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H200 ROCK DRILL

MAINTENANCE MANUAL

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1- GENERAL ARRANGEMENT ............................ 4

1-1 RETICULATION ................................................................................. 4
1-2 STORAGE ........................................................................................ 5
1-3 GENERAL REQUIREMENT .................................................................. 5
1-3-1....................... EQUIPMENT REQUIRED : ................................................................... 6
1-3-2....................... CHECKING AND TESTING AFTER ASSEMBLY :...................................... 6

2- DISMANTLING.................................................. 7
2-1 WORK HOLDING ............................................................................... 7
2-2 ROTATION AND PERCUSSION ASSEMBLIES ......................................... 7
2-3 HIGH PRESSURE ACCUMULATOR ASSEMBLY....................................... 7
2-4 DISSASSEMBLY OF THE PERCUSSION UNIT......................................... 7
2-4-1....................... WORK HOLDING............................................................................... 7
2-4-2....................... PISTON COVER ................................................................................ 8
2-4-3....................... REAR FLANGE .................................................................................. 8
2-4-4....................... REAR BEARING ................................................................................ 8
2-4-5....................... PISTON ............................................................................................ 9
2-4-6....................... VALVE ............................................................................................ 9
2-4-7....................... EALS AND O’RINGS........................................................................... 9
2-5 DISASSEMBLY OF THE ROTATION UNIT ............................................. 11
2-5-1....................... WORK HOLDING............................................................................. 12
2-5-2....................... FRONT CAP.................................................................................... 12
2-5-3....................... REMOVE THE MAIN PINION. ............................................................. 13
2-5-4....................... REMOVE THE HYDRAULIC MOTOR .................................................... 13
2-5-5....................... - REMOVE THE REAR BEARING ........................................................ 13
2-6 HIGH PRESSURE ACCUMULATOR ..................................................... 14
2-6-1....................... THREADED CAP TYPE ..................................................................... 14
2-6-2....................... SCREW TYPE ACCUMULATOR .......................................................... 15

3- INSPECTION .................................................. 16
3-1 MOUNTING FACES .......................................................................... 16
3-2 ROTATION ..................................................................................... 17
3-2-1....................... FRONT FLANGE AND ROTATION BODY .............................................. 17
3-2-2....................... DRIVER PINION............................................................................... 18
3-2-3....................... MAIN PINION ASSEMBLY .................................................................. 19
3-2-4....................... HYDRAULIC MOTOR ASSEMBLY ....................................................... 22
3-3 PERCUSSION ................................................................................. 23
3-3-1....................... PISTON .......................................................................................... 23
3-3-2....................... PERCUSSION BODY ........................................................................ 25
3-3-3....................... SHUTTLE VALVE ............................................................................. 27
3-4 HIGH PRESSURE ACCUMULATOR ..................................................... 28
3-4-1....................... THREADED CAP TYPE ..................................................................... 28
3-4-2....................... SCREWED ACCUMULATOR .............................................................. 29

4- ASSEMBLY ..................................................... 30
4-1 ROTATION UNIT .............................................................................. 30
4-1-1....................... MAIN PINION .................................................................................. 30
4-1-2....................... ROTATION HYDRAULIC MOTOR ........................................................ 33

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4-2 PERCUSSION UNIT .......................................................................... 34

4-2-1 ...................... FRONT PISTON SEALS ..................................................................... 34
4-2-2 ...................... REAR FLANGE................................................................................. 35
4-3 HIGH PRESSURE ACCUMULATOR ...................................................... 36
4-3-1 ...................... THREADED CAP TYPE ...................................................................... 36
4-3-2 ...................... SCREWED TYPE .............................................................................. 37
4-3-3 ...................... ACCUMULATOR INFLATION ............................................................... 39
4-4 FINAL ASSEMBLY ............................................................................ 40
4-4-1 ...................... ASSEMBLY OF THE ROTATION UNIT .................................................. 40
4-4-2 ...................... ASSEMBLY OF H.P. ACCUMULATOR. ................................................ 40
4-4-3 ...................... ASSEMBLY OF THE SHUTTLE VALVE ................................................. 40

5- DRIFTER CRADLE ......................................... 42

6- TIGHTENING TORQUE .................................. 44
7- HYDRAULIC MOTOR ..................................... 45
7-1 HYDRAULIC MOTOR TEST ................................................................ 46
7-2 DISMANTLING ................................................................................. 46
7-3 MODIFICATION OF MOTOR SINCE NOVEMBER 1999............................ 47
7-3-1 ...................... HOUSING MODIFICATION .................................................................. 48
7-4 ASSEMBLY...................................................................................... 49

8- WATER INJECTION HEAD............................. 52

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1-GENERAL ARRANGEMENT

ROTATION PERCUSSION

HIGH PRESSURE ACCUMULATOR

REAR FLANGE

PISTON COVER

P
T P
R
A

R
HYDRAULIC MOTOR

ROTATION BODY

1-1 Reticulation
Rotation
port P: oil supply
port R: main return
port T: case drain
CAUTION : The case drain port must not be connected to a return filter system. Any back pressure
generated by the return filter element will damage the lip seals and cause oil leakage.

PERCUSSION
port P: oil supply
port R: main return
port A: lubricated air

NOTE : DUE TO THE PRESSURE INVOLVED IN THE H.P. PERCUSSION CIRCUIT, SECOMA
RECOMMENDS THE USE OF 4 SPIRAL HOSES, SAE 100 R9 TYPE. SIMILAR HOSES SHOULD BE
INSTALLED ON THE DRILL FEED, AS THESE HOSES ARE TENSIONNED AROUND THE HOSE
REEL.
MAJOR ASSEMBLIES
The HYDRASTAR drifter consists of two independant assemblies : the rotation assy and the
percussion assy.

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Rotation assembly
The rotation assy includes an hydraulic motor which is directly coupled to a mechanical reducer
consisting of 2 rearing mounted pinions.
The assembly is lubricated by means of hydraulic fluid ; tightness of assy is assured owing to lipseals.

Percussion assembly
The percussion assy consists of :
a percussion body a piston a rear flange a high pressure accumulator an hydraulic directional control
valve a spring accumulator on the return circuit.

Instructions to end-users of HYDRASTAR 300-200 drifters

The complete rotation assy as well as the high pressure accumulator and the directional control valve
are common and can be used on both model 200 and 300 drifters.

1-2 Storage
The drifter should be thoroughly blown out to eliminate any dampness by means of compressed air,
outside, inside and the A port of the lubricated air supply circuit.

Dry compressed air should be used for blowing out via a water separator.

Storage procedure :
Lubricate the drifter by spraying storage oil or hydraulic oil on all external parts of the drifter as well as
through the A port of the lubricated air supply.
Plug the front cap.
Ensure that the rotation and percussion assemblies are filled with clean hydraulic oil : that is free of
impurities or water.
Place metallic caps over all feeder connections, and ensure that they are thoroughly tightened.
Wrap the drifter in a plastic film so as to protect it against dust and dirt.
Store the drifter in a dry and clean area.

1-3 General requirement

Assembly and disassembly of a drifter is not a very difficult operation, but it requires the highest
cleanliness possible and must only be carried out by skilled staff who are well versed in the procedures
described in this manual.
The assembly area of the workshop must be maintained in a spotless condition and protected against
the ingress of dust.

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1-3-1 Equipment required :

A source of clean and dry compressed air.
A cleaning bay with grease removing facilities.
N.B. : Follow the local rules as far as grease removing and ventilation are concerned.
Note : Parts that are assembled with loctite should be correctly cleaned to ensure maximum
effectiveness of this product.
Cleaning solvents should be filtered and replaced on a regular basis.
Hydraulic oil and grease should be clean and free of water.
Specific tools for assembly and disassembly should be to hand.
Torque wrenches should be correctly specified to meet the newton metres recommended in this
procedure.
Vice jaws should be protected by means of copper or aluminium inserts.
The following requirements should be reinforced :
the correct method and sequence of assembly the recommended torque settings the systematic
replacement of all seals during re-assembly.

1-3-2 Checking and testing after assembly :

It is recommended that the drifter is tested and checked before use or storage. A hydraulic test bench
will be required to ensure that all components have been correctly assembled, and that the following
test parameters are met :
oil flow oil pressures percussion rate rotation rate and wear of hydraulic motor
.
CAUTION : A shank should always be inserted in the drifter prior to operating it in the
percussion mode. Failure to comply with this requirement will cause the piston to jam
in the percussion body

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2-DISMANTLING

LIFTING HOOK 2-1Work holding

- Clamp the drifter in a vice.
- The vice jaws should be located
as shown.
- Remove caps from the feeder
connections.

2-2Rotation and percussion

assemblies
- Install a lifting hook in the
rotation assembly.
ZONE A VICE JAW LOCATION - Attach a lifting facility to the
lifting hook.
ASSEMBLY NUTS
- Unscrew the 4 assy nuts. Use a
24 mm ring spanner.
- Part the rotation assembly from the percussion assembly by gently knocking with a plastic mallet
alternatively on each side of the rotation body at zone A as shown.

2-3 High pressure accumulator assembly

O’RING

- Remove the 4 screws - use a 10 mm ’Allen’ key

- Remove the seals between accumulator and percussion body.
- Plug the hole in on the percussion body in order to avoid introduction of dust.
THE ACCUMULATOR SHOULD BE OVERHAULED AFTER EACH DISASSEMBLY.

2-4 Dissassembly of the percussion unit

2-4-1 Work Holding

- Clamp the percussion unit in a vice as shown on para. 2.1.

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2-4-2Piston cover
Unscrew and remove the piston. Use a 60 mm flat spanner.
This cover is assembled with « loctite « and it may be
necessary to heat it slightly (max. : 150°C/248°F).

2-4-3 Rear flange

- unscrew the 4 screws, use 14mm «ALLEN» key
.

- remove the rear flange, use extractor 070 0622.

2-4-4Rear bearing

- Remove the rear bearing.

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2-4-5 Piston

- Remove the piston by means of the hook

- Remove any Loctite residue left inside the "F"

tapped hole by means of a tap M18-150 .

2-4-6Valve
- Unscrew the valve cap - Use a 27 mm wrench.
- Remove the unit valve/ring manually.

2-4-7eals and O’rings.

Remove all piston seals.

The piston is sealed by means of 2 seals.
Each seal consists of an O-Ring seal mounted at the bottom of the groove and a jointing seal.

DO NOT FORGET TO REMOVE THE ’O’-RINGS.

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SEAL 1 SEAL 2

O-RING

SEAL

Cleaning
Remove any loctite residue on the following
- the supporting faces
- the assy screws the thread of the front flange and the rotation body
- the thread of the return accumulator : cover, body, rear flange inside the threads as described in para. 2-4-6 as
well as threads of the high pressure accumulator.Use a tap M12-125 (screw-type).

CAUTION : If loctite residue is left at the bottom of a hole and is not cleaned out, then the correct
contact between parts cannot be acheived during assembly despite the application of the
recommended torque.

ENSURE THAT ALL COMPONENTS ARE THOROUGHLY CLEANED AND BLOWN DRY WITH
COMPRESSED AIR.

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2-5 Disassembly of the rotation unit

REAR

MAIN PINION

REAR BEARING

SHANK STOP

FRONT BEARING

FRONT CAP

BRONZE DRIVER

FRONT

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2-5-1 Work Holding

- Clamp the rotation unit in the vice

- The vice jaws should be located as shown

Caution
DO NOT OVERTIGHTEN THE VICE
IN ORDER NOT TO COLLAPSE
THE SIDES OF THE ROTATION UNIT

VICE LOCATION

2-5-2 Front cap

Loosen and remove the front cap, by means of tool 065 0137.

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2-5-3Remove the main pinion.

Apply pressure to the shank stop. Do not use metallic
devices to remove the front bearing and the main
pinion.
Apply moderate pressure sufficient to overcome the
O’ring which seals the front bearing.

HYDRAULIC MOTOR
MOUNTING SREWS
2-5-4Remove the hydraulic motor
F
- Unscrew the 4 assy screws by means of a 12 mm ’Allen’
key.
- Take care not to loosen the mounting bolts in the
motor head as this will require specialized repair.
- Remove any « loctite « residue on the inside of the
F tapped holes by means of a tap M14-150

2-5-5- Remove the rear bearing

Install tool 834 0028 on the rear bearing and screw in
to pull the bearing off.

INSTALLATION OF TOOL 8340028

ON REAR BEARING

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2-6 High pressure accumulator

2-6-1 Threaded cap type

- Clamp the accumulator unit in a vice as shown.
- Remove the safety cap. Use a 46 mm spanner ref 365
0610.

WARNING : ENSURE THAT THE ACCUMULATOR

IS DEFLATED BEFORE ANY ATTEMPT IS MADE TO
DISMANTLE IT.

Vice location

065 0137 - Unscrew the plug (3 or 4 revolutions) by means of a 6 mm

’Allen’ key.
CAP - Remove the cover, by means of tool 065 0137.
- Remove all seals. Do not forget to remove the O-ring under
the cover.
PLUG - remove the accumulator diaphram.
RING - Clean all parts thoroughly.

O-RING

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2-6-2 Screw type accumulator

- Clamp the accumulator unit in a vice as shown.

- Remove the safety plug by means of a 46 mm spanner ref

365 0610.

WARNING : ENSURE THAT THE ACCUMULATOR

IS DEFLATED BEFORE ANY ATTEMPT IS MADE TO
DISMANTLE IT.

VICE LOCATION

- Unscrew the plug (3 or 4 revolutions) by means of a 6 mm

’Allen’ key.
- Remove the assy screws and install the pentagonal key
834 0034 in a 13 mm socket wrench.
- Remove the cover.
- Remove all seals.
- remove the accumulator diaphragm.
- Clean all parts thoroughly.

PENTAGONAL WRENCH 1Establish front flange thread backslash

834 0034 - Threads must necessarily be free of "Loctite" residue.
- Screw the front flange into the rotation body, leaving a
gap of 5 mm as shown.
- Install a dial indicator device as shown on the above figure.
- Measure the maximum backlash in the threads by pulling and pushing the front flange in
the rotation body.
If backlash is higher than 0,8 mm the front flange must be replaced.
- The bearing must be clean and free of grease :

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3-INSPECTION

3-1 Mounting faces

This method is used to check all contact faces between the various components of the drifter for wear.
Place a straight edge on the surface to be checked.
Determine the extent of wear by inserting a feeler gauge between the surface to be checked and the
straight edge.
Repeat the same operation on the other edges of the bearing face.
MAXIMUM WEAR ALLOWED IN THE MIDDLE OF EACH FACE: 0,1mm.

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3-2 Rotation

3-2-1 Front flange and rotation body

90.03 Maximum
CLEARANCE 5 mm

DIAL INDICATOR C

1 check front flange thread backslash

- Threads must necessarily be free of "Loctite" residue.
- Screw the front flange into the rotation body, leaving a gap of 5 mm as shown.
- Install a dial indicator device as shown on the above figure.
- Measure the maximum backlash in the threads by pulling and pushing the front flange in the rotation
body.
If backlash is higher than 0,8 mm the front flange must be replaced.

2 rotation body thread backlash:

Repeat the same operation with a new flange. In this case, the maximum backlash must not exceed 0,4
mm. Replace the rotation body if backlash is higher than 0,4 mm.

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3 Contact face

CARACTERISTIC
A WEAR

C
Measure the diameter B, MAXIMUM DIAMETER ALLOWABLE 90.05MM.

Measure the diameter of B, MAXIMUM DIAMETER ALLOWABLE 90.05MM.

Measure the wear on contact faces A and C as described Mounting faces page 16.
Maximum wear allowed in the middle of each face is 0.1mm.
Wear is shown by a discoloration of the metal.

3-2-2 Driver pinion

A A

C B

Check working areas A, B and C. Replace all parts that show deep score marks.
There should be no wear in driver pinion parts under normal running conditions.
CAUTION: Scoring and wear is caused by a dirty oil (foreign particles).

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3-2-3 Main pinion assembly

FRONT BEARING E

MAIN PINION
SPECIAL COATING

B
REAR BEARING

- Check: the condition of contact areas A and the condition of contact area of the rear bearing with the
corresponding areas of pinion B.
Replace all parts that show deep score marks.
CAUTION: Scoring and wear is caused by dirty oil (foreign particles).
- Measure the dimension E, minimum dimension = 49.80mm.

a) Rear bearing
This bearing carries most of the strain when
the drifter is in operation.
E
Important: Carry out a dye penetration
crack test.
- The bearing must be clean and free of
grease:
- Spray on the red product. Wait for at least
10 minutes. Wipe the part thoroughly and
then spray on the white detector product.
Any cracks will then become visible.

REPLACE BEARINGS THAT SHOW ANY

SIGNS OF CRACK.
- MEASURE DISTANCE E, MINIMUM: 9,90
MM

AREA TO BE CHECKED

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1 Main pinion
Maximum wear of the bronze driver.
Use a new shank to check for sleeve wear.
Put the shank into the sleeve. Measure the wear in one of the
grooves by means of a feeler gauge.
Maximum permissible wear is 5 mm.
CAUTION: Untimely wear of the bronze driver shows a lack of
lubrication.
Check the running condition of the air lubricator if excessive
wear is found.

MAXIMMUM WEAR
5mm

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2 Removal of bronze driver and stop shank

- Check the wear of the shank stop. Replace the stop if the wear is greater than 2 mm.
.

DISASSEMBLY
BRONZE
SHANK STOP
MAXIMUM WEAR DRIVER

2mm

SHANK STOP

DRIVER

PINION

DETAIL SHOWING CORRECT

POSITION OF THE DRIVER
TUBE

ASSEMBLY

Use a new shank during the assembly and disassembly process shown above.
Disassembly:
Use a press to push out the main pinion bronze driver and shank stop.
CAUTION: Take care not to damage the special coating on the pinion at the seal contact area.
Recommended method of assembly:
- Pre-heat the pinion in an oil bath (temperature: 150°C/ 302°F)
- Immerse the shank stop and the bronze driver in liquid nitrogen
In this case, it is not necessary to use a press.
DANGER: AVOID BURNS BY WEARING PROTECTIVE GLOVES AND USE PLIERS TO,
HANDLE PARTS.
If no liquid nitrogen is available:
- pre-heat the pinion by immersing it in a oil bath (temperature 150°C/302°F).
- install the stop shank by using a press. Use the same tools as for disassembly.

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Bronze driver:
- position the bronze driver by hand.
ENSURE THAT THE OUTER DRIVER SPLINES ARE LINE UP WITH THOSE OF THE PINION.
Before attempting to use the press make sure that the splines of the tool are fully in contact with the
driver splines.
- Press the bronze driver.
- when assembly is completed, the drive hole axis must be level with the pinion edge.
i

CAUTION: BEFORE DISASSEMBLING THE PINION, CHECK THE

POSITION OF THE DRIVER RELATIVE TO THE PINION. IF THE
DRIVER IS IN FRONT OF THE DRIVE HOLE AXIS THEN THIS SHOWS
THAT DRIFTER HAS BEEN USED WITHOUT A SHANK. THIS MAY
RESULT IN THE PISTON BEEN JAMMED IN THE PERCUSSION BODY
AND CAUSING SERIOUS DAMAGE.

3-2-4 Hydraulic motor assembly

A
- Check condition of spigot B.

CAUTION: wear to the spigot area B

can be caused by vibrations arising
out of operating the drifter with the
hydraulic motor not correctly tightened
onto the rotation housing.

Check for wear on mounting face A by using the

procedure Mounting faces page 16.
B
HYDRAULIC MOTOR ASSEMBLY Maximum allowable wear: 0.1 mm.

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3-3 Percussion

3-3-1 Piston

A
AFTER AREA B
GRINDING

AREA C AREA D

PISTON EDGE

STRIKING FACE DETAIL

- Check the striking face of the piston. After extensive use the piston can develop an edge as shown
above.
- grind the edge so as to re-establish the original piston profile.
- this area should be polished out after grinding.

Check surface condition on working areas B, C and D. Scratches or marks should be polished out
before re-use.
If it is not possible to polish out deep score marks, then the piston should be replaced.
Scoring is caused by foreign particles in the hydraulic oil. Take care to blow out and cap hydraulic
hoses when replace them. If the piston shows deep scratches all around the area C, this indicates that
the drifter has been used without a shank adaptor. In such a case, it may be difficult to remove the

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piston from the percussion body due to jamming.

Carry out the following procedure in the event of jamming in area C:

- Remove the piston.

- Remove all seals.
- Remove scratches within the percussion body bore by lapping it with an old piston and lapping paste.

If scoring is severe, polish with a ball hone and then lap with an old piston and paste.

Thoroughly clean the percussion body. Do not install any seals.

Oil and try a new piston. The piston should move without any resistance.
A new piston should be installed if lapping process has been carried out.

Annular jamming in area D is caused by misalignment between the rear bearing and the piston.
This misalignment is due to wear on the contact area of the rear flange and/or wear on contact area of
the percussion body.

NEVER TRY TO RE-USE A PISTON OR A REAR BEARING WHICH HAVE JAMMED

INTO THE PERCUSSION BODY

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3-3-2 Percussion body

1 Contact face

- Check the contact face of the rear flange for wear.

MAXIMUM WEAR: 0,1 mm
- In the same manner, check the contact face of the rotation body for wear.
MAXIMUM WEAR: 0,1 mm.

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2 Accumulator contact face

O-RING
A B C

Check for corrosion on faces A and B.

- In the event of severe corrosion, the percussion body should be machined out in order to re-establish
a good mounting condition.

Caution : Corrosion in the accumulator area is due to water penetrating between the
accumulator and the percussion body. Correct assembly by means of a new O-RING and grease,
will prevent corrosion in this area.

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3-3-3 Shuttle valve

RING SPOOL
AREA B AREA A AREA C

WEARING DETAIL

PLUG

- check for scratches in areas A and B and polish out light scratches. Annular wear calls for
replacement of component. The drifter efficiency depends on the good condition of the shuttle valve.

- REPLACE THE PLUG IF IT HAS BEEN GROOVED BY THE SPOOL.

- Polish the facing body bore of area C using an old valve and lapping paste, if scratches are present.
LAPPING PROCEDURE:
¤ coat the area C of an old spool with lapping paste.
¤ the outer end of the spool is threaded so as to install the drifter lifting hook for lapping process.
¤ finish lapping by using the finest grade paste.
¤ thoroughly clean and blow out the bore.
¤ oil a new spool then try it. Repeat the lapping process until the spool will move freely within the body.
¤ INSTALL THE NEW SPOOL.

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3-4 High pressure accumulator

3-4-1 Threaded cap type

DIAL INDICATOR

5mm

MOUNTING FACE

Thread test procedure:

- set a 5mm gap between the cap and the body.
- install dial indicator on top of the cap.
- Move the cap up and down in the.
WARNING: SAFETY RULE
REPLACE BOTH COMPONENTS: CAP AND BODY IF THE BACKLASH IS BEYOND 0.3mm.
Check the mounting face for corrosion. Corrosion can be eliminated by using the correct assembly
procedure (grease and O-RING).

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3-4-2 Screwed accumulator

MOUNTING SCREW

MOUNTING FACE

- check the mounting face for corrosion. Corrosion can be eliminated by using the correct assembly
procedure (grease and O-RING).

Mounting screws
- measure the length L of all screws.
WARNING: SAFETY RULE
REPLACE SCREW IF THE MEASURED LENGTH IS BEYOND 45.3mm.

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4-ASSEMBLY

4-1 Rotation unit

4-1-1 Main pinion

1Rear lip seal
- slightly oil the rear bearing the seal and the tool
834 0026.
- install the lip seal together with its ring in the
tool.
- place the tool in a vertical position as shown.
- Knock the tool shaft gently with a plastic mallet
O-RING to insert the seal.
TOOL 834 0026 - Remove the tool.
Ensure that the seal is correctly positioned. It
must be parallel to the edge of the bearing.
- install the O-RING.

SEAL

REAR BEARING
2Rear bearing
position the rotation body vertically as shown
FLAT AREA
- oil the bore carrying the rear bearing

- install the bearing by hand in order to line up

the two locking flat areas.

- press in the bearing

- fill up the lip spring area with grease

3Install the main pinion

- keep the rotation body in the same position.
- Oil the guiding bore of the rear bearing.
- install the main pinion by hand.
- rotate the pinion while easing past the lip of the seal.
CAUTION : check that the lip of the seal has not been rolled outward during pinion installation.

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4 Front bearing
- Install the lip seal - use tool 834 0031.
NOTE : for seal installation refer to the detailed
view.
- install the outer O-RING.

LIP SEAL DETAIL

O-RING

LINE UP
MARKS - Oil the body bore carrying the bearing.

. Position the rotation body as shown in the

LOCKING PIN opposite figure and install the front bearing
manually.

NOTE : note the position of the locking pin

rebates. The two line up marks should be
opposite each other once the bearing is in
position.
INNER FACE - push the front bearing fully into position using
tool 834 0031.

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5 Preassembly of the front flange

.- install the dust seal within the flange by hand.
Do not use any tool. Note the position of the lip of
the seal which must be turned towards the front
CHAMFER
of the drifter. As indicated in the diaphragm.

- install the bronze ring.

NOTE : THE CHAMFER SHOULD BE FACE
TOWARD THE FRONT BEARING.

LOCKING RING

6Front flange
- thoroughly, clean the threads of the rotation
body and the front flange.
- apply some "Loctite 242E" to the threads.

DO NOT INSTALL THE LOCKING RING ON A

DRIFTER ALREADY USED.
- screw ON the front flange and firmly thighten it
using tool 065 0137.

TOOL 065 0137

Install the rear dust seal with the lip facing towards
the rear of the rotation body.
Press against the bottom of the seal with a suitable
screwdriver until it is seated on its full diameter.

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4-1-2Rotation hydraulic motor

Driver pinion bronze bearing :
- place the locking pin in position on the bearing and
apply some grease to maintain the pin in position.
- oil the rotation housing bore.
Seal
- install the bearing into the housing by hand, so as
to line up the pin with one of the two locking holes.
- to complete the installation, knock gently with a
PIN plastic mallet.
- put a new seal on the drain port
Carry out the same process to fit the second bronze
bearing into the assembled motor.
Assembly of hydraulic motor to rotation body:
O-RING - oil both bronze bearings.
- Put a new O-ring on the assembled motor.
- Install the driver pinion onto the motor.
- Spread some grease 208 5150 over the whole seat.
Insure that all mating surfaces of the hydraulic motor
and the rotation body are covered. The recommended
grease is waterproof and prevents corrosion in this
area.
- Place the motor in the rotation body.
- Turn the main pinion in order to line up the teeth on
both pinions.
CONTACT FACE
Use a shank for this purpose.
- Strike the back ot the hydraulic motor with a plastic
mallet to obtain the correct positionning of the outer
O-Ring.
- Coat the assy screws with "Loctite 242E" and insert them in their respective holes.
- Tighten the screws - torque 15 m/daN.
Use a 12 mm ’Allen’ key.
ASSEMBLY OF THE ROTATION UNIT HAS NOW BEEN ACHEIVED.

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4-2 Percussion unit

4-2-1 Front piston seals

O-RING

PISTON SEAL

NOTCHE

DUST SEAL

O -RING

PISTON

FRONT REAR

- Oil the two O-rings and put them in their respective grooves.
Installation of piston seals :
- Bend the seal manually, as shown in the diagram opposite in order to allow its introduction in the
percussion body.
Notches must face towards the inside of the percussion body.
- Put the area A fully in contact with the O-ring.
- Return the seal progressively to its former shape.
- Complete the installation by using a plastic tool (for instance a screw-driver handle)
- Oil the seals once the assembly is completed.

Carry out the same process to install the dust seal.

area A

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4-2-2 Rear flange

REAR BEARING
CONTACT FACE

NOTCHE

PERCUSSION BODY

PISTON END CAP

- Install the seals on the percussion body. Observe the direction of the backup rings.
- Install the piston seals on the rear bearing.
Carry out the same process as described for the installation of the front piston seals, and ensure that
the notches are turned toward the inside of the percussion body.
Install the outside seals on the rear bearing. Observe the direction of the backup rings.
Fit the piston cap - use ’’Loctite 242 E’’ on threads. Tighten the cap firmly.
Clamp the percussion body in the vice with the vice jaws located as in para. 2-1.
Oil the piston thoroughly.
Put the piston into the percussion body and knock it gently with a plastic mallet to ensure that the seals
are correctly seated.
Oil the rear bearing. Place the rear bearing in the rear flange as shown above. Knock gently with a
plastic mallet to ensure that the O-Ring is correctly seated.
Coat the seat of percussion body with ’’Loctite 573’’ P/N 371 2040.
Place the rear flange in position by hand, knock the piston cap with a plastic mallet to ensure that the
O-Ring is correctly seated.
Coat the assembly screw threads with ’’loctite 242’’ and insert them in their respective holes.
Tighten the screws, torque 35 m/daN.
Use a 27 mm spanner.

4-3 High pressure accumulator

4-3-1 Threaded cap type

- Grease thoroughly the body part designed to carry the diapragm. Use grease 208 5150.
This grease is included in the accumulator repair kit.
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SAFETY CAP PLUG

CAP
SEAL RING
O-RING

O-RING

BODY

CORROSION MARK DIAPHRAGM

O-RING GROOVE
OIL SUPPLY

- Put the diapragm into the accumulator body.

- Grease the inside of the cover that bears against the diaphragm. Install the O-ring.
- Screw the cover onto the accu body firmly. Use tool 065 0137
DO NOT FASTEN THE COVER WITH A LOCTITE PRODUCT.
- Oil the cover port thread and the nitrogen plug. Fit a seal ring to the plug and screw it into the port.
Tighten the plug until it makes contact with the cover. Unscrew 2 revolutions in order to let the nitrogen
flow when inflating.
- Have the accumulator inflated. Refer to the inflation procedure.
CAUTION thoroughly check :
- Accumulator seals : immerse the accumulator in water. Check specially the plug area.
No leak - even small - is allowed. If leakage is detected, replace the plug and/or the seal ring.
- after inflating, the mark located in the center of the diaphragm, must be perfectly concentric to the oil
inlet port.
If not, it shows that the diapragm has been twisted during the tightening process and it’s life will be
consequently greatly reduced. If this should happen, bleed the accumulator and repeat the assembly
process.
- install the safety cap together with its O-RING.

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4-3-2 Screwed type

PLUG SCREW
SAFETY CAP
COVER SEAL RING
O-RING

BODY
DIAPHRAGM
CORROSION
O-RING

- Grease thoroughly the body part designed to carry the diaphragm. Use grease 208 5150.
This grease is included in the accumulator repair kit.
- Put the diaphragm into the accumulator body.
- Grease the inside of the cover that bears against the diaphragm.

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SCREW 2

5 7
3

6
8 4

SCREW 1

- Tighten screws number 1&2 in order to compress the diaphragm until the cover is in CONTACT WITH
THE BODY.
- Tighten the other screws manually until they make CONTACT WITH THE COVER.
- Ensure that the contact is correct by using the pentagonal key 834 0034 mounted in a 13 mm socket.
For this operation, do not use a ratchet or a lever.
TIGHTENING OF SCREWS.
- Install the socket fitted with the pentagonal wrench onto a ratchet.
- Tighten each screw by 90° in the following sequence :
3-4-5-6-7-8.
- Unscrew the screws 1 and 2.
- Repeat the sequence for both screws.
- Oil the cover port and the nitrogen plug. Tighten the plug until it makes contact with the cover. Then
unscrew by 2 revolutions in order to let the nitrogen flow when inflating.
- Have the accumulator inflated. Refer to the inflation procedure.

CAUTION thoroughly check :

- Accumulator seals : immerse the accumulator in water. Check specially the plug area. No leak - even
small - is allowed. If leakage is detected, replace the plug and/or the O-ring.

- Install the safety cap together with its O-ring.

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4-3-3 Accumulator inflation

INFLATION KIT
SAFETY CAP
KNOB

HOSE
O-RING

BLEEDER GAUGE

NUT PLUG

6mm ’ALLEN’ WRENCH

ACCUMULATOR
WARNING : THE ACCUMULATOR MAY ONLY BE INFLATED WITH NITROGEN N2.
OTHER GASES COULD CAUSE AN EXPLOSION.
- Install the inflation kit ref. 7684001 onto the cover. Be sure that the ’allen’ key is correctly placed in the
plug.
Turn slightly the knob if necessary. Screw firmly the nut manually.
- thight the bleeder
- Open progressively the nitrogen bottle. Shut when pressure reaches 65 bars. Let the pressure
stabilized, adjust if need be.
- The nitrogen bottle being thoroughly closed, adjust the pressure at 55 bar by unscrewing very slightly
the bleeder so that to eliminate the over-pressure.
- Tight manually the plug by using the knob.
Do not use a plier in order not to deteriorate the inflator.
- Drain the pressure enclosed within the inflator and hose by unlocking the bleeder.
- Remove the inflator
- Lock the jointing screw by using a 6 mm ’Allen’ key.
- Process with sealing test by immersion into water before fastening of the cap.

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4-4 Final assembly

4-4-1 Assembly of the rotation unit

.

CONTACT FACE

NUT

- Coat the contact face with "Loctite 573".

- Tighten the nuts - torque 20 m/daN. Use a 24 mm spanner.

4-4-2Assembly of H.P. accumulator.

- Install the seal on the percussion body
- Coat the seats with grease 208.5150
O-RING - Install the accumulator. The machined bleeding
groove should face toward the rear flange.
SEAL
- Insert the assy screws. Tighten 2 screws.
Remove excess grease from the O-ring slot. -
Loosen the screws.
- Install the corrosion O-ring
- Coat the screws with "Loctite 242 E" and tighten
torque 6,5 m/daN.
Use a 10 mm ’Allen’ key.

4-4-3Assembly of the shuttle valve

- Install the ring on the valve spool. Refer to

detailled view for correct positionning of the ring.

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SHUTTLE VALVE RING DETAIL

PERCUSSION BODY

O-RING

SPOOL

RING
CAP

- Oil all parts : spool, ring and cap.

- Place the spool and the ring into the percussion body and ensure that parts are correctly seated.
NEVER FORCE THE VALVE INTO POSITION BY USING A TOOL OR THE CAP.

- Fit the O-ring into the cap.

- Screw on the cap, use a 27 mm socket.

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5-Drifter cradle

ORIGINAL DIMENSION

WEAR LIMIT

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THE DRIFTER CRADLE MAINTAIN THE FLUSHING END, THE DRIFTER ITSELF AND THE SHANK
ADAPTOR LINE UP.
For maximum efficiency the cradle should be checked on regular basis. This control should be
conducted more often when the drilling conditions are severe : hard ground, acid water.

Thoroughly check :
- the contact area of the flushing head and its relevant spigot bore..
- the dimension of the locking key.

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6-Tightening torque

C D
A

Tightening procedure without the use of a torque wrench.

- Screw in the bolt or the nut until mechanical contact is made between the part to be fasten together.
ENSURE THAT THE BOLT OR NUT ARE NOT SUBJECT TO ANY PRELOAD.

- Position the pool so as to perform the tightening angle in one operation. Note the starting position of
the wrench.
Refer to the figure below in order to carry out the correct tightening.
TIGHTENING TORQUE :
Both screws A : tightening angle after contact 90°
0

60 0
90
0

Both screws B : tightening angle after contact 45° 45

0
30

4 Nuts C : tightening angle after contact 90° 11 12 1

10 2
4 Screws D : tightening angle after contact 90°
9 3

4 Screws E : tightening angle after contact 60° 8 4

7 5
6

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7-Hydraulic motor

MAIN SHAFT

DISTRIBUTOR SHAFT

DISTRIBUTOR

FLANGE

INLET FLANGE

MOTOR

SPRING

BODY

BASE PLATE

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7-1 Hydraulic motor test

Once the assembly of the drifter has been completed,

connect the port P of the motor to an hydraulic power pack.
Lock the main pinion using a shank and appropriate tool.
Install two short hoses on port R and T to collect the oil
leakage from those ports.
Check and record the flow from ports R & T,
MAXIMUM FLOW ALLOWABLE 6liters /mn using an inlet
pressure of 100bar.
Replace the motor if the oil leakage exceeds this level.

NOTE : DO NOT DISMANTLE THE HYDRAULIC MOTOR

IF THE LEAKAGE RECORDED IS BELOW 6 litres/mn.

7-2Dismantling
- Remove the motor.
It is not necessary to remove the rotation unit if only the
hydraulic motor is being removed.
- Place the hydraulic motor in the vice, the shaft located as shown.
- Undo the 4 screws using a 12mm ’Allen’ key.
- Remove the flange and the main shaft.
- Remove the motor by sliding it toward.
- Remove the base plate, the distributor shaft and the distributor.
- To remove the inlet flange knock the mounting face on a piece of wood or plastic.

ALL THE PARTS SHOULD BE REPLACED AT THE SAME TIME.

Clean and blow out the motor body.

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7-3 modification of motor since november 1999

Distributor plate driver shaft

THIN TEETH
ROTOR SIDE

THICK TEETH
DISTRIBUTOR SIDE

Supply flange

Spacer

Lock pin

Supply flange

O rings

Spring

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7-3-1 housing modification

Proceed with housing modification after complete disassembly of the hydraulic motor.
The modification consist in drilling a hole to allow installation of the new lock pin.
Remove both O Rings from the supply plate.

HOLE DETAIL

5 mm
9.5 mm

Place the supply plate in the housing.

NOTE: There is no angular position for this supply plate.
Using the plate as a guide drill a 5 mm diameter hole in the rotation housing, refer to hole detail.
Clean up thoroughly the motor housing after drilling.
Install the lock pin, P/N 373 0203, supplied together with the new hydraulic motor kit.
Lock pin dimension: Ø5mm x 15mm.

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7-4 Assembly
- Place the motor in the vice..
SPACER PIN - Oil the inlet flange together with both O’rings.
- Install the spring.
- Install the inlet flange by hand, the lock pin facing the hole
within the body.
- Install the spacer pin.
- Using the handle of a hammer or a plastic tool force the
inlet flange fully into position..

PIN
HOW TO OBTAIN THE CORRECT ROTATION DIRECTION.
SPRING The two moving parts within the hydraulic motor are : the
rotor and the distributor. Both parts are connected by the
distributor shaft
The direction of rotation depends on the correct timing between those two parts.
NOTE : on the distributor, one tooth is alway directed between two ports.
on the rotor, one tooth is alway directed to the narrow part of the rotor and the other tooth
faces the wider part.
DISTRIBUTOR ROTOR
- Put a paint marks on any opposite teeth of the distributor shaft as shown .
Pressure Correct position
Correct position
During assembly of the distributor shaft, install the marked tooth in any of the distributor teeth shown as
correct. ONE PRESSURE PORT SHOULD BE LOCATED AT THE RIGHT HAND SIDE OF THE
MARKED TOOTH OF THE SHAFT, THE RETURN PORT ( hole directed to the side ) LOCATED AT
THE LEFT HAND SIDE.

lock pin
- Install the distributor.
drain
DISTRIBUTOR SHAFTshaft refering to the correct
- Install the distributor
positionning.
Return
distributor shaft
- Install the base plate. The lock pin and the drain port
should be located in the position shown
DISTRIBUTOR

NEW MOUNTING

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 MEYZIEU cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
 50/52 H200 ROCK DRILL 25-04-2005 ER-OR-FL

Insert the shaft in the distributor and place the thick marked tooth between two ports as shown.

ROTOR

Correct position of the marked tooth

THIN TEETH ROTOR SIDE

THICK TEETH DISTRIBUTOR SIDE

Correct position of the marked tooth

Pressure
inlet

DISTRIBUTOR
Return
outlet

- Graisser la garge du joint torique afin de la maintenir en

position

Mettre en place le joint torique

O-Ring groove DRAIN

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 MEYZIEU cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
25-04-2005 ER-OR-FL H200 ROCK DRILL 51/52

- Mettre en place le moteur. Respecter la position du tou de

JOINT drainage, engager le pion d’immobilisation dans le trou du
TORIQUE
moteur.
- Install the motor unit. Ensure that the drain port is facing
the drain port of the base plate, the lock pin should be in the
MOTEUR
correct position in the motor hole.
Special care should be taken to maintain the rotor roller pins
in the origal position.
Refer to the correct positioning of the rotor.
- Put some grease in the O-Ring groove so as to maintain
CORPS
the O-Ring in position during the assembly process.

- Install the main shaft.

- Install the flange. The drain hole should be facing the drain
hole of the motor.

- Put some ’LOCTITE 242 E’ on the screw threads.

- Install the bolts so as to keep all the components in the
correct place.
The motor assembly can then be rotated in the vice to make
the tightening easier.

- Use a 12mm ’’ALLEN’’ key.

TIGHTENING TORQUE : 60 mN or using the angular
rotation of 40° after contact.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 MEYZIEU cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
 52/52 H200 ROCK DRILL 25-04-2005 ER-OR-FL

8-Water injection head

BODY
A
CHECK VALVE
LUBRICATION CHANNEL
FLANGE
SHANK GUIDE

B
WATER SEALS

BODY :
- Check the contact face A, MAXIMUM WEAR 0.2mm.
- Check that the face A is perpendicular to the bore B.

FLANGE :
- Maximum allowable wear on the shank contact face 2mm

SHANK GUIDE CARTRIDGE :

SAFETY SEAL

WATER SEALS

LUBRIFICATION
GROOVES

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 MEYZIEU cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80