Hydraulic Rotation Unit

DHR 6H Ver. B
Maintenance

Original Instructions
2018-05-03 | No: 9852 3277 01d. 6740581259.1 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 Maintenance Tables ............................................................................................  11

3.1 New or Overhauled Rotation Unit........................................................................................... 11
3.2 Calender Interval ...................................................................................................................... 11
3.3 Percussion Hours .................................................................................................................... 11

4 Lifting Rotation Unit............................................................................................  13

5 Lubricating...........................................................................................................  15
5.1 Hydraulic and Lubricant Recommendations......................................................................... 15
5.1.1 Hydraulic Fluid........................................................................................................................  15
5.1.2 Pneumatic Tool Oil .................................................................................................................  16
5.1.3 Grease....................................................................................................................................  17
5.2 Lubricating the Rotation Unit.................................................................................................. 17

6 Tools.....................................................................................................................  19
6.1 Standard Tools ......................................................................................................................... 19
6.2 Special Tools ............................................................................................................................ 21

7 Hose Connections...............................................................................................  23

7.1 Connect Hoses ......................................................................................................................... 23

8 Torques ................................................................................................................  25

8.1 Tighten All Threaded Unions .................................................................................................. 25

9 Check Wear on Seals..........................................................................................  27

10 Replacing Hydraulic Motor.................................................................................  29

10.1 Removing Hydraulic Motor ..................................................................................................... 29
10.2 Installing Hydraulic Motor ....................................................................................................... 29

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Hydraulic Rotation Unit DHR 6H Ver. B Table of Contents

11 Replacing Seals...................................................................................................  31

11.1 Disassembling Air Connection and Seals ............................................................................. 31
11.2 Assembling Air Connection and Seals .................................................................................. 32
11.3 Removing Hydraulic Motor and Seals.................................................................................... 35
11.4 Installing Hydraulic Motor and Seals ..................................................................................... 36

12 Fixed Adapter ......................................................................................................  39

12.1 Disassembling Fixed Adapter................................................................................................. 39
12.2 Assembling Fixed Adapter...................................................................................................... 40

13 Floating Adapter..................................................................................................  41

13.1 Replacing Floating Adapter .................................................................................................... 41
13.1.1 Removing Floating Adapter ....................................................................................................  41
13.1.2 Installing Floating Adapter ......................................................................................................  42
13.2 Replacing Floating Adapter Seals .......................................................................................... 42
13.2.1 Disassembling Floating Adapter.............................................................................................  42
13.2.2 Assembling Floating Adapter..................................................................................................  45

14 Function and Condition Test Hydraulic Motor .................................................  49

14.1 Testing Hydraulic Motor .......................................................................................................... 49
14.2 Performing Belle Test Hydraulic Motor.................................................................................. 50
14.3 Performing Half Belle Test ...................................................................................................... 50

15 Rotation Unit Overhaul .......................................................................................  53

15.1 Installing Rotation Unit after Overhaul .................................................................................. 53
15.2 Removing Rotation Unit for Overhaul.................................................................................... 54

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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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Hydraulic Rotation Unit DHR 6H Ver. B 2 General Information

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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Hydraulic Rotation Unit DHR 6H Ver. B 2 General Information

• 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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Hydraulic Rotation Unit DHR 6H Ver. B 2 General Information

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 Maintenance Tables

3 Maintenance Tables

Overhaul period may vary based on local condition. Maintenance 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 need of servicing the Rotation Unit.
Epiroc Rotation Unit Overhaul Kits are designed to optimize the performance and service
life of the rotation unit. Information about the overhaul kits and part numbers are available
in the spare parts catalog for each rotation unit.

3.1 New or Overhauled Rotation Unit

Maintenance Task Work Shift First Service

5.1.1 Hydraulic Fluid Before

5.1.2 Pneumatic Tool Oil Before

5.1.3 Grease Before

8.1 Tighten All Threaded Unions After

3.2 Calender Interval

Maintenance Task Calendar Time

9 Check Wear on Seals Daily

3.3 Percussion Hours

Maintenance Task Percussion Hours

5.2 Lubricating the Rotation Unit 50

11 Replacing Seals 1000

13.2 Replacing Floating Adapter Seals 1000

15.2 Removing Rotation Unit for Overhaul 2000

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Hydraulic Rotation Unit DHR 6H Ver. B 3 Maintenance Tables

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Hydraulic Rotation Unit DHR 6H Ver. B 4 Lifting Rotation Unit

4 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 4 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 5 Lubricating

5 Lubricating

5.1 Hydraulic and Lubricant Recommendations

5.1.1 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:

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Hydraulic Rotation Unit DHR 6H Ver. B 5 Lubricating

• 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.

5.1.2 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

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Hydraulic Rotation Unit DHR 6H Ver. B 5 Lubricating

5.1.3 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

5.2 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

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Hydraulic Rotation Unit DHR 6H Ver. B 5 Lubricating

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.

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Hydraulic Rotation Unit DHR 6H Ver. B 6 Tools

6 Tools

6.1 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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Hydraulic Rotation Unit DHR 6H Ver. B 6 Tools

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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Hydraulic Rotation Unit DHR 6H Ver. B 6 Tools

6.2 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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Hydraulic Rotation Unit DHR 6H Ver. B 6 Tools

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 7 Hose Connections

7 Hose Connections

7.1 Connect Hoses

WARNING
Pressurized Systems
Can cause serious injury to eyes and skin.
u Always de-pressurize hydraulic, lubrication, and flushing system before any mainte-
nance work.
u Never replace new hoses with hoses of lower grade and quality.
u Always use gloves and eye protection.

Pos. Function

1 Air, intake (DTH)

2 Rotation, intake (RRR)

3 Rotation, return (RRL)

4 Drain, (RRD)

5 ECL, hammer (HECL)

n Always clean the hose connections before removing the protective caps.

n Pressure hoses with an internal diameter of 19 mm (3/4") or greater, must be of grade

SAE 100 R 9R.

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Hydraulic Rotation Unit DHR 6H Ver. B 7 Hose Connections

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Hydraulic Rotation Unit DHR 6H Ver. B 8 Torques

8 Torques

8.1 Tighten All Threaded Unions

n Check all tightening torques on the Rotation Unit according to the torque table.
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).
Always use a calibrated torque wrench.

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 8 Torques

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Hydraulic Rotation Unit DHR 6H Ver. B 9 Check Wear on Seals

9 Check Wear on Seals

1. Look for grease or feel with your hand over the filter plug (182). A small amount of
grease can emerge due to thermal expansion. If air or oil or water emerges, then the
air connection seals must be replaced.

2. Look if oil or grease comes through the filter plug (170). If oil or grease emerges then
the hydraulic motor seals and sealing sleeves must be replaced. See Chapter Replac-
ing Seals / Removing Hydraulic Motor and Seals.

3. Check at regular intervals that the filter plugs (170, 182) are not clogged.

4. Send the rotation unit in for service if oil or water is found in the gear housing. See
Chapter: Rotation Unit Overhaul / Removing Rotation Unit for Overhaul.

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Hydraulic Rotation Unit DHR 6H Ver. B 9 Check Wear on Seals

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Hydraulic Rotation Unit DHR 6H Ver. B 10 Replacing Hydraulic Motor

10 Replacing Hydraulic Motor

10.1 Removing Hydraulic Motor

1. Undo and remove the hydraulic hoses.

2. Mark the position of the hydraulic motors with marker pen or tape.

3. Undo the screws (156) and remove the hydraulic motor (1).

4. Remove the O-ring (195).

10.2 Installing Hydraulic Motor

1. Lubricate and install the new O-ring (195) on the hydraulic motor (1).

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Hydraulic Rotation Unit DHR 6H Ver. B 10 Replacing Hydraulic Motor

2. Lubricate the hydraulic motor splines with grease and install the hydraulic motor (1)
with the screws (156).

3. Tighten the screws (156) to 79 Nm (58 lbf-ft).

4. Install the hoses. See chapter: Hose Connection.

5. Check that the correct direction of rotation is obtained.

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Hydraulic Rotation Unit DHR 6H Ver. B 11 Replacing Seals

11 Replacing Seals

11.1 Disassembling Air Connection and Seals

1. Undo the screws (156) and remove the air connection (111).

2. Remove the O-ring (183).

3. Remove the circlip (181) using snap ring pliers.

4. Remove the radial seals (180).

5. Remove the circlip (130) using snap ring pliers.

6. Remove the support ring (129) and radial seal (128).

7. Remove the connection pipe (131).

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Hydraulic Rotation Unit DHR 6H Ver. B 11 Replacing Seals

8. Replace the sealing sleeve (126) if it is worn, use a puller to remove it.

9. Remove the circlip (130) using snap ring pliers.

10. Remove the support ring (129) and radial seal (128).

11.2 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).

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Hydraulic Rotation Unit DHR 6H Ver. B 11 Replacing Seals

2. Install the support ring (129).

3. Install the circlip (130) using snap ring pliers.

4. Fill area (A) of the seal with grease.

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.

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Hydraulic Rotation Unit DHR 6H Ver. B 11 Replacing Seals

8. Install the radial seals (180) using the tool (6) and the circlips (181) in the air connec-
tion (111).

9. Fill area (A) of the seal with grease.

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.

12. Tighten the screws (156) to 79 Nm (58 lbf-ft).

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.

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Hydraulic Rotation Unit DHR 6H Ver. B 11 Replacing Seals

11.3 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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Hydraulic Rotation Unit DHR 6H Ver. B 11 Replacing Seals

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).

11.4 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).

2. Make sure that the radial seals are properly lubricated to avoid wear.

3. Fill area (A) of the seal with grease.

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Hydraulic Rotation Unit DHR 6H Ver. B 11 Replacing Seals

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

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).

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Hydraulic Rotation Unit DHR 6H Ver. B 11 Replacing Seals

11. Lubricate the hydraulic motor splines with grease and install the hydraulic motor (1)
with the screws (156).

12. Tighten the screws (156) to 79 Nm (58 lbf-ft).

13. Install the hoses. See chapter: Hose Connection.

14. Check that the correct direction of rotation is obtained.

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Hydraulic Rotation Unit DHR 6H Ver. B 12 Fixed Adapter

12 Fixed Adapter

12.1 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.

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).

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Hydraulic Rotation Unit DHR 6H Ver. B 12 Fixed Adapter

12.2 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).

6. Tighten the screws (236) to 47 Nm (35 lbf-ft).

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Hydraulic Rotation Unit DHR 6H Ver. B 13 Floating Adapter

13 Floating Adapter

13.1 Replacing Floating Adapter

13.1.1 Removing Floating Adapter

1. Undo the hose scrwes (236) and remove the guard (214).

2. Remove the plug (155) with the seal washer (154) and install a grease nipple.

3. Apply grease under high pressure into the grease nipple.

4. Remove the adapter (A) using wrenches (3 and 4).

5. Remove the O-rings (231, 233) and support rings (232, 234) on the intermediate shaft
(212).

6. Remove the grease nipple and reinstall the plug (155) with the seal washer (154).

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Hydraulic Rotation Unit DHR 6H Ver. B 13 Floating Adapter

13.1.2 Installing Floating Adapter

1. Install the support ring (232, 234) and the O-ring (231, 233) on the intermediate shaft
(212).

2. Install the floating adapter (A) in the spindle (122).

3. Tighten the floating adapter (A) with wrenches (3 and 4).

4. Lubricate the guard screws (236) with (oil).

5. Slide the guard (214) over the cover plate and install the guard screws.

6. Tighten the guard screws (236) to 47 Nm (35 lbf-ft).

13.2 Replacing Floating Adapter Seals

13.2.1 Disassembling Floating Adapter

1. Undo the screws (236) and remove the guard (214).

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Hydraulic Rotation Unit DHR 6H Ver. B 13 Floating Adapter

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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Hydraulic Rotation Unit DHR 6H Ver. B 13 Floating Adapter

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 wiper (219), the U-seal (217), and the guide ring (215) in the adapter
housing (211).

9. Remove the buffer (223) in the adapter housing (211). Remove the grease nipples
(224) with protective caps (225).

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Hydraulic Rotation Unit DHR 6H Ver. B 13 Floating Adapter

13.2.2 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 accordance to the fig-
ure in the adapter housing (211).

3. Install the seal (216) in accordance to the figure in the groove on the adapter (204),
apply grease in the groove and on the seal.

4. Check that the stop screw (218) is fitted in one of the holes.

5. Install the seal (216) in accordance to the figure in the intermediate shaft (212), apply
grease in the groove and on the seal.

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Hydraulic Rotation Unit DHR 6H Ver. B 13 Floating Adapter

6. Install the connection pipe (213) in the intermediate shaft (212).

7. Install the buffer (222) on the connection pipe (213).

8. Install the adapter (204) on the intermediate shaft (212) and lubricate the splines on
the adapter.

9. 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.

10. Tighten with the wrench and a box-end wrench to 171 Nm (126 lbf-ft).

11. 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.

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Hydraulic Rotation Unit DHR 6H Ver. B 13 Floating Adapter

12. Install the guard (214), apply Loctite 243 on the screws (236).

13. Tighten the screws (236) to 47 Nm (35 lbf-ft).

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Hydraulic Rotation Unit DHR 6H Ver. B 13 Floating Adapter

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Hydraulic Rotation Unit DHR 6H Ver. B 14 Function and Condition Test Hydraulic Motor

14 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.

14.1 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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Hydraulic Rotation Unit DHR 6H Ver. B 14 Function and Condition Test Hydraulic Motor

14.2 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

14.3 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.

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Hydraulic Rotation Unit DHR 6H Ver. B 14 Function and Condition Test Hydraulic Motor

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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Hydraulic Rotation Unit DHR 6H Ver. B 14 Function and Condition Test Hydraulic Motor

52 No: 6740581259.1 en-US

Hydraulic Rotation Unit DHR 6H Ver. B 15 Rotation Unit Overhaul

15 Rotation Unit Overhaul

15.1 Installing Rotation Unit after Overhaul

WARNING
Pressurized Systems
Can cause serious injury to eyes and skin.
u Always de-pressurize hydraulic, lubrication, and flushing system before any mainte-
nance work.
u Never replace new hoses with hoses of lower grade and quality.
u Always use gloves and eye protection.

1. Sling and lift the machine according to chapter Lifting Rotation Unit.

2. Lubricate the eight screws (A) with oil and install them.

3. Tighten the screws (A) alternately to 350-400 Nm (258-295 lbf-ft).

4. Remove all protective caps from the connections.

5. Install the hoses according to chapter Connect Hoses.

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Hydraulic Rotation Unit DHR 6H Ver. B 15 Rotation Unit Overhaul

15.2 Removing Rotation Unit for Overhaul

WARNING
Pressurized Systems
Can cause serious injury to eyes and skin.
u Always de-pressurize hydraulic, lubrication, and flushing system before any mainte-
nance work.
u Never replace new hoses with hoses of lower grade and quality.
u Always use gloves and eye protection.

NOTE: Overhaul period may vary based on local condition. 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 need of servicing the Rotation Unit.

1. Undo and remove the hoses.

2. Install protective caps on all connections on the machine.

3. Undo and remove the eight screws (A).

4. Sling and lift the machine according to chapter Lift Rotation Unit.

5. Send the machine to the workshop for overhaul. Make sure that it is securely an-
chored for transportation.

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 15 Rotation Unit Overhaul

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 2018-05-03 | No: 9852 3277 01d. 6740581259.1

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