 6

3. SPARE PART SETS........................................................................................... 7Floating head....................................................................................................................... 7

4. HOSE CONNECTIONS ...................................................................................... 84.1 Connecting the hoses.......................................................................................................... 8

5. LUBRICATION POINTS..................................................................................... 95.1 Lubricant recommendations ................................................................................................ 95.2 Lubrication points ................................................................................................................ 9

6. TIGHTENING TORQUES ................................................................................. 106.1 Tightening torque, rotation unit.......................................................................................... 106.2 Tightening torque, floating head........................................................................................ 11

7. CHANGING THE HYDRAULIC MOTOR.......................................................... 12Dismantling........................................................................................................................ 12Assembly........................................................................................................................... 12

8. CHECK ............................................................................................................. 138.1 Check wear of seals .......................................................................................................... 13

9. SLINGING, WEIGHT AND STORAGE............................................................. 149.1 Slinging.............................................................................................................................. 149.2 Rotation unit weights ......................................................................................................... 149.3 Long-term storage ............................................................................................................. 15

10. HYDRAULIC FLUID AND LUBRICANT RECOMMENDATIONS.................... 1610.1 Hydraulic fluid.................................................................................................................... 1610.2 Grease............................................................................................................................... 16

General 1

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1. GeneralThese instructions are intended as a guide for the maintenance of your rotation unit.

1.1 Environment

1.2 Safety regulationsThe Safety chapter contains important information for the prevention of accidents.

Important reading before starting

Environmental regulationsThink of the environment!Leaking hydraulic couplings and grease are hazardous to the environment.Changing oils, hydraulic hoses and various types of filter can be hazardous to the environ-ment.Always collect rest oil, oil spill, oily waste and grease rests and spill. Treat according to local regulations.Use biodegradable hydraulic fluid and lubrica-tion oil wherever possible.

Important! Do not operate or handle the rotation unit unless you have been trained to do so.

The rotation unit must only be used for the purposes for which it is designed.

Read through all instructions carefully for both rig and rotation unit. Always follow the instructions given.

Ensure that the hydraulic, water and air sys-tems are depressurised and the electrical sys-tem is de-energised prior removing the rotation unit or starting work on the system.

Make sure that the rotation unit has been maintained in accordance with the current instructions.

Important! Make sure that the safety labels are fitted, clean and fully legible.

Always use a helmet, protective safety glasses and hearing protection while drilling is in progress. In addition, observe local regula-tions.

Before moving the drill rig and rotation unit, or before starting to drill, make sure that there are no personnel in the immediate vicinity of the drill rig.

Use only Atlas Copco original parts. Any damage or malfunction caused by the use of parts other than Atlas Copco original parts will not be covered by warranty or product liability.

Never attempt to carry out maintenance while the rotation unit is in operation.

Checks and adjustments that are necessary when the rotation unit is in operation must be carried out by at least two persons. One per-son must then be present at the operating sta-tion and have a good view of the work.

To prevent injury during service and mainte-nance, all components that could possibly move or drop must be supported safely on blocks or trestles, or secured by means of adequately dimensioned slings.

Check that the hoses used are of the right quality, and that all hose connections are in good condition and properly tightened. Hoses that loosen could cause serious injury.

Make sure that the place of work is well ven-tilated.

Particular attention must be paid to all warn-ings in the manual.

Use approved lifting devices when handling the rotation unit. Avoid lifting heavy weights yourself.

Service interval 2

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2. Service intervalRead all safety regulations before starting to work on the machine.

Warning!Before starting any maintenance work, make sure that the electrical system is dead.

There is a risk of injury if these instructions are not observed!

Caution!Exercise caution when jointing drill rods and with drill bit handling. Watch your fingers!

Make sure that clothes do not come too close to rotating machine parts.

Negligence could cause serious injury.

Always use hearing protection when drilling. High noise levels damage the hearing.

Never attempt maintenance or any work in the rotation unit, connections or hoses while the hydraulic, lubrication or flushing systems are pressurised. Air or oil can spray out at high pressure and high temperature. There is a risk of serious injury to the eyes and skin.

Important!Observe great cleanliness when intervening in the rotation unit or its hydraulic circuit.

Important!Ensure bolted joints are tightened to the correct tightening torques when reconditio-ning the rotation unit.

Important!Servicing should be carried out at appropriate time intervals based on local conditions. The condition of the rock has a major affect on the amount wear and with that the need of over-haul.

Service interval 2

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2.1 Before starting a new or newly overhauled rotation unit

2.2 After each shift when using a new or newly overhauled rotation unit

2.3 Every week

2.4 After every 500th percussion-hour

2.5 After every 1000th percussion-hour

Action ChapterConnect up the hoses 4Select a suitable hydraulic oil and lubricant 10Pump grease into the gear 5

Action ChapterTighten all threaded unions 6

Action ChapterCheck the wear of the seals 8

Action ChapterRemove the floating head from the rotation unit. Transport the floating head to a su-itable workshop for overhaul

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Action ChapterRemove the rotation unit from the drill rig. Transport the rotation unit to a suitable workshop for overhaul

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Important!Always function test the rotation unit after service.

Spare part sets 3

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3. Spare part setsThese spare parts sets are available for sche-duled overhauls

Rotation unit

Floating head

Spare part set 1000 hours 4350 2584 30Spare part set 2000 hours 4350 2584 40

Spare part set 500 Hours 4350 2584 50Spare part set 1000 hours 4350 2584 60

Important!The rotation unit must always be function tested before its operation is resumed. Perform this with the rotation unit correctly fitted and connected to the rigs hydraulic system. Test run unloaded for 5 minutes and check that the spindle rotates evenly and without jarring noise.

Hose connections 4

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4. Hose connections

1. Air2. Hydraulic oil3. Drain

4.1 Connecting the hoses Clean the rotation units hose connections before undoing the protective caps.

Never remove a protective cap until the hose is ready to be connected.

Always store the rotation unit with all hose connections plugged. Use suitable protective caps, and makesure that they are clean.

CAUTION!Never attempt maintenance or any work in the rotation unit, connections or hoses while the hydraulic or lubrication systems are pressu-rised. Air or oil can spray out at high pressure and high temperature. There is a risk of serious injury to the eyes and skin.

Pressure hoses with an internal diameter of 19 mm (3/4") or greater are of the quality SAE 100 R9R (high-pressure hose with four layers of steel reinforcement). See the rotation units spare parts list. For reasons of safety, under no circumstance may these hoses be replaced with hoses of a lower quality. There is a risk of injury if these instructions are not observed!

1

2 3

1250

0405

37

Lubrication points 5

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5. Lubrication points

5.1 Lubricant recommendationsGrease: Lithium complex, mineral oil based EP-grease.NLGI 2, viscosity 300-600 cSt at 40C.Mechanically stable, intended for use in vibration applications (shell: Limona LX").Do not use other types of grease, as some of them are not miscible.

5.2 Lubrication points

NB! In the event of poor performance, due to changes in the consistency or discoloration of the grease, send the rotation unit to an authorised workshop for a complete overhaul and grease change.

Lubrication and check points No. Of pump strokes

Interval with 12 hr work/day Interval with 24 hr work/day

A. Cover - Bearings and gears 4-5 Every 2 weeks 1 x per weekB. Cover - V-ring 4-5 Every 4th month 1 x per alternate monthC. Gear housing - Bearings and gears

4-5 Every 4th month 1 x per alternate month

E. Gear housing - Bearings 4-5 Every 4th month 1 x per alternate monthF. End plate - Bearings 4-5 Every 2 months 1 x per monthG. End plate - Seals 4-5 Every 4th month 1 x per alternate monthH. Adapter housing / Scraper until grease

leaks outEvery 2 months 1 x per month

I. Adapter housing 4-5 Every 2 months 1 x per monthK. Adapter housing 4-5 Every 2 months 1 x per month

H IK

A BC E

G F

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5 31

E

Tightening torques 6

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6. Tightening torques

6.1 Tightening torque, rotation unit

Ref. No. Check point/Procedure Threaded unions

Tightening torques

Nm Kpm Ibf.ft Quantity

1 Air connection 79 8 58 42 Cover - Gear housing 171 17 126 83 Cover - Gear housing 171 17 126 84 Rotation unit - Cradle 350-400 35-40 258-295 85 Hydraulic motor - Cover 79 8 58 86 Guards bolt 47 5 35 47 Lifting eye 97 10 72 1

1

23

4

5 67

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019

5 30

Tightening torques 6

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6.2 Tightening torque, floating head

*NB! Add oil under the head of the bolt and on the nuts threads. Oil must not enter between the flange plane.

Ref. No. Check point Nm Quantity

7 Adapter house screw 171* 128 Guards bolt (hexagon head) 47 4

1250

017

9 91

78

Changing the hydraulic motor 7

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7. Changing the hydraulic motor

Dismantling Dismantle the hydraulic hoses (1 and 5).

Undo the bolts (2) and remove the hydraulic motor (3).

Assembly Lubricate the hydraulic motor splines with grease.

Fit the hydraulic motor (3) to the gear housing (4)

Tighten the bolts (2) to tightening torque 79 Nm.

Connect the hydraulic hoses (1 and 5). Check that the correct direction of rotation is obtained.

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023

7 961

2

3 4

5

Check 8

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8. Check

8.1 Check wear of seals Feel with your hand over the plug (1). If air is escaping then the seal (16) and the seals (52) (see spare

parts catalogue) must be replaced.

Remove the plugs (2). If grease or oil emerges then the seals (1) (see spare parts catalogue) must bereplaced.

Send the rotation unit in for service if air is leaking or if grease or oil is found.

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023

6 51

1

2

Slinging, weight and storage 9

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9. Slinging, weight and storage9.1 Slinging

Make sure that the rotation unit is safely slung for lifting. Make sure that the rock drill is securely anchored for transportation.

9.2 Rotation unit weights

Caution!Lifting devices and straps must be approved for lifting at least 500 kg.

Incorrect lifting devices could cause the rota-tion unit to start moving or fall down.

Incorrect operation could cause crushing damage.

DHR 6H (Fixed) 180 kgDHR 6H (Floating) 243 kg

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Slinging, weight and storage 9

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9.3 Long-term storage

If the rotation unit is not going to be used for a long time, the following precautions should be taken.

Check that all connections are fitted with suitable protective caps. Clean the rotation unit carefully. Use degreasing agent and rinse with water. Lubricate the parts Store the rock drill in a dry place.

1250

023

7 95

Hydraulic fluid and lubricant recommendations 10

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10. Hydraulic fluid and lubricant recommendations10.1 Hydraulic fluid

A good hydraulic fluid provides superior protection against wear, rust and oxidisation as well as good anti-foaming and air and water separation properties.

In order to ensure a lowest level on these properties the mineral oil based and synthetic (polyalphao-lefin) hydraulic fluids must conform to the standard ISO 11158 HM/HV or DIN 51524 HLP/HVLP.

Environmentally friendly hydraulic fluids must fulfil ISO 15380It is essential to choose a hydraulic fluid of a suitable viscosity for the operating temperature of the rota-

tion unit. Select a viscosity grade (VG) and viscosity index (VI) as specified in the following table. A high viscosity index reduces the effect of temperature on the hydraulic fluid.

The hydraulic fluid must be filtered to a purity of 20/18/15 in accordance to ISO 4406.The viscosity will change during the period that the hydraulic fluid is used. In general viscosity will drop

with increased operating hours. To ensure that the viscosity of the fluid does not drop to a critical level before the recommended service interval, a hydraulic fluid of sufficient stability must be used. The viscosity in cSt of suitable hydraulic fluids shall drop a maximum of 25% when tested for shear stability in accordance with DIN 51350-6 at 100C.

The hydraulic fluid must be changed at regular intervals. Factors influencing the interval between changes: The viscous stability of the hydraulic fluid as specified above. The hydraulic fluid must be changed before

the viscosity drops to a critical level. Contamination with water. If the hydraulic fluid becomes cloudy and light grey, the water content has

become such that the hydraulic fluid must be changed. Deterioration of properties such as oxidation inhibition and anti-foaming.

10.2 Grease NB! Because of the operating temperature in the rock drill gear housing, always use a high-temperature

grease with lithium complex soap based on a synthetic base fluid (polyalphaolefin/synthetic ester) with additives that protect against oxidation, corrosion and wear at high loads and with EP additive.

Normal operating temp. CViscosity 25-50 cSt

Min start temp. C(Viscosity min. 1000 cSt)

Max temp. C Viscosity grade VG(ISO 3448) Viscosity index VI

+50 to +70 +5 80 ISO VG 100 Min. 100+45 to +60 -5 75 ISO VG 68 Min. 100+35 to +50 -10 65 ISO VG 46 Min. 100+25 to +40 -15 55 ISO VG 32 Min. 100+10 to +25 -25 35 ISO VG 15 Min. 100

NLGI number Drop point Base oil viscosity Operating Temperature

2 285 C 560 cSt at 40 C -25 to +150 C

ENVIRONMENT!Dispose of surplus and/or consumed hydraulic fluid/oil and lubricant in an environmentally-friendly manner as prescribed by the authorities.

Hydraulic fluid and lubricant recommendations 10

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Always use Atlas Copco original parts. Any damage or malfunction caused by the use of unapproved spare parts is not covered by warranty and product safety undertakings.This publication only applies to the products described.When ordering spare parts, please specify part number (not reference number) as well as quantity.