Overhauling instructions for

DIAMEC® U6 Rotation unit

Printed Matter No 6991 1230 01

2
Overhauling instructions for

DIAMEC® U6 Rotation unit

All rights reserved.

The owner of the equipment is granted the permission to take copies of this
publication solely for internal use.
It is recommended, however, to order additional copies from Atlas Copco
representative in order to benefit from the latest revision.
Atlas Copco Craelius AB reserves the right to make changes in its products in order
to improve design or performance characteristics without notice.
The information in this publication is assumed to be accurate at the time of
publication, but is subject to changes in order to remedy detected deficiencies or to
follow changes in the product.
Any user of this publication is requested to inform Atlas Copco Craelius AB about
deficiencies found, particularly in matters concerning product safety.

ATLAS COPCO CRAELIUS AB

MÄRSTA - SWEDEN 2002-10

Printed Matter No 6991 1230 01

3
Contents
Page

General ........................................................................... 5

Disassembling ................................................................ 6

Assembling.................................................................... 11
Mounting of outer and inner race bearings............ 11
Assembling of seals in the seal holder................... 12
Assembling the seal holder in rotation head ......... 12
Mounting front bearing and shaft ........................... 13
Mounting of rear seals of the chuck housing ......... 14
Mounting of chuck housing on the rotation head . 15
Assembling sleeve and jaw holder in the chuck.... 16
Assembling parts in the gear box ........................... 18
Mounting guide bushing in the rotation head....... 22
Rotation unit oil level................................................ 23

4
 Safety instructions
1.0 General
This Overhauling instruction book is part of the
complete delivery of your new diamond core
drill DIAMEC® U6 Crawler.
1.1 Hydraulic and electrical systems are of a
complex nature - and can cause injury or
damage if not handled with care. Repair
and service shall be carried out by
personnel with documented experience for
these systems.

1.2 Welding repairs should only be carried out

by an authorized welder in order to meet GENUINE PARTS
the high standards that apply to Atlas
Copco products. Special attention must be
given to components which could cause
injury or serious damage. Fig. 1.9 Use only genuine Atlas Copco parts.

1.3 After repair make sure that the rig has

been inspected and approved by the 1.7 Before any repair or service is carried out
proper authorities before being brought on the rig's hydraulic or water systems,
back to normal operation. make sure the engine is stopped and
systems are depressurized.
1.4 Never make alterations or modifications to
components of the unit. 1.8 Be very careful while tracing leaks in the
The manufacturer’s approval should be pressurized systems. Hydraulic oils, water
requested for any modification done to the or air under pressure could penetrate
unit. under the skin and cause complicated
injuries or infection. If this happens, see a
1.5 Use extreme caution while handling starter doctor at once.
batteries. Wear gloves and protective
glasses when servicing batteries. The 1.9 Use only authorized parts (Atlas
batteries contain strong acid, which can Copco parts). Any damage or
seriously burn eyes, skin and damage malfunction caused by the use of
cloth, insulation and metal. First aid in unauthorized parts is not covered by
case of acid in the eyes: wash with plenty warranty.
of clean water and seek medical help.
1.10 Any warranty for work performed,
Disconnect the earth cable from the battery only covers Atlas Copco Products,
before carrying out service in the electrical Atlas Copco components and work
system. performed by authorised personnel.
The battery gas is explosive! Never use
matches when checking the acid level.
Any question or to get additional
Be careful using tools made of iron near information, please phone, mail or fax:
the battery, a spark might set off an Atlas Copco Craelius AB
explosion. Read the battery manufacturer’s S-195 82 Märsta, Sweden
manual for further information as well as
the “Environmental instructions” chapter. Phone: +46 (8) 58778587
Fax: +46 (8 )591 187
1.6 Hydraulic oils are poisonous. Use eye E-mail: jerzy.lederman@atlascopco.com
protection and gloves. See the
“Environmental instructions” chapter for
further information.

5
Overhauling instructions - Disassembling
2.0 Disassembling of rotation head
The rotation unit holds 0,6 liters of synthetic oil
(see Lubricant specifications).
The oil can be drained at 90 degrees down.
When refilled to the top plug (1, see Fig. 2.0), the 1
gearcase contains 0,6 liters of oil.

IMPORTANT
Leaks of hydraulic and lubrication oils pose an
environmental threat. Changing lubricating and
hydraulic oils, hydraulic hoses and hydraulic
filter elements also pose a threat to the
2
environment. Collect all oil spills and waste (e.g.
oil filter elements) contaminated with oil. Oil drain at 90°
Dispose of according to national regulations.

Fig. 2.0. Draining oil in the rotation head

1. Top plug
2. Oil drain plut

64
Proceed as follows
1. Disassemble the hydraulic motor (64).

2. Disassemble the cover (19), guide bushing

(68), locking ring (18) with O-ring (45) and
V-seal (34).

34 18 45 68 19 52

Fig. 2.1 Demounting of guide bushing with seals etc.

18 Locking ring
19 Cover
34 V-seal
45 O-ring
52 Screws
64 Hydraulic motor
68 Bushing
6
Overhauling instructions - Disassembling
3. Disassemble the flange (15) with O-ring 49
(39) and seal (31) from shaft (2), Fig. 2.2.
48
4. Undo the cap screws (56) and disassemble
the top lid (10), Fig. 2.2.

15
56

2
49 11 65 49

Fig. 2.3

10

Fig. 2.2

5. Remove the guide pins (49) and the gasket

A
(65) from the housing, Fig. 2.3.
NOTE, It is important the old gasket is
properly removed before mounting a new 27 67
28 11
gasket.

6. Bend out the locking notch (A) and undo Fig. 2.4
the bearing nut (28) with a KM 20 socket
(SKF), Fig. 2.4.
M12 hole
7. Disassemble the lock washer (27) and the
indicator disc (67), Fig. 2.4.

8. Disassemble the gear (11) and the

key (48), Fig. 2.5. The gear wheel have two
M12 threaded holes for extracting the gear
wheel. Use the two M12x50 screws in the
tool box to pull the gear wheel of the shaft.
When the gear wheel is extracted from the
shaft it is easy to get the inner flange (16)
which holds the two inner seals (32).
M12
(To be able to change the two seals (32)
hole
and O-rings (40 and 41) between the
11 48
commutator and the gear housing the gear
wheel (11) has to be removed).
Fig. 2.5

7
Overhauling instructions - Disassembling
9. Disassemble the wear ring (14).
10. Disassemble the inner flange (16) with
O-rings (40, 41) and seals (32).
11. Turn the rotation head around. 14
12. Undo the eight bolts (54), and remove the
outer cover (8).
16
13. Remove the jaw inserts (29).
14. Undo the four screws (60), and remove the
inner cover (7) together with the O-ring Fig. 2.6
(42).
15. Remove jawholder (24) ,springs (23),
sleeve (21) at the same time.
16. Remove wear plate (6) and O-ring (42)
17. Press the jawholders (24) and springs(23)
out of the sleeve (21).
18. Disassemble the O-ring (42) and the wear
plate (6) in the bottom of the chuck
housing.
19. Disassemble the chuck housing (5) with 16
viper (35), O-rings (43) and support
rings (47).
20. Clean all parts thoroughly, including the
inside of the chuck housing. At the same
time, inspect all parts and replace any Fig. 2.7
found damaged or eccessively worn
before reassembling.

5 42 6 21 24 29 42 7 60 8 54

23 20
35, 43, 47

5. Chuck housing 29 Inserts

6 Wear plate 35 Viper
7 Inner cover 42 O-ring
8 Outer cover 43 O-rings
Fig 2.7 Diamec® U6 rotation unit 47 Support rings
20 Guide pins
21 Sleeve 54 Bolts
23 Springs 60 Screws
24 O-ring

8
Overhauling instructions - Disassembling

21. Disassemble the wear ring (9) with seal

(43). 9, 43
1
4
22. Disassemble the front flange (4) with seals
(32 and 41).

23. Press out the shaft (2) with front bearing

(25, Fig. 2.9.1) from the rear bearing (26,
Fig. 2.9). Press off the front bearing (26)
from shaft (2).

Fig. 2.8

26
2

Fig. 2.9

25

Fig. 2.9.1

9
Overhauling instructions - Disassembling

24. Undo the lock screw (B) and remove the

seal holder (3) from the rotation head 26
using two bolts (A), Fig. 2.9.2.

25. Remove the seals and pins from the seal

holder.

26. The outer race bearing (26) and the inner

race bearing (25) is to be pressed out from
the rotation head, Fig. 2.9.3 - 2.9.4.

A
A

3 Fig. 2.9.3 Outer race bearing (26)

25
1

Fig. 2.9.2 Fig. 2.9.4 Inner race bearing (25)

10
Overhauling instructions - Assembling

3.0 Mounting of outer and inner

26
race bearings
The outer race bearing (26) and the inner race
bearing (25) is mounted into the rotation head by
pressing it in position, or first freezing them in.

Fig. 3.0 Mounting of outer race bearing.

26. Bearing in position

25

Fig. 3.01 Mounting of inner race bearing.

25. Bearing in position

11
Overhauling instructions - Assembling
3.1 Assembling of seals in seal
holder
Mount the pins (61) and the seals (33) in the seal
holder (3). Lubricate the seal and seal holder.
See Fig. 3.1.1 - 3.1.3.
Note: Check that the pins (61) are inside the
groove, see Fig. 3.1.1.

Fig. 3.1 Seal holder with pins and seals

3. Seal holder
33. Seals (4 pcs)
3 61
61. Pins (4 pcs) 33

61

Fig. 3.1.1 Pins mounted in the seal holder Fig. 3.1.3 Seals mounted in the seal Holder
61. Pins 33. Seals

3.2 Assembling the seal holder A

into rotation head 1
A
1. Put a wood block or fixture under the
rotation head.

2. Use two bolts (M8x60) to facilitate 3

mounting of the seal holder into the
rotation head. The seal holder is held in
position with the aid of the bolts while the
lock screw (B) is tightened with a allen key,
see Fig. 3.1.2. 2
1

Fig. 3.1.2 Mounting the seal holder into the rotation

head.
A. Mounting bolts
B. Lock screw.
1. Rotation head
3. Seal holder B

12
Overhauling instructions - Assembling

4.0 Mounting of front bearing and

shaft 2
25
1. Mount the rubber plugs (37) in the shaft
front end, see Fig. 4.0)

2. Heat the front bearing (25) before

mounting it on the shaft (2), see Fig. 4.0.1) 2

3. Put down the shaft (2) into the housing (1)

of the rotation head.

4. Mount the front flange (4) with seals (32

and 41).

5. Mount wear ring (9) with seal (43).

3
1

32
41

Fig. 4.0 Mounting of rubber plugs in shaft

2. Shaft
3. Rubber plug, 4 pcs
4

Fig. 4.0.1. Mounting of shaft in rotation head

housing
9, 43
5
4
1. Housing
2. Shaft
4. Front flange with seals 32 and 41
9. Wear ring with seal
25. Bearing
32. Seal
43. O-ring

13
Overhauling instructions - Assembling
5.0 Mounting of rear seals of the
chuck housing
Mount the two support rings (47, yellow), the two
O-rings (43), the viper (35, 1 pcs) and the four
plugs (36) at the back of the chuck (facing the
shaft), see Fig. 5.0 and 5.0.1.
NOTE: Apply grease on the viper (35) when
mounting.

47

43

36

35

Fig. 5.0 The rear end of the chuck housing

35. Viper
36. Expanding plugs (Mounted at factory)
43. O-rings
47. Support rings (Yellow)

35

Fig. 5.0.1 Items 35, 36, 43 and 47 in place.

14
Overhauling instructions - Assembling
5.1 Mounting of chuck housing on
the rotation head
1. Mount the chuck housing (5) with it’s items
on the shaft, see Fig. 5.1.

NOTE, the hole pattern have to be fitted so

the extracting holes have a free surface,
see Fig. 5.1.1.

2. Mount the wear plate (6) with O-ring 42) in

the chuck housing, see Fig. 5.1.2.

Fig. 5.1.1

5 6
1

42

Fig. 5.1 Chuck housing with the items 35, 36, Fig. 5.1.2 Mounting of wear plate in bottom of
43 and 47 in place on the shaft the chuck housing

15
Overhauling instructions - Assembling
5 42 6 21 24 29 42 7 60 8 54
23 1
29
24

23 20
21
5 Chuck housing 24 Jaw holder
6 Wear plate 29 Inserts
7 Inner cover 42 O-ring
8 Outer cover 54 Bolts
20 Guide pins 60 Screws 2
21 Sleeve
23 Springs
Fig. 5.2

5.2 Assembling sleeve and jaw-

holder in the chuck, Fig. 5.2 - 5.2.1 3
1. Push the jaw inserts (29) into the jaw holder
(24).

2. Assemble the jaw holders (24) and the springs

(23) in the sleeve (21).

3. Position the rubber sleeve with jaw holders in

the chuck housing.

4. Assemble the inner cover (7) with o-ring (42)

4
42

42

Fig. 5.2.1

16
Overhauling instructions - Assembling
5 42 6 21 24 29 42 7 60 8 54
1

23 20
8
5 Chuck housing 20
24 Jaw holder
6 Wear plate 29 Inserts
7 Inner cover 42 O-ring
8 Outer cover 54 Bolts
20 Guide pins 60 Screws 20 2
21 Sleeve
23 Springs
Fig. 5.2.2

5. Assemble the outer cover (8) in place. 3

NOTE! Make sure the guide pins (20) fits
perfectly in the recessed grooves in the
jaw holder. The tightening torque for the
bolts (54) is 100Nm, see Fig. 5.2.2 - 5.2.3.

7 54

Fig. 5.2.3

17
Overhauling instructions

6.0 Assembling parts in the gear box

40
1. Turn the rotation head around and check that
the housing is clean inside, Fig. 6.0.1.
3
2. Heat the rear bearing (26) before assembling,
Fig. 6.0.2
32
3. Mount the O-rings (40 and 41) and the seals
(32, 2 pcs) on the inner flange (16), see Fig.
6.0.3
41
4. Mount the Inner flange (16) with O-rings and
seals, see Fig. 6.0.4.
16
40
1
41

16 4

32

Fig. 6.0.1 Fig. 6.0.3

26
2 16
5

Fig. 6.0.2. Fig. 6.0.4.

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Overhauling instructions

5. Mount the wear ring (14, with O-ring 46,

Fig. 6.0.5) for the lower seal.

Check measurement:
128 mm from top surface of the wear ring
to top of the shaft.

6. Put the key (48) onto the shaft and mount

the gear (pre-heat gear wheel (11) to +70°C
for easier assembling), Fig. 6.0.6.

7. Mount the indicator disc (67, lock washer

(27) and the bearing unit (28), Fig. 6.0.7.
14

Fig. 6.0.5.

48

11

Fig. 6.0.6.

67
28
27

Fig. 6.0.7.

19
Overhauling instructions

7. Tighten the bearing nut (28) with a KM 20

socket (SKF). The whole assy is tightened
by altering between rotating the housing A
several turns and tightening the bearing
nut until no play is achieved. Pretension
the bearing by tightening one notch (A)
and then lock the nut (B), see arrow Fig.
6.0.8.

8. Clean the interior housing.

9. Put the guide pins (49) in position and B

mount the gasket (65) by applying grease
before it is put in position, Fig. 6.0.9.
28
10. Mount the top lid (10), Fig. 6.1.0 and
tighten the cap screws (56). Fig. 6.0.8.

49

49
49

Fig. 6.0.9.

56

10

Fig. 6.1.0

20
Overhauling instructions

11. Mount the O-ring (36) and seal (31) on the

rear (top) flange (15), Fig. 6.1.1. 15 1
12. Mount the flange (15) on the top lid (10).
NOTE: Apply grease on the shaft (2) before
mounting, Fig. 6.1.1.

31

15
2

36

2 36 3

Fig. 6.1.1.

21
Overhauling instructions

7.0 Mounting guide bushing in the

rotation head, see Fig. 7.0 - 7.0.1
The diameter of the guide sleeve (68) must be
chosen to suit the drilling equipment to be used
(see spare part list).
1. Mount the V-seal (34).

2. Mount the locking ring (18). It is held in

place by the O-ring (45) in the groove.

3. Insert a guide bushing (68).

4. Assemble the cover (19), check that the

screw holes in the cover line up with the
holes in the locking ring (18) and tighten 34 18 45 68 19 52
the screws (52).
Fig. 7.0 Mounting guide bushing with seals etc.
18 Locking ring
19 Cover
34 V-seal
45 O-ring
52 Screws
68 Bushing

1 2 3
18

45

18

52
45

Fig. 7.0.1
4

22
Overhauling instructions
8.0 Rotation Unit oil Level
The rotation unit holds 0,6 liters of synthetic oil
(see Lubricant specifications).
The oil level can be accurately checked in the
three positions shown, 90 degrees down, 45
degrees down, and 45 degrees up.
It is important to have the correct oil quantity
when drilling at 90 degrees down and 90
degrees up. In these positions 0,6 liters is
needed to maintain lubrication of the gears.
When drilling between 45 degrees up and 45
degrees down, the oil level is correct as long as
oil can be seen in one of the two sight glasses.
The oil can be drained at 90 degrees down. Refilling and
When refilled to the top plug (1, see Fig. 8.0), the oil level check
gearcase contains 0,6 liters of oil. at 90° drilling
down (1)
Important: Do not overfill the gearcase as this
will cause overheating.

Oil drain at 90°

Oil level
check at 45°
drilling up

70, 75
62

62

Oil level check at

45° drilling down

Fig. 8.0. Rotation Unit oil level

1. Top plug

23
Printed Matter No. 6991 1230 01 Date: 02-10-10