概要信息：

SPUR- ROTARY HEAD
ASSEMBLY TRAINING
MANUAL
DM45/L
    Read this instruction manual before operating this equipment.
      This manual contains important safety information.
      Do not destroy this manual.
This manual must be available to the personnel who operate and maintain
this machine.
57788853
Atlas Copco Drilling Solutions DM45/L Spur – Rotary Head
Assembly/Rebuild Page 1 57788853
Spur Gear Rotary Head Assembly and Rebuild - 57788853
     Reference Drawing – 57562639
DESIGN FEATURES
The spur gear rotary head provides the rotation speed and the rotary torque
required for both rotary and downhole hammer drilling with Atlas Copco DM45,
DM50 and DML drills. The rotary head is a simple, compact and efficient unit
featuring axial piston hydraulic motor(s) mounted at the top of the gear case for
easy access. In certain applications, where dual motors are supplied, they will be
located at the front and rear of the rotary head case. The rotation motor(s),
powered by hydraulic oil from the main pumps, drive the spindle through a series
of spur gears, hence the name spur gear rotary head.
The rotation speed is determined by the output of the main pumps. This output is
variable through speed controls on the operator's panel at a maximum working
pressure of 4500 psi. This arrangement enables the head to provide rotation
speed infinitely variable between (0 and 200 RPM with one variable and one
fixed displacement rotation motor with maximum available torque of 7700 ft.-lbs
and 160 hp.)
The internal bearings, pinions and gears in the rotary head are cooled and
lubricated with EP 90 gear oil (splash lubed).  Mobil SHC 634 oil is approved for
use. Approximately 11 gallons of oil are required to bring the oil to its proper level
in the gear case. Proper oil level should always be verified using the sight gauge
on the front side of the gear case. The rotary head is attached by pin connections
to the feed system upper chains and lower feed cables.
Another feature of the rotary head is a special drill pipe adapter that serves as a
spindle sub. This sub is screwed tightly into the spindle and held in position by
welded locking tabs. Should the spindle sub break or the threads become
damaged, the sub can be removed, thus eliminating the need for replacement of
the more costly spindle.
Bearings Design and Gear Maintenance
Items 4 and 33 are single row, tapered roller bearing and are the most widely
used throughout the industry. Especially suitable for carrying radial and axial
loads acting simultaneously when the radial loading is greater than the axial.
Items 16 and 22 are single row, medium type and deep groove ball bearings.
They will sustain radial load and substantial thrust load in either direction, even at
high speed. This advantage results from intimate contact between the balls and
the deep continuous groove in each ring.  For this type of bearing, careful
alignment between shaft and housing is essential. These bearings are supplied
with 2 red shields to for roller protection from dirt and other contaminates.
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Item 27 is a spherical roller bearing with cylindrical bore, narrow width and
medium type design. It has excellence radial load carrying capacity due to the
number, size and shape of the rollers and the accuracy with which they are
guided.
Being inherently self-aligning, angular mis-alignment between the shaft and the
housing has no detrimental effect and full bearing capacity is always available for
loading. Considerable thrust loading may be carried in either direction.
Recommended Lube Oil
Gears contact pressures are very high, therefore extreme-pressure EP gear oil
must be used to prevent rupture of the oil film and the resulting metal–to-metal
contact of the parts. EP oils contain additives that increase the load-carrying
properties, highly resistant to oxidation, non-corrosive to metals and highly
resistant to foaming.
The SSU viscosity at 100°F should be a minimum of 2060 and at 210°F, 189.
Maximum pour point is -40°F.
EP 90 Gear oil is installed at the factory, p/n 52182938 for 1 quart.
Mobil SHC 634 is optional, p/n 50422849 for 1 gallon.
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GENERAL DATA
Rotary Head.....................................................  DM45, DM50 and DML’s
Available Rotation Torque Ratings
High speed- Low torque as standard package
 Dual Motor 4SV-2-10, Variable speeds 0-200 RPM, Maximum torque 7700
ft.-lbs. (10,400 N-m)
Gear Ratio ........................15 to 1
Spindle Thread Size 4 inch F.H. API
Rotation Motor... Fixed and Variable Displacement Piston, Bi-Directional
Weight (Approx.) 2600 Ibs.
Lube Oil Capacity 11 Gal.
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The following safety, cleanliness and maintenance guidelines are to be
used throughout the assembly process for the spur gear rotary head:
A. Wash all parts thoroughly in a safe cleaning solvent (paint prep thinner S910)
and blow dry with compressed air.
B. Inspect all bearings, gears and shafts for wear, cracks discoloration and
looseness. Check all new parts for damage that may have occurred in shipment
and replace all unserviceable parts.
C. Keep hands and tools clean.
D. Wipe a film of oil over all working parts such as bearings, shafts, seals and
O-rings as they are assembled, except where specified otherwise.
E. Do not allow dirt, cuttings or brass shavings to enter the rotary head during
assembly.
F. Except for press-fit bearings and bushings, parts should fit together easily. If
force is required, a part is out of tolerance or alignment and must be corrected to
prevent binding or possible damage.
G. Remove all nicks, burrs or any foreign matter from the rotary head housing,
inside and out.
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STEP 1
1. Lift machined housing (item 8, 57395444) and place in the rotary head-working stand
(57788051) with cover (52231008) pointing upward. Cover supplied with item 8.
     
STEP 2
2. Secure the housing to the stand with flat washers (95094314), screws (95934501) and
replace the top half of the stand pillow block with screws and eyebolt (57788069) as
shown.
STEP 3
3. Clean slide guide machine surfaces with paint prep thinner S910 to remove dirt,
grease, metal shavings.
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STEP 4
4. Remove cover screws with impact wrench.
                                              
STEP 5
5. Use impact wrench with the special socket drive (57788085) and screw-in the all-
thread (57788077) to evenly pull-up the cover from the dowel pins.
                           
STEP 6
6. Clean and remove dirt, grease, metal shavings and any other contaminants inside the
rotary head housing, cover and all bearing surfaces.
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STEP 7
7. After removing the cover and securing it on a separate support or table, clean all
machine surfaces with paint prep thinner S910 to remove dirt, grease, and metal
shavings.
     
STEP 8
8. Add silicone (50700731) to fill 2 holes that are used to push the bearing cone
(item 33, 95434569) out during disassembly. (Reference step13).
  
STEP 9
9. Install pipe dope with all pipe plugs (item 70, 95246724), relief fitting
(item 88, 95246724), elbow (item 99, 95040952) and install per print.
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STEP 10
10. Heat bearing cone (item 4, 95434551) on an induction heater or in an oil bath to
approximately 300’F. Place the spindle (item 1, 57546343) in a large, clear, flat area.
Be sure to have enough room to lower the bearing onto the spindle in a later step.
                                                       
STEP 11
11. Clean the surface and threads of the spindle with solvent. Confirm no thread damage
to the spindle and adjusting nut (item 24, 57291304) by hand-threading the nut onto
the entire thread length surface. After confirmation, remove the nut from the spindle.
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STEP 12
12. Use protective gloves (57788093) to remove bearing cone from the heater and
immediately slide bearing cone over the spindle until it rests on the bearing cone
shoulder of the spindle. Allow time for the bearing cone to cool and shrink-fit onto
the spindle. Once cooled, apply a coat of grease (item 119, 52180957) onto the
bearing cone.
                       
STEP 13
13. Ensure inside surface of the housing is free of dirt, metal shavings and other
contaminants by blowing shop air pressure into the housing.
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STEP 14
14.  Install o-ring plugs (item 125, 95323465), pipe dope with plugs (item 18, 95033585)
and magnetic drain plug (item 107, 50137256).
                            
STEP 15
15. Install pipe sealant plug (item 67, 95249587). This is the port utilized for the
magnetic sending unit with the rotary head option.
                    
STEP 16
16. Install the cup of  bearing (item 4, 95434551) evenly into the lower housing (item 8,
57395444). Using a bronze drift (57788101), made from 1” square key stock and a
rawhide hammer or a rubber mallet to tap the cup 90 degrees opposite side to evenly
and fully seat the cup in the housing.
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STEP 17
17. Use special tool tee-rod-hook (57788119) to pull the chain through the spindle with
bearing cone attached.
                                                   
STEP 18
18. Attach ring-lock tool (57788705) to chain hook for lifting the spindle.
                                                                        
STEP 19
19. Insert spindle with bearing (items 1 and 4) into lower bearing race.
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STEP 20
20. Clean surface of lower seal housing (item2, 57578023), then install the first lower
seal (item 3, 52146784).
                      
STEP 21
21. Use small steel hammer and bronze square head key stock (57788713), evenly seat
the seal by tapping 90 degrees opposite sides. Then repeat for the second seal.
                         
STEP 22
22. After fully seating the seal, use grease (item 119, 52180957) for lubricating both
seals.
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STEP 23
23. Use grease (item 119) to lubricate the spindle area prior to installing the lower seal.
                                                                               
STEP 24
24. Inject silicone (item 120, 50700731) onto the circumference surface of the lower
housing to form a gasket prior to inserting the lower seal housing (57578023) with
enclosed seals over the spindle. Care should be taken not to damage or distort the
seals as they slip onto the spindle.
                                                      
STEP 25
25. Align and insert screws and washers (items 5 & 6, 95934551 & 95934733) and
tighten with socket-air ratchet.
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STEP 26
26.  Remove both eyebolts (57788069) from the rotary head stand, do not remove the
upper half of the pillow block and BE CAREFUL, STAND AWAY when rotating
the rotary head housing with top pointing upward. Re-insert both eyebolts into the
stand.
                                                                
STEP 27
27. Use the hydraulic jack attached to the stand and the round plate (57788721)
underneath the spindle so that the cup and cone of the lower bearing are pushed
tightly together. The spindle must be supported tightly to ensure proper placement of
the output gear. Remove the upper half of the pillow blocks during this process to
observe shaft lift which indicates the lower bearing cup is fully seated, causing the
rotary head assembly to lift.
                                                                       
STEP 28
28. Insert spacer (item 174, 57546319) over spindle.
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SHRINK FIT OUTPUT GEAR
                                                                             
STEP 29
29. Insert the custom key (item 11, 57546327) into the keyway in the spindle. Ensure the
corners and edges of the key are clean, smooth and properly dressed to accept the
output gear. The fit to the gear should be snug, but not interference fit. The key
should be tightly fit within the groove, and should be fully seated against the bottom
depth of the keyway, with contact surface to spacer (item 174). Insert the key with the
threaded, jacking hole to the top as shown.
                                                            
STEP 30
30. Insert 2 special threaded eyebolts and shackle (57788739, 57788747 & 57788861) to
lift the output gear (item 10, 57546301).
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STEP 31
31. Measure the hub inside diameter on the output gear (item 10) including key height.
Maximum diameter of the hub and keyway must not exceed 5.376”. This will ensure
that the output gear will fit over the key during installation.
      
STEP 32
32. Insert the output gear onto the induction heater or into an oil bath and heat to 430’F.
Ensure the gear is thoroughly heated. The fit to the spindle is a shrink fit up to 0.004”.
Binding problems may arise if the gear is not sufficiently heated.
                                              
STEP 33
33. With insulated gloves (57788093), remove the output gear from the induction heater
and position the gear with the high-pressure grease hole to the top.
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STEP 34
34. With the spindle supported and lower bearing properly seated in the bearing race,
align the keyway, install the heated gear onto the spindle. The keyway should be flush
to the key as shown. Care should be taken during gear installation not to damage the
threads on the spindle.
 STEP 35
35. Notice the position of the high-pressure grease hole to the top. After installation,
allow the gear and spindle to cool for at least 1.5 hours to properly shrink fit to the
shaft.
                                                       
STEP 36
36. Install the 2nd spacer (item 174, 57546319) on top of the output gear.
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STEP 37
37. Temporarily, install the retaining collar (item 176, 57546335) with a feeler gauge.
Remove the retaining collar and spacer. Install shims (item 175, 57546384) in equal
thickness to the gap measured. Reinstall the spacer and retaining collar.
                                  
STEP 38
38. Secure the retaining collar with cap screws (item 178, 95935235), flat washer (item
179, 95922225) and lock nut (item 180, 95923371). Place flat washers between the
halves of the retaining collar. There should be no gap remaining between the gear and
the retaining collar. Peen the threads after inserting the lock nut.
                                      
STEP 39
39. Installation for locknuts are opposite and the air gun is used to clean the housing of
metal shavings, dirt and other contaminates.
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INTERMEDIATE GEAR ASSEMBLY
                                                                         
STEP 40
40. Heat the intermediate gear (item 20, 57159113) on the induction heater or in an oil
bath to 400’F. Insert the key (item 19, 57159139) into the keyway in the intermediate
shaft (item 17, 57191017).
STEP 41
41. After heating the intermediate gear to 400’F, lower it onto the shaft until it rests
against the shoulder. Ensure the key is smooth and properly fit into the keyway. Key
height and shaft OD should be checked with calipers to ensure that there is no
interference between the gear keyway and the key. Threaded lifting holes are
provided in the intermediate gear. They should face towards the end of the
intermediate shaft with 3 threaded holes (top). Allow the gear to cool at least 1.5
hours to shrink-fit onto the shaft.
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STEP 42
42. Heat the lower spherical bearing (item 27, 95711156) on the induction heater or oil
bath to 300’F and install it onto the bottom of the intermediate shaft.  Use small steel
hammer and intermediate shaft tool (57192577) for installation. Allow the bearing to
cool onto the shaft.
                                                   
STEP 43
43. Install the intermediate shaft tool (57192577) to prevent the outer race from pivoting
during installation.
Note: If the outer race falls out of position, reposition the rollers and roll the race
back into place by hand. Do not force the race in place, this can damage the bearing.
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STEP 44
44. Be sure input pinions (item 21, 57170110) are free of any debris before installing
lower bearing (item 16, 95214037) and upper bearing (item 47, 52209939).
STEP 45
45. Position input pinion with upper and lower bearing located on the press machine prior
to pressing bearings operation.
STEP 46
46. Press the upper and lower bearing operation performed with spacer (57159121)
chamfer end down and round bar (57788754) onto the input pinion (item 21,
57170110), fully shoulder seated. Apply press force only against the inner races,
otherwise, bearing damage can occur.  Note: The upper bearings are permanently
sealed and lubed. Care should be taken not to dislocate the upper and lower seals.
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STEP 47
47. Notice the before and after bearing press operation. Remove the first input pinion/
bearing assembly and repeat the previous step.
                                                                    
STEP 48
48. Notice lower and upper bearing installation after press operation before installing into
the rotary housing.
                                           
STEP 49
49. Insert intermediate spacer (item 23, 57159121), chamfer end up, on upper end of the
intermediate shaft (item 17, 57191017) and screw eyebolt and shackle (57788770 &
57788861) into one of the tapped holes in the shaft.
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STEP 50
50. Insert the intermediate shaft tool (57192577) for positioning the intermediate gear
assembly in the rotary housing with an overhead hoist and chain connected to the
eyebolt and shackle (57788770 & 57788861). Clean the assembly with cleaning
solvent to remove any dust, dirt and contaminates prior to installing into the rotary
housing.
                                    
STEP 51
51. Lightly coat each input pinion bearing cavity in the rotary head housing with grease
(item 119, 52180957).
                                  
STEP 52
52.  Lower the intermediate assembly into the bearing cavity with a hoist and the
intermediate shaft tool in place. Mesh 1 intermediate pinion (item 17) with the output
gear (item 10), while keeping the spherical bearing (item 27) square to the lower bore,
until the intermediate shaft tool rests on the bottom of the housing.
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STEP 53
53. Remove the intermediate shaft tool and then fully seat the bearing into the housing.
Fully seated, the bearing should be approximately 1/8” to 3/16” below the inside
surface of the housing boss. The bearing should push easily into its bore. If not, the
intermediate shaft (item 17) may be tapped with a rawhide mallet to seat the bearing.
                                                                                 
STEP 54
54. Lower the input pinion assembly (item 16, 21, 47) into place in the housing. Take
care not to allow the lower bearing to contact the intermediate gear. Mesh the pinion
gear with the intermediate gear. The assembly should slide easily into position. If not,
use a rawhide hammer to tap in place.
                                                                         
STEP 55
55. For two motor rotary head assemblies, repeat steps 50 through 55.
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STEP 56
56. Internal installation prior to replacing the cover supplied with the rotary housing
(item 8, 57395444).
                                                
STEP 57
57. Lightly coat molycote grease (item 119, 52180957) to top-edge surface of upper
bearing (item 47, 52209939) to lubricate internal cavity of the cover.
                   
STEP 58
58. Secure when lifting the cover with two eyebolts and shackle
(57788770 & 57788861), hoist and clean the underneath surface of the cover from
dirt, debris and any other contaminates, prior to installing on the rotary housing.
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STEP 59
59. Apply a bead of silicone (item 120, 50700731) around the edge of the housing and
lower the cover into place.
             
STEP 60
60. Take care not to damage threads on the spindle. Align the locator dowel pins with the
dowel holes in the cover. Bolt the cover in place.
STEP 61
61. Fill the two threaded “push” holes in the upper seal area with silicone (item 120,
50700731) as shown. This is to prevent bearing grease from the upper bearing
chamber from entering the rotary head gear case.
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STEP 62
62. Install the upper seal (item 34, 58229915) into the counter bore in the housing cover.
The seal should be installed in such a way as to hold grease within the bearing
chamber. Use a small steel hammer and bronze flat bar (57788713) to press the seal
flush within the bore. Care should be taken not to damage or deform the seal during
installation.
                                                              
STEP 63
63. Install upper intermediate bearing (item 22, 95434874) on top journal of the
intermediate shaft. Use intermediate bearing drive assembly tool (57562910), as
shown to press the bearing onto the shaft. Ensure the bearing is fully seated against
the shoulder of the shaft. Repeat these steps for two motor rotary head assemblies.
STEP 64
64. Input and intermediate shafts fully installed.
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STEP 65
65. Install the intermediate shaft end shim (item 49, 57243719) and plate (item 126,
57191033) and secure with 3 cap screws (item 128, 95101762). Torque the capscrews
to 80 ft-lbs lube, 110 ft-lbs dry. Lockwire (item 127, 50344605) the cap screws in
place.
                         
STEP 66
66. Silicone (item 120, 50700731) the top of the housing and install bearing cap (item 15,
57191025). Secure the cap with screws (item 45, 95934659) and lock washers (item
6, 95934733).
              
STEP 67
67. Lightly coat with molycote grease (item 119, 52180957) the oring groove and
machined surface of the motor adapter (item 26, 57368052), then insert oring (item
156, 95097929). Repeat this step for the 2nd motor adapter.
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STEP 68
68. Install the motor adapter and attach to the housing with socket screw (item 41,
95055216). Care should be taken not to damage the oring. Repeat this step for the 2nd
motor adapter.
                                                                
STEP 69
69. Lightly coat with molycote grease the oring groove and machined surface of the
motor adapter (item 26, 57368052), then insert oring (item 12, 95086724). Repeat this
step for the 2nd motor adapter.
STEP 70
70. Heat wear sleeve (item 36, 50822097) on the induction heater or oil bath to 100’F.
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STEP 71
71. With insulated gloves (57788093), install the upper grease seal using wear sleeve tool
(57512410). Carefully drive the wear sleeve down evenly until it contacts the
shoulder on the spindle just above the keyway.
                                                       
STEP 72
72. Place the cup of the upper spindle bearing (item 33, 95434569) into the cover. Use a
small steel hammer and bronze drift pin (57788713) to evenly and fully seat the cup.
Take care not to strike the bearing surface. Apply a heavy coat of grease (item 119) to
the cup.
STEP 73
73. Heat the upper spindle bearing cone (item 33) to 300’F using the induction heater or
hot oil bath.
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STEP 74
74. With insulated gloves, lower the bearing onto the spindle, tapered end down. Tap the
inner race of the bearing with a hammer and drift pin (57788713) to seat it properly.
Proceed to the next step while the bearing is still warm.
SETTING SPINDLE BEARING PRELOAD - ROLLING TORQUE
Note: Setting proper preload for the spindle bearings is the most important process within
the assembly. Special tools required are listed in the assembly, rebuild manual and kit.
                                                      
STEP 75
75. Lightly coat with molycote grease (item 119) the exposed spindle threads. Verify the
spindle (item 1) is supported so that the cup and cone of the spindle lower bearing are
pressed tightly together. Install the bearing adjusting nut (item 24, 57291304) and
tighten against the upper bearing cone, inner race.
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STEP 76
76. With the input pinion tool (57466369) attached and the ratchet located in the motor
adapter spline, two angles (57788788), located 180 degrees apart and connected to the
rotary housing, 2 screws (95934659) and flat washers (95972238), and adjustment
locking ring tool (57788796) are required for the setting from the kit.
                          
STEP 77
77. Install the adjustment locking ring (57512436) in the grooves on the adjusting locking
nut (item 24, 57291304) as shown. The wings on item 24 will contact the surfaces of
the angles (57788788) to prevent spindle rotation, therefore increasing preload on the
spindle bearing when the input pinion tool is rotated. Tighten the 2 screws and
lockwashers to hold the angles after alignment to the wings as shown. Tighten the
locknut (item 24) by turning (counter-clockwise) the gear train through the input
shaft. Use input pinion tool (57466369) to turn the input pinion shaft. The 15:1 gear
reduction makes tightening the locking nut easier. Strike the inner race of the upper
bearing with a steel hammer and bronze drift a couple of times 180 degrees opposing
points. The rolling torque will drop-off by less resistance through the input pinion
tool.
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STEP 78
78. Lower the hydraulic jack supporting under the spindle. Repeat tightening the lock nut,
turning the input pinion tool. Repeat striking the inner race process.
                                   
STEP 79
79. Periodically remove the adjustment locking ring tool (57788796) and measure the
rolling torque through the spindle. Use the spindle rotation tool (57512428) and dial
type torque wrench (57788812) to measure the preload. Continue tightening through
the input shaft until torque required to turn the spindle reaches 100-150 ft-lbs.
Measure rolling torque through the spindle not the input shaft.
     As the rolling torque measure approaches the required setting, strike the inner
race of the upper bearing with a hammer and bronze drift a couple of times 180
degrees opposing points. Repeat these steps until the torque value remains constant
at 120-130 ft-lb after striking the race.
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STEP 80
80. After properly setting rolling torque, install the tongued lock washer (item 31,
57291288). Insert the tongue into the keyway of the spindle.
                                                                               
STEP 81
81. Lightly coat with loctite (56784267) onto 6 screws (item 25, 95270815) to secure the
tongued washer to the preload lock nut. If the bolt holes do not line up, tighten the
preload slightly until the holes align.
Note: Sufficient preload is critical. Insufficient preload will allow the upper spindle-
bearing race to slip under the lock nut during drilling and breakout operations.
This slipping of the race will quickly wear away the bottom of the locknut. Any
existing preload will be lost resulting in endplay. Endplay in the spindle assembly
is harmful to bearings and other components. Life expectancy of the rotary head
will be shortened.
Historical root causes: Repeated problems with the swivel packing assembly i.e. water
leaks, missing packing rings, etc may be an indication of loss of preload of the main
bearing / spindle assembly.
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STEP 82
82. Lightly coat the spindle threads with molycote (item 119), install oil seal (item 35,
52164282) into the upper seal housing (item 32, 52248150) and tap the seal to secure
within the housing.
  
STEP 83
83. Install and tighten lube fitting (item 69, 95201547), insert silicone (item 120,
50700731) around the housing machined surface, then insert the upper seal housing
(item 32, 52248150) over the spindle and align the holes. Care should be taken not to
damage or deform the seal during installation. Insert 2 screws (item 51, 95104204),
180 degrees apart to secure the seal housing for the following steps.
                             
STEP 84
84. Inspect the thread in spindle cap (item 39, 57347379) to remove any dirt, rust or
damage threads, prior to inserting ring thread (item 42, 50610971) and lightly coat
with molycote grease.
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Assembly/Rebuild Page 36 57788853
                                                      
STEP 85
85. Insert slinger (item 38, 52187804) over the spindle and onto the top surface of the
seal housing. Use flat head screwdriver, if required for installation.
                                    
STEP 86
86. Place o-ring (item 154, 95086625) into spindle groove, prior to connecting spindle
cap (item 39, 57347379).
                   
STEP 87
87. Attach input pinion tool (57466369) to ratchet and insert into the motor adapter input
spline. Connect a 48” pipe wrench to the flats on the spindle cap (item 39, 57347379)
and secure against the rotary housing’s anchor guide. Tighten item 39 by rotating the
ratchet counter-clock wise.
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Assembly/Rebuild Page 37 57788853
                    
STEP 88
88. Insert swivel (item 37, 52248176), align swivel flange hole to upper seal housing,
insert 6 screws and lockwashers (item 51, 95104204; item 6, 95934733), then tighten
with impact wrench.
                    
STEP 89
89. Invert swivel cap (item 50, 57183329), insert one packing (item 43, 50694876) and
lightly lubricate with molycote grease (item 119) the packing top surface and the
swivel cap machined surface.
  
STEP 90
90. Insert the 2rd packing supplied with item 43 inside the spindle cap (item 39) and
lightly lubricate with grease (item 119) the packing surfaces as shown.
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Assembly/Rebuild Page 38 57788853
             
STEP 91
91. Insert wear bushing (item 43) in the groove of item 39 on top of the 2rd packing.
                
STEP 92
92. Screw 2 threaded rods (57788820) into swivel (item 37, 52248176) for shim set (item
46, 52210317) and swivel cap (item 50, 57183329) for installation  and alignment.
                 
STEP 93
93. Shim to 0.125” (57788838) clearance between machined surfaces of items 37 and 50
for swivel packing proper preload. Insert screws and lockwashers (items 5 and 6,
95934451 and 95934733) and tighten.
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Assembly/Rebuild Page 39 57788853
                                                       
STEP 94
94. Apply pipe dope, connect elbow (item 134, 95286910) into the swivel cap and brush
anti-fretting agent (57396854) onto the splined shaft of the motor and input pinion
spline.
STEP 95
95. Apply pipe dope to thread of 1/8 inch pipe plugs (95033585) and install plugs into
controller on side of hydraulic motor.
Atlas Copco Drilling Solutions DM45/L Spur – Rotary Head
Assembly/Rebuild Page 40 57788853
                                     
STEP 96
96. Install 2 eyebolts (57788846 & 57788861) into motor flange bolt pattern, lift the
motor (item 28, 57209637), insert into the input pinion and secure with screws (item
9, 95930723), tube (item 13, 56951700) and lockwashers (95934741).
    
STEP 97
Reference Rotary Head Commons Drawing (57519878)
97. Install eyebolts and shackle (57788846 & 57788861) into motor (item 160,
57110157), lift, insert and secure the motor in the second input pinion as shown on
drawing 57519878. Install relief valves (item 129, 57568487) in each motor on the
opposite side of the case drain port.
                
STEP 98
98. Confirm 3 orings located in control valve (item 161, 57167298) prior to installation,
then insert 3 screws and lockwashers (item 162, 95958948 and item 163, 95934303)
and tighten assembly.
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Assembly/Rebuild Page 41 57788853
                                                
STEP 99
99. Lightly coat with molycote oring grooves and pre-assemble 4 block flanges (item
155, 57213936) with plugs (item 173, 95666996) and test fitting (item 131,
57328676).
                   
STEP 100
100. Install socket head screws and washers (item 152, 95013702; item 153, 95209425)
and tighten with impact wrench. Insert fitting (item 146, 57167942) into case drain
port motor (item 28, 57209637).
                                             
STEP 101
101. Install elbow fittings (item 132, 57174070) to motor (item 28, 57209637) and tee
fitting (item 145, 57209728) to motor (item 160, 57110157) as shown.
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STEP 102
102. Install hose assemblies (item 166, 57342891) for pilot control valve and (item 147,
57396806) for motor case drain.
       
STEP 103
103. Align and install hose assemblies (item 150, 57396822 and item 151, 57406977) to
motor ports (A and B).
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STEP 104
104. Screw thread stud (57788820) into side of housing to guide installation of hose
bracket (item 139, 56244684), then secure with screws (item 158, 95705364) and
lock-wire (item 59, 50344605).
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Assembly/Rebuild Page 44 57788853
      
STEP 105
105. Install bulkhead fittings (item 157, 57174070), align and install hose assemblies (item
148, 57406985 and item 149, 57406993) to the tee fitting on motor ports (A and B).
         
STEP 106
106. Install bulkhead fitting (item 133, 57167934 and item 144, 95650149), align and
install hose assembly (item 140, 57298069) to the tee fitting on the case drain port.
                                                          
STEP 107
107. Place bracket (item 137, 57559577) into the vise. Apply pipe dope to the threads, then
connect elbow (item 136, 95279147) and hose stem (item 138, 50023910).
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Assembly/Rebuild Page 45 57788853
                               
STEP 108
108. Wrap a 4000 pounds chain capacity around the elbow connected to the swivel inlet,
remove the screws connecting the rotary stand to the rotary housing and lift the rotary
head assembly with the hoist.
                                                                
STEP 109
109. To install item 137, remove 2 screws from the rotary housing, align item 137 hole
pattern and secure to the housing with screws (item 45, 95934659), lock washers
(item 6, 95934733) and flat washers (item 57, 95064697).
                                      
STEP 110
110. Remove pipe plug (item 70, 95249694), insert nozzle and fill with 44 quarts of gear
oil (item 118, 58209651) to centerline of sight gauge (item 98, 52253176). Add pipe
dope to item 70 and replace.
Atlas Copco Drilling Solutions DM45/L Spur – Rotary Head
Assembly/Rebuild Page 46 57788853
  Disassemble the Rotary Head
                                                                     
STEP 111
111. Lift the rotary head assembly with a 4000 pound hoist and chain capacity, secure the
rotary head assembly in the rotary stand (57788051) with required screws (95934501)
and lock washers (95094314).
                                                  
STEP 112
112. Remove the 2 motors and adapter plates and intermediate cover plates and all related
piping, including the swivel (item 37) and adjusting nut (item 24).
                                               
STEP 113
113. Remove all the screws and lock washers from the top cover. Screw 2 all-threads
special tool (57788077), inline with the sight glass and use an impact wrench with
special socket-drive (57788085) to pull the cover and upper bearing (item 33). Insert
2 eyebolts and shackle (57788739 & 57788861) into the tapped cover holes
(lengthwise of the cover), 180 degrees apart from the all-threads and simultaneously
lift with the hoist.
Atlas Copco Drilling Solutions DM45/L Spur – Rotary Head
Assembly/Rebuild Page 47 57788853
                                               
STEP 114
114. Connect a strap around the input pinions for removal, then screw eyebolt and shackle
(57788770 & 57788861) into one of the intermediate pinions tapped holes. With the
chain and hoist, lift and remove the intermediate assembly. Be careful when removing
the assemblies for both were slightly press-fit during installation. Gently tap with a
rawhide hammer, if required. Do not distort the cavity in the rotary housing. Use
intermediate shaft tool 57192577 for positioning and lifting the assembly.
                            
STEP 115
115. Remove retaining collar (item 176) and shims (items 175 and 177.
STEP 116
116. Use the special machine to pull the output gear (item 10, 57546301) from the spindle
(item 1, 57546343), key (item 11) and spacer (item 174).
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Assembly/Rebuild Page 48 57788853
                        
STEP 117
117.  Remove the eyebolts from the rotary stand pillow blocks (do not remove the screws)
and be careful when rotating the rotary head 180 degrees, as shown. Then, remove the
screws and lock washers (items 171 and 172) retaining the lower seal housing
(item 2).
                                      
STEP 118
118. Use special tool tee-rod-hook (57788119) to pull the chain through the spindle.
                                  
STEP 119
119. Attach ring-lock tool (57788705) to the chain hook for lifting the spindle.
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Assembly/Rebuild Page 49 57788853
                                                                    
STEP 120
120. Remove spindle with bearing (items 1 and 4) from bearing cup and tap the bearing
with a small steel hammer and bronze drift (57788101) to remove from the spindle.
STEP 121
121. Remove the eyebolts from the rotary stand pillow blocks (do not remove the screws)
and be careful when rotating the rotary head 180 degrees in the upright position.
Then, use the small steel hammer and bronze drift to remove the bearing cup.
                                                
STEP 122
122. Ensure inside and outside surfaces of the rotary housing is free of dirt, metal shavings
and other contaminants by blowing shop air pressure into the housing prior to re-
assembly.

Atlas Copco Drilling Solutions, Inc.                                      A Company Within the Atlas Copco Group
P.O.Box 462288, 2100 North First Street Phone: +1 972-496-7400
Garland, Texas 75046-2288 Fax: +1 972-496-7425
www.atlascopco.com/drillingsolutions info.acds@atlascopco.com