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

INTERMEDIATE GEAR ASSEMBLY

STEP 40

40. Heat the intermediate gear (item 20, 57159113) on the induction heater or in an oil
bath to 400F. 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 400F, lower it onto the shaft until it rests
against the shoulder. Ensure the key is smooth and properly fit into the keyway. Key
height and shaft OD should be checked with calipers to ensure that there is no
interference between the gear keyway and the key. Threaded lifting holes are
provided in the intermediate gear. They should face towards the end of the
intermediate shaft with 3 threaded holes (top). Allow the gear to cool at least 1.5
hours to shrink-fit onto the shaft.

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

STEP 42

42. Heat the lower spherical bearing (item 27, 95711156) on the induction heater or oil
bath to 300F and install it onto the bottom of the intermediate shaft. Use small steel
hammer and intermediate shaft tool (57192577) for installation. Allow the bearing to
cool onto the shaft.

STEP 43

43. Install the intermediate shaft tool (57192577) to prevent the outer race from pivoting
during installation.
Note: If the outer race falls out of position, reposition the rollers and roll the race
back into place by hand. Do not force the race in place, this can damage the bearing.

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

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.

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

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.

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

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, 57818221).

STEP 52

52. Lower the intermediate assembly into the bearing cavity with a hoist and the
intermediate shaft tool in place. Mesh 1 intermediate pinion (item 17) with the output
gear (item 10), while keeping the spherical bearing (item 27) square to the lower bore,
until the intermediate shaft tool rests on the bottom of the housing.

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

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 and maintain gear teeth alignment. If required, use a
special tool. The assembly should slide easily into position. If not, use a rawhide
hammer to tap in place.

STEP 55

55. For two motor rotary head assemblies, repeat steps 50 through 55.

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

STEP 56

56. Internal installation prior to replacing the cover supplied with the rotary housing
(item 8, 57395444).

STEP 57

57. Lightly coat grease (item 119, 57818221) to top-edge surface of upper bearing (item
47, 52209939) to lubricate internal cavity of the cover.

STEP 58

58. Secure when lifting the cover with two eyebolts and shackle
(57788770 & 57788861), hoist and clean the underneath surface of the cover from
dirt, debris and any other contaminates, prior to installing on the rotary housing.

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

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. With an air socket wrench bolt the cover in place with 24
capscrews (95934659) and washers (95934733).

STEP 61

61. Fill the two threaded push holes in the upper seal area with silicone (item 120,
50700731) as shown. This is to prevent bearing grease from the upper bearing
chamber from entering the rotary head gear case.

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STEP 62

62. Install the upper seal (item 34, 58229915) into the counter bore in the housing cover.
The seal should be installed in such a way as to hold grease within the bearing
chamber. Use a small steel hammer and bronze flat bar (57788713) to press the seal
flush within the bore. Care should be taken not to damage or deform the seal during
installation.

STEP 63

63. Install upper intermediate bearing (item 22, 95434874) on top journal of the
intermediate shaft. Use intermediate bearing drive assembly tool (57562910) and
socket (57788885), as shown to press the bearing onto the shaft. Ensure the bearing is
fully seated against the shoulder of the shaft. Repeat these steps for two motor rotary
head assemblies.

STEP 64

64. Input and intermediate shafts fully installed.

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

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 grease (item 119, 57818221) the oring groove and machined surface
of the motor adapter (item 26, 57368052), then insert oring (item 156, 95097929).
Repeat this step for the 2nd motor adapter.

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