eee Aldlas Copeo 80088 DH 48H 201 1222-09 Overhaul instructions for Rotation unit DHR 48H LA Special attention must be paid to information carrying this symbol. ATLAS COPCO MCT AB. STOCKHOLM « SWEDEN MCT + No. 9853 0860 01General ‘These instuctions are intended to help those carrying ‘out overhaul and/or repairs on the rotation unit DHR 48, Special attention must be paid to information carrying this symbol Workshop requirements ‘The workshop must be free fom al kinds of particle producing atv, euch as grinding woding et. «The workshop should be claan and fee fom dit or dus © it should be equipped with the necessary equipment for ‘washing, rinsing and air blow cleaning components © It should be equipped withthe necessary standard and special tools Personnel requirements © Workshop personne! must have undergone training at Allas Copco beforehand hoses, when the hydraulics or compressed air systems are connected. IMPORTANT! Never attempt to work on the rotation unit, couplings or Observe the strictest hygiene and cleanliness whenever working on the rotation unit. Any repairs should be catried out in a suitably equipped workshop. About these instructions These instructions start with a ist ofthe tools that will be re- uired. Instructions are then given as how to disassemble the rotation unit, how to carry out inspection and replace- ‘ment of worn or damaged components ‘These instructions end by explaining the order of re assembly, and which less or checks should be carried out after overhaul or repaic The figures given in brackets in the text refer to the exploded drawing on page 35 Contents Page General 2 Tals ists 3 Rotation unt, ain components 5 Disassembing main componans of the roaion unt 8 — Hydraulic motors and cover 8 = Gear housing 3 Pretensioning the roler bearings 8 ‘Hydraulic motor 22 Hycrauic moter, exploded crewing 2 Roassemblng main compononis of the rlalon un 28 Function ist 31 Recommended lbscants 2 Lubrication points: 32 Tightoning torques 33 Rotation unit, exploded draing 35List of standard tools RATES| 1, Plastic mallet Papeee eee eeeeecoet oo 2. Copper hammer [ome 3, Sledge hammer —S 4, Usting spanners. 6 Width across flats 24 mm Allen key. Width across flats 8 mm Screwdrivers Mandrels. Circlip pliers (for female/mate cit resp.) ‘Torque wrenches. Range 0-200 Nm (0-20 kpm — 148 Ibf. ft) Torque wrench sockets. Width across flats 24 mm 1 12. 18. ‘Torque wrench sleeves. Width across flats 8 mm Ratchet spanner ExtractorList of standard tools 14. Expander extractor (3091 0455 90) 15. Hydraulic press (min 20 tons) for assembly/disassembly List of special tools "Teo! Part No. Description Usage a 3115 1741 00 ‘Adaptor spanner | Assemblyidisassembly of the adaptor (1). Spacer For pretensioning of the B (fo 3118188300 Aza mm + 0,05 mm roller bearings (10, 23). 9118174200 9115174300 | Stop lug For assembly of the ring Washer spring (25) and the lock rut (26),Rotation unit, main components 1 Adaptor 2 Cover 3. Gear housing 4 Hydraulic motor Fig 1. Main components ofthe rotation unitDISASSEMBLING THE MAIN COMPONENTS OF THE ROTA- TION UNIT Order of disassembly: Hydraulic motors and cover © Hydraulic motors Disassembly © Cover © Gear housing Undo and remove the adaptor (1) using adaptor spannet (S115 1741 00), (see Fig A, page 4). Then remove the Viring @ NB: If the adaptor is point-welded, the walded joint should first be ground of ‘Mark the exact positions ofthe hydraulic motors (a8) with a ‘marker pan or with igh! taps with @ punch [Undo the screws (41) and remove the hydraube motors (48) Fig 4. Disassembling the hycraulte motorsFig 6 Disassembling the cover Fig 7. Disassembling the gears Undo the sorows (41) and remove the connecting pipes (38 a5) Undo the screws (29) and remove the cover (28) by pulling it straight out Remove the gears (43) by puling them straight outRemove the roller beerings (45) from the cover (28), using the extractor and a 36~48 mm (1,42—1.81 in) expander Inspection, replacement of parts Boforeingpection, clean al parts in a grease dissolvent beforehand Check the rote bearings (45) by rotating tem onthe bearing races of the gears (43) The bearings should rotate freely nd evenly Replace the bearings i any dissonance or damage s found Fig 9 Checking the roller bearings Ifthe inner rings for the oker bearings (46) need to be re Placed, then disassemble them as shown in Fig 10 Fig 10. Disassembling the inner rings ofthe roller bearings Ingpect the seats (46) to see if they are worn or damaged. I they need to be replaced, remove the old seals with a screwdriver as shown in Fig 1 FFig 11 Inspecting the sealsFig 15. Disassembing the ring spring Inspect the seals (46) If these need to be replaced, then frst remove the circlip (8} and backup ring 7) ‘Then remove the seals using a screw-driver as shown in Fig 12 Inspect the connecting pipe (88), the O-ring (97) and the ‘ther connecting pipe (5) Hf wear grooves are found on ‘connecting pipo (5) attar the seals (6), then the pipe can be turned round during reassembly to provide a new surface for the seals Gear housing Disassembly Inspection, replacement of parts Undo and ramove the lock nut (28) The thread on this nut is slighty urdercimensioned in arder to provide afr grip on the spindle Disassembly is as flows: © Undo the sorew (27) «Press or tap down the blade o! a screvcrverin the stot ‘on the nut so that it opens slighty “The nut should now be easy to unthread and remove Remove the ring spring (25) inthe folowing manner: ‘© Undo the screws alternately and in stages © Now remove the ring spring in its entialy orn pioces {tthe spring should break or split during disassembly, then the three screws marked in the Fig. opposite should be un- done. The soakels for these screws have a larger thread on the front ring to enable the spring to be removed with the aid cof thiee long screws.Remove the cover (16) by undoing the screws (7). Tap the Cover and pry itloose with two screwdrivers as show in Fig, 6 Fig. 16. Disassembiing the cover, ‘Remove the back-up ring (19) and spacers (11). Fig 17. Disassembling the back-up sing and spacers. Press out the spindle (2) andthe outer ring for roller bearing (10) as folows: © Position two wooden blocks to support the gear housing (9) in the hydraulic press: ‘© Position the gear housing as showin in Fig. 18. Make sure there is sufficient space between the mooden blocks to tenable the ring for roller bearing (10)10 pass freely through. © Insert a washer between the spindle (2) and the hydraulic ‘ylindar to prevent damage tothe threads, © Carelully press the spindle and bearing ring out of postion IMPORTANT: Make sure the bearing ring and spindle can- not fall down and become damaged when freeing Fig 18 Disassembling the spindle. 10Fig 21 Disassembling the cirli, backup ring and roller bearing Lit up and remove the gear (20) and spacer sleeve (24) from the gear housing 0} Remove the roller bearings (42) withthe aid of the extractor ‘anda 36-46 mm (1.42—1.81 in) expander. Remove the cirlip (21) and backup ring (22) ‘Then remove the roller bearing (23) by tepning i ree with a ‘hammer and a copger mandrel "Fig. 23. Inspecting he lock aut 25 Fig 24 Replacing the ring spring Fig. 26 Checking the roller bearing. 2 Tap the wedge (4) out of the groove on the spindle (2) Inspection, replacement of parts All components should have been cleaned in a grease dissolvent before inspection commences ‘Cheok that the lock nut (26) si has a firm grip on the thread fn the spindle 2), and that the thread is undamaged Ifthe thread is damaged then replace the lock nut Replace the ring spring (25) fit is worn or damaged Inspect the gear (20) to soe i itis worn or damaged Replace when necessary Check to see if the spacer sloeve (24) has been damaged and requires replacing Check the roller bearing (28) by mounting it on the inner ring con the gear (20) NB: The bearing should tate easily and evenlyFig 30. Disassembling the roller bearings: if the roller bearing (23) needs replacing, then first remove the innes ring by carefully heating it. See Fig. 27 Inspect the spindle (2) Replace it the thread is worn or the contact surfaces are damaged Inspect the seals (6) on spindle (2). If these require re- placing, remeve the circlip () and then the backup ring (7) Demolish the seals with a screwdriver as shown in Fig. 28 Inspect the wedge (4) and replace itt itis worn or damaged Inspect the coller bearings (10) Replace i found worn oF damaged It the bearings (10) need replacing, then fist remove the ‘outer bearing ring by lightly tapping with a mallet and mandrel 19ES Fig 31. Disassembiing the roller beerings Fig 32. Disassembling the seals Fig 33. Checking the roller bearings Fig 94, inspecting the Vring 4 Rlemove the roller bearings (1) from the spindle (2) by posi- tioning the outer bearing ring on the bearing, which is then pressed from the spindle in the hydraulic press. Use a suit ably dimensioned sleeve as an aid IMPORTANT! This should only be done ifthe bearings need tobe replaced Disassembly in this manner could ‘cause damage to them Inspect the seals (14) In the cover (15). Replace if found worn ‘or damaged, Remove the old seals with a screwdriver ‘Check the roller bearings (42) by positioning them on the inner rings ofthe gear (43). They should roate freely and evenly. Replace them i dissonance is heard or damage is found Inspect the Ving (2) Replace if found worn or damagedReassembly Coat all parts with clean hydrauli ol before starting reassembly Reassemble the seal (6), back-up ring (7)and_circip(@) on the spindle (2). NB: The seals should be turned and facing as shown in Fig, 36 Reassemble the seals (14) the cover (15) NB: The seals should be facing as shown in Fig 36, eassemble the roller bearing (23) in the gear housing (2) Reassembly must be done in the hydraulic press. Use a suitably dimensioned sleeve as an aid during reassembly “The bearing can also be tapped back in position using & hammer and a copper mandrel Reassemble the backup ring (22) and circlip (21) Fig 97. Reassembling the roller bearingFig 98. Reassembiing the roller bearings in the gear housing Fig 29 Reassembling the outer bearing race ofthe roller bearing SUT ee es a ee 16 Reassemble the roller bearings (42) in the gear housing (9) bby tapping them in place with a copper hammer Reassemble the outer bearing race for roller bearing (10) in position in the gear housing () in the hydraulic press Use a suitable sleeve or a hammer and copper mandrel as aids during reassembly Reassemble the spacer sleeve (24) for roller bearing (23) on the gear (20) in the hydraulic press. Use a suitebly dimen sioned sleeve during assemblyFig 41. Reassembiing the roller bearings onto the spinal Fig 42. Reassembiing the wedge Fig 43. Reassembiing the spindle, gear and spacer sleeve inthe gear housing Mount the roller bearings (10) individually onthe spindle (2) Use the hydaulle press and a suitably dimensioned sleeve against the inner rings ofthe bearings ‘Tap the wedge (4) down into the slot on the spindle Reassembie the spindle (2), gear (20) and spacer sleove (24)in the gear housing (9), Reassembly in the hydraulic, press should be carried outas fllons: © Position the spindle and gear housing in the hydraulic press as ilistrated in Fig 43 «© Assemble the spacer sleeve on the gear and postion the ‘gear on the spindle shaft © Turn the gear so thatthe wedge (4) centres with the ‘wedge slot on the gear © Carefully press the gear on the spindle Use a suitably ‘dimensioned sleeve so that he gear can be pressed ‘down beneath the end ofthe spindle. IMPORTANT: I the spacer sleeve falls down in the gear housing during the pressing cycle and aligns eccentrical, this could damage the sleeve Consequently, bore pressing, check that the spacer sleeve is firmly and correctly positioned on the gear Hfittends 1 loosen too easily, then the contact surfaces ‘should be coated with grease ”10 Fig 44. Reassembling the outer bearing race on the bearing 7 Fig 46. Pretensioning the rotter bearings Fig 46. Reassembiing the adaptor an the spindle 1% Reassemble the outer beating race on the roller bearing (10) Pretensioning the roller bearings Bearings and bearing races should be fee from grease and oil The following tools are needed for pretensioning the roller bearings in the gear housing: ‘One spacer PartNo. 3115 188300 ‘and eighty cup springs Part No. 0884831200 Pretension the roller bearings as follows: ¢ Measure the thickness of the spacer (3115 188300) with a micrometer and note down this value + Mount the measured back-up ing instead ofthe shims a © Assemble the cover (15) together with the screws (17), positioning ten cup springs under each screw asi lustrated (Fig 45) ‘Tighten the sores just enough to ensure that he cup ‘pring io againt the cover (16) and gear housing (0) re speaively Then tghtan the screws once more about *i2.complete turns. The spring pressure wil en coce- spond toa pretension of about 2100 kp ‘Assemble the adaptor (1) on the spincle (2) Fltate the spindle § or 6 complete turns fo enable the bearings to settle correctly ‘Now measure the clearance (A) between the cover (16) and the gear housing (9) with a fester gauge Measure a three different points with about 120 degrees betwean each point Fleduce the noted thickness measurement of the back-up ring (B) with the measured clearance (A) ‘Measurement (8) minus measurement (A) shows the necessary thickness of the shims in order to pretension the bearings correctlyCombine a number of clean and dry shims (11) together so that ther total thickness does not differ more than 005 mm trom the calculated measurement (B minus A | Remove the adapter (1), the cover (15) and the back-up ring 3) Remove the spacer (3115 188300, see Fig B, page 4) end assemble the measured number of shims in place. Betore reassembling the cover (16) back in position, il the space between the seals 14) with grease Use a grease gun toil the entre area between the seals ‘Apply plenty of grease to the roller bearings (10) as well Coat the contact surtace ofthe caver (16) against the gear ‘housing (9) with some kind of sealing agent, such as PERMATEX for example Fig 48. Lubricating the seals in the cover Reassemble the back-up ring (19), cover (15), stop lug (8115 174200) and washer (3115 174300) in place. See Fig G, page 4). Tighten the screws (17) alternately and just enough to keep the cover in position Tightening torque: 25-50 Nm (2.5~5.0kpm) (19-37 Ib ft) Coretully wipe clean the ring spring (25) and the contact surlaces of the spring against the spindle (2) “The ting spring is held in position by friction Cleantiness is therefore important to prevent it from loosening and causing damage Fig 50 Cleaning the contact surtaces ofthe ring spring 19‘Mount the ring spring (25) in position and tighten the screnss alternately and just enough to stat tensioning the ting spring ‘Continue by tepping the heads of all he serews with a hammer and mandrel ‘Take care lo ensure that the ring spring botioms correctly. Tighten the screws alternately and in stages toa tightening torque of 70 Nm (7 kom — 52 lot.) Then tighten each screw at leat three times using ful torque Fig 52. Checking the position ofthe ring spring ‘Apply a heavy blow withthe hammer and mandrel on each ‘screw, and then tighten all the screws atleast once more vith a tightening torque of 70 Nm (7 kpr — 82 Ib. Fig 53. Tightening the screws 20Fig. 54. Antirust treatment ofthe ring spring Fig 57. Disassembling the stop lugs Spray the entre suriace of the cing spring with TEGTYL or a similar low viscous anti-corrosive agent: Make sure the rust preventive coats the entire suriace properly “ap or push down the blade of the screwdriver inthe slot on ‘the lock nut (26) ‘Assemble the lock nut and lighten slightly though not too hard lemave the screwdriver and the lock nut will now aria around the spindle The threads wil press the nut against the gear. Tighten the sorew (27) Coat the lock nut (26) with antisust Use the same ant Corrasive agent as that sprayed on the ring spring (25) emove the stop lug (3115174200) and the washer (8115174300) see Fig. C, page). Then tighten the screws. in the cover (16) alternately to a torque of 200 Nm (20 kpm~148 ib. aFig $9. Lubricating the bearings ‘Mount the inner rings ofthe roller bearings (42 & 45) on the gears (43) Use the hydraulic press and suitably dimen: sioned sleeves during assembly Coat the bearings with grease and assemble the gears (43) in the gear housing (9). Fig 60. Removing the plugs and sorews from the hycrauilc motor. 2 The hydraulic motor Disassembly Inspection, parts replacement Reassembly Function and condition testing DISASSEMBLY ‘Tension the motor in a vice. Use a S18” Allen key to remove the two plugs (21) above the control valves Undo and remove the four screws (18) that hold the motor together. Use a 17 mm (0.67 in) socket and ratchet spanner Liftoff the valve housing and turn it upside down so thet the springs (20) and balls (19) can be removed.Fig. 63. Disassombly of internal parts from the valve housing Flemove the spacer pin (14) and valve pinion () Liftoff and remove the cog assembly (5). Remove the drive ‘shat (2) and O-ring (4) that remain on the mounting flange @ Carefully tap out the internal components from the valve housing (7) against the vice Hold your hand undemeath the housing to prevent descending parts from becoming, damaged. 23Inspection, replacement of components ‘Thoroughly clean all pars before starting inspection Carotlly inspect all components fr sign f damage or wear Delectve paris should be immediately replaced All Oings and seals shoul be replaced automatically Inspec! the cog aesemily as iluttated in Fig. 64 When the clearance between tv loth point ofthe rotor and the role ismore han 01 mm, replace the cog essemily Fig 64 Inspecting components Reassemble the drive shaft (3) and O-ing (4 in position Fig 65 Reassembly of the drive shaft and O-ring Position the cog assembly (6) over the mounting flange (2) and check thal the guide pin (6s in position CChack also that the drainage duct inthe cog assembly is correctly aligned withthe duct inthe flange Fig 68 Reassembly ofthe cog assembly 24Mount the valve pinion (7) in position Mark the cog assembly's rotor with an arrow at the point where the bottom of the splines aligns immediately infront ofthe bottom of the cog in the cuter cog circle Move the ‘mark up tothe upper splines on the valve pinion | ties Fig 67. Reassembly ofthe valve pinion ‘Attach the O-ring (in place on the duct plate (8) with ‘grease and then mount ths unit on the cog assembly (5), Note the guide pin (6). Fig 68 Reassembly ofthe O-ring and duc plate Position the swash plate (9) wit is hole (8) centred opposite the mark on the valve pinion (7) ‘Tur the swash plato (9) anti-clockwise until the splines engage Fig 69 Reassembly o the swash platePace the spring ring (15) in the valve housing (17) Mount the O-rings (12 & 13) on the balance plate (10) with ‘grease Press the balance plate dawn into the valve housing (17) Coat the spacer pin (14) with grease so that t remeins in position ater reassembly Fig 70. Reassembly of internal components in the valve housing Mount the valve housing (17) in position and tighten the bolts (6) alternately with torque of 50 Nin (& kom — 37 lt) Insert the balis (19) and springs (20) in the two holes in the valve housing (17) and thread the two plugs (2) nto piace using a 98” Alien key Fig 72 Reassembly ofthe balls and springs in the valve housing, 26Hydraulic motorREASSEMBLING MAIN COMPONENTS OF THE ROTATION UNIT The hydraulic motors and cover Coat all parts with clean hydraulic oll before starting reassembly Assemble the seals (46) in lace Poston the roller beatings (25) with the ae of the hydraulic press, or alternatively tap them down into positon using te plasio mallot Fig 72 Reassembling the seals and bearings 37 8 (So < Mount the seals (6), back-up ring (7), circip (8) and O-ring (87) on connecting pipe (38) NB: The seals should be turned and facing as shown in Fig 74 Fig 74 Reassembling the seals, back-up ring, crcip and (Ovving on the connecting pie 28Coat the contact surace ol the cover (28) with a sealing agent Chock thatthe cylinetical pins (1) are correctly positioned in the cover Lubricate the roller bearings (45) with grease Fig 75. Lubricating the cover Fill he cover (28) and gear housing (8) to about 2/Srds with grease ‘Assemble the cover (28) in position and tighten the screws (29) with a torque of 200 Nm (20 kom — 148 lft) 29 Fig, 78. Reassembling the cover ‘Assemble connecting pipe (6) n place, and then connecting pipe (@8) Tighten screws (41) with a torque of 85 Nm (25 kom — 63 Io.) Fig. 77, Reassembling the connecting pipes 29Fig 78. Reassembling he hydraulic motors Fig. 79. Reassembling of the adaptor and then positioning the V-ring on the spindle. Fig 80 Lubricating the gear housing with grease Check that the O-ings (47) are assembled on the hydraulic ‘motors (48) Then assemble the motors and tighten the sereas (4) with a torque of 85 Nm (&S kpm — 63 io ft) Reassemble the adaptor (1) and spot weld it. Then position the V-ing 3) on to the spindle (2). Check thatit seals pro- perly against the cover (15) Frilthe goat housing (8 wth grease. Use a grease gun and connect 0 nipple (16) Fil with grease unt it seeps out through the hole 1 valve (35)Function test ‘The rotation unit must always be function tested before its to recommence operation. Carry out this test with the rotation unit coreecily assembled and connected to the rig's hydraulic system. Test run unloaded for about § minutes, checking thal the spindle rotates evenly and without dissonance. Lock all movement of the spindle with the stop lug and the washer. Connect one of the motors to the rig's hydraulic system, and connect a pressure and flow gauge to the pressure line. Replug the lines leading to the other motor. Limit the pressure in the line to 20 bar (290 psi), and then ‘measure the leakage flow from the motor. I the low is loss than § Vinin, this indicates that the motor isin a satisfactory condition Repeat the same procedure with the other motor lobo: 12 2 725 :0 3S esf é IMPORTANT! Remove the stop lug and the washer before carrying out a test run. Connect both motors tothe rig's hydraulic system, ‘and connect a pressure and flow gauge to the pressure line ‘Allow the motors to rotate for about 1 minute, with a max. flow of 10\/min. ~ (2.2 imp. gal. ~ 26US gal) Check that the shaft of the spindle rotates smoothly and without dissonance. ZS Og 102 bey 31Recommended lubricants Grease [Lithium—complex, [Viscosity _ EP grease, mineral | 150-220 cSt oil base. at 40°C (104°7) Mechanically stable. |NLGI 2. Intended for use on vibrating units Lubrication points Lubrication points Lubrication points No. of pump strokes Intervals ‘A Cover ~ Shaft seal 4-8 Every 2 weeks B. Gear housing ~ Bearings and gears 4-5 Every 8rd month C, Gear housing ~ Bearings 4-5 Every 3rd month, NB: In the event of poor performance, due to changes in the consistency or discoloration of the grease, send the rotation unit to an authorized workshop for a complete overhaul and grease change. 32Tightening torques Ref. Check poin/Procedure Tightening torque No. Threaded unions Nm. kpm Ihe aly 1 Connection pipe ~ Cover 85 as 63 4 2 Cover ~ Gear housing 200 20 148 8 3 Cover — Gear housing 200 20 148 8 4 Rotation unit ~ Cradle 350-400 95-40 259-296 6 5 Hydraulic motor ~ Cover 85 8 63 8 * Exhaust from pneumatic rock drills contains oil. Oil fog is dangerous if inhaled. Adjust the lubricator so that the correct dosage is supplied, and make sure the worksite is well ventilated. © Always wear ear mufflers when drilling. © Take great care when jointing drill tubes. Make sure there is no chance of fingers becoming pinched or crushed during jointing, or clothing becoming entangled during rotation of the drill string. * Make it a habit to always check that hoses, hose nipples and hose clamps are undamaged and ‘securely tightened. All hoses should be additionally secured with wire ropes firmly fixed to the rotation unit. This also applies to the hose between the compressor and the drill rig. © If the DTH drill is to operate at pressures above 10 bar, (145 psi) then local regulations governing the type and quality of air hoses and couplings to use, must be complied with in full. 33‘© ALINAYS use ear mutters when dling ‘© Take great care when jointing dil tubes. Make sure thera is no chance ot fingers becoming jammed du ring jeinting, o: clothing becorning entangled during rotation of the dill tube sting © ALWAYS CHECK HOSES, HOSE NIPPLES AND HOSE CLAMPS TO ENSURE THEY ARE PROPERLY TIGHTENED, UNDAMAGED AND SECURED. 34H8> HHG HUN uoHeIoYy