DM, DML. Rotary Head Rebuild, 2008

Atlas Copco Drilling Solutions
MODELS: DM45/50/L, ROTARY HEAD REBUILD

Atlas Copco Drilling Solutions, LLC
2100 North First Street
Garland, Texas, 75040
(972)496-7400
Read the 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.
TABLE OF CONTENTS
Instruction Manual: DM45/50/L Rotary Head Rebuild
TITLE PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
DESIGN FEATURES (Reference Drawing - 57562639). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Bearings Design and Gear Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Recommended Lube Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
WEIGHTS and OUTPUT GEAR TOLERANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
HOUSING TOLERANCES and REBUILD KIT LIST DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
DM45/50/L ROTARY HEAD REBUILD KIT LIST 57558736. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
REBUILD CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SPUR ROTARY HEAD SPECIFICATIONS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
STANDARD TORQUE VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Head Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Recommended Torque in Foot Pounds (ft./lbs.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Recommended Torques in Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SERVICING TIME TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
REQUIRED TOOLS / SPECIAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
ROTARY HEAD REBUILD REFERENCE NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
PROPER BEARING OIL SEAL ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
PREVENTATIVE MAINTENANCE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
SAFETY/ PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
PREPARATION / BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Pulling the Main Gear from the Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Removing the Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
ASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
SET-UP AND PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Shrink Fit Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
Shrink Fit Output Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
Shrink Fit Intermediate Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
Shrink Fit Lower Spherical Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59
Shrink Fit Wear Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73
Shrink Fit Upper Spindle Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75
Setting Spindle Bearing Preload Rolling Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-76
SAFETY WIRE INSTALLATION INSTRUCTIONS / EXAMPLES . . . . . . . . . . . . . . . . . . . . . 1-90
GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA TOC-i

TABLE OF CONTENTS
Instruction Manual: DM45/50/L Rotary Head Rebuild
TITLE PAGE
TOC - ii © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

DM45/50/L Rotary Head Rebuild Atlas Copco Drilling Solutions, LLC
INTRODUCTION
GENERAL INFORMATION
The purpose of this manual is to provide all necessary information required by site
maintenance personnel for the proper assembly / disassembly of the DM45/L/50/L Spur
Rotary Head.
If any part of this manual cannot be understood, contact your supervisor or local Atlas
Copco Distributor.
NOTICE
The use of repair parts other than those included within the Atlas Copco
approved parts list may create hazardous conditions over which Atlas
Copco has no control. Therefore Atlas Copco cannot be held responsible
for equipment in which non-approved repair parts are installed.
All information, illustrations and specifications in this manual are based

on the latest information at the time of publication. Product improvement
is a continuous goal at Atlas Copco. Design and specifications are
subject to change without notice or obligation of notice.
When the life of the tool has expired, it is recommended that the tool be
disassembled, degreased, and parts be separated by materials so that
they can be recycled.
NOTICE
SAFETY ALWAYS is the primary concern, for the protection of both
personnel and the equipment during assembly / disassembly. All
personnel must thoroughly understand all safety precautions and
procedures before doing any maintenance work on the spur rotary head.
Safety is an integral part of every individual’s job responsibility. Every

employee must be committed to these beliefs and must work in a manner
that demonstrates that commitment.
© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA 1-1

Atlas Copco Drilling Solutions, LLC DM45/50/L Rotary Head Rebuild
DESIGN FEATURES (Reference Drawing - 57562639)

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 Drills. The
rotary head is a simple, compact and efficient unit featuring axial piston hydraulic motors
mounted at the top of the gear case for easy access. The rotation motors, 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 various combinations of fixed and variable displacement of the rotation motors’
related torque and horsepower.
The internal bearings, pinions and gears in the rotary head are cooled and lubricated with EP
80W90 gear oil (splash lubed). 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 bearings 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.
Item 27 is a spherical roller bearing with cylindrical bore, narrow width and medium type
design. It has excellent 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

EP oils contain additives that increase load-carry properties, highly resistant to oxidation, non-
corrosive to metals and highly resistant to foaming. 80W90 gear oil is installed at the factory.
1-2 © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

WEIGHTS and OUTPUT GEAR TOLERANCES

Table 1: Component / Assemblies Weights
Component Part Number Part Weight Assembly Weight

Spindle 57546343 108.90 lbs. (49.5 kg.) w/ bearing - 121.87 lbs.
(55.4 kg.)
Intermediate 57159113 66.60 lbs. (30.3 kg.) w/ shaft & bearing - 95.0 lbs.
Gear (43.2 kg.)
Input Pinion 57170110 17.30 lbs. (7.9 kg.) w/ bearings - 25.35 lbs.
(11.5 kg.)
Rotary Head 57562639 assy 1,365 lbs. (260.5 kg.) 2,747 lbs. (1248.6 kg.)
57149031 bare
head
Output gear 57546301 140 lbs. (63.6 kg.) --
Output Gear Tolerances

HOUSING TOLERANCES and REBUILD KIT LIST DRAWINGS

TOLERANCES and REBUILD KIT LIST DRAWINGS(cont.)

DM45/50/L ROTARY HEAD REBUILD KIT LIST 57558736

REBUILD CHECK SHEET

INITIAL / DATE....PROCEDURAL STEPS
______ / ______ 1. Properly mount housing into rebuild stand.

______ / ______ 2. Remove cover, clean and set aside.
______ / ______ 3. Inject silicon into two push-holes used to remove bearing cone during
disassembly.
______ / ______ 4. Thoroughly clean housing.
______ / ______ 5. Record rotary head housing bearing cavity tolerances:

(1) - Upper input pinion bearing measurement _________
(2) - Lower input pinion bearing measurement _________
(3) - Upper intermediate shaft bearing measurement _________
(4) - Lower intermediate shaft bearing measurement _________
(5) - Upper intermediate shaft bearing measurement _________
(6) - Lower intermediate shaft bearing measurement _________
(7) - Upper spindle bearing measurement_________
(8) - Lower spindle bearing measurement _________
(9) - Upper input pinion bearing measurement _________
(10) - Lower input pinion bearing measurement _________
______ / ______ 6. While heating bearing cone, clean spindle.

______ / ______ 7. Verify spindle threads ok via running adjusting nut all the way on, then
remove.
______ / ______ 8. Fully seat heated bearing cone onto spindle.
______ / ______ 9. Install two hex head plugs, square head plug, and magnetic drain plug.
______ / ______ 10. Fully seat bearing cup into lower housing.
______ / ______ 11. Attach ring-lock tool and then lift and insert spindle into housing.
______ / ______ 12. Properly orient and install seals in lower seal housing.
______ / ______ 13. Apply silicon to machined surface of housing and install lower seal
housing.
______ / ______ 14. Use a jack to tightly press cup and cone of lower bearing together.
______ / ______ 15. Fully seat spacer and keyway on spindle.

INITIAL / DATE....PROCEDURAL STEPS (cont.)
______ / ______ 16. Install heated output gear and ensure it’s fully seated.
______ / ______ 17. Install second spacer and retaining collar, and measure gap.
______ / ______ 18. Properly install shims, replace spacer and secure retaining collar.
______ / ______ 19. Insert keyway into intermediate shaft, and then fully seat heated
intermediate gear on shaft.
______ / ______ 20. Fully seat heated lower spherical bearing utilizing intermediate shaft tool.
______ / ______ 21. Fully seat bearings on input pinion.
______ / ______ 22. Install intermediate shaft spacer, and thread eyebolt into shaft.
______ / ______ 23. Coat intermediate bearing and input pinion bearing cavities with grease.
______ / ______ 24. Lower intermediate assembly into housing and fully seat it.
______ / ______ 25. Fully seat input pinion in housing.
______ / ______ 26. After using compressed air to ensure housing is clean, coat upper pinion
with grease.
______ / ______ 27. Lift housing cover with shackle and thoroughly clean both topside and
underside of it.
______ / ______ 28. Apply silicone to top edge of housing and install cover.
______ / ______ 29. Properly orient upper seal and install into housing.
______ / ______ 30. Install upper intermediate bearing.
______ / ______ 31. Insert relief valve into 90o elbow and install in housing.
______ / ______ 32. Install square head pipe plug in housing.
______ / ______ 33. Install sight gauge and pipe sealant plug in housing.
______ / ______ 34. Install intermediate shaft end shim and plate and lockwire.
______ / ______ 35. Apply silicone to housing and install intermediate shaft bearing cap.
______ / ______ 36. Lightly grease o-ring groove of motor adapter plate, insert o-ring and
install plate on housing.
______ / ______ 37. Rotate wear sleeve while heating it and then install on spindle, seating it
fully.

INITIAL / DATE....PROCEDURAL STEPS (cont.)
______ / ______ 38. Install upper spindle bearing cup in housing, seating it fully.
______ / ______ 39. Grease bearing cup and install heated upper spindle bearing.
______ / ______ 40. Verify spindle is firmly supported such that cup and cone of lower bearing
are pressed tightly together.
______ / ______ 41. Lightly grease spindle threads, install adjusting nut .
______ / ______ 42. Install adjustment locking ring tool and angles; insert input pinion tool,
and perform procedure for setting preload rolling torque.
______ / ______ 43. After properly setting preload rolling torque, install tongued lock washer.
______ / ______ 44. Install properly oriented seal into upper seal housing and lightly grease it.
______ / ______ 45. Apply grease to wear sleeve and silicone to machined surface of housing
that mates to the upper seal housing.
______ / ______ 46. Install lube fitting and relief fitting in upper seal housing.
______ / ______ 47. Install upper seal housing securing it temporarily with two capscrews.
______ / ______ 48. Clean spindle cap, insert threaded ring and lightly grease.
______ / ______ 49. Install slinger.
______ / ______ 50. Place o-ring in spindle groove and install spindle cap.
______ / ______ 51. Brace pipe wrench against slide glide.
______ / ______ 52. Use input pinion tool and pipe wrench to tighten spindle cap.
______ / ______ 53. Install swivel on upper seal housing.
______ / ______ 54. Insert packing in swivel cap and lightly grease.
______ / ______ 55. Insert packing in spindle cap, lightly grease it and place wear bushing on
top of it.
______ / ______ 56. Insert two threaded alignment rods in swivel, install shim set (setting
clearance to 0.125”) and install swivel cap.
______ / ______ 57. Remove pipe plug and fill housing with approximately 23 quarts of gear
oil (to middle of sight glass).
______ / ______ 58. Use grease gun to fill upper bearing area with grease until pin extension
occurs on relief fitting.

SPUR ROTARY HEAD SPECIFICATIONS AND LUBRICANTS
Table 2: Specifications
Standard Optional
Model 4SV-2-10.0 4SF-2-8
Speed Range: Variable, 0 to 160 RPM Variable, 0 to 120 RPM
Maximum Torque: 9,000 ft/lb. @ 95 RPM 7,200 ft/lb. (9,763 N-m)
5,400 ft/lb. @ 160 RPM
Rotary Head Motors: Two
Type: One-variable Displacement Two - Fixed Displacement
One - Fixed Displacement
Reduction: 15:1
Main Gear Face Width: 2.5 in. (63.5 mm)
Rotary Head Weight: 2600 lb. (1179 kg)
Head Guides: Replaceable, Nylatron
Table 3: Lubricants
Item Type Capacity

Rotary Head Grease: Extra HD Moly 2 Add grease until the relief valve
pops out
Rotary Head Oil: SAE 80W90 gear oil 44 quarts or 11 gallons (42 liter)
p/n 58209651 (1 qt.) (Fill to mark on the sight level
p/n 57641458 (55 gal.) gauge)
SHC 634 is optional,

p/n 50422849 (1 gal.)
The SSU viscosity at 100oF should be at a minimum of 2060, and at 210oF, 189.
Maximum pour point is -40oF.

STANDARD TORQUE VALUES
General Information
! CAUTION
Use only the proper tools (inch or metric) on hardware. Other tools may
not fit properly. They may slip and cause injury.
Head Markings
Fasteners should be replaced with the same grade or a higher grade. If higher grade fasteners
are used, these should only be tightened to the strength of the original grade fastener.
Do not use these values if a different torque value or tightening procedure is listed for a specific
application. Torque values listed are for general use only. All values are suggested maximum
with dry plated hardware.
Make sure fastener threads are clean and you properly start thread engagement. This will
prevent them from falling when tightening.
The following pages list the recommended tightening torques for the various size bolts used
by Drilling Solutions. Proper torque specifications should be used at all times.
The head of grade five (5) is marked with three (3) short lines. The head of a grade eight (8)
is marked with six (6) short lines.
In the following tables, DRY means “clean dry” threads and LUBE means a “light film” of oil.
Excess oil in a threaded dead end hole can create a hydraulic lock giving a false torque
reading.

Recommended Torque in Foot Pounds (ft./lbs.)

This page lists the recommended tightening torques, in foot pounds (ft/lbs), for the various size
bolts and nuts that are used. Proper torque specifications should be used at all times.
Table 4: Recommended Torque in ft./lbs.
Size SAE Grade 5 Torque SAE Grade 8 Torque

. Dry Lube Dry Lube
5/16 - 18 NC 16 - 17 12 - 13 23 - 25 17 - 18
5/16 - 24 NF 18 - 19 13 - 14 . 19 - 20
3/8 - 16 NC 28 - 30 21 - 23 42 - 45 33 - 35
3/8 - 24 NF 33 - 35 23 - 25 47 - 50
7/16 - 14 NC 47 - 50 33 - 35 65 - 70 51 - 55
7/16 - 20 NF 51 - 55 37 - 40 74 - 80 56 - 60
1/2 - 13 NC 70 - 75 51 - 55 102 - 110 74 - 80
1/2 - 20 NF 84 - 90 61 - 65 112 - 120 84 - 90
9/16 - 11 NC 102 - 110 74 - 80 140 - 150 102 - 110
9/16 - 18 NF 112 - 120 84 - 90 158 - 170 121 - 130
5/8 - 11 NC 140 - 150 102 - 110 205 - 220 158 - 170
5/8 - 19 NF 158 - 170 121 - 130 223 - 240 167 - 180
3/4 - 10 NC 242 - 260 186 - 200 353 - 380 260 - 280
3/4 - 16 NF 279 - 300 205 - 220 391 - 420 298 - 320
7/8 - 9 NC 400 - 430 298 - 320 558 - 600 428 - 460
7/8 - 14 NF 437 - 470 326 - 350 614 - 660 465 - 500
1 - 8 NC 595 - 640 446 - 480 837 - 900 632 - 680
1 - 12 NF 651 - 700 493 - 530 930 - 1000 688 - 740
1-1/8 - 7 NC 744 - 800 558 - 600 1190 - 1280 893 - 960
1-1/8 - 12 NF 818 - 880 614 - 660 1339 - 1440 1004 - 1080
1-1/4 - NC 1042 - 1120 781 - 840 1693 - 1820 1255 - 1360
1-1/4 -12 NF 1153 - 1240 856 - 920 1860 - 2000 1395 - 1500
1-3/8 - 6 NC 1358 - 1460 1023 - 1100 2213 - 2380 1655 - 1780
1-3/8 - 12 NF 1562 - 1680 1172 - 1260 2530 - 2720 1897 - 2040
1-1/2 -6 NC 1804 - 1940 1358 - 1460 2939 - 3160 2195 - 2360

Recommended Torques in Nm
This page lists the recommended tightening torques, in newton-meters (Nm), for the various
size bolts and nuts that are used. Proper torque specifications should be used at all times.
Table 5: Recommended Torque in Nm
Size SAE Grade 5 Torque SAE Grade 8 Torque

. Dry Lube Dry Lube
5/16 - 18 NC 22 - 27 16 -17 31 - 33 23 - 24
5/16 - 24 NF 24 - 26 17 - 19 . 26 - 27
3/8 - 16 NC 37 - 40 28 - 31 56 - 60 44 - 47
3/8 - 24 NF 44 - 47 31 - 33 63 - 67 .
7/16 - 14 NC 63 - 67 44 - 47 87 - 93 68 - 73
7/16 - 20 NF 68 - 73 49 - 53 97 - 107 75 - 80
1/2 - 13 NC 93 - 100 68 - 73 136 - 147 99 - 107
1/2 - 20 NF 112 - 120 81 - 87 149 - 160 112 - 120
9/16 - 12 NC 136 - 147 99 - 107 187 - 200 136 - 147
9/16 - 18 NF 149 - 160 112 - 120 211 - 227 161 - 173
5/8 - 11 NC 187 - 200 136 - 147 273 - 293 281 - 227
5/8 - 18 NF 211 - 227 161 - 173 297 - 320 223 - 240
3/4 - 10 NC 323 - 347 248 - 267 471 - 507 347 - 373
3/4 - 16 NF 372 - 400 273 - 293 521 - 560 397 - 427
7/8 - 9 NC 533 - 573 397 - 427 744 - 800 571 - 613
7/8 - 14 NF 583 - 627 435 - 467 819 - 880 620 - 667
1 - 8 NC 793 - 853 595 - 640 1116 - 1200 843 - 907
1 - 12 NF 868 - 933 657 - 707 1240 - 1333 917 - 987
1-1/8 - 7 NC 992 - 1067 774 - 800 1587 - 1707 1191 - 1280
1-1/8 - 12 NF 1090 - 1173 819 - 880 1785 - 1920 1339 - 1440
1-1/4 - 7 NC 1389 - 1493 1041 - 1120 2257 - 2427 1687 - 1813
1-1/4 - 12 NF 1537 - 1653 1141 - 1227 2480 - 2667 1860 - 2000
1-3/8 - 6 NC 1811 - 1947 1364 - 1467 2951 - 3173 2207 - 2373
1-3/8 - 12 NF 2083 - 2240 1563 - 1680 3373 - 3627 2529 - 2720
1-1/2 -6 NC 2405 - 2587 1811 - 1947 3917 - 4213 2927 - 3147

SERVICING TIME TABLES

Table 6: Mean Time Between Service (MTBS)
Rotary Head Oil Level Check and Upper Bearing Greasing

LIGHT-DUTY NORMAL-DUTY HEAVY-DUTY
8 - 10 hours or daily 8 - 10 hours or daily 8 - 10 hours or daily
Table 7: Mean Time Between Maintenance (MTBM)
Change Rotary Head Oil

1200 hours 1000 hours 800 hours
Table 8: Mean Time Between Failure (MTBF)
Average Time Between Recommended Rotary Head Rebuilds

12,000 hours 10,000 hours 8,000 hours
Table 9: Mean Time To Repair (MTTR)
Average To Remove From Rig Average To Rebuild Rotary Head

8 - 10 hours 12 - 16 hours
NOTE: Life cycle calculation is based on the average expected life of the
part. It does not imply that the part will be covered under any
warranty for that period.
NOTE: Duty Guidelines / Definitions:
• Light - Sand and Gravel, Rotary Drilling

• Normal - Soft Rock, Rotary Drilling
• Heavy - Hard Rock, Hammer Drilling

REQUIRED TOOLS / SPECIAL EQUIPMENT

Before starting the rotary head rebuild, certain special tools are required and available from
Atlas Copco. Many of these tools are in a Tophead Rework Tools Kit (57512469). This kit
includes:
• Input Pinion Tool

• Intermittent Shaft Assembly Tool
• Wear Sleeve Tool
• Lock-ring Adjustment Tool
• Spindle Rotation Tool
• Rotation Torque Tool
• Hex Cap Screw
• Jacking Plate
• Bearing Drive Assembly Tool
Some additional tools are required for this rotary head model that are not included with the
Tophead Rework Tools Kit, but are required for a successful rebuild. These tools include:
• Rotary Head Working Stand (57788051)

• Round Plate with Holes (57787821)
• Tee Rod Hook (57788119)
• Ring-Lock Tool (57788705)
• Two Special Threaded Eyebolts (57788739)
• One Special Threaded Eyebolt (5778870)
• Shackle (57788861)
• Insulated Gloves (57788093)
• An Induction Heater or Oil Bath Heater capable to 450oF
• Hoist with a minimum of 4000 Lbs. capacity
• Hydraulic Press

ROTARY HEAD REBUILD REFERENCE NUMBERS

Table 10: Rotary Head Rebuild Kit Number / Bare Part Number
Rebuild Parts Kit # Rebuild Tool Kit # Rotary Head Part #

57558736 with Output Gear 57512469 57562639 complete assembly
57684516 without Output Gear 57395444 bare housing
PROPER BEARING OIL SEAL ORIENTATION

The lip of the seal points to the highest (see arrow) pressure side. Seals can be doubled up.
For oil retention, the seal lip must be mounted with the lip pointing inwards toward the bearing
/ oil cavity in order to seal the oil in (see lip / spring below). The bearing seal has a spring
retention design system, the spring will always be towards the inside of the cavity.

TERMINOLOGY
Throughout the manual, Danger, Caution, Warning, Notice and Note are used to provide the
reader with special noteworthy information.
These terms, as listed below, have the following significance:
! DANGER
Danger is used to indicate the presence of a hazard which will cause
severe personal injury, death, or substantial property damage if the
warning is ignored.
! WARNING
Warning is used to indicate the presence of a hazard which can cause
severe personal injury, death, or substantial property damage if the
warning is ignored.
! CAUTION
Caution is used to indicate the presence of a hazard which will or can
cause minor personal injury or property damage if the warning is ignored.
NOTICE
Notice is used to notify people of installation, operation, or maintenance
information which is important but not hazard related. Hazard warnings
should never be included under the Notice signal word.

PREVENTATIVE MAINTENANCE INSPECTIONS
! CAUTION
Historically, repeated problems with the swivel head packing assembly,
e.g. water leaks, missing packing rings, etc., may be an indication of loss
of preload of the main bearing assembly.
Sufficient preload is critical. Insufficient preload will allow the upper

spindle bearing inner-race to spin under the lock-nut during drilling and
breakout operations. This spinning of the race will quickly wear away the
bottom of the lock-nut and any existing preload will be lost resulting in
endplay. This endplay in the spindle assembly is harmful to bearings and
other components. Life expectancy of the rotary head will be shortened.
In addition to the rotary head service recommendations in the Maintenance

Manual, the following is suggested:
1. Check preload every 2,000 hours. Use a machinist’s magnetic base with
adjustable arm and dial-gauge attached to the end, mount near the top of
spindle to check vertical movement, track / chart the readings. Horizontal
runout can be measured by placing the indicator on the side of the spindle and
using the motor to rotate the spindle.
2. At each of the recommended 1,000 service-hour changes of the rotary head oil
(see Table 7 for more information), carefully inspect the magnetic drain plug as
well as the oil itself for evidence of ground-up metal / shavings (some is to be
expected, excessive amounts could be an indication of a problem).
3. It’s recommended that as a minimum, at each 500 service-hour interval, have

oil samples tested and create a chart to track any changes in the content of
dissolved metals or contaminants.
4. Changes should be fairly linear. Any sudden or dramatic changes could be an

indication that there has been a loss of preload on the main bearing (or
problems elsewhere).
5. If major changes are noted in the metal content of the oil, if a dramatic loss of
preload or other serious problem is discovered / observed, consultation with
Atlas Copco Technical Services is recommended.

SAFETY/ PRECAUTIONS
! CAUTION
The following safety, cleanliness and maintenance guidelines are to be
used throughout the assembly / disassembly process for the spur head:
A. Clean the exterior of the spur head before tearing it down.
B. Dismantle the spur head in a clean area.
C. Pay close attention to the identities of the parts during disassembly, this will
make reassembly much easier.
D. Use a soft-faced hammer and soft drifts to remove heavier parts.
E. Handle parts carefully. Hardened parts may chip or break if they are dropped
on a hard surface.
F. Clean all parts thoroughly in an approved cleaning solvent (paint prep thinner
S910) and blow dry with compressed air. Do this in a well ventilated area.
G. Inspect all bearings, gears and shafts for wear, cracks, discoloration and/or
looseness. Check all new parts for damage that may have occurred in shipment
and replace all unserviceable parts.
H. Remove all nicks, burrs or any foreign matter from the spur head housing,
inside and out.
I. Do not allow dirt, cuttings or brass shavings to enter the spur head during
assembly.
J. Keep hands and tools clean.
K. 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.
L. Except for press-fit bearings and bushings, parts should fit together easily. If
force is required, a part is either out of tolerance or alignment, and must be
corrected to prevent binding and possible damage.

DISASSEMBLY PROCEDURE
PREPARATION / BREAKDOWN
STEP 1
Remove the sight glass (Item 98, 52253176), catch gear oil in a drip pan. Connect a chain to
a hoist with a 4000 pound capacity to lift the rotary head assembly.
Secure the rotary head assembly in the rotary stand (57788051) with required cap-screws
(95934501) and flat-washers (95094314).

STEP 2
To remove the bulkhead hose support-bracket, cut the lock-wire, remove screws and washers
with the impact wrench.

STEP 3
Remove the two motors with all related piping, including the swivel (Item 37) and adjusting nut
(Item 24) with appropriate special tools.
Place on pallet as shown.

STEP 4
Attach a 48" pipe wrench to the spindle cap (Item 39), bracing the handle against the rotary
housing's cable anchor (as shown). Insert the special input pinion tool (57466369) and using
ratchet rotate it counter-clockwise to remove the cap.
STEP 5
Use a flat head screwdriver and small pry-bar to remove the slinger (Item 38), being careful
not to damage threads on spindle.

STEP 6
Insert two screws (95930723) into the 5/8" tapped push hole. With the air socket, remove the
upper seal housing (Item 32).
STEP 7
With upper seal housing removed, note damage to upper bearing caused by insufficient
grease during the initial installation.

STEP 8
! CAUTION
Locate an oil drip container and grease rags for potential overflow when
motor adapters are removed. Comply with work area cleanliness / safety.
Remove the screws retaining the intermediate cover, tap with a small steel hammer and use
small pry-bar for removal.
Remove the screws retaining the motor adapters, tap with a small steel hammer and use small
pry-bar for removal.

STEP 9
Remove lock tongue washer (Item 31).
Install the special lock ring tool (57512436) and retain with angles (57788788), cap-screws
and lock-washers as shown.

STEP 10
Insert input pinion tool and use ratchet to rotate clockwise to loosen the lock-tongue washer
(Item 31) and then remove it from the spindle (along with lock-ring tool and angle brackets).
STEP 11
Attach two eyebolts (57788747) to the cover of the rotary housing and to the chain hoist.
Screw in two square head all-thread 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 12
! CAUTION
Take extra care to not distort the cavity in the rotary housing when
removing the assemblies as both were slightly press-fit during
installation. If required, gently tap with a rawhide hammer to loosen.
Wearing work gloves for hand protection, connect the chain to the hoist and around the input
pinion assembly and carefully remove it.
Dip the assembly in an oil bath for cleaning, wrap with a clean cloth after removal from the oil
bath to prevent oil from dripping on the floor of the work area.

STEP 13
! CAUTION
Take extra care to not distort the cavity in the rotary housing when
removing the assemblies, as both were slightly press-fit during
installation. If required, gently tap with a rawhide hammer to loosen.
Cut and remove the lock-wire (Item 127) retaining the end plate. Remove one bolt and replace
with an eyebolt and shackle (57788770 & 57788861).
Insert intermediate shaft tool (57192577) for maintaining bearing position, and lift with the
chain and hoist for removal of the intermediate assemblies.

STEP14
Remove retaining collar (Item 176), and spacer (Item 174.
Remove shims (Items 175 and177) and clean the main gear of dirt, metal shavings and any
other contaminates.

STEP 15
Position special plate w/ holes (57791725) on top of the spindle and insert four special all-
thread rods (57791733) and thread into the main gear. Lower the jack supporting the spindle
to relieve bearing compressive loading.

STEP 16
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).

STEP 17
Review all connections and alignment of the cylinder, plate and bar to ensure proper set-up.
Tighten the four lock-nuts on the threaded rods (57791733) to secure the plate.
STEP 18
With a torch, heat the main gear (for approximately 30 seconds in a small circular motion) in
four locations, 90 degrees apart, for gear expansion near the spindle.

STEP 19
While heating the fourth location, slowly engage the cylinder to pull the main gear (Item 10).
! CAUTION
The red ring indicates fully stroked cylinder, do not attempt to extend
further.
Once gear is freed, ease off air pressure to cylinder until gear has settled. Loosen the four lock-
nuts and remove the plate, threaded rods, cylinder and related components.

STEP 20
Screw two eyebolts (57788739) into the tapped holes of the main gear.
! CAUTION
Be careful not to damage threads on spindle when removing main gear.
Connect shackle (57788861) to chain and hoist to remove gear from spindle.
STEP 21
Screw in cap-screw (95935235) into the tapped hole to remove the custom key (Item 11) from
the spindle slot.
If applicable, remove the magnetic sending unit from the side of the rotary housing.

Removing the Spindle

STEP 22
! CAUTION
Use caution when rotating the rotary head, allow appropriate clearance.
Remove the eyebolts from the rotary stand pillow blocks (do not remove the screws) and
carefully rotate the rotary head 90 degrees, catching gear oil in a drip pan.
Clean the inside of the rotary housing of all metal chips and contaminates.
Rotate a further 90 degrees so the bottom of the spindle is at the top (as shown).

STEP 23
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, insert the chain-hook end down through the spindle and attach
lock-ring (57788705) to hook.
With lock-ring (57788705) attached to the hook, pull the spindle up through the housing.

STEP 24
! CAUTION
Use caution when rotating the rotary head, allow appropriate clearance.
Note bearing cup remaining. Remove the eyebolts from the rotary stand pillow blocks (do not
remove the screws) and carefully rotate the rotary head 180 degrees.
Use a small steel hammer and bronze drift (57788101) to remove the bearing cup.
Use a putty knife to remove silicone from the ridge of the housing. Ensure inside and outside
surfaces of the rotary housing are free of dirt, metal shavings and any other contaminants prior
to re-assembly.

ASSEMBLY PROCEDURE
SET-UP AND PREPARATION

STEP 1
Lift machined housing (Item 8, 57395444 for DM45/50/L) and position in the spur head working
stand (57788051) with cover (52231008) pointing upward (cover supplied with Item 8).
STEP 2
Secure the housing to the stand with flat-washers (95094314) and cap-screws (95934501).
Replace the top half of the stand pillow-blocks, screws and eyebolts (57788069), as shown.

STEP 3
Clean slide-guide machine surfaces with paint prep thinner (S910) to remove any dirt, grease
or metal shavings.
STEP 4
Remove cover screws with impact wrench.
Hand thread the four all-thread rods (57788077) into the four specially threaded holes in cover.

STEP 5
Use impact wrench with the special drive socket (57788085) to alternately/evenly run in the
all-thread rods (57788077) to pull up the cover from the dowel pins.
STEP 6
Clean inside the spur head housing, cover and all bearing surfaces with paint prep thinner
(S910) to remove any dirt, grease or metal shavings.

STEP 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 any dirt or grease.
Use compressed air to ensure it’s free of any metal shavings.
STEP 8
Add silicone (50700731) to fill the two holes that are used to push out the bearing cone (Item
33, 95434569) during disassembly.

STEP 9
Apply pipe dope on relief fitting (Item 88, 95246724, elbow (Item 99, 95040952), all pipe plugs
(Item 70, 95246724) and install per print.
Shrink Fit Bearing Cone

STEP 10
Heat bearing cone (Item 4, 95434551) on an induction heater (or in an oil bath) to
approximately 300°F.
While bearing cone is heating, prepare the spindle (Item 1, 57546343) for it by thoroughly
cleaning spindle and placing it in a large, clean, flat area (ensuring you have enough room to
lower the bearing onto the spindle when it has reached 300°F).

STEP 11
After cleaning the surface and threads of the spindle with solvent, confirm there’s no thread
damage to the spindle or 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
! WARNING
Proper caution and approved safety gloves must be utilized to avoid
possible serious injury when handling the hot bearing cone.
Using protective gloves (57788093) slide bearing cone over the spindle until it rests on the
bearing cone shoulder. Allow time for the bearing cone to cool and shrink-fit onto the spindle.
Once cooled, apply a coat of Ronex-HD Grease (Item 119, 52180957) to the bearing cone.

STEP 13
Ensure inside surface of the housing (previously cleaned with solvent) is free of dirt, metal
shavings and other contaminants by blowing compressed air into the housing.
STEP 14
Apply pipe dope and install hex-head o-ring plugs (Item 125, 95323465), square-head plugs
(Item 18, 95033585) and magnetic drain plug (Item 107, 50137256).

STEP15
Apply pipe dope and install pipe sealant plug (Item 67, 95249587). This is the port utilized for
the magnetic sending unit option.
STEP 16
Insert the bearing cup (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), tap the cup on alternate sides to evenly and fully seat the cup in the housing.

STEP 17
Use special tool, tee-rod-hook (57788119), to pull the chain-hook end through the spindle
(note bearing cone in place).
STEP 18
Attach ring-lock tool (57788705) to chain hook for lifting the spindle.
STEP 19
With ring-lock lifting tool in place, lift and insert spindle (Items 1 and 4) into lower bearing race.

STEP 20
Thoroughly clean surface of lower seal housing (Item 2, 57578023) and then insert the first
lower seal (Item 3, 52146784). Ensure seals are properly oriented (per print).
STEP 21
Using small steel hammer and bronze square-head key stock (57788713), evenly seat the
seal by tapping on opposite sides. Insert second seal directly on top of first and repeat the
process.
STEP 22
After fully seating the seals, use Ronex-HD Grease (Item 119, 52180957) for lubricating both
seals.

STEP 23
Use Ronex-HD Grease (Item 119) to lubricate the spindle area as shown.
Apply silicone (Item 120, 50700731) onto the circumference surface of the lower housing to
form a gasket prior to placing the lower seal housing (57578023).
STEP 24
Lower seal housing (57578023) over the spindle (with enclosed seals). Care should be taken
not to damage or distort the seals as they slip on to the spindle.

STEP 25
Align and insert cap-screws and lock-washers (Items 5 & 6, 95934451 & 95934733) and
tighten with socket / air ratchet.
STEP 26
Remove both eyebolts (57788069) from the rotary head stand in order to rotate it.
! CAUTION
Ensure the pillow blocks are in place. Allow ample clearance for yourself
when rotating the rotary head housing.
Remove eyebolts and rotate rotary head 180 degrees (until the top is pointing upward).
Re-insert both eyebolts into the stand.

STEP 27
Operate the jack located underneath the spindle [with attached round plate (57788721)] so
that the cup and cone of the lower bearing are pressed tightly together. The spindle must be
supported tightly to ensure proper placement of the output gear.
With the jack in position, temporarily remove the upper half of the pillow blocks during this
process to observe shaft lift which verifies the lower bearing cup is fully seated, (causing the
rotary head assembly to lift slightly with it).
STEP 28
Place spacer (Item 174, 57546319) over spindle and seat it all the way down.

STEP 29
Verify spacer (Item 174) is in full surface contact. Before inserting the 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 output gear should be tight but not
be an interference fit.
The key should fit tightly within the groove on spindle and be fully seated against the bottom
depth of the keyway. Insert the key with the threaded jacking hole located at the top as shown.
STEP 30
Insert two special threaded eyebolts (57788739) into output gear (Item 10, 57546301).

STEP 31
Use shackle (57788861) to lift the output gear (Item 10, 57546301).
Measure the inside hub diameter of the output gear, including the keyway height. Maximum
diameter of the spindle and key must not exceed this measurement. This will ensure that the
output gear will fit during installation.
Shrink Fit Output Gear

STEP 32
Place the output gear onto the induction heater (or into an oil bath) and heat to 430°F.
The fit to the spindle is a shrink fit up to 0.004". Ensure the specific temperature is reached,
binding problems may arise if the gear is either over or under heated.

STEP 33
! WARNING
possible serious injury when handling the hot output gear.
With insulated gloves (57788093) and shackle (57788861), remove the output gear from the
induction heater. Position the gear with the high-pressure grease hole to the top.
STEP 34
! CAUTION
Be careful not to damage threads on spindle during gear installation.
With the spindle supported and lower bearing properly seated in the bearing race, align the
keyway and install the heated gear onto the spindle. With gear fully seated the keyway should
be flush to the key as shown.

STEP 35
Verify the position of the high-pressure grease hole is on 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
Install the second spacer (Item 174, 57546319) and fully seat it on top of the output gear (note
the groove for retaining collar just above it, groove should be unobstructed by spacer).

STEP 37
Install (temporarily) the retaining collar (Item 176, 57546335) into groove above spacer and
measure gap between the retaining collar and spacer with a feeler gauge.
Remove the retaining collar and spacer and install shim(s) (Item 175, 57546384) under spacer
(as shown) in equal thickness to the gap measured.
STEP 38
Reinstall retaining collar and secure with cap-screws (Item 178, 95935235) and lock-nuts
(Item 180, 95923371). Installation for lock-nuts are reversed (facing opposite sides).
Ensure there is no gap remaining between the gear, spacer or the retaining collar.
Peen the threads after tightening the lock-nut.

STEP 39
Use the air nozzle to thoroughly clean the housing of any metal shavings, dirt or other
contaminates.
Shrink Fit Intermediate Gear Assembly

STEP 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
! WARNING
possible serious injury while handling the hot intermediate gear.
Measure key height and shaft OD with calipers to ensure that there will be no interference
between the gear keyway and the key.
After heating the intermediate gear to 400°F, remove it from heater (threaded lifting holes are
provided in the intermediate gear). The lifting holes should face towards the end of the
intermediate shaft with the three threaded holes on top.
Using insulated gloves (57788093), lower it onto the shaft until it rests against the shoulder.
Ensure the key is a smooth and proper fit into the keyway.
Allow the gear to cool at least 1.5 hours to fully shrink-fit onto the shaft.

Shrink Fit Lower Spherical Bearing

STEP 42
! WARNING
possible serious injury while handling the hot spherical bearing.
Heat the lower spherical bearing (Item 27, 95711156) on the induction heater (or oil bath) to
300°F. Using insulated gloves (57788093), install it onto the bottom of the intermediate shaft.
Use small steel hammer and intermediate shaft tool (57192577) for installation.
STEP 43
The intermediate shaft tool (57192577) is used 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. Allow
the bearing to cool onto the shaft.

STEP 44
Ensure input pinions (Item 21, 57170110) are free of any debris before placing lower bearing
(Item 16, 95214037) and upper bearing (Item 47, 52209939) on pinions.
STEP 45
Position input pinion (with upper and lower bearings as shown) on the press machine.

STEP 46
! CAUTION
Only apply press force against the inner races, otherwise bearing
damage can occur. The upper bearings are permanently sealed and
lubed, take care to not dislocate/damage the upper and lower seals.
The upper and lower bearing press operation must be performed with spacer (57159121)
placed with chamfer end down, and round bar (56971872) on the input pinion (Item 21,
57170110). Press until fully shoulder seated.
STEP 47
Notice the before and after (bearing press operation) appearance. Remove the first input
pinion / bearing assembly and repeat the previous steps for the second.

STEP 48
Verify proper lower and upper bearing installation after press operation, before installing into
the rotary housing.
STEP 49
Install intermediate spacer (Item 23, 57159121), chamfer end up, on upper end of the
intermediate shaft (Item 17, 57191017).
Thread eyebolt (57788770) into one of the tapped holes in the shaft (as shown) and use
shackle (57788861) for lifting the assembly.

STEP 50
With the intermediate shaft tool (57192577) inserted (for positioning the intermediate gear
assembly in the rotary housing), use an overhead hoist and chain connected to the eyebolt
and shackle (57788770 & 57788861) to thoroughly clean the assembly with cleaning solvent
to remove any dust, dirt or contaminates.
STEP 51
Lightly coat each input pinion bearing cavity in the rotary head housing with Ronex-HD Grease
(Item 119, 52180957).

STEP 52
Lower the intermediate assembly into the bearing cavity with a hoist (with the intermediate
shaft tool in place).
Mesh 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
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
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 mallet to tap in place).
STEP 55
Repeat steps 50 through 54 for second intermediate assembly.

STEP 56
Appearance of completed internal installation just prior to replacing the cover supplied with the
rotary housing (Item 8, 57395444).
STEP 57
Lightly coat with Ronex-HD Grease (Item 119, 52180957) the top-edge surface of upper
bearing (Item 47, 52209939) to lubricate internal cavity of the cover.

STEP 58
Lift the cover using two eyebolts and shackle (57788770 & 57788861) and clean the underside
surface of the cover. Thoroughly remove all dirt, debris and any other contaminates, prior to
installing on the rotary housing.
STEP 59
! CAUTION
Take special care not to damage the threads on the spindle while
lowering cover.
Apply a bead of silicone (Item 120, 50700731) around the edge of the housing and lower the
cover into place. Align the locator dowel pins with the dowel holes in the cover, use rawhide
mallet to tap cover into place.

STEP 60
Insert 24 cap-screws (95934659) with 24 lock-washers (95934733) and bolt the cover in place.
STEP 61
Ensure the two threaded "push" holes in the upper seal area are filled with silicone (Item 120,
50700731) as shown (per an earlier step). This is to prevent bearing grease from the upper
bearing chamber from entering the rotary head gear case.

STEP 62
Install the upper seal (Item 34, 58229915) into the counter bore of the housing cover. The seal
must be properly oriented in order 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
Insert upper intermediate bearing (Item 22, 95434874) on top journal of the intermediate shaft.
Use intermediate bearing drive assembly tool (57562910) and socket (57788846) to press the
bearing onto the shaft. Ensure the bearing is fully seated against the shoulder of the shaft.
Repeat for second motor adapter.

STEP 64
Input and intermediate shafts fully installed.
STEP 65
Install the intermediate shaft end shim (Item 49, 57243719).

STEP 65 (continued)
Install the intermediate shaft plate (Item 126, 57191033) atop the end shim and secure with
three cap screws (Item 128, 95101762).
Torque the cap-screws to 80 ft-lbs lubed, 110 ft-lbs dry.
Lock-wire (Item 127, 50344605) the cap-screws in place utilizing tie-wire pliers (57791873),
(see back page for lock-wire installation examples).
STEP 66
Apply silicone (Item 120, 50700731) to 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
Lightly coat the o-ring groove and machined surface of the motor adapter (Item 26, 57368052)
with Ronex-HD Grease (Item 119, 52180957), then place o-ring (Item 156, 95097929).
Repeat this step for the second motor adapter.
STEP 68
Install the motor adapter and attach to the housing with two socket screws (Item 41,
95055216). Care should be taken not to damage the o-ring.

STEP 69
Lightly coat the o-ring groove and machined surface of the motor adapter (Item 26, 57368052)
with Ronex-HD Grease.
Insert o-ring (Item 12, 95086724) and then add another light coat.
Shrink Fit Wear Sleeve
STEP 70
Heat wear sleeve (Item 36, 50822097) on the induction heater (or oil bath) to 100°F.

STEP 71
! WARNING
possible serious injury while handling the hot wear sleeve.
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
Insert the cup of the upper spindle bearing (Item 33, 95434569) into the cover. Use a small
steel hammer and bronze bar (57788713) to fully seat the cup. Take care not to strike the
bearing surface.

Shrink Fit Upper Spindle Bearing Cone

STEP 73
Heat the upper spindle bearing cone (Item 33) to 300°F using the induction heater (or hot oil
bath).
STEP 74
! WARNING
possible serious injury while handling the hot upper spindle bearing
cone.
With insulated gloves, lower the bearing onto the spindle, tapered end down. Tap the inner
race of the bearing with a hammer and bronze bar (57788713) to seat it properly. Proceed to
the next step while the bearing is still warm.

Setting Spindle Bearing Preload Rolling Torque
! WARNING
Setting proper preload for the spindle bearings is the most important
process within the assembly. (Special tools required for this setting are
from the kit [Kit, Rework Tophead Tools DM45/50/L (57512469)] and listed
/ used in the following steps.
STEP 75
Lightly coat the exposed spindle threads with Ronex-HD Grease (Item 119).
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
Set-up: The input pinion tool (57791766) attached to the ratchet (57791717) and inserted into
the motor adapter spline.
Set-up: Two angles (57788788), located 180 degrees apart and connected to the rotary
housing via two cap-screws (95934659) and flat- washers (95972238).
Set-up: Adjustment locking-ring tool (57788796) in place.

STEP 77
With the adjustment locking ring tool (57512436) installed in the grooves on the adjusting
locking nut (Item 24, 57291304), the wings on Item (57512436) will contact the surfaces of the
angles (57788788) to prevent spindle rotation, thereby increasing preload on the spindle
bearing when the input pinion tool is rotated. Tighten the two screws and lock washers to hold
the angles after alignment to the wings.
The 15:1 gear reduction makes tightening the locking nut easier by turning the gear train
through the input shaft. Use ratchet (57791717) attached to input pinion tool (57791766) to
turn the input pinion shaft counter-clockwise to tighten the locknut (Item 24).
Strike the inner race of the upper bearing with a steel hammer and bronze drift a couple of
times at alternately opposing points. The rolling torque will drop-off evidenced by less
resistance through the input pinion tool.

STEP 78
Lower the hydraulic jack (57791865) supporting the spindle. Repeat tightening the lock nut by
turning the input pinion tool. Repeat process of striking the inner race using a hammer and
bronze drift.
STEP 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
the torque required to turn the spindle reaches a minimum of 150 ft-lbs. Always measure
rolling torque through the spindle, not through the input shaft.
NOTE: 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 times at 180 degree opposing points. Repeat until the torque value
remains constant at 120 to 130 ft-lb, after striking the race.

STEP 80
After properly setting rolling torque, install the tongued lock washer (Item 31, 57291288). Insert
the tongue into the keyway of the spindle. If the bolt holes do not line up, tighten the preload
slightly until the holes align.
STEP 81
Lightly coat six cap-screws (Item 25, 95270815) with Loctite (56784267) and secure the
tongued washer to the preload lock-nut.
! WARNING
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.
Note: 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
Lightly coat the spindle threads with Ronex-HD Grease (Item 119). Install oil seal (Item 35,
52164282) into the upper seal housing (Item 32, 52248150) and tap the seal to secure flush
to top surface of the housing. The seal must be properly oriented in order to hold grease in
housing.
STEP 83
Install and tighten lube fitting (Item 69, 95201547). Apply silicone (Item 120, 50700731) around
the housing machined surface, then slide 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 two cap-screws (Item 51, 95104204), 180 degrees apart, to temporarily
secure the seal housing for the next step.

STEP 84
Inspect the thread in spindle cap (Item 39, 57347379) for damaged threads. Remove any dirt
or rust. Lightly coat with Ronex-HD Grease after inserting ring thread (Item 42, 50610971).
STEP 85
! CAUTION
If required, use flat head screwdriver for slinger installation, taking extra
care to not damage the threads
Insert slinger (Item 38, 52187804) over the spindle and onto the top surface of the seal
housing.

STEP 86
Place o-ring (Item 154, 95086625) into spindle groove, and then thread the spindle cap (Item
39, 57347379) onto the spindle.
STEP 87
With ratchet attached, insert modified input pinion tool (57791766) into the motor adapter input
spline.
Connect a 48" pipe wrench to the flats on the spindle cap (Item 39, 57347379) and secure
wrench handle against the rotary housing's anchor guide.
Tighten spindle cap by rotating the ratchet clockwise.

STEP 88
Remove two cap-screws inserted earlier to temporarily secure upper seal housing, place
swivel (Item 37, 52248176) over it and align swivel flange holes to holes in seal housing.
Insert six cap-screws and lock-washers (Item 51, 95104204; Item 6, 95934733), then tighten
with impact wrench.
STEP 89
Invert the swivel cap (Item 50, 57183329) and insert one (uni-directional) packing (Item 43,
50694876).
Lightly lubricate the packing top surface and the swivel cap machined surface with Ronex-HD
Grease (Item 119, 52180957).

STEP 90
Screw in two threaded rods (57788820) into the swivel.
Insert the second (uni-directional) packing supplied with Item 43 inside the spindle cap (Item
39).
After insertion, lightly lubricate the packing surfaces with Ronex-HD Grease (Item 119) as
shown.

STEP 91
Insert wear bushing (Item 43) in the groove of Item 39, on top of the second packing.
STEP 92
Use two threaded rods (57788820) in swivel (Item 37, 52248176) for installation / alignment
of shim set (Item 46, 52210317) and swivel cap (Item 50, 57183329).

STEP 93
Shim to 0.125" (57788838) clearance between machined surfaces of Items 37 and 50 for
swivel packing proper preload.
Insert cap-screws, lock-washers (Items 5 & 6, 95934451 & 95934733) and tighten.

STEP 94
Remove pipe plug (Item 70, 95249694), insert nozzle and fill with approximately 44 quarts of
gear oil (Item 118, 58209651), to center line of sight gauge (Item 98, 52253176).
Add pipe dope to Item 70 and replace.
STEP 95
With a grease gun, lubricate the upper bearing (Item33, 95434569) area with Ronex-HD
Grease (Item 119, 52180957) until pin extension occurs from relief fitting (Item 88, 95246724).

STEP 96
Apply pipe dope, thread 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 97
Apply pipe dope to thread of 1/8 inch pipe plugs (95033585) and install plugs into controller on
side of hydraulic motor.

SAFETY WIRE INSTALLATION INSTRUCTIONS / EXAMPLES

GLOSSARY OF TERMS
~A~
Actuator
A motor or cylinder that is being put into motion by the flow of a hydraulic pump.
Adapter-Adaptor (both spellings are accepted)
A device used to connect two different sizes or types of threads. It is used to connect
rotary head spindles to drill pipe, drill pipe to stabilizers and stabilizers to drill bits.
ANFO
Ammonium Nitrate Fuel Oil mixture: explosive most commonly used in blastholes.
Annulus
The space between the drill pipe and the outer diameter of the hole made by the bit.
Annunciator
An electrical signaling device on a switchboard.
API
American Petroleum Institute.
ASME
American Society of Mechanical Engineers.
ASTM
American Society of Testing Materials.
Auto Lube System
An air powered pump that provides grease to various components of the drill through
hoses. It can be manual or computer controlled.
Axle (Main Shaft)
The tube connecting the tracks of a Blasthole drill to the main frame.
~B~
Bank
Vertical surface of an elevation; also called face.
Beco Thread
A coarse type of thread used on drill pipe for blastholes.
Bench
Work area on top edge of an elevation. The work area for blasthole drills.
G-1
Bit, Auger
A type of bit used to drill soft formations. It usually has a series of flutes on the outside.
Bit, Claw
A wing-type bit that has multiple flukes. Sometimes called a Drag Bit.
Bit Breaker
A device installed in the centralizer table to hold a bit stationary while the drill pipe is
being removed from the bit by reversing the rotation. Also called Bit Basket.
Bit, DHD
A solid, one piece bit, with shaped tungsten carbide inserts in the face. Used in
percussion drilling.
Bit, Roller
Also called a Tricone bit. It usually has three conical rollers fitted with steel or tungsten
carbide teeth that rip the rock loose using down pressure.
Bits
Tools that pulverize formations so that material can be removed from the hole.
Generally 3-blade, 3-cone or percussion.
Blasthole
A drilled hole used for purposes of excavation rather than exploration, geological
information or water wells. Usually limited to 200 feet.
Blasting
The act of igniting explosives in a borehole to produce broken rock.
Blowdown
Term used when releasing compressed air from the receiver tank on a compressor
when the drill is stopped.
Blowdown Valve
The valve that opens when the drill is stopped and releases all the air pressure in the
receiver tank.
Bore
To make a hole in the ground with a drill.
Borehole
The hole made by a bit.
Box End
Fitting on the female end of a drill pipe. See Pin End.
Breakout
Refers to the act of loosening threaded pipe joints; and of unscrewing one section of
pipe from another, while coming out of the hole.
G-2
Breakout Wrench
A wrench, connected to a hydraulic cylinder, used to turn the upper piece of pipe while
the lower pipe is being held by the Fork Chuck or Sliding Wrench.
Bridge
An obstruction in the hole. Usually caused by a caving formation or something falling
in the hole.
Burden
Distance from the blasthole to the nearest face. Distance measured from face to a row
of holes.
Buttons
Short, rounded teeth of sintered tungsten carbide inserts which serve as teeth in drill
bits used for drilling very hard rock.
Butterfly Valve
The inlet valve of the air compressor.
Burden
Distance between a blasthole and the nearest free or open face; the material to be
displaced.
~C~
Cable
A strong, heavy steel, wire rope. Also known as Wire Rope. Used for pull-down and
pullback in the derrick. Also used in hoisting. May be rotating or rotation resistant.
Cable Reel
A device that holds the electrical power cable on electric driven blasthole drills.
Carousel
A rotating device that holds extra drill pipe. It can be moved under the rotary head to
add and remove drill pipe from the string, or the rotary head moves over it.
Carbide, Tungsten
W2C. A very hard compound used in inserts in rock bits. It has a very high melting
point. It is very strong in one direction but very brittle in another.
Casing
Special pipe used to hold the overburden back in water wells. May be steel or plastic.
Casing, Drive Shoe
Coupling of forged steel to protect lower end of casing in overburden.
Cathead
Rotating drum used to spool hemp rope to pick up tools manually.
G-3
Catwalks
Walkways around a working area of a drill.
Cavitation
The pitting of a solid surface by the formation of low pressure bubbles formed in the
fluid. Air being allowed into the inlet of pumps.
Centralizer Bushing
A circular ring installed around the drill pipe in the drill table to keep the pipe aligned
properly with the rotary head. It usually has a replaceable insert in the center.
Chain Wrench
A special wrench, consisting of a chain section and a metal vee section, with jaws, that
grips the drill pipe and/or the DHD to tighten or loosen the connections.
Clinometer
A device for measuring the angle of the drill pipe with the ground. Also referred to as
an Inclinometer.
Collar the Hole
Opening at the top of the blasthole; the mouth where rock has been broken by blasting.
Usually the first few feet of the blasthole that are cracked and broken.
Compressor
An asymmetrical rotary screw driven device for compressing air. May be single or two
stages, depending on the discharge pressure.
Console
The panel that contains most of the drill’s controls. Also called the Operator’s Panel.
Conventional Mud
A drilling fluid containing essentially bentonite clay and water.
Conveyor
Equipment used to carry material to crushers and screens for reduction and
separation.
Cooler (HOC, COC)
Most drills have two coolers; one for the hydraulic fluid and the other for the
compressor oil. The engine radiator is sometimes referred to as an engine cooler.
Coring
The act of procuring a sample of the formation being drilled for geological information
purposes.
Coupling
A connector for drill rods, pipe or casing with identical threads, male or female, at each
end.
G-4
Cribbing
A set of wooden ties or metal plates used to add surface area to the jack pads to
prevent the pad from sinking into the ground. Also called blocking.
Crown Sheaves
The upper sheaves in a derrick that supports the cable that connects to the rotary
head.
Crosshead
The outer metal can surrounding the leveling jack cylinders. The crosshead slide is
the lower portion that connects to the bottom of the cylinders and the crosshead cap
is the flanged piece on top of the crosshead.
Crusher
Device used to reduce broken rock to a smaller fragment size.
Cut (verb)
Process of excavating material to lower the level of part of an elevation.
Cut (noun)
Part of an excavation of a specified depth an width.
Cuttings
Particles of formation obtained from the hole during drilling operations.
~D~
Decking
Process of alternating explosives with inert material in a blasthole to properly distribute
explosives or reduce vibrations. Also refers to the metal catwalks around the outside
of the drill.
Deephole
Rotary drills used to drill water wells, exploration holes and monitoring holes.
Delay Interval
Elapsed time between detonation of individual blastholes in a multiple hole blast.
Derrick
A tall framework over a drilled hole used to support drilling equipment. The part of the
drill that contains the feed system and the rotary head. See Tower and Mast.
DHD
Down Hole Drill. An air driven, piston powered device for drilling hard rock. It is also
called a Hammer.
G-5
DHD Bushings
The split bushings used to maintain alignment of the DHD while passing through the
drill table. See Split Bushings.
Differential Pressure
The difference in pressure between the inlet and outlet of a component, i.e., a cooler.
Dip
The angle between a horizontal plane and the plane of the ore vein, measured at right
angles to the Strike.
Diverter Valve
A two position, three way, valve that allows one hydraulic pump to perform two
separate functions.
Dressing a Bit
Sharpening DHD drill bits with a grinder to shape the carbides.
Drifter
An out-of-the-hole drill that rotates the drill rod and provides a percussive force, by
means of a striking bar, through the rod to the bit.
Drill
A machine for drilling rock, or unconsolidated formations. Also called a Rotary Drill.
The act of boring a hole in the ground.
Drill Collar
A heavy, thick-walled section of pipe used to add drilling weight to the bit and stabilize
the drill string.
Drill Rod
See Drill Pipe. Hollow, flush-jointed, coupled rods used on small percussion type rock
drills. Used with drifters mostly
Drill Pipe
Hollow tubing, specially welded to tool joints, used in drilling larger holes than drill rods.
Drill/Propel Valve
A switch that shifts the diverter valves to allow pump flow to go from drill functions to
propel motors.
Drill String
The string of pipe, including subs, stabilizers, collars and bit, extending from the bit to
the rotary head, that carries the air or mud down to the bit and provides rotation to the
bit.
Driller (Operator)
The employee directly in charge of a drill. Operation of the drill is their main duty.
G-6
Drill Table
The area at the bottom of the derrick that contains the centralizer bushing or master
bushing that the drill pipe travels through.
Dust Collector
A vacuum device with a hose attached to the dust hood that pulls cuttings away from
the hole and deposits them to the side of the drill.
Duty, Light
Rotary drilling in sand and gravel.
Duty, Normal
Rotary drilling in soft rock.
Duty, Heavy
Hammer drilling in hard rock.
~F~
Face
Vertical surface on an elevation. Also called bank.
Feed Cable
Cables, anchored on the top and the bottom of the derrick, that pass through the
traveling sheave block and connect to the top and bottom of the rotary head. They are
adjusted by tightening the threaded rods on each end.
Feed Chain
Heavy duty chain links connected to the rotary head through upper and lower
sprockets and the traveling sheave block. They are adjusted similar to cable.
Fill
Process of moving material into a depression to raise its level; often follows the cut
process.
Fish
An object accidentally lost in the hole.
Fishing
Operations on the drill for the purpose of retrieving the fish from the hole.
Fishing Magnet
Run in the hole on non-metallic line, to pick up any small pieces of metal.
Fishing Tools
Tools of various kinds run in the hole to assist in retrieving a fish from the hole.
Overshots fit over the pipe while Taps fit inside the pipe.
G-7
Flats
Machined areas on the side of drill pipe or other components where wrenches can be
installed to hold or break the joints. Some pipe has two flats, others have four flats.
Floor
Level area at the base of a bank or face.
Fork Chuck
The hand held or “flop-down” wrench used to hold the top of the pipe in the Drill Table
while adding or removing other pipe.
~G~
Grouting
To fill the hole or annulus with grout, i.e., cement and water.
~H~
Hammer
A different name for a Down Hole Drill.
Hammer Bushing
Split bushings installed in the drill table to allow the DHD to start the hole in a straight
line. It is removed once the DHD is below the table. Also called DHD Bushings.
Haul Distance
Distance material has to be moved, such as from a cut to a fill.
Hauling Equipment
Trucks and other conveyances for moving material. Also called Haul Trucks.
Hazard
Any condition of the drilling equipment or the environment that might tend to cause
accidents or fire.
Hoist
Windlass used to pick up drill pipe and other heavy objects. See Winch.
Hoist Plug
A lifting device installed in the box end of a tool. Opposite of Lifting Bail.
Hole
A bore made by rotating a bit into the ground.
Hole Openers
Large bit with pilot used to increase the diameter of a hole.
G-8
Hose, Drilling
Connects rotary head to top of hard piping to allow movement of rotary head. Also
called Standpipe Hose.
Hose, Suction
Attaches to mud pump inlet with other end submerged in mud pit.
Hydraulic Cylinders
Double acting cylinders that are extended and retracted to perform various functions
on a drill. They are powered by hydraulic fluid from a pump.
Hydraulic Motors
Piston or vane type motors, driven by hydraulic pumps, that rotate various devices on
a drill.
Hydraulic Pumps
Piston, vane and gear type hydraulic pumps that provide flow for the various actuators
on the drill.
Hydrostatic Head
The pressure exerted by a column of fluid, usually expressed in pounds per square
inch.
~I~
Inclinometer
An instrument for measuring the angle to the horizontal or vertical of a drill hole or vein.
I.W.R.C.
Abbreviation for Independent Wire Rope Center. This refers to type of construction of
wire rope. This wire rope center is in effect a separate wire rope in itself that provides
a core for the line and prevents it from crushing.
Interstage Pressure
The air pressure present between stages of a two-stage compressor while the
compressor is making air.
~J~
J Wrench
Specially shaped wrench to fit the backhead of a DHD. Used to hold DHD in the table
or to remove the backhead from the wear sleeve.
~K~
Kelly Bar
A fluted or square drill pipe that is turned by a rotary table using a set of pins.
G-9
~L~
Leveling Jacks
Hydraulic cylinders mounted in a crosshead that raise and lower the drill.
Also referred to as Outriggers or Stabilizers.
Lifting Bail
A threaded cap for picking up pipe, bits, DHDs and stabilizers. It screws on the pin end.
Some bails have a swivel hook while others have solid tops. See Hoist Plug.
Loaders
Large, front end bucket equipment used to pick up material for loading in various types
of hauling equipment.
~M~
Main Frame
The welded component of a track mounted drill. The truck frame on a wheeled drill.
Makeup
The act of tightening threaded joints. Making a connection.
Making Hole
The act of drilling.
Making Up a Joint
The act of screwing a joint of pipe into another joint or section of pipe.
Manifold
A pipe or chamber that has several openings for hose connections.
Mast
A vertical pole. See Derrick.
MTBF
Mean Time Between Failure is the mean (average) time between failures of a system.
MTBM
Mean Time Between Maintenance is the mean (average) time between system level
maintenance actions.
MTBS
Mean Time Between Service is the mean (average) time between regularly required
lower level maintenance functions being performed.
G-10
MTTR
Mean Time To Repair is the mean (average) time indicating how long it takes (usually
expressed in hours) to repair a system that is down due to a failure.
Micron -:- Mu
A unit of length equal to one millionth part of a meter, or one thousandth part of a
millimeter. About 4/100,000th inch.
Mid-Inlet Swivel
Device for removing cuttings from the hole while drilling with Reverse Circulation
Equipment.
Mine Plan
Plan for making cuts and creating elevations, benches for efficient removal of material.
The mine plan considers a variety of factors, including: the type and location of
material, the size and number of shovels, loaders, and hauling equipment, haul
distances, blasthole patterns, etc.
Mist Drilling
A method of rotary drilling where water is dispersed in the air as the drilling fluid.
Mud
A water or oil -base drilling fluid whose properties have been altered by solids. Mud is
a term commonly given to drilling fluids. It is used in place of air when drilling
unconsolidated formations.
Mud Drilling
Using a bentonite clay and water as the drilling fluid.
Mud Pit
A hole dug in the ground or a steel pit to hold the drilling mud as it is being circulated
in the hole.
Mud Pump
Pumps that are used to circulate the drilling mud.
~O~
Oscillation Yoke
The beam connecting each track of a blasthole track drill with the main frame that
allows the tracks to move independently up and down.
Open Hole
Any uncased portion of a hole.
Operator
The person who performs the drilling operation with the drill. See Driller.
G-11
Overburden
Any unconsolidated material lying on top of the bedrock or the coal seam.
~P~
Parasitic Load
The load imposed on the engine by the direct connection of the compressor and main
pump drive during starting.
Pattern
Layout and distances between blastholes, specifically including burden and spacing.
Penetration Rate
Speed at which a bit advances while drilling, measured in feet per hour.
Percussion Drill
Drill that chips and penetrates rock with repeated blows.
Pin End
Fitting on male end of drill pipe. See Box End.
Pioneer Work
Drilling in rough, broken or inclined areas. Removing the original layers of dirt and
rock.
Pipe Dope
Special lubricant used to protect the threads on pipe joints. See Thread Lube.
Pipe Support
A device that holds the lower section of pipe in place while connecting to the next joint
with the rotary head when angle drilling. Also called Rod Support.
Pit
An excavation in the ground for the removal of mineral deposits.
PLC
Programmable Logic Controller. A device that monitors many aspects of a drill’s
operation.
Potable Water
Water that is safe to drink.
Powder Factor/Specific Charge
Relationship between the weight of explosives in a blasthole and the volume of
materials to be displaced. It is measured in pounds per cubic yard or kilograms per
cubic meter.
G-12
Power Pack Base
The welded channel frame that contains the prime mover, the compressor and the
hydraulic pumps and gearbox.
Power Pack
he complete sub-assembly of base, engine, compressor, and hydraulic drive.
Presplitting
Process of drilling a line of small diameter holes spaced relatively close together,
generally before drilling a production blast and loaded with light explosive charges to
create a clean, unbroken rock face.
Production Rate
Penetration during a given reporting period. This rate includes all lost time, including
maintenance, breakdowns, long moves, inclement weather, etc.
Propel
To cause to move forward or onward. To drive or tram.
Protectors, Thread
Steel or plastic covers to cover the box and pin ends of drill pipe when they are not
being used.
Pump, Water Injection
Pump used to pump water into the drill air stream to keep the dust settled and to assist
in flushing the hole.
Pullback
The force available to remove the drill string from the hole.
Pull-down
Force exerted on the drill bit by the thrust of the drill rig and from the weight of the drill
string.
~R~
Raise
A mine opening, like a shaft, driven upward from the back of a level to a level above,
or to the surface.
Rate Of Penetration
The rate in which the drill proceeds in the deepening of the hole. It is usually expressed
in feet per hour.
Reamer
Bit-like tool, generally run directly above the bit to enlarge and maintain a straight hole.
G-13
Reservoir
The tank used for storing the hydraulic oil used in the hydraulic system.
Reverse Circulation Drilling
Using a double wall pipe to force air/water down the hole and removing the cuttings
between the two pipes. See Mid-Inlet Swivel.
Rod Changer
See Carousel. A device that holds extra drill rod (pipe).
Rotary Drilling
The method of drilling that depends on the rotation of a column of pipe to the bottom
of which is attached a bit. Air or fluid is circulated to remove the cuttings.
Rotary Head
A movable gearbox used to provide rotation to the drill string. It is connected to the
feed chains or cables on each end and to the drill string through the spindle.
~S~
Safety Hook
Attached to end of hoist line to secure hoist plug or lifting bail. Has a safety latch to
prevent load from slipping off hook.
Scales
Equipment used to determine the weight and value of material being transported from
a quarry.
Screens
Devices used to separate broken material into groups of similar size.
Shock Sub
A device used to isolate the shock of drilling from the rotary head. It is made of hard
rubber layers mounted inside of steel outer rings.
Shooting
Exploding high explosives in a hole to shatter the rock. See Blasting.
Single Pass Drill
Drill rig with a long tower that permits drilling a blasthole without stopping to add drill
pipe (rod). Uses a Kelly in place of regular pipe. Uses a rotary table to turn the Kelly
instead of a rotary head.
Stemming
Material of a specified depth added on top of a powder column to confine the blasthole
and make the explosion more efficient.
G-14
Strip Mine
A large section of land used to remove coal deposits.
Shot
A charge of high explosives deposited in a series of holes to shatter the rock
Shutdown
A term that can mean the end of the shift or workday or an unplanned stopping of the
drill due to a system failure.
Sliding Fork
A wrench that slides around the flats of the drill pipe to hold lower section. Controlled
by hydraulic cylinder(s). Used in place of Fork Chuck.
Slips
Used in the rotary table to hold and break out drill pipe. Also used to hold casing in the
table.
Spacing
Distance between blastholes measured parallel with the face.
Spear
Tools of various design that are screwed or wedged inside of bits, pipe, etc., that are
lodged in the hole. See Fishing Tools.
Spindle
The short section of pipe that rotates within the rotary head and protrudes out each
end.
Speed Switch
An electronic device that changes states when the engine reaches a certain speed.
Used to control dual oil pressure switches.
Split Bushings
The removable bushings that allow the DHD or Stabilizer to pass through the drill table
while drilling a straight hole. See DHD Bushings.
Stabilizer, Drill Pipe
Heavy -walled pipe having special spiral or fluted ribs extending around the diameter,
within 1/8 “to 1/4” of hole size. Most stabilizers are fitted just above the bit, while in-line
stabilizers keep the hole straight.
Standpipe
Part of the circulating system. The hard and flexible piping from the main valve to the
flexible hosing leading to the rotary head. Water injection, DHD oil and foam are
injected into this line.
Static Water Level
The distance from the top of ground down to the standing water level.
G-15
Strike
The bearing of the outcrop of an inclined bed or structure on a level surface. See Dip.
Stuck In The Hole
Refers to drill pipe inadvertently becoming fastened in the hole.
Subdrilling
Bottom portion of a blasthole drilled below the floor level to permit upward
displacement of material and thereby prevent a toe at the bottom of a face.
Substitute (Sub)
A coupling with different type or diameter of threads at either end. The term pin
denotes a male thread, and box, a female thread. To connect two components with
different threads. See Adapter.
Supercharge Pressure
Inlet oil pressure to the main pump(s) that has been pressurized to prevent cavitation.
Swivel
A coupling on top of the rotary head to allow the spindle to rotate while the main hose
remains stationary.
~T~
Table Drive
Drill design that locates the drill pipe rotation mechanism on the drill deck in a
stationary position instead of using the rotary head.
Threaded and Coupled Casing (TANDC)
Steel casing using a coupling between each section of pipe. Thread style is right hand,
fine thread.
Thread Lube
A special compound used to lubricate the threads of drill pipe. See Pipe Dope.
Tongs
A type of wrench used to make up and break out drill pipe using external forces, such
as hydraulic cylinders or cables.
Tool Joint
A drill pipe coupler consisting of a pin and box of various designs and sizes. Deephole
drills normally use API style threads, while Blasthole drills use Beco style threads.
Top Head Drill
Drill design that locates the drill pipe rotation head in the drill tower and it moves up
and down with the drill string. See Rotary Head.
G-16
Torque
A turning or twisting force. A moment caused by force acting on an arm. A one pound
force acting on a one foot arm would produce one lb.-ft. of torque.
Tower
A tall, slender structure used for observation, signaling or pumping. See Derrick and
Mast. Term used to indicate the derrick on a blasthole drill.
Turning To The Right
Slang term for making hole.
Tram
A cable car or a four-wheeled open box in a coal mine. See Propel.
Trammed
To move in a tram.
Tramming
Process of moving a drill with the tower up from a completed blasthole to the location
of the next. See propelling
Traveling Sheave Block
A series of sheaves, connected to the feed chains or cables, that are moved up and
down the derrick by the feed cylinders.
Twist Off
To twist a joint of pipe in two by excessive torque applied by the rotary head or rotary
table.
~U~
UL88
The unloader valve that controls pressure and volume on a high-pressure compressor
system.
Undercarriage
The means of moving a track type vehicle. It contains the track frame, rollers,
grousers, rock guards, drive sprocket, propel motors and planetary drive.
Uphole Velocity
The speed (in feet per minute) that the cuttings travel out of the hole.
This is dependent on the bit size, the compressor size and the pipe size.
~W~
Washpipe
Hard surfaced steel tubes inserted in swivels to allow rotation of drill string and prolong
life of packing. They are replaceable in most swivels.
G-17
Water Table
The underground level at which water is found. See Static Level.
Water Well
A hole drilled for the purpose of obtaining potable water.
Weight On Bit
In rotary drilling, a specified weight is required on the bit for maximum performance. A
gauge on the console is calibrated to correspond to the drill string weight.
Whipstock
A device inserted in the well used for deflecting or directional drilling.
Wiggins Quick Fill
A Centralized Service Station that connects to various systems on the drill to allow
remote filling of engine oil, compressor oil and hydraulic oil.
Winch
A stationary hoisting machine having a drum around which is wound a rope.
Wiper, Pipe
An annular rubber disk for wiping drill pipe clean of cuttings when it is being withdrawn
from the hole.
Wire Rope
Rope made of twisted strands of steel wire. Also called Cable.
G-18
NOTES
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We are committed to your
superior productivity through
interaction and innovation.
© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

9881 0054 01
Atlas Copco Drilling Solutions, LLC

A Company Within the Atlas Copco Group
P.O. Box 462288, 2100 North First Street
Garland, Texas 75040 USA
www.atlascopco.com/drillingsolutions

DM, DML. Rotary Head Rebuild, 2008

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DM, DML. Rotary Head Rebuild, 2008

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Atlas Copco Drilling Solutions

MODELS: DM45/50/L, ROTARY HEAD REBUILD

Read the instruction manual before operating this equipment.

© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA TOC-i

TOC - ii © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

All information, illustrations and specifications in this manual are based

Safety is an integral part of every individual’s job responsibility. Every

© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA 1-1

DESIGN FEATURES (Reference Drawing - 57562639)

Bearings Design and Gear Maintenance

Recommended Lube Oil

1-2 © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

WEIGHTS and OUTPUT GEAR TOLERANCES

Component Part Number Part Weight Assembly Weight

Output Gear Tolerances

© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA 1-3

HOUSING TOLERANCES and REBUILD KIT LIST DRAWINGS

1-4 © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

TOLERANCES and REBUILD KIT LIST DRAWINGS(cont.)

© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA 1-5

DM45/50/L ROTARY HEAD REBUILD KIT LIST 57558736

1-6 © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

REBUILD CHECK SHEET

______ / ______ 1. Properly mount housing into rebuild stand.

______ / ______ 4. Thoroughly clean housing.

______ / ______ 5. Record rotary head housing bearing cavity tolerances:

______ / ______ 6. While heating bearing cone, clean spindle.

______ / ______ 8. Fully seat heated bearing cone onto spindle.

______ / ______ 15. Fully seat spacer and keyway on spindle.

© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA 1-7

INITIAL / DATE....PROCEDURAL STEPS (cont.)

______ / ______ 21. Fully seat bearings on input pinion.

______ / ______ 25. Fully seat input pinion in housing.

______ / ______ 30. Install upper intermediate bearing.

______ / ______ 32. Install square head pipe plug in housing.

1-8 © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

INITIAL / DATE....PROCEDURAL STEPS (cont.)

______ / ______ 49. Install slinger.

______ / ______ 51. Brace pipe wrench against slide glide.

______ / ______ 53. Install swivel on upper seal housing.

© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA 1-9

SPUR ROTARY HEAD SPECIFICATIONS AND LUBRICANTS

Item Type Capacity

SHC 634 is optional,

1-10 © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

STANDARD TORQUE VALUES

© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA 1-11

Recommended Torque in Foot Pounds (ft./lbs.)

Size SAE Grade 5 Torque SAE Grade 8 Torque

1-12 © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

Size SAE Grade 5 Torque SAE Grade 8 Torque

© 2008 Atlas Copco Drilling Solutions, Garland Texas, USA 1-13

SERVICING TIME TABLES

Rotary Head Oil Level Check and Upper Bearing Greasing

Table 7: Mean Time Between Maintenance (MTBM)

Change Rotary Head Oil

Table 8: Mean Time Between Failure (MTBF)

Average Time Between Recommended Rotary Head Rebuilds

Table 9: Mean Time To Repair (MTTR)

Average To Remove From Rig Average To Rebuild Rotary Head

NOTE: Duty Guidelines / Definitions:

• Light - Sand and Gravel, Rotary Drilling

1-14 © 2008 Atlas Copco Drilling Solutions, Garland Texas, USA

REQUIRED TOOLS / SPECIAL EQUIPMENT

/ 1. Properly mount housing into rebuild stand.

/ 4. Thoroughly clean housing.

/ 5. Record rotary head housing bearing cavity tolerances:

/ 6. While heating bearing cone, clean spindle.

/ 8. Fully seat heated bearing cone onto spindle.

/ 15. Fully seat spacer and keyway on spindle.

/ 21. Fully seat bearings on input pinion.

/ 25. Fully seat input pinion in housing.

/ 30. Install upper intermediate bearing.

/ 32. Install square head pipe plug in housing.

/ 49. Install slinger.

/ 51. Brace pipe wrench against slide glide.

/ 53. Install swivel on upper seal housing.