Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

TRAINING MANUAL
Spur Gear Rotary Head Assembly and Rebuild
PART NUMBER: 57788853
WARNING
Export of this manual to countries Copyright 2006
Outside of the U.S. is subject to U.S. Atlas Copco Drill Solutions Company
Export Administration Regulations. All Rights Reserved

Drawn By: Mark Halpain 08/05/05

Checked By:
001 MEH 07/24/06 Approved Larry Washington
By:
000 7007-006 LW 08/05/05
Rev. E/C Number Revised By Date Signature Date
No.

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Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

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 DM30,
DM45, DM50 and DML and T4 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 to 200 RPM with varies combination of fixed
and variable displacement rotation motor with related torque and horsepower.

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 8 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 with cables (DM30), with upper chains and lower feed cables
(DM45/L), with chains (T4s).

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.

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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 metalto-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 100F should be a minimum of 2060 and at 210F, 189.
Maximum pour point is -40F.

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

Single and Dual piston motors, bi-directional with fixed and variable
displacements related to advertised speed and torque.

Gear Ratio .................. 15 to 1

Spindle Thread Size 4 inch I.F. API

Weight (Approx.), DM45/L, T4 2600 Ibs.

Weight (Approx.), DM30 1500 Ibs.

Lube Oil Capacity, DM45/L, T4 8 Gal

Lube Oil Capacity, DM30 6 Gal.

Reference Assembly Drawings

DM30, 57570004 rev 005

DM45/L, 57562639 rev 001

T4BH High Speed, 57594624 rev 003

T4BH High Torque, 57569980 rev 002

T4W High Torque, 57570012 rev 002

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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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Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 1

1. Lift machined housing (item 8, 57395444 for DM45/L, 57367917 for T4s and
57149031 for DM30s) and place in the rotary head-working stand (57788051 for
45/L, T4 and 57794653 for DM30) with respective cover pointing upward. Cover
supplied with rotary housing.

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.

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 300F. 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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