Atlas Copco

Maintenance instruction
Rotation unit
DHR 6H

Atlas Copco Rock Drills AB

Örebro, 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 Örebro, Sweden
 Contents

Contents
1. GENERAL .......................................................................................................... 4
1.1 Environment ........................................................................................................................ 4
1.2 Safety regulations................................................................................................................ 4
Important reading before starting ........................................................................................ 4

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

2.1 Before starting a new or newly overhauled rotation unit ..................................................... 6
2.2 After each shift when using a new or newly overhauled rotation unit.................................. 6
2.3 Every week.......................................................................................................................... 6
2.4 After every 500th percussion-hour ...................................................................................... 6
2.5 After every 1000th percussion-hour .................................................................................... 6

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

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

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

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

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

5.1 Lubricant recommendations ................................................................................................ 9
5.2 Lubrication points ................................................................................................................ 9

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

6.1 Tightening torque, rotation unit.......................................................................................... 10
6.2 Tightening torque, floating head........................................................................................ 11

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

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

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

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

9.1 Slinging.............................................................................................................................. 14
9.2 Rotation unit weights ......................................................................................................... 14
9.3 Long-term storage ............................................................................................................. 15

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

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

3
General 1
1. General
These instructions are intended as a guide for the
maintenance of your rotation unit.
1.1 Environment
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 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.
1.2 Safety regulations
The Safety chapter contains important information
for the prevention of accidents.
Important reading before starting
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.
4
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

2. Service interval
Read 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!
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.

Caution!
Exercise caution when jointing drill rods and Important!
with drill bit handling. Watch your fingers!
Servicing should be carried out at appropriate
Make sure that clothes do not come too close time intervals based on local conditions. The
to rotating machine parts. condition of the rock has a major affect on the
amount wear and with that the need of over-
Negligence could cause serious injury.
haul.
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.

5
Service interval 2

2.1 Before starting a new or newly

overhauled rotation unit

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

2.2 After each shift when using a new

or newly overhauled rotation unit

Action Chapter
Tighten all threaded unions 6

2.3 Every week

Action Chapter
Check the wear of the seals 8

2.4 After every 500th percussion-hour

Action Chapter
Remove the floating head from the rotation unit. Transport the floating head to a su- 9
itable workshop for overhaul

2.5 After every 1000th percussion-

hour

Action Chapter
Remove the rotation unit from the drill rig. Transport the rotation unit to a suitable 9
workshop for overhaul

Important!
Always function test the rotation unit after service.

6
 Spare part sets 3

3. Spare part sets

These spare parts sets are available for sche-
duled overhauls

Rotation unit

Spare part set 1000 hours 4350 2584 30

Spare part set 2000 hours 4350 2584 40

Floating head

Spare part set 500 Hours 4350 2584 50

Spare 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 rig’s hydraulic system. Test run unloaded for 5 minutes
and check that the spindle rotates evenly and without jarring noise.

7
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 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 unit’s
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!

1250 0405 37

1
2
3

1. Air
2. Hydraulic oil
3. Drain

4.1 Connecting the hoses

• Clean the rotation unit’s 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.

8
 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 40ºC.
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.

G F

E
1250 0195 31

E
C
A B

K
H I

5.2 Lubrication points

Lubrication and check points No. Of pump Interval with 12 hr work/day Interval with 24 hr work/day
strokes
A. Cover - Bearings and gears 4-5 Every 2 weeks 1 x per week
B. Cover - V-ring 4-5 Every 4th month 1 x per alternate month
C. Gear housing - Bearings 4-5 Every 4th month 1 x per alternate month
and gears
E. Gear housing - Bearings 4-5 Every 4th month 1 x per alternate month
F. End plate - Bearings 4-5 Every 2 months 1 x per month
G. End plate - Seals 4-5 Every 4th month 1 x per alternate month
H. Adapter housing / Scraper until grease Every 2 months 1 x per month
leaks out
I. Adapter housing 4-5 Every 2 months 1 x per month
K. Adapter housing 4-5 Every 2 months 1 x per month

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.

9
Tightening torques 6

6. Tightening torques

5 7 6
1

2
3
4
1250 0195 30

6.1 Tightening torque, rotation unit

Ref. No. Check point/Procedure Tightening torques

Threaded unions
Nm Kpm Ibf.ft Quantity

1 Air connection 79 8 58 4
2 Cover - Gear housing 171 17 126 8
3 Cover - Gear housing 171 17 126 8
4 Rotation unit - Cradle 350-400 35-40 258-295 8
5 Hydraulic motor - Cover 79 8 58 8
6 Guard’s bolt 47 5 35 4
7 Lifting eye 97 10 72 1

10
 Tightening torques 6

1250 0179 91

8 7

6.2 Tightening torque, floating head

Ref. No. Check point Nm Quantity

7 Adapter house screw 171* 12
8 Guard’s bolt (hexagon head) 47 4

*NB! Add oil under the head of the bolt and on the nut’s 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

9.1 Slinging

1250 0237 94

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 rota-

tion 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

9.3 Long-term storage

1250 0237 95
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 (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 15380
It 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.

Normal operating
Min start temp. ºC Viscosity grade VG
temp. ºC Max temp. ºC Viscosity index VI
(Viscosity min. 1000 cSt) (ISO 3448)
Viscosity 25-50 cSt
+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

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 100ºC.

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.

Operating
NLGI number Drop point Base oil viscosity
Temperature
2 285 ºC 560 cSt at 40 ºC -25 to +150 ºC

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.