Atlas Copco

Maintenance instruction
Rotation unit
DHR 6H

Atlas Copco Rock Drills AB

rebro, Sweden
Atlas Copco Rock Drills AB, 2010, All rights reserved

No. 9852 2088 01b

 Copyright 2010, Atlas Copco Rock Drills AB, Sweden

All 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 AB

SE-70191 rebro, Sweden

Contents

Contents
1.

GENERAL .......................................................................................................... 4
1.1
1.2

2.

SERVICE INTERVAL ......................................................................................... 5

2.1
2.2
2.3
2.4
2.5

3.

Environment ........................................................................................................................ 4
Safety regulations................................................................................................................ 4
Important reading before starting ........................................................................................ 4

Before starting a new or newly overhauled rotation unit ..................................................... 6

After each shift when using a new or newly overhauled rotation unit.................................. 6
Every week.......................................................................................................................... 6
After every 500th percussion-hour ...................................................................................... 6
After every 1000th percussion-hour .................................................................................... 6

SPARE PART SETS........................................................................................... 7

Floating head....................................................................................................................... 7

4.

HOSE CONNECTIONS ...................................................................................... 8

4.1

5.

LUBRICATION POINTS ..................................................................................... 9

5.1
5.2

6.

Lubricant recommendations ................................................................................................ 9

Lubrication points ................................................................................................................ 9

TIGHTENING TORQUES ................................................................................. 10

6.1
6.2

7.

Connecting the hoses.......................................................................................................... 8

Tightening torque, rotation unit.......................................................................................... 10

Tightening torque, floating head........................................................................................ 11

CHANGING THE HYDRAULIC MOTOR.......................................................... 12

Dismantling........................................................................................................................ 12
Assembly........................................................................................................................... 12

8.

CHECK ............................................................................................................. 13
8.1

9.

Check wear of seals .......................................................................................................... 13

SLINGING, WEIGHT AND STORAGE............................................................. 14

9.1
9.2
9.3

Slinging.............................................................................................................................. 14
Rotation unit weights ......................................................................................................... 14
Long-term storage ............................................................................................................. 15

10. HYDRAULIC FLUID AND LUBRICANT RECOMMENDATIONS .................... 16

10.1 Hydraulic fluid.................................................................................................................... 16
10.2 Grease............................................................................................................................... 16

General 1

1. General

Important!

These instructions are intended as a guide for the

maintenance of your rotation unit.

Make sure that the safety labels are fitted,

clean and fully legible.

1.1 Environment

Always use a helmet, protective safety

glasses and hearing protection while drilling is
in progress. In addition, observe local regulations.

Environmental regulations
Think 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 environment.
Always collect rest oil, oil spill, oily waste and
grease rests and spill. Treat according to local
regulations.
Use biodegradable hydraulic fluid and lubrication oil wherever possible.

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 person must then be present at the operating station and have a good view of the work.

1.2 Safety regulations

The Safety chapter contains important information
for the prevention of accidents.

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

Important reading before starting

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

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.

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.

Make sure that the place of work is well ventilated.

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

Particular attention must be paid to all warnings in the manual.

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

Make sure that the rotation unit has been

maintained in accordance with the current
instructions.

Service interval 2

2. Service interval
Important!

Read all safety regulations before starting to work

on the machine.

Observe great cleanliness when intervening in

the rotation unit or its hydraulic circuit.

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

Important!

There is a risk of injury if these instructions are

not observed!

Ensure bolted joints are tightened to the

correct tightening torques when reconditioning the rotation unit.

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

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 overhaul.

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.

Service interval 2

2.1 Before starting a new or newly

overhauled rotation unit
Action

Chapter

Connect up the hoses

Select a suitable hydraulic oil and lubricant
Pump grease into the gear

4
10
5

2.2 After each shift when using a new

or newly overhauled rotation unit
Action

Chapter

Tighten all threaded unions

2.3 Every week

Action

Chapter

Check the wear of the seals

2.4 After every 500th percussion-hour

Action

Chapter

Remove the floating head from the rotation unit. Transport the floating head to a suitable workshop for overhaul

2.5 After every 1000th percussionhour

Action

Chapter

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

Important!
Always function test the rotation unit after service.

Spare part sets 3

3. Spare part sets

These spare parts sets are available for scheduled overhauls
Rotation unit
Spare part set
Spare part set

1000 hours
2000 hours

4350 2584 30
4350 2584 40

500 Hours
1000 hours

4350 2584 50
4350 2584 60

Floating head
Spare part set
Spare part set

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

4. Hose connections
CAUTION!
Never attempt maintenance or any work in the
rotation unit, connections or hoses while the
hydraulic or lubrication 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.

1250 0405 37

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

1. Air
2. Hydraulic oil
3. 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 make
sure that they are clean.

Lubrication points 5

5. Lubrication points
5.1 Lubricant recommendations
Grease: 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.

1250 0195 31

A B

H I

5.2 Lubrication points

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

B. Cover - V-ring
C. Gear housing - Bearings
and gears
E. Gear housing - Bearings
F. End plate - Bearings
G. End plate - Seals
H. Adapter housing / Scraper

4-5
4-5
4-5

Every 2 weeks
Every 4th month
Every 4th month

1 x per week
1 x per alternate month
1 x per alternate month

4-5
4-5
4-5
until grease
leaks out
4-5
4-5

Every 4th month

Every 2 months
Every 4th month
Every 2 months

1 x per alternate month

1 x per month
1 x per alternate month
1 x per month

Every 2 months
Every 2 months

1 x per month
1 x per month

I. Adapter housing
K. Adapter housing

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.

Tightening torques 6

6. Tightening torques
1

1250 0195 30

6.1 Tightening torque, rotation unit

Ref. No.

Check point/Procedure
Threaded unions

Tightening torques
Nm

Kpm

Ibf.ft

Quantity

Air connection

79

58

Cover - Gear housing

171

17

126

Cover - Gear housing

171

17

126

Rotation unit - Cradle

350-400

35-40

258-295

Hydraulic motor - Cover

79

58

Guards bolt

47

35

Lifting eye

97

10

72

10

1250 0179 91

Tightening torques 6

6.2 Tightening torque, floating head

Ref. No.

Check point

Nm

Quantity

Adapter house screw

171*

12

Guards bolt (hexagon head)

47

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

11

Changing the hydraulic motor 7

7. Changing the hydraulic motor

1250 0237 96

1
2

3 4

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.

12

Check 8

8. Check

1250 0236 51

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

13

Slinging, weight and storage 9

9. Slinging, weight and storage

1250 0237 94

9.1 Slinging

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

Caution!
Lifting devices and straps must be approved
for lifting at least 500 kg.
Incorrect lifting devices could cause the rotation unit to start moving or fall down.
Incorrect operation could cause crushing
damage.

9.2 Rotation unit weights

DHR 6H (Fixed)

180 kg

DHR 6H (Floating)

243 kg

14

Slinging, weight and storage 9

1250 0237 95

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.

15

Hydraulic fluid and lubricant recommendations 10

10. Hydraulic fluid and lubricant recommendations

10.1 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 (polyalphaolefin) hydraulic fluids must conform to the standard ISO 11158 HM/HV or DIN 51524 HLP/HVLP.
Environmentally friendly hydraulic fluids must fulfil ISO 15380
It is essential to choose a hydraulic fluid of a suitable viscosity for the operating temperature of the rotation 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.
Normal operating
temp. C
Viscosity 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
+45 to +60
+35 to +50
+25 to +40
+10 to +25

+5
-5
-10
-15
-25

80
75
65
55
35

ISO VG 100
ISO VG 68
ISO VG 46
ISO VG 32
ISO VG 15

Min. 100
Min. 100
Min. 100
Min. 100
Min. 100

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.
NLGI number

Drop point

Base oil viscosity

Operating
Temperature

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.

16

Hydraulic fluid and lubricant recommendations 10

17

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.