DM45_SPUR1

SPUR- ROTARY HEAD ASSEMBLY TRAINING MANUAL

DM45/L

Read this instruction manual before operating this equipment.

This manual contains important safety information. information. Do not destroy this manual. This manual must be available a vailable to the personnel who operate and maintain this machine.

57788853

Atla Atlas s Copc Copco o Dril Drilli ling ng Solu Soluti tion ons s

DM30 DM30/4 /45/ 5/L/ L/T4 T4 Spur Spur Rota Rotary ry Head 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 ada pter that serves as 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

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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 ada pter that serves as 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

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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 Gear oil o il is installed at the factory, p/n 52182938 for 1 quart. Mobil SHC 634 is optional, p/n 50422849 for 1 gallon.

Assembly/Rebuild

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Atlas Copco Drilling Solutions

DM30/45/L/T4 Spur Rotary Head

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.)

•

Lube Oil Capacity

Assembly/Rebuild

2600 Ibs. 11 Gal.

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The following safety, cleanliness and maintenance guidelines are to be used throug hout t he assembly pro cess for th e 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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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 allthread (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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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 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.

Assembly/Rebuild

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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 ke y 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).

Assembly/Rebuild

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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. hea ted. 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.

Assembly/Rebuild

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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 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 ho urs to properly shrink fit to the shaft.

STEP 36

36. Install the 2nd spacer (item 174, 57546319) on top of the output gear.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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 bea ring.

Assembly/Rebuild

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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 (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.

Assembly/Rebuild

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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 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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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, 9543487 4) 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.

Assembly/Rebuild

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STEP 65

65. Install the intermediate shaft end shim (item 49, 5724371 9) 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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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 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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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 spindlebearing 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 t he spindle assembly is harmful to bearings and other components. Life expectancy of the rotary head will b e 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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

Assembly/Rebuild

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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.

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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 va lve 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 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.

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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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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.

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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).

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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.

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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).

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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.

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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 locktongue washer (item 31) from the spindle.

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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.

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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.

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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.

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STEP 130 th

130. While heating the 4 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.

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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.

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Ensure inside and outside surfaces of the rotary h ousing is free of dirt, metal shavings and other contaminants by blowing shop air pressure into the housing prior to re-assembly.

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DM45_SPUR1

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