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

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 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 100F.

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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 300F 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 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 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 (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.

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STEP 78

78. Lower the 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 through 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.

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

STEP 80

80. After properly setting rolling torque, install the tongued lock washer (item 31,
57291288). Additional tightening through the input shaft maybe required for
alignment of holes in items 24 and 31.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 grease (item 119), install oil seal (item 35,
52164282) into the upper seal housing (item 32, 52248150), to hold dirt out and tap
the seal to secure flush to top surface of the housing. Refer to oil seal design and
selection for proper installation and function.

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 grease.

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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 housings anchor guide.
Tighten item 39 by rotating the ratchet clock wise.

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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 grease (item 119, 57818221) 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.

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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 torque to requirement.

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