DM45 Spur1

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 DM30/45/L/T4 Spur Rotary Head
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 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 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 two red shields for roller protection from dirt and other contaminates.
Assembly/Rebuild Page 1 57788853

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.

GENERAL DATA
• 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 F.H. API
• Weight (Approx.) 2600 Ibs.
• Lube Oil Capacity 11 Gal.

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.

STEP 1
1. Lift machined housing (item 8, 57395444 for DM45/L and 57367917 for T4’s) 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.

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.

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.

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.

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.

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.

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.

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.

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.

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 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.

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 & 57788861) to lift the
output gear (item 10, 57546301).

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.

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.

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.

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.

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.

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 (56971872) 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.

STEP 47
47. Notice the before and after bearing press operation. Remove the first input pinion/
bearing assembly and repeat the previous steps for the second.
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.

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.

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.

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.

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.

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) and
socket (57788846), 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.

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 utilizing tie-wire pliers (57791873).
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.

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.

STEP 71
71. With insulated gloves (57788093), insert the wear sleeve with the bevel edge pointing
down, 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 bar (57788713) to evenly and fully seat the cup. Take
care not to strike the bearing surface.
STEP 73
73. Heat the upper spindle bearing cone (item 33) to 300°F using the induction heater or
hot oil bath.

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 bar (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 following assembly steps.
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.

STEP 76
76. With the input pinion tool (57791766) attached and the ratchet (57791717) 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 (57791766) 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.

STEP 78
78. Lower the hydraulic jack (57791865) 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 (57788804) 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 measured 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.

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.

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.

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 modified input pinion tool (57791766) to the ratchet (57791717) 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 clock wise.

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, 52180957) the packing top surface
and the swivel cap machined surface.
STEP 90
90. Insert the 2nd packing supplied with item 43 inside the spindle cap (item 39) and
lightly lubricate with grease (item 119) the packing surfaces as shown.

STEP 91
91. Insert wear bushing (item 43) in the groove of item 39 on top of the 2nd 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.

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.

STEP 96
96. Install 2 eyebolts (57788747 & 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).
DM45\L, Motors and External Components – Refer to Drawing

(57519878). For T4’s – Refer to Drawings 57594624, 57570012 and
57569980.
STEP 97
97. Install eyebolts and shackle (57788747 & 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.

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.

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).

STEP 104
104. Screw a ¾-10unc stud 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). Use pliers (57791873) if required.

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).

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.

STEP 111
111. With a grease gun, lubricate the upper bearing (item33, 95434569) area with grease
(item 119, 52180957) until pin extension from relief fitting (item 88, 95246724).

Disassemble Procedure for DM45\L, T4’s
STEP 112
112. Remove the sight glass (item 98, 52253176), connect a chain to a 4000 pound hoist
capacity to lift the rotary head assembly. Secure the rotary head assembly in the
rotary stand (57788051) with required screws (95934501) and lock washers
(95094314).
STEP 113
113. To remove the bulkhead-hose support bracket, cut the lock wire, remove screws and
washers with the impact wrench.
STEP 114
114. Remove the 2 motors and all related piping, including the swivel (item 37) and
adjusting nut (item 24) with appropriate special tools and place on pallet as shown in
the photos.

STEP 115
115. Attach a 48” pipe wrench to the spindle cap (item 39) bracing against the rotary
housing’s cable anchor as shown, insert the special tool input pinion (57466369) and
ratchet and rotating counterclock-wise to remove the cap.
STEP 116
116. Use flat head screwdriver and appropriate tools to remove the slinger (item 38). Insert
2 screws (95930723) into the 5/8” tapped push hole and with the air socket, remove
the upper seal housing (item 32).

STEP 117
117. Review the damaged upper bearing resulting from lack of grease during the initial
installation.
STEP 118
118. Remove the screws retaining the intermediate cover and motor adapters, tap with a
small steel hammer and bar for removal.

STEP 119
119. Locate an oil drip container for potential overflow when motor adapters are removed.
Comply with work area cleanliness statement mentioned earlier.
STEP 120
120. Remove lock tongue washer (item 31) and install the special lock ring (57512436)
and retain with angles (57788788), screws and lock washers as shown.
STEP 121
121. Connect the input pinion tool to the ratchet and rotate clockwise to loosen the lock-
tongue washer (item 31) from the spindle.

STEP 122
122. Attach 2 eyebolts (57788747) to the cover of the rotary housing and to the chain
hoist; screw 2 square head threaded bolts (57788077) as shown with an air socket.
Drive the cover off while lifting with the hoist and tapping the top of the intermediate
assembly and the input pinion to retain their position. Locate the jack under the
spindle for support.
Pulling the Main Gear from the Spindle
STEP 123
123. Wearing work gloves for protection, remove the input pinion assemblies, connect the
chain to the hoist and around the input pinion assembly for removal. 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. Dip the assembly in an oil bath for cleaning, wrap with a cloth after removal
from the oil bath to prevent oil dripping on the floor of the work area.

STEP 124
124. Wearing work gloves, cut and remove the lock wire (item 127) retaining the end
plate. Remove one screw and replace with one eyebolt and shackle (57788770 &
57788861) into one of the intermediate pinions tapped holes. Connect a chain through
the shackle for removal. Use intermediate shaft tool 57192577 for positioning and
lifting with the chain and hoist, for removal of the intermediate assemblies. 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.
STEP 125
125. Remove retaining collar (item 176), shims (items 175 and177) and clean the main
gear of dirt, metal shaving and any contaminates.
STEP 126
126. Position special plate w/holes (57791725) on top of the spindle for hole alignment
and insert 4 special thread rods (57791733), screw connect to the main gear and lower
the jack supporting the spindle to relieve bearing compressive loading.

STEP 127
127. Position bar handle (57788754) on top of the spindle and align the porta-power air
cylinder (57791741) between the bar handle and the plate (57791725). Use special
tool (57791758) to retain the round bar as shown.
STEP 128
128. Review all connections and alignment of the cylinder, plates and bars to assure proper
assembly, then tighten the 4 lock nuts to secure the plate to the threaded rods
(57791733).
STEP 129
129. With a torch, heat the main gear (for approximately 30 seconds in small circular
motion) in 4 locations, 90 degrees apart for gear expansion near the spindle.

STEP 130
130. While heating the 4th location, slowly engaging the cylinder to pull the main gear
(item 10). The red ring indicates fully stroked cylinder, do not extend further. Loosen
the 4 lock nuts to remove the plate, threaded rods, cylinder and related components.
STEP 131
131. Screw 2 eyebolts (57788739) into the main gear tapped holes, connect shackle
(57788861) to chain and hoist to remove from the spindle.
Removing the Spindle
STEP 132
132. To remove the custom key (item 11) from the spindle slot, screw 95935235 into the
tapped hole. Remove the magnetic sending unit, if applicable from the side of the
rotary housing.

STEP 133
133. Remove the eyebolts from the rotary stand pillow blocks (do not remove the screws)
and be careful when rotating the rotary head 180 degrees. Clean the inside of the
rotary housing of all metal chips and contaminates.
STEP 134
134. Use impact wrench to remove screws and lock washers (item 170-173) retaining the
lower seal housing (item 2). Connect the chain to the hoist and insert the chain-hook
end through the spindle with bearing. Attach lock ring (57788705) to the hook and
pull the spindle through the housing, bearing cup remaining.
STEP 135
135. Remove the eyebolts from the rotary stand pillow blocks (do not remove the screws)
and be careful when rotating the rotary head 180 degrees. Use a small steel hammer
and bronze drift (57788101) to remove the bearing cup and silicone from the ridge of
the housing.

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

DM45 Spur1

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What is the purpose of the spur gear rotary head?

What is the purpose of the spur gear rotary head?

What bearings are used in the rotary head and what are their purposes?

What bearings are used in the rotary head and what are their purposes?

SPUR- ROTARY HEAD

Read this instruction manual before operating this equipment.

This manual contains important safety information.

Spur Gear Rotary Head Assembly and Rebuild - 57788853

Bearings Design and Gear Maintenance

Assembly/Rebuild Page 1 57788853

Recommended Lube Oil

EP 90 Gear oil is installed at the factory, p/n 52182938 for 1 quart.

Assembly/Rebuild Page 2 57788853

• Dual piston motors, bi-directional with fixed and variable displacements

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

• Spindle Thread Size 4 inch F.H. API

• Weight (Approx.) 2600 Ibs.

• Lube Oil Capacity 11 Gal.

Assembly/Rebuild Page 3 57788853

The following safety, cleanliness and maintenance guidelines are to be

C. Keep hands and tools clean.

Assembly/Rebuild Page 4 57788853

Assembly/Rebuild Page 5 57788853

4. Remove cover screws with impact wrench.

Assembly/Rebuild Page 6 57788853

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28. Insert spacer (item 174, 57546319) over spindle.

Assembly/Rebuild Page 14 57788853

SHRINK FIT OUTPUT GEAR

Assembly/Rebuild Page 15 57788853

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INTERMEDIATE GEAR ASSEMBLY

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64. Input and intermediate shafts fully installed.

Assembly/Rebuild Page 27 57788853

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SETTING SPINDLE BEARING PRELOAD - ROLLING TORQUE

Assembly/Rebuild Page 31 57788853

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