REPAIRS MANUAL
IR 10, IR 12, IR 20, IR 22
Art nr 1025 915
Engelska
2005 01 05
Indexator AB, Box 11, S-922 21 Vindeln, Sweden
Tel + 46 933 148 00, Fax + 46 933 148 00
[email protected] Assembly aids:
Lifting eyelet 2 off M16/M20/M24
Lifting eyelet 2 off M10
Nut wrench 1 off IR 1, IR 12 8000 345
IR 20, IR 22 8000 545
Vane compressor 1 off IR 10, IR 12 L 8000 354
IR 20, IR 22 8000 581
IR 12 3120 329
Adapter plate main shaft 1 off IR (All models) 3100 324
Adapter plate motor 1 off IR 10, IR 12 3120 044
IR 20, IR 22 3120 139
Assembly tool stator frame 1 off IR 10, IR 12L 3100 328
IR 20, IR 22 3100 327
IR 12 3120 630
Rotation tool 1 off IR (All models) 3100 329
The following illustrations show Rotator IR 10/20H
(Hydraulic). The IR 10M and IR 20M (Mechanical)
have a swivel cover instead of the hydraulic motor.
These instructions apply also in principle for all IR
models.
Maintenance instructions.
Grease the rotator (Statiol Uniway Li62 or
equivalent).
Lubricating intervals for normal use every 50 hours.
In very
dirty conditions at least twice daily.
Ensure that all bolts joints are properly tightened.
Ensure that there are no cracks in the rotator mounts.
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Important! If necessary to change a roller
bearing, the complete bearing set needs
to be replaced. A complete bearing set
includes the roller bearing and bearing
race.
Fig. 1
Turn the rotator upside down before starting to
dismantle it. Unscrew the motor from the swivel
section. Lift the motor with the aid of the lifting
eyelets (M10).
(Repair of motor, see figures 16-26.)
Fig. 2
Loosen set screws in the nut. The locking pins will
not be fully released by loosening the set screws.
Lightly tap the nut, with a plastic mallet close to the
set screws to loosen the locking pins. Use the nut
wrench to screw the nut off the shaft thread.
Fig. 3
Screw in two screws in the sides of the swivel
housing. Using a crane, carefully lift the swivel
housing from the main shaft. The roller bearing will
then be released from the swivel centre and follow
the upward movement.
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Fig. 4
Remove the glide O-rings from the swivel housing.
Using a sharp knife sever the glide sleeves, taking
great care not to damage sealing surfaces. Then
thoroughly clean the sealing surfaces and the glide
O-ring grooves.
Fig. 6
Oil the glide O-rings before fitting. Fit the new glide
O-rings in the grooves by carefully bending them
into a kidney shape. It is essential that sharp bends
are avoided. Use a finger to return the O-rings to
their normal shape.
Fig. 7
Proper tools for dismounting and mounting are
required when bearing races need to be replaced.
The housing should be preheated to 50-60°C (120-
140°F) when mounting new races.
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Fig. 8
When replacing the roller bearing on the swivel
centre the bearing should be preheated to
40-60°C ( 100-140°F). Grease the taper roller
bearing so that it is filled with grease even inside the
roller cage. Then clean the sealing surfaces and oil
the swivel centre before refitting the swivel housing.
Fig. 9 (IR10 /20HPL only)
Before the swivel housing assemblies back on the
main shaft, the pressure valves for the grapple
functions should be disassembled and cleaned.
Assembled it back in following order, pressure
valve, spring and plug. Tighten the plug with 40 Nm
(29 lbf·ft)
Fig. 10
Carefully lower the swivel housing onto the main
shaft. (See figure 3). Preheat the roller bearing to 40-
60°C (100-140°F), fill the roller bearing cavity with
grease and mount onto the main shaft.
Fig. 11
Lubricate the nut with oil. Tighten the lock nut with
a torque wrench while rotating the swivel housing at
the same time (important). Use a calibrated torque
wrench to ensured the correct torque. IR 10/12: 450
±100 Nm (330lbf·ft),
IR 20/22: 900 ±100 Nm (665 lbf·ft). Secure the nut
by first screwing the set screws lightly against the
shaft thread, then tighten the screws alternately and
evenly to a torque of 35 Nm (25lbf·ft) (same for all
IR rotators).
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Fig. 12
Top up the space with grease.
Fig. 13
Place the O-rings in position and fit the hydraulic
motor, or the swivel cover. Make certain that the
guide pins fit into the proper holes. Tighten the
screws crosswise to a torque of 120 Nm (90 lbf·ft).
Fig. 14
Fit the dust seal in the joint between the main shaft
and the housing.
Fig. 15
Fill the rotator with grease through the grease nipple.
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Fig. 16
Motor repair
Remove the two screws holding the motor together,
and carefully tap away the motor end cover with a
plastic mallet. Also remove the pressure valve and
spring, and the plug in the motor end cover. Remove
the magnetic plug.
Fig. 17
Carefully lift up the stator ring a little way, with the
aid of a suitable tool, and take away the pressure
valve to allow the vane compressor tool to be
positioned.
Fig. 18
Hold the spring-loaded vanes in the closed position
with the vane compressor. Now lift off the stator
ring.
Carefully release the vane compressor and take out
the vanes and springs.
Fig. 19
Lift out the motor shaft. Remove the glide O-rings
from the motor top and end cover. Using a sharp
knife sever the glide sleeves, taking great care not to
damage the sealing surfaces. Then thoroughly clean
the glide O-ring grooves. Oil the seals before fitting
them. Fit the new seals in the grooves by carefully
bending them into a kidney shape.
It is essential that sharp bends are avoided. Use a
finger to return the glide O-rings to their normal
shape.
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Fig. 20
Oil the swivel chamber, then mount the shaft and
new O-ring in the motor end cover. The vane springs
must be positioned in their matching spring seats
when the vanes are fitted in place. Press the vane
assembly together using the vane compressor.
Fig. 21
Oil the inside of the stator ring and mount the stator
ring into position as shown by figure 21. Fit the
pressure valve, first the spring with the narrow side
upwards and then the pressure valve with its taper
upwards. Tap the stator ring down carefully using
a plastic mallet. Check the position of the O-ring.
Ensure that the pressure valve comes into position as
the stator ring is being tapped into place. Check, for
example using a screwdriver, that the pressure valve
has spring action (important).
Fig. 22
Clean the restrictors from dirt. Mount the restrictors
as shown in the above illustration.
Fig. 23
Oil the o-ring and place it in its groove. Then fit the
bottom motor end cover. Make certain the guide pins
are aligned.
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Fig. 24
Fit the next pressure valve through the hole in the
motor end cover, with the taper first. After that the
spring with the narrow side first. Then screw the
plug and the rubber-steel washer back into place.
Tighten to about 40 Nm (30lbf·ft).
Fig. 25
Screw the motor together with the two M10 screws.
(Max. 60 Nm(45lbf·ft).)
Fig. 26
Position the small O-rings and mount the hydraulic
motor, lifting the motor with the help of the eyelets.
Make certain that the guide pins align properly with
their holes. Tighten the screws crosswise to a torque
of 120 Nm (90lbf·ft).
Fig. 27
Hoist the rotator with the aid of the lifting eyelets
screwed into the swivel centre.
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