9853 1287 01d Overhaul Instructions DHR6 H Ver. B PDF

Hydraulic Rotation Unit
DHR 6H Ver. B
Overhaul
Original Instructions
2018-05-03 | No: 9853 1287 01d. 6741372555.1.6741964811 en-US
Hydraulic Rotation Unit DHR 6H Ver. B Table of Contents
Table of Contents
1 Introduction ........................................................................................................... 5
1.1 Safety first................................................................................................................................... 5
1.2 The Purpose of This Publication .............................................................................................. 5
1.3 Target Group .............................................................................................................................. 6
1.4 Feedback and Contact Information .......................................................................................... 6
2 General Information .............................................................................................. 7

2.1 Component Replacement.......................................................................................................... 7
2.2 Manufacturing Number.............................................................................................................. 7
2.3 Cleaning ...................................................................................................................................... 8
2.3.1 Safety Precautions Before Cleaning......................................................................................... 8
2.3.2 Cleaning ................................................................................................................................... 8
2.3.3 Hydraulic Hoses ....................................................................................................................... 8
2.4 Hydraulic Components.............................................................................................................. 9
2.4.1 General..................................................................................................................................... 9
2.4.2 Hydraulic Workshops................................................................................................................ 9
2.4.3 Hydraulic Hose Replacement ................................................................................................. 10
2.5 Welding ..................................................................................................................................... 10
2.6 Long Period of Storage ........................................................................................................... 10
2.7 After Long Period of Storage .................................................................................................. 10
3 Lifting Rotation Unit............................................................................................ 11
4 Tools..................................................................................................................... 13
4.1 Standard Tools ......................................................................................................................... 13
4.2 Special Tools ............................................................................................................................ 15
5 Torques ................................................................................................................ 17

5.1 Tightening Torques.................................................................................................................. 17
6 Main Parts ............................................................................................................ 19
7 Disassembling Main Components..................................................................... 21

7.1 General Rotation Unit Condition ............................................................................................ 21
7.2 Disassembling Fixed Adapter................................................................................................. 21
7.3 Disassembling Floating Adapter ............................................................................................ 22
7.4 Removing Hydraulic Motor and Seals.................................................................................... 25
7.5 Disassembling Air Connection and Seals ............................................................................. 26
7.6 Disassembling Gear Housing ................................................................................................. 28
7.7 Disassembling Spindle............................................................................................................ 29
8 Inspecting and Replacing Parts......................................................................... 35
9 Assembling Main Components ......................................................................... 37

9.1 General Condition Assembling............................................................................................... 37
9.2 Assembling Spindle Bearings ................................................................................................ 37
9.3 Assembling Spindle................................................................................................................. 38
9.4 Preloading Bearings with Disc Spring ................................................................................... 39
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Hydraulic Rotation Unit DHR 6H Ver. B Table of Contents
9.5 Preloading Bearings with Torque Wrench............................................................................. 41

9.6 Assembling Gear...................................................................................................................... 44
9.7 Assembling Clamping Sleeve ................................................................................................. 45
9.8 Assembling Gear Housing ...................................................................................................... 46
9.9 Assembling Gear Housing Cover ........................................................................................... 48
9.10 Assembling Air Connection and Seals .................................................................................. 49
9.11 Installing Hydraulic Motor and Seals ..................................................................................... 51
9.12 Assembling Fixed Adapter...................................................................................................... 53
9.13 Assembling Floating Adapter ................................................................................................. 54
10 Function and Condition Test Hydraulic Motor ................................................. 59

10.1 Testing Hydraulic Motor .......................................................................................................... 59
10.2 Performing Belle Test Hydraulic Motor.................................................................................. 60
10.3 Performing Half Belle Test ...................................................................................................... 60
11 Lubricating........................................................................................................... 63
11.1 Hydraulic and Lubricant Recommendations......................................................................... 63
11.1.1 Hydraulic Fluid........................................................................................................................ 63
11.1.2 Pneumatic Tool Oil ................................................................................................................. 64
11.1.3 Grease.................................................................................................................................... 65
11.2 Lubricating the Rotation Unit.................................................................................................. 65
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Hydraulic Rotation Unit DHR 6H Ver. B 1 Introduction
1 Introduction
1.1 Safety first
WARNING
Serious injury
Risk of personal injury!
u Never operate the Rotation Unit in any explosive environment.
u Always read the machine Safety Manual before start maintenance work on the Rotation
Unit.
u Always observe local regulations.
u Always carry out a documented risk analysis and take the necessary precautions be-
fore maintenance work.
u Only use clean, calibrated tools in good condition.
u Only use approved handling and working equipment in good condition.
u Always use personal protective equipment.
u During maintenance work, the equipment should be shut down, in service mode, and
the main switch turned off and locked.
u Attach WORK IN PROGRESS signs according to local regulations, or at least at the
main switch and operator's station.
WARNING
Serious injury or death
Serious danger when working on the hydraulic system!
u Ensure that the air, water and hydraulic system is depressurised before starting work.
u Adjacent moving units should always be anchored before working on a system part.
u Always stop work if there is an unforeseen or suspected risk.
1.2 The Purpose of This Publication

The objective of these instructions is to detect and rectify faults at an early stage so that
breakdowns, costly secondary damage and accidents can be prevented. Regular mainte-
nance is a precondition for planning necessary interruptions in operation such as recondi-
tioning and repairs. This allows work to be carried out when it's most suitable with regard to
production instead of causing complete breakdown.
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Hydraulic Rotation Unit DHR 6H Ver. B 1 Introduction
1.3 Target Group
! NOTE: This instruction is an example of workflow during maintenance.
The maintenance instructions are intended for use by maintenance and service personnel.
Persons working to these instructions must have completed relevant Epiroc training for the
Rotation Unit.
1.4 Feedback and Contact Information

Epiroc works actively to develop and continuously improve its products and associated
documentation. Provide your feedback on products and documentation by contacting your
local supplier at https://www.epiroc.com, under "Contact us."
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Hydraulic Rotation Unit DHR 6H Ver. B 2 General Information
2 General Information
2.1 Component Replacement

Use original Epiroc Spare Parts to guarantee the safety and reliability of the Rotation Units
function and design.
2.2 Manufacturing Number

All Rotation Units are given a manufacturing number depending on place of Manufacture,
Year, Family, and Version. The manufacturing number is stamped on and the location on
the Rotation Units varies, depending on the model.
1. Factory code for manufactured unit:

AVO = Epiroc Rock Drills AB
2. Year that the product was produced.
3. Family letter that identifies the number series:
D = Hydraulic Rock Drills
P = Pneumatic Rock Drills
T = Rotation Units
4. Serial number in the family group.
5. Version letter for the product, shows which Manual and Spare part list that is relevant.
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2.3 Cleaning
2.3.1 Safety Precautions Before Cleaning
WARNING
Serious Injury
Risk of personal injury
u Always read general safety regulations before starting maintenance work. Refer to
Safety manual.
u Always turn off the equipment and the main switch before cleaning and maintenance
work is carried out. Set up WORK IN PROGRESS warning signs at the main switch
and control positions.
u Be aware of the units kinetic energy due to accumulated hydraulic pressure. Relieve
pressure in hydraulic, water, and compressed air systems and always secure moving
units.
2.3.2 Cleaning
First read: Safety Precautions Before Cleaning [} 8]
1. Clean the Rotation Unit frequently from rock fragments, drill cuttings and accumula-
tions of dust.
2. Clear away fragments of rock and other objects from air, water and hydraulic hoses
and cables frequently to avoid the risk of chafing on sharp edges.
3. Rinse the Rotation Unit with water after every work shift. Use only rinsing pressure
and avoid spraying directly at seals. Wipe away any accumulations of water.
2.3.3 Hydraulic Hoses
WARNING
Serious Injury
Risk of abrasions and crushing injuries.
u Always change damaged hoses and couplings.
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• Wet areas around hoses and connections is a sign for leaks that can cause spurting oil
or burst hoses if the leak worsens.
• The hose casing must be intact without any swelling (sign of inner hose or cord break-
age).
• Couplings must not have indentations or cracks and must make a secure connection.
Retighten or feel the coupling connection manually if a leak is suspected.
• Check that all hose attachments and clamps are intact. Loose attachments means that
hoses are damaged or get jammed during angle adjustment or when lowering the ma-
chine.
• Replace or rectify in the event of any faults.
2.4 Hydraulic Components
2.4.1 General
The hydraulic system is sensitive to contamination. The environment where the machine is
normally used is generally an unsuitable place for repairing hydraulic components. Inter-
vention in hydraulic systems in workplaces must be limited. Components must be repaired
in an adapted environment, refer to Hydraulic Workshops.
Observe the following points to avoid breakdowns and interruptions in operation due to
fouled hydraulic oil:
• Keep the machine clean. Hose it down at regular intervals using a degreasing additive.
• Before opening any connection, clean the area around it.
• Use clean tools and work with clean hands.
• Always plug hydraulic connections immediately after they have been detached. Use
clean protective plugs.
• Hydraulic components like hoses, valves, engines must always be stored with suitable
protective plugs fitted in place.
2.4.2 Hydraulic Workshops

Workshops that are used for the repair of hydraulic components must:
• Be separate from activities which generate dust and particles, such as welding, grind-
ing, the transportation of machines.
• Have own suitable washing equipment required for repairing the components.
• Use only tools from a hydraulic workshop consisting of standard and special tools.
• Have a ventilation system that does not admit dust into the premises.
• Use trained mechanics.
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2.4.3 Hydraulic Hose Replacement

Load, vibration, and other mechanical stresses place high demands on hydraulic hoses.
When replacing hydraulic hoses, check that they are replaced with hydraulic hoses:
• With the correct crimped couplings
• Of the correct quality class
• Of the correct dimensions
All pressurized hoses have pressed couplings and can therefore be purchased ready made
from Epiroc. Grades and dimensions of hoses are specified in the spare part catalog for
the machine in question. Also make sure that hose couplings are clean, not damaged and
properly tightened.
2.5 Welding
• All welding on the Rotation Unit is forbidden.
2.6 Long Period of Storage

Action must be taken to protect the equipment from corrosion and storage damage if stor-
age expected to last longer than three months.
• Wash the equipment and thoroughly wipe it dry. Use compressed air to blow any col-
lections of water out of cavities and pockets.
• Store equipment on site with regulated temperature and ventilation. Recommended
storage environments maintain a temperature of 10-20 ºC and max 20–50% humidity.
• Apply corrosive protection compound to machined surfaces.
• Apply touch up paint to any scratches and damage on painted areas.
• Cover with plastic.
• Clean old grease away from lubrication points to prevent coke formation. Pump new
grease into the lubrication nipples. Ensure that you use the correct grease for each
point.
• Hoses and rubber parts can be packed in airtight plastic to reduce desiccation, but en-
sure that the components are dry before packing.
2.7 After Long Period of Storage

• Change lubricant and hydraulic oil where appropriate.
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Hydraulic Rotation Unit DHR 6H Ver. B 3 Lifting Rotation Unit
3 Lifting Rotation Unit
WARNING
Risk of Lifting the Rotation Unit
Incorrect handling can cause serious crushing injury or death.
u Use extreme caution when strapping and lifting heavy objects.
u Lifting must be done through the center of gravity.
u Only use straps that are intact and designed for the load they will carry.
u Do not approach a suspended load.
1. Lifting eye must be in line with the rotation unit. Shim the lifting eye with shims
(165-167) if the lifting eye is not in line with the rotation unit.
Shimming, Lifting Eye
165 Shim 3 mm
166 Shim 2 mm
167 Shim 1.5 mm
168 Lifting eye
2. Tighten the lifting eye firmly to the rotation unit.
3. Make sure that the rotation unit is safely slung for lifting, and make sure that it is se-
curely anchored for transportation.
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Hydraulic Rotation Unit DHR 6H Ver. B 3 Lifting Rotation Unit
Rock Drill Weight
DHR6 H (Floating) 245 kg
DHR6 H (Fixed) 180 kg
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Hydraulic Rotation Unit DHR 6H Ver. B 4 Tools
4 Tools
4.1 Standard Tools
Ref. No. Tools
A1 Plastic mallet
A2 Sledge hammer
A3 U-ring wrenches, 10–36 mm
A4 Allen keys 4–10 mm
A5 Screwdriver
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Ref. No. Tools
A6 Mandrel
A7 Internal snap ring pliers
A8 Torque wrench 10–350 Nm
A9 Socket wrench set with sockets 8–36 mm
A10 Puller
A11 Hook wrench 40/135–145
A12 Vernier caliper
A13 Feeler gauge 0.03–0.10 mm with 0.01–mm inter-

vals
Feeler gauge 0.05–1.00 mm with 0.05–mm inter-
vals
Table 1: Standard tools
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4.2 Special Tools
Ref. No. Tools Part Number
1* Set: 80 disc springs, 10 screws 4350 2618 40
2* Hydraulic motor fixture (Cover 3115 3507 12

shaft lock)
3* Wrench 95 mm 4350 2618 27
4* Wrench 140 mm 4350 2618 28
5* Assembly tool, Seal, Air connec- 4350 2618 23

tion
6* Assembly tool, Rear bearing, 4350 2618 21

Sleeve, Seal
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Ref. No. Tools Part Number
7* Assembly tool, hydraulic motor 4350 1000 56

seal
8* Assembly tool, Sealing sleeve, 4350 2618 26

Gear plate screw, 2 screws
9* Assembly tool, cassette seal 4350 2651 15
10* Assembly tool, inner ring for 4350 2618 22

gear
11* Assembly tool, Taper bearing in- 4350 2618 24

ner rings
12* Lifting tool, lifting eye tools, di- 4350 2617 38

rections for use
13* Tools, Cover, Hexagonal screw, 4350 2651 10

2 screws, 2 nuts
* Tool kit (tool kits with * are in- 4350 2760 55

cluded in this tool kit)
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Hydraulic Rotation Unit DHR 6H Ver. B 5 Torques
5 Torques
5.1 Tightening Torques

Precondition p A calibrated torque wrench must be used for tightening.
1. Lubricate only under the heads of the screws (221) and the threads of the nuts (220)
with oil. Check that there is no oil under the flange surfaces, it only applies to position
(221, 220).
Ref. No. Quantity Check Point Torque Nm Lubricant
A 8 Rotation unit, 350-400 Nm oil

cradle (258-295 lbf-ft)
143 8 Cover, Gear 171 Nm (126 oil

Housing lbf-ft)
145 8 Cover, Gear 171 Nm (126 oil

Housing lbf-ft)
156 12 Air Connec- 79 Nm (58 lbf- oil

tion, Hydraulic ft)
Motors
221 12 Adapter hous- 171 Nm (126 oil

ing screw lbf-ft)
236 4 Guards 47 Nm (35 lbf- oil

ft)
Recommended Oil
Hydraulic oil or Motor oil
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Hydraulic Rotation Unit DHR 6H Ver. B 5 Torques
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Hydraulic Rotation Unit DHR 6H Ver. B 6 Main Parts
6 Main Parts
1a Floating Adapter
1b Fixed Adapter
2a Guards
2b Guards
3 Gears
4 Hydraulic Motors
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Hydraulic Rotation Unit DHR 6H Ver. B 6 Main Parts
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Hydraulic Rotation Unit DHR 6H Ver. B 7 Disassembling Main Components
7 Disassembling Main Components
7.1 General Rotation Unit Condition

• Always wash the Rotation Unit externally using grease solvent before disassembling.
• In the event of leakage, always identify the leak before removing the Rotation Unit
from the rig.
• Always exercise cleanliness during work in the Rotation Unit or its hydraulic circuit.
7.2 Disassembling Fixed Adapter

1. Undo the screws (236) and remove the guard (235).
2. Remove the plug (155) with the seal washer (154) and install a grease nipple.
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3. Apply grease under high pressure into the grease nipple.
4. Remove the adapter (201) using two wrenches (4).
5. Remove the O-rings (231, 233) and support rings (232, 234) fitted in the adapter
(201).
7.3 Disassembling Floating Adapter

1. Undo the screws (236) and remove the guard (214).
2. Undo the screws (221) and the nuts (220).
3. Lift away the adapter (204) and adapter housing (211) from the intermediate shaft
(212)
4. Remove the connection pipe (213) and the buffer (222) from the intermediate shaft
(212).
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5. Remove the seal (216) from the groove in the intermediate shaft (212).
6. Remove the adapter housing (211) from the adapter (204).
7. Remove the seal (216) from the groove in the adapter (204).
8. Remove the plug (155) with the seal washer (154) and install a grease nipple.
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9. Apply grease under high pressure into the grease nipple.
10. Remove the intermediate shaft (212) using wrenches (3 and 4).
11. Remove the O-rings (231, 233) and support rings (232, 234) on the intermediate shaft
(212).
12. Remove the wiper (219), the U-seal (217), and the guide ring (215) in the adapter
housing (211).
13. Remove the buffer (223) in the adapter housing (211). Remove the grease nipples
(224) with protective caps (225).
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7.4 Removing Hydraulic Motor and Seals

1. Mark the position of the hydraulic motors with marker pen or tape.
2. Undo the screws (156) and remove the hydraulic motor (1).
3. Remove the O-ring (195).
4. Remove the sealing sleeves with the removal tool (8), install the screw (A) in the seal-
ing sleeve. Undo the sealing sleeve by screwing down the tool screw against the
spacer (134) with a socket wrench.
A Screw, removal tool
8 Removal tool
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133 Gear
134 Spacer
136 Sealing sleeve
137 O-ring
5. Remove the O-rings (137).
6. Remove the radial seals (140) and the spacer ring (141).
7.5 Disassembling Air Connection and Seals

1. Undo the screws (156) and remove the air connection (111).
2. Remove the O-ring (183).
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3. Remove the circlip (181) using snap ring pliers.
4. Remove the radial seals (180).
6. Remove the support ring (129) and radial seal (128).
7. Remove the connection pipe (131).
8. Replace the sealing sleeve (126) if it is worn, use a puller to remove it.
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10. Remove the support ring (129) and radial seal (128).
7.6 Disassembling Gear Housing

1. Undo the screws (143) and tap loose the cover (138) using a hammer and a crowbar.
2. Remove the roller bearings (139) from the cover (138) with a hammer and a mandrel.
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3. Remove the roller bearing (135) from the cover (138).
4. Remove the grease nipple (172) and protective cap (173).
5. Remove the filter plugs (170).
7.7 Disassembling Spindle

1. Remove the gears (133) from the bearings (132).
2. Remove the spacers (134) from the gears (133).
3. Remove the bearing inner ring (121) from the spindle using the puller.
4. Remove the inner rings for the roller bearings (132, 135) using the puller.
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5. Before starting to remove the clamping unit, check that there is no torque or axial
force on the clamping unit, spindle, or gear.
a. Check that the inner sleeves (2, 4) can move axially. It is necessary to be able to
remove the sleeves. Check that the uncoupling threads are intact.
NOTE: Check that the screws that are used for uncoupling are
! ground flat and have a bevel to avoid damage to the screws and
threads during removal.
6. Remove all lock screws and move several of them to the uncoupling threads in the in-
ner sleeve (2).
7. Remove the inner sleeve (2) by cross-tightening the uncoupling screws a 1/4 turn at a
time in several rounds.
8. Move the screws that were used to remove the inner sleeve (2) to the uncoupling
threads that are in the center sleeve (3).
9. Remove the center sleeve (3) by cross-tightening the uncoupling screws a 1/4 turn at
a time in several rounds.
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10. Remove the inner sleeve (4).
11. Lift out the gear (124).
12. Remove the bearings (132) with a puller.
13. Remove the axial seal (153). Undo the screws (147) and remove the cover (146).
14. Undo the screws (145) and lift away the cover (144).
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15. Remove the seal (152) and O-ring (151).
16. Remove the shims (148-150) and the bearing outer ring (121).
17. Lift out the spindle (122) with bearing (121) using the lifting tool (12) and approved lift-
ing device.
18. Remove the rear outer bearing ring (121) from the gear housing using a hammer and
mandrel.
19. Remove the grease nipples (172) and protective caps (173) on the gear housing
(110).
20. Set the spindle (122) on the assembly tool (13).
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21. Undo the screws on the lock nut (123) using a 5mm Allen key.
22. Undo the lock nut (123) using the hook wrench and a plastic mallet.
23. Press off the bearings (121) in a press.
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Hydraulic Rotation Unit DHR 6H Ver. B 8 Inspecting and Replacing Parts
8 Inspecting and Replacing Parts
Precondition p The parts must be washed with grease solvent before the inspection.
n Inspect all parts, replace worn and defective parts.
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Hydraulic Rotation Unit DHR 6H Ver. B 8 Inspecting and Replacing Parts
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Hydraulic Rotation Unit DHR 6H Ver. B 9 Assembling Main Components
9 Assembling Main Components
9.1 General Condition Assembling
! NOTE: All parts must be well cleaned before assembly, parts must be lubricated with
clean hydraulic oil during the installation.
• O-rings must be replaced with lubricated new ones.
9.2 Assembling Spindle Bearings

1. Press the first roller bearing (121) to the spindle (122) using assembly tool (11).
2. Press on the second roller bearing (121) using assembly tool (11).
3. Check that the roller bearings bottom out against the edge of the spindle (122).
4. Grip the tool (13) in a vice.
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5. Set the spindle (122) on assembly tool (13).
6. Install the lock nut (123), tighten the lock nut using the hook wrench D155/65.
7. Apply Loctite 243 on the lock screws.
8. Tighten the lock screws to 35 Nm.
9.3 Assembling Spindle

1. Install the outer ring (121) in the gear housing using a plastic mallet and mandrel.
2. Lift the spindle (122) with bearing (121) into the gear housing (110). Use the lifting
tool (12) and approved lifting device.
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3. Install the second outer ring (121) using a plastic mallet.
9.4 Preloading Bearings with Disc Spring

1. Position various shims on the front bearing outer ring, at least 1.4 mm (dimension B).
Measure the thickness carefully.
2. Install the cover (144) without seal (152). Install tool (1), 8 x 10 disc springs and
screw.
3. Install the washers in accordance with the illustration to achieve the correct load.
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4. Tighten screws alternately until the height of the spring bars is 20 mm, the bearings
then have the correct preload.
5. Rotate the spindle at least five turns to seat the bearings. Use the tool (13) to rotate
the spindle. The spindle must hang freely in the bearing during the preload.
6. Check that the measurement (B) is large enough for the distance (A) between cover
(144) and housing (110). If not, the thickness (B) must be increased.
7. Measure the distance (A) between cover (144) and gear housing (110) with a feeler
gauge. Repeat the measuring at several places around the cover and derive an aver-
age value.
8. Remove the cover (144) and install the number of shims so that the thickness of
shims = B-A.
9. Lubricate the O-ring (151) and install the O-ring on the cover.
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10. Apply Loctite 5923 onto the contact surfaces between the cover (144) and the gear
housing
11. Turn the covers flat part against the gear housing.
12. Install the cover (144) with the screws (145). Tighten the screws alternately to 171
Nm (126 lbf-ft).
13. Install the seal (152) using the assembly tool (9).
14. Install the seal washer (154) and plug (155) into the spindle.
15. Apply Loctite 5923 on the inner edge of the cover (144) where the cover (146) are in-
stalled. See the red arrow.
16. Install the cover (146).
17. Install in the cover (146) with the screws (147).
18. Apply a small amount of grease to the cover (146) and Install the axial seal (153).
19. Rotate the spindle several turns.
9.5 Preloading Bearings with Torque Wrench

1. Position various shims on the front bearing outer ring, at least 1.4 mm (dimension B).
Measure the thickness carefully.
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2. Install the cover (144) with four screws (145) in accordance with the illustration, the
cover without seal (152).
3. Pull down the cover evenly by tightening the screws alternately a little at a time until
the cover makes contact against the gear housing. Tighten the screws alternately to
40 Nm.
4. Rotate the spindle at least five turns to seat the bearings. Use the tool (13) to rotate
the spindle. The spindle must hang freely in the bearing during the preload.
5. Measure the distance (A) between cover (144) and gear housing (110) with a feeler
gauge and note the measurement.
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6. Remove the cover (144) and install the number of shims so that the thickness of
shims = B-A.
7. Install the cover (144) with all eight screws (145) and tighten them alternately to 171
Nm.
8. Rotate the spindle at least five turns.
9. Check the tightening torque on the spindle using tool no. (13). Set the torque wrench
(II) to 20 Nm and rotate the spindle gently. Increase to 21 Nm and try again if the
spindle is fixed and the torque wrench clicks. Repeat the operation until the spindle
starts to move.
10. If the tightening torque is:
a. Between 23–32 nm, proceed to step 11.
b. Lower than 23 Nm, increase shim thickness by 0.05 mm, and restart from step
(7).
c. Higher than 32 Nm, decrease shim thickness by 0.05 mm, and start from step (7)
11. Remove the screws (145) and cover (144).
12. Lubricate the O-ring (151) and install the O-ring on the cover.
13. Apply Loctite 5923 onto the contact surfaces between the cover (144) and the gear
housing
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14. Turn the covers flat part against the gear housing.
15. Install the cover (144) with the screws (145). Tighten the screws alternately 171 Nm
(126 lbf-ft).
16. Install the seal (152) using the assembly tool (9).
17. Install the seal washer (154) and plug (155) into the spindle.
18. Apply Loctite 5923 on the inner edge of the cover (144) where the cover (146) are in-
stalled. See the red arrow.
19. Install in the cover (146) with the screws (147).
20. Apply a small amount of grease to the cover (146) and Install the axial seal (153).
21. Rotate the spindle several turns.
9.6 Assembling Gear

1. Use Loctite cleaning agent or similar to remove the oil from the outer ring of the roller
bearing (132).
2. Apply Loctite 638 to the roller bearings outer ring and use a plastic mallet and a man-
drel to install the bearings.
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3. Install the gear (124) over the spindle (122) in the gear housing.
9.7 Assembling Clamping Sleeve
New clamping units are supplied ready for installation.

When a clamping unit is reused, make sure that in addition to lined-up slits in all sleeves,
inner sleeves (2, 4) are not reversed. They are assembled correctly if there are no holes or
threads behind threaded holes in the inner sleeve (2) and no threads behind the threaded
holes in center sleeve (3). In order to have correct function of the clamping unit, the contact
areas of screws, tapers, shafts, and hub must be lightly oiled.
Use ordinary machine oil for lubrication.
NOTE: Never use molybdenum disulphide (for example, Molykote, Never-Seeze, Loc-
! tite LB 8009 or similar lubricant) when installing the clamping unit since it loses its func-
tion.
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1. Make sure that locking screws, sleeves, spindle, and gear wheel contact surfaces are
clean and that all slits are aligned.
2. Loosen all screws by minimum 2 turns and transfer at least 2 screws to push-off
threads in inner sleeve (2) and center sleeve (3) in order to disengage tapers for easy
installation of clamping unit.
3. After installation of clamping unit, relocate locking screws used for separation of
sleeves.
4. Hand tighten connection and assure that inner sleeve (2) is parallel with face of gear
wheel.
5. Torque screws in a crosswise pattern using sequence 1-11.
! NOTE: Note that the two screws adjacent to the slit should be tight-
ened one after each other to avoid possible twisting of the sleeves.
6. Use a torque wrench and set it to 87 Nm (64 lbf-ft). Torque screws in a correct se-
quence, using only 1/4 turns for several passes until 1/4 turns can no longer be
achieved on any screw.
7. Still apply over torque for 1-2 passes. This is required to compensate for a system-re-
lated relaxation of locking screws since tightening of a given screw will always relax
adjacent screws. Without overtorquing an infinite number of passes would be needed
to reach specified tightening torque.
8. Reset torque wrench to 83 Nm (61 lbf-ft) and check all locking screws. No screw
should turn at this point otherwise repeat step 6 for 1 or 2 more passes. It is not nec-
essary to re-check tightening torque after equipment has been in operation.
9.8 Assembling Gear Housing

1. Install the inner ring for the roller bearing (139) on the spindle using the assembly tool
(6), with the flange against the gear.
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2. Install the inner ring for the roller bearing (132) on the gear using the plastic mallet
with the flange against the gear.
3. Install the inner ring for the roller bearing (135) using the assembly tool (10) with the
flange against the gear.
4. Apply grease in the bearings (132).
5. Install the gears (133) in the gear housing (110).
6. Install the spacers (134) in the gears (133).
7. Fill grease through the nipple (A) until grease appears under the gear (124).
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8. Fill the gear housing with grease, also fill grease around the bearings inner rings (135,
139).
9.9 Assembling Gear Housing Cover

1. Use Loctite cleaning agent or similar to remove the oil from the roller bearings outer
ring (135).
2. Apply Loctite 638 on the outer ring and install bearings in the cover (138) using a
mandrel and plastic mallet (AA).
3. Install the grease nipple (172), protective cap (173), and the filter plugs (170).
4. Use Loctite cleaning agent or similar to remove the oil from the roller bearings outer
ring (139).
5. Apply Loctite 638 on the outer ring and install the bearing in the cover (138) using a
mandrel and plastic mallet (AA).
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6. Use Loctite cleaning agent or similar to remove the oil from the cover (138) sealing
surfaces.
7. Apply Loctite 5923 on the cover sealing surfaces and install the cover on the gear
housing with the screws (143).
8. Tighten the screws (143) to 171 Nm (126 lbf-ft).
9.10 Assembling Air Connection and Seals

Make sure that the radial seals are properly lubricated with grease to avoid wear.
1. Lubricate and install the radial seal (128) in accordance to the figure using the assem-
bly tool (5).
2. Install the support ring (129).
3. Install the circlip (130) using snap ring pliers.
4. Fill area (A) of the seal with grease.
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5. Install the sealing sleeve (126) on the spindle using the tool (6).
6. Install the connection pipe (131).
7. Install the radial seal (128) using the assembly tool (5), the support ring (129), and the
circlip (130) in the air connection (111).
! NOTE: The radial seals (128, 180) must be turned in accordance

with the figure.
8. Install the radial seals (180) using the tool (6) and the circlips (181) in the air connec-
tion (111).
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10. Install the O-ring (183), apply grease to the O-ring.
11. Install the air connection (111) with the screws (156) against the cover end piece.
13. Remove the filter plug (182) and remove the protective cap on the grease nipple
(172). Lubricate with a grease gun until grease appears in the hole for the filter plug.
14. Check that the filter plug is not clogged and reinstall the filter plug and the protection
cap for the grease nipple.
9.11 Installing Hydraulic Motor and Seals

1. Install the radial seal (140) in accordance to the figure using the assembly tool (7),
add the spacer ring (141). Install the next radial seal (140).
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2. Make sure that the radial seals are properly lubricated to avoid wear.
4. Install the O-ring (137) in the seal sleeve (136), apply grease to the O-ring.
8 Removal tool
133 Gear
134 Spacer
136 Sealing sleeve
137 O-ring
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5. Remove the spacer (134) to expose the gear (133) thread. Install the sealing sleeve
(136) on the gear.
6. Thread the tool screw (8) into the gear thread (133).
7. Pull down the sealing sleeve (136) using the wrench.
8. Undo the tool screw (8) from the gear thread (133).
9. Install the spacer (134) in the gear (133).
10. Lubricate and install the new O-ring (195) on the hydraulic motor (1).
11. Lubricate the hydraulic motor splines with grease and install the hydraulic motor (1)
with the screws (156).
13. Install the hoses. See chapter: Hose Connection.
14. Check that the correct direction of rotation is obtained.
9.12 Assembling Fixed Adapter

1. Install the support ring (232, 234) and the O-ring (231, 233) on the adapter (201).
2. Install the adapter (201) in the spindle (122).
3. Tighten the adapter (201) with two wrenches (4).
4. Install the plug (155) with the seal washer (154).
5. Install the guard (235), apply Loctite 243 on the screws (236).
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9.13 Assembling Floating Adapter

1. Install the grease nipples (224) with protective caps (225), and the buffer (223) in the
adapter housing (211).
2. Lubricate and install the guide rings (215) and U-seal (217) in the adapter housing
(211).
! NOTE: The U-seal (217) must be turned in accordance with the fig-
ure.
3. Install the seal (216) in the groove on the adapter (204), apply grease in the groove
and on the seal.
! NOTE: The seal (216) must be turned in accordance with the fig-
ure.
4. Check that the stop screw (218) is fitted in one of the holes.
5. Install the support ring (232, 234) and the O-ring (231, 233) on the intermediate shaft
(212).
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6. Install the intermediate shaft (212) in the spindle (122).
7. Tighten the intermediate shaft (212) with wrenches (3 and 4).
8. Install the plug (155) with the seal washer (154).
9. Install the seal (216) in the intermediate shaft (212), apply grease in the groove and
on the seal.
! NOTE: The seal (216) must be turned in accordance with the fig-
ure.
10. Install the connection pipe (213) in the intermediate shaft (212).
11. Install the the buffer (222) on the connection pipe (213).
12. Install the adapter (204) on the intermediate shaft (212) and lubricate the splines on
the adapter.
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13. Install the adapter housing (211) on the adapter (204) with oiled screws (221) and
nuts (220).
! NOTE: No oil or grease between the contact surfaces for the

adapter housing and intermediate shaft.
14. Tighten with the wrench and a box-end wrench to 171 Nm (126 lbf-ft).
15. Install the wiper (219) on the adapter housing (211). Apply Loctite 638 on the outside
of the wiper.
! NOTE: The wiper (219) must be turned in accordance with the fig-
ure.
16. Install the guard (214), apply Loctite 243 on the screws (236).
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Hydraulic Rotation Unit DHR 6H Ver. B 10 Function and Condition Test Hydraulic Motor
10 Function and Condition Test

Hydraulic Motor
The following test gives an approximation of the present state of the motor. The following
are required to conduct the test:
• Apparatus for hydraulic flow and pressure.
• Pressure gauge.
• Flow meter 0-15 l/min.
• Couplings and hoses to assemble the components.
• Motor fixture for the hydraulic motor.
• Oil grade HLP46 at 50 °C and viscosity approximate 35 CST.
10.1 Testing Hydraulic Motor

1. Connect the hydraulic pressure hose (P) to port (A) and the return hose (R) to port (B)
on the hydraulic motor.
2. Install the test tool (2) sealing cap with O-ring (195) without shaft lock (2a) for the mo-
tor shaft. The tool can be ordered. See chapter: Tool list for part no.
3. Allow the motor to rotate for approx. 30 seconds with a maximum flow of 10 l/min.
4. Check that rotation is constant and without any abnormal noise.
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10.2 Performing Belle Test Hydraulic Motor

For motors with external drain line only
The test indicates the general condition of the motor, including axial wear, condition of
seals, valves. Replace the motor if the size of the leak exceeds table value
1. Plug port "B" with a suitable plug.
2. Install the test tool (2) sealing cap with O-ring (195) without shaft lock (2a) for the mo-
tor shaft. The tool can be ordered. See chapter: Tools for part no.
3. Connect a flow meter to the motor drain line.
4. Make sure that the motor shaft can rotate freely.
5. Pressurize port "A" in accordance with the table, make sure that you use the correct
pressure for the current motor type.
6. Measure the flow from the drain line. Replace the motor if it exceeds the specified
value.
Motor Type Pressure Port (A) Bar Permitted Flow in Drain Line l/min
MSS 210 bar 3.5 l/min
10.3 Performing Half Belle Test

The following test indicates the condition of the gear wheel in the motor. The test can be
used for all motors.
Connect the drain line to port "B" with a T-coupling to the motor.
60 No: 6741372555.1.6741964811 en-US

1. Install the test tool (2) sealing cap with O-ring (195) and shaft lock (2b) for the motor
shaft. The tool can be ordered. See chapter: Tools for part no.
2. Connect the flow meter to port "B" on the motor.
3. Pressurize port "A" in accordance with the following table, make sure that you use the
correct pressure for the current motor type.
4. Measure the flow from port "B" (if necessary, with the drain line).
5. Replace the motor if it exceeds the specified value.
Motor Type Pressure Port (A) Permitted Flow in Drain Line l/min
MSS 80-160 140 bar 10 l/min
MSS 110 bar 10 l/min

210-315
MSS 70 bar 10 l/min

400-475
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62 No: 6741372555.1.6741964811 en-US

Hydraulic Rotation Unit DHR 6H Ver. B 11 Lubricating
11 Lubricating
11.1 Hydraulic and Lubricant Recommendations
11.1.1 Hydraulic Fluid

The hydraulic fluid of rock drill, in addition to containing decent lubrication properties,
should provide superior protection against wear, rust and oxidation, as well as good an-
tifoaming, water resistance, and air separation properties. For a hydraulic fluid, it is essen-
tial to have high shear stability, to ensure that viscosity and viscosity index remain con-
stant, even at high-pressure drops over sealing gaps and valves. The use of an appropri-
ate hydraulic fluid with proper viscosity, guarantee minimum energy losses in hydraulic
systems.
There are various hydraulic fluids to fulfil all limit values of viscosity as required for different
operating conditions and ambient temperatures. Various types of oils across these ranges,
may differ from mineral to synthetic based. Epiroc recommends the use of hydraulic fluids,
which conform to standards ISO 11158 HM, DIN 51524 HLP/HVLP and ISO 15380 (for en-
vironmentally friendly hydraulic fluids and biodegradable options).
Hydraulic fluids shall be chosen in relation to operational requirements and varying temper-
ature ranges. It is important to select a hydraulic fluid of the correct viscosity (VG), suited to
your operating temperature and environment. Viscosity is highly affected by temperature. A
high viscosity index (VI), reduces the effect of temperature on the hydraulic fluid. The fol-
lowing table can be used to choose an appropriate viscosity grade (VG) and viscosity index
(VI), based on your needs:
Normal Operat- Min. Start Temp Max. Operating Viscosity Grade Viscosity Index
ing Temp °C °C Temp °C VG VI
Viscosity 25-50 ISO 3448
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
! NOTE: In compliance with ISO 4406, the hydraulic fluid must be filtered to the purity
class of 20/18/15.
If viscosity is too low:

• The hydraulic fluid may not form a lubricating layer between surfaces, thus increasing
the risk of wear.
• The hydraulic fluid can leak past seals more easily in the rock drill, causing fluid losses
and increasing energy requirements.
If viscosity is too high:
63 No: 6741372555.1.6741964811 en-US

• Flow losses in the hydraulic lines are increased. The high flow losses amplify energy
consumption and pressure levels, and put increased strain on seals.
• The risk of cavitation increases, which leads to the risk of damage to the rock drill and
hydraulic pumps.
The hydraulic fluid must be changed at regular intervals
Oil viscosity changes 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 suffi-
cient stability must be used. In compliance with DIN 51350-6, viscosity of suitable hydraulic
fluids shall drop a maximum of 25% when tested at 100 ºC for shear stability.
Factors influencing the interval between changes are:
• 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 wa-
ter content has become such that the hydraulic fluid must be changed.
• Deterioration of properties such as oxidation inhibition and anti-foaming.
11.1.2 Pneumatic Tool Oil

Pneumatic tool oil is used for cooling and lubricating your rock drill. Depending on ambient
temperature, the oil should have the following viscosity grades if the viscosity index (VI) is
about 100:
Ambient Temperature C° Viscosity
-30 to ±0 VG 32-68
-10 to +20 VG 68-100
+10 to +50 VG 100-150
The tool oil must have an EP additive which covers the following load-bearing properties:
Referenced Standard Load-Bearing Property
ASTM D 2783 Min. 250 kg
ASTM D 4172 (40 kg) Max. 0.5 mm
The tool oil should also have the following properties:

• The oil must have good lubricating properties, intended for compressed air tools.
• The oil must have good adhesion capacity.
• The oil must have additives that prevent foam formation.
Epiroc recommends the use of Epiroc COP OIL which has been specially developed for
our hydraulic rock drills. COP OIL is an environmentally friendly, biodegradable oil, which
can be used in ambient temperatures between -25 ºC and +50 ºC. COP OIL can be or-
dered with the following part numbers:
1 Can of 4 litres 1 Can of 20 litres 24 Can of 20 litres 1 Barrel of 208 litres
3115 3125 02 3115 3125 01 3115 3126 01 3115 3127 00
64 No: 6741372555.1.6741964811 en-US

11.1.3 Grease
Considering the high operating temperature in the rotation units gear housing, always use
a high-temperature grease with lithium complex grease based on high viscous mineral oils,
containing anti-oxidants, EP- and wear preventive additives and rust inhibitors. The grease
should meet the specifications, specified in the table below:
NLGI Number Drop Point Base Oil Viscosity Operating Temp (In-
termittently)
1 285 °C 550 cSt at 40 °C -25 to +150 (200) °C
! NOTE: Molybden (Molybden disulfide) grease is harmful for seals. Molybden grease
shall be avoided.
Epiroc recommends the use of Shell Gadus S3 V550L 1, for rotation units.
Grease Temperature Biodegradable Viscosity Minimum Re-

Zone quirements
Shell Gadus S3 - - - Contact Epiroc

V550L 1
11.2 Lubricating the Rotation Unit
n Lubricate the rotation unit.
A Cover, Bearing, Seal 1-2 pump strokes
B Cover, V-ring Until grease emerges at the

seal
C Gear Housing, Bearing, and Gear housing 2-3 pump strokes

(Tapered on Spindle)
D Gear Housing, Bearing (Cylindrical on Gear) 1-2 pump strokes
E Cover, Bearing (Cylindrical on Spindle) 1-2 pump strokes
65 No: 6741372555.1.6741964811 en-US

F Air Connection, Seals Until grease emerges through

the filter plug
n Check grease amount on gears.
Adapt the amount of grease in accordance with below:
If a lot of grease emerges from the rubber valve, then reduce the amount of grease.
If no grease at all comes out, increase the amount of grease slightly.
Normally, a small amount of grease emerges, now and then.
In the event of a suspicion that there is a major shortage of grease in the

gear, then fill it in accordance with the following.
Lubricate points A, D, F with 5-10 pump strokes. Then fill into C until grease comes
out of the rubber valve.
n Lubricate floating adapter.
G Adapter Housing, Wiper, Until grease emerges at

and Seal the wiper
H Adapter Housing, Guide 1-2 pump strokes

Ring
I Adapter Housing, Splines 1-2 pump strokes
n Check floating adapter.
If too much grease emerges from the floating adapter during operation, either inside
the adapter or at the wiper, then reduce the amount of grease.
If too much grease is used in the floating adapter, it may prevent the movement of
the adapter.
If too little grease is used then it may lead to increased wear on the floating adapter.
66 No: 6741372555.1.6741964811 en-US

11 Lubricating
67 No: 6741372555.1.6741964811 en-US

2018-05-03 | No: 9853 1287 01d. 6741372555.1.6741964811
www.epiroc.com

9853 1287 01d Overhaul Instructions DHR6 H Ver. B PDF

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Hydraulic Rotation Unit

2 General Information .............................................................................................. 7

3 Lifting Rotation Unit............................................................................................ 11

5 Torques ................................................................................................................ 17

6 Main Parts ............................................................................................................ 19

7 Disassembling Main Components..................................................................... 21

8 Inspecting and Replacing Parts......................................................................... 35

9 Assembling Main Components ......................................................................... 37

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9.5 Preloading Bearings with Torque Wrench............................................................................. 41

10 Function and Condition Test Hydraulic Motor ................................................. 59

iv No: 6741372555.1.6741964811 en-US

1.1 Safety first

1.2 The Purpose of This Publication

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1.3 Target Group

! NOTE: This instruction is an example of workflow during maintenance.

1.4 Feedback and Contact Information

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2.1 Component Replacement

2.2 Manufacturing Number

1. Factory code for manufactured unit:

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2.3.1 Safety Precautions Before Cleaning

2.3.3 Hydraulic Hoses

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2.4 Hydraulic Components

2.4.2 Hydraulic Workshops

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2.4.3 Hydraulic Hose Replacement

2.6 Long Period of Storage

2.7 After Long Period of Storage

10 No: 6741372555.1.6741964811 en-US

3 Lifting Rotation Unit

Shimming, Lifting Eye

167 Shim 1.5 mm

168 Lifting eye

2. Tighten the lifting eye firmly to the rotation unit.

11 No: 6741372555.1.6741964811 en-US

Rock Drill Weight

DHR6 H (Floating) 245 kg

DHR6 H (Fixed) 180 kg

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4.1 Standard Tools

Ref. No. Tools

A3 U-ring wrenches, 10–36 mm

A4 Allen keys 4–10 mm

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Ref. No. Tools

A7 Internal snap ring pliers

A8 Torque wrench 10–350 Nm

A9 Socket wrench set with sockets 8–36 mm

A11 Hook wrench 40/135–145

A12 Vernier caliper

A13 Feeler gauge 0.03–0.10 mm with 0.01–mm inter-

Table 1: Standard tools

14 No: 6741372555.1.6741964811 en-US

4.2 Special Tools

Ref. No. Tools Part Number

1* Set: 80 disc springs, 10 screws 4350 2618 40

2* Hydraulic motor fixture (Cover 3115 3507 12

3* Wrench 95 mm 4350 2618 27