8.-Rock Drill - Disassemble - HPR5128 6832

29/8/2018 MD5125 Hydraulic Track Drill Engine only SEZ00001-UP (MACHINE) POWERED BY C11 Engine(SEBP7135 - 10) - Documentation

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Welcome: franciscoolivares
Product: ROTARY/TRACK DRILLS
Model: MD5125 ROTARY/TRACK DRILLS SEZ
Configuration: MD5125 Hydraulic Track Drill Engine only SEZ00001-UP
(MACHINE) POWERED BY C11 Engine

Disassembly and Assembly

MD5125 Rotary / Track Drill Machine Systems
Media Number -UENR7309-04 Publication Date -01/09/2016 Date Updated -19/09/2016
i06772734
Rock Drill - Disassemble - HPR5128 / 6832

SMCS - 79D0-015
General Tips on Drill Overhaul
Wear eye protection in order to prevent possible personal injury while

performing the following steps.
NOTICE
DO NOT wear loose clothing that can get caught in rotating parts.
Note: Replace all seals when drill is being disassembled for rebuild. Refer to parts manual for seal kits.
Special Tools
Table 1
Special Tools
Tool Part Number Part Description
A Locktite Thread Locking Compound

B Locktite 518 Gasket Eliminator
507-2345 Seal installation tool (seal size 1 1/2 in. I.D. to 2 in. I.D.).
C
507-2346 Seal installation tool (seal size2 in. I.D. to 3 in. I.D.).
D 398-3129 Tool Group (Hydraulic Rock Drills)
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Drill Disassembly General Information
Illustration 1 g06111230
HPR5128 Major Components
(1) Water Swivel Housing
(2) Rotation Housing
(3) Cylinder
(4) Backhead
(5) Low Pressure Accumulators
(6) High Pressure Accumulators
(7) Automatic Valve
The drill is made up of three basic sections, water swivel, rotation housing, and cylinder / back-head area. Refer to
illustration .
Water Swivel - The swivel contains a bushing to guide the front of the shank and seals to direct the water into the
shank and to the bit.
Rotation Housing - The rotation mechanism is made up of the chuck driver assembly, rotation motor, and the
bearings and bushings to support the drive components.
Cylinder / Backhead - The cylinder / backhead area contains the hammer and hammer bearings, the automatic
valve components and the high and low-pressure accumulators. The cylinder is closed at the back by the backhead.
Note: For complete disassembly of the drill, discharge the accumulators first.
Water Swivel Assembly - Removal
Water Swivel Housing Removal
1. Remove locknuts (1), spring washers (2) and bolts (3) that retain the water swivel.
2. Remove the swivel assembly (4).
3. Remove the shank (5) and thrust plate (6).
Reference: For inspection and repair procedures refer to M0074441 Hydraulic Percussion Rock Drills HPR5128
& HPR6832 Reuse and Salvage Guideline
Rotation Motors - Removal
Rotation Motors Removal
The motors can be removed from the adapter plates (3) by removing the four allen head bolts (1), or they can be
removed with the adapter plates (3) by removing the two nuts (2) that hold the adapter plates (3) to the rotation
housing.
Note: It is not necessary to remove the motors from the adapter plates, unless they have been leaking or need to be
replaced. Generally the motors are trouble free except for occasional shaft seal replacement.
Rotation Housing - Removal
Personal injury or death can occur from heavy components falling

during removal or installation.
Properly support the component with a suitable lifting device during

removal or installation.
Rotation Housing Removal
With drill secured on workbench and rotation housing supported with a suitable lifting devise; remove the five
bolts (1) and nuts (2) that hold the rotation housing to the cylinder. Separate the rotation housing from the cylinder;
you may need to use a screwdriver to pry them apart.
Rotation Cover - Removal
Rotation Cover - Removal of two lower bolts
Rotation Cover - Removal


With the rotation motors removed there remains only two bolts (1) that need to be removed at the bottom of the
cover. After removing these two bolts, lift off the rotation cover; you may need to pry the cover from the housing
with a screwdriver.
Rotation Housing - Internal Parts
Rotation Housing Internal Parts
(1) Seal
(2) Rotation Cover
(3) Bushing
(4) Seal
(5) Roller Bearing
(6) Dowel Pin
(7) Thrust Plate
(8) Chuck Driver
(9) Shank Bushing
(10) Thrust Washer
(11) Chuck
(12) Adapter Cover
(13) Pinion Gear
(14) Bearing Plate
(15) O-Ring
(16) Rotation Housing
(17) Adapter Plate
(18) Vent Plug
Chuck Driver and Pinion Gears - Removal
Chuck Drivers and Pinion Gears - Removal


Remove pinion gears (1) and chuck driver assembly (2).
Reference: For inspection and repair procedures refer to , M0074441 Hydraulic Percussion Rock Drills HPR5128
Chuck Driver Bearing Plate - Removal
Chuck Driver Bearing Plate
Inspect the bearing plate (1). Wear can be seen at the edge of the plate, where it is held by the chuck driver bushing
( item (3) in illustration 7). Do not attempt removal unless wear is in excess of 0.69 mm (0.027 inch). Pressing the
bearing plate (1) out will usually result in damage to the plate. Replace bearing plate seal (item (1) in illustration
7).
Thrust Washer Inspection

Cylinder Internal Parts
Cylinder Internal Parts
(1) Dowel Pin
(2) Cylinder
(3) Front Cylinder (Hammer) Bushing
(4) Seal
(5) O-Ring
(6) Hammer
(7) Rear Cylinder (Hammer) Bushing
(8) Seal
(9) Backhead
(10) Accumulator Base
(11) O-Ring
(12) Accumulator Cover
(13) Diaphram
Cylinder - Component Parts

There are four main components that make up the cylinder:
Backhead
Hammer and Hammer Bushings
Shuttle Valve
Accumulators
Backhead - Removal
Remove the four bolts that hold the backhead (item (9) in illustration 10) to the cylinder.
Hammer and Bushings - Removal

1. Push hammer (item (6) in illustration 10) forward until it seats against the front cylinder bushing (item (3) in
illustration 10). Place driver of Special Tooling (D) against rear face of hammer (item (6) in illustration
10)and drive out front cylinder bushing (item (3) in illustration 10) .
2. Push hammer (item (6) in illustration 10) back in until it seats against rear cylinder bushing . Place driver
(Tooling D) against front face of hammer (item (6) in illustration 10) and drive out rear cylinder bushing
(item (7) in illustration 10) .
3. Carefully slide the hammer (item (6) in illustration 10) and bushing (item (7) in illustration 10) out of the
cylinder.
Shuttle Valve - Removal
Dust Cap - Right Side
Dust Cap - Left Side
1. Remove the two outer bolts (1) that retain the dust caps and remove the caps. A notch (3) is provided to pry
off cap
Refer to illustration 11 and illustration 12.
Note: Earlier model drills have a round dust cap with only one bolt.
2. Remove the center bolt (2) that retains the valve seat.
Note: The right side cap (Illustration 11) and left side cap (Illustration 12) are different.
NOTICE
DO NOT hammer on retainer plug to drive shuttle valve out of
cylinder. Thread damage can result, causing failure of retainer plug.
3. Remove retaining ring (8) with snap ring pliers. Using Special Tooling (D), remove the retainer plugs (6).
Refer to illustration 13.
4. Remove the valve seats (3) and (4) using Special Tooling (D).
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Shuttle Valve - Internal Parts
(1) Bolt
(2) Valve Housing
(3) Valve Seat (long)
(4) Valve Seat (short)
(5) Automatic Valve
(6) Retainer Plug
(7) Protector Cap
(8) Retaining Ring
(9) Cap - R.H.
(10) O-Ring
(11) Backup Ring
(12) O-Ring
(13) Backup Ring
(14) O-Ring
(15) O-Ring
(16) Spring Washer
(17) Cap L.H.
5. Remove the automatic valve (5).
6. The valve housing (2) can be removed by first removing the large retaining ring (8) and pressing or driving
the valve housing (2) out of the cylinder. If a press is not available, use Special Tooling (D) to prevent
damage to valve housing (2). Screw the cap into the right side (retaining ring side) of the valve housing so
the shoulder of the cap is against the outside diameter of the valve housing and drive valve housing out of
cylinder.
Accumulators - Removal and Disassembly

Pressurized System!
Hydraulic accumulators contain gas and oil under high pressure. DO

NOT disconnect lines or disassemble any component of a pressurized
accumulator. All gas pre-charge must be removed from the accumulator
as instructed by the service manual before servicing or disposing of the
accumulator or any accumulator component.
Failure to follow the instructions and warnings could result in personal

injury or death.
Only use dry nitrogen gas to recharge accumulators. See your Cat
dealer for special equipment and detailed information for accumulator
service and charging.
Personal injury can result from the sudden release of high pressure oil.
Be sure the engine has been shut off for a minimum of five minutes to
ensure that the accumulator pressure is zero.
The accumulator is filled with dry nitrogen. Do not loosen or remove the
valve or the cap from the top of the accumulator.
Dry nitrogen is the only gas approved for use in the accumulators. The
charging of oxygen gas in an accumulator will cause an explosion. An
explosion can be eliminated by using nitrogen gas cylinders with
standard CGA (Compressed Gas Association, Inc.) No. 580 connectors.
When nitrogen gas is ordered, make sure to order the cylinders with
CGA No. 580 connectors.
Do not rely on color codes or other methods of identification to tell the

difference between nitrogen and oxygen cylinders. In any application,
never use an adapter to connect your nitrogen charging group to a valve
outlet used on both nitrogen, oxygen, or other gas cylinders. BE SURE
YOU USE DRY NITROGEN (99.8% purity).
Accumulator - Internal Parts
(1) Spring Washer
(2) Spring Washer
(3) Accumulator
(4) O-Ring
(5) Accumulator Cover
(6) Diaphram
(7) Bolt
(8) Bolt
1. Remove safety cap from pressure valve (1). Turn the valve counterclockwise until you hear the nitrogen gas
escaping. The valve should loosen easily, as it should never be torqued more than 13.6 N·m (10.0 lb ft) to
avoid damage to the valve seat. Remove pressure valve (1) and O-ring (2) from each accumulator.
Accumulators
2. Remove the 8 hex head bolts (3) that hold each accumulator to the cylinder. Lift the accumulator (item (5) or
(6)) straight away from the cylinder. There is a notch on each side of the accumulator base to insert a
screwdriver to pry the accumulator from the cylinder if it gets in a bind.
Note: You may want to loosen the 4 allen head bolts (4) on each accumulator before removing them from
the drill. The bolts are torqued to 816 N·m (600 lb ft). Use Special Tooling (D) for this.
Copyright 1993 - 2018 Caterpillar Inc. Wed Aug 29 2018 18:44:06 GMT-0500 (hora de verano central)
All Rights Reserved.
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29/8/2018 MD5125 Hydraulic Track Drill Engine only SEZ00001-UP (MACHINE) POWERED BY C11 Engine(SEBP7135 - 10) - Documentation

Disassembly and Assembly

Rock Drill - Disassemble - HPR5128 / 6832

General Tips on Drill Overhaul

Wear eye protection in order to prevent possible personal injury while

A Locktite Thread Locking Compound

Drill Disassembly General Information

Water Swivel Assembly - Removal

2. Remove the swivel assembly (4).

3. Remove the shank (5) and thrust plate (6).

Rotation Motors - Removal

Rotation Housing - Removal

Personal injury or death can occur from heavy components falling

Properly support the component with a suitable lifting device during

Rotation Cover - Removal

Personal injury or death can occur from heavy components falling

Properly support the component with a suitable lifting device during

Rotation Housing - Internal Parts

Chuck Driver and Pinion Gears - Removal

Personal injury or death can occur from heavy components falling

Properly support the component with a suitable lifting device during

Remove pinion gears (1) and chuck driver assembly (2).

Chuck Driver Bearing Plate - Removal

Thrust Washer Inspection

Cylinder Internal Parts

Cylinder - Component Parts

There are four main components that make up the cylinder:

Hammer and Hammer Bushings

Hammer and Bushings - Removal

Shuttle Valve - Removal

Refer to illustration 11 and illustration 12.

Refer to illustration 13.

5. Remove the automatic valve (5).

Accumulators - Removal and Disassembly

Hydraulic accumulators contain gas and oil under high pressure. DO

Failure to follow the instructions and warnings could result in personal

Do not rely on color codes or other methods of identification to tell the

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