Atlas Copco DM45 DM50 DML Rotary Head Rebuild Manual 2010

Description

Atlas Copco DM45 DM50 DML Rotary Head Rebuild Manual

This Atlas Copco DM45 DM50 DML Rotary Head Rebuild Manual is the complete guide for disassembling and rebuilding the spur gear rotary head used on DM45, DM50 and DML blasthole drills. The manual walks through every stage of the rebuild process in sequential order, from removing the rotary head from the rig through to setting final spindle bearing preload and refilling the gear case. If you are rebuilding an Atlas Copco rotary head in a workshop or maintenance facility, this is the reference document that keeps the job measurable and repeatable.

File Details

• Manual Type: Rotary Head Rebuild Manual
• Brand: Atlas Copco
• Models Covered: DM45, DM50, DML
• Component: Spur Gear Rotary Head (DM45/50/L)
• Language: English
• Page Count: 113
• File Format: PDF
• Publication Date: 2010
• Publisher: Atlas Copco Drilling Solutions, Garland, Texas, USA

Chapters Covered

• General Information
• Design Features (Reference Drawing 57562639)
  • Bearings Design and Gear Maintenance
  • Recommended Lube Oil
• Weights and Output Gear Tolerances
• Housing Tolerances and Rebuild Kit List Drawings
• DM45/50/L Rotary Head Rebuild Kit List 57558736
• Rebuild Check Sheet
• Spur Rotary Head Specifications and Lubricants
• Standard Torque Values
  • Head Markings
  • Recommended Torque in Foot Pounds (ft./lbs.)
  • Recommended Torques in Nm
• Servicing Time Tables
• Required Tools / Special Equipment
• Rotary Head Rebuild Reference Numbers
• Proper Bearing Oil Seal Orientation
• Terminology
• Preventative Maintenance Inspections
• Safety / Precautions
• Disassembly Procedure
  • Preparation / Breakdown
  • Pulling the Main Gear from the Spindle
  • Removing the Spindle
• Assembly Procedure
  • Set-Up and Preparation
  • Shrink Fit Bearing Cone
  • Expansion Fit Lower Housing Bearing Cup
  • Shrink Fit Output Gear
  • Shrink Fit Intermediate Gear Assembly
  • Shrink Fit Lower Spherical Bearing
  • Shrink Fit Wear Sleeve
  • Shrink Fit Upper Spindle Bearing Cone
  • Setting Spindle Bearing Preload Rolling Torque
• Safety Wire Installation Instructions / Examples
• Glossary of Terms

The Atlas Copco DM45 DM50 DML Rotary Head Rebuild Manual is not a general overview. It is a step-by-step procedure manual with numbered steps that follow the actual rebuild sequence used on the spur gear rotary head. Each disassembly and assembly step is tied to the tools, torque values and temperature ranges needed at that point. The manual covers the complete bearing set in the rotary head, including the single row tapered roller bearings, deep groove ball bearings and the spherical roller bearing, and explains how each one is removed, fitted and preloaded.

One of the most useful parts of this rebuild manual is the shrink fit and expansion fit section. It details the heating temperatures and handling requirements for the output gear, intermediate gear assembly, lower spherical bearing, wear sleeve and upper spindle bearing cone. The freeze temperature for the lower housing bearing cup is also given. These procedures are easy to get wrong in the field, and the manual gives the specific temperatures needed to avoid binding or damaging the fits.

The Atlas Copco DM45 DM50 DML Rotary Head Rebuild Manual also includes the rebuild check sheet, which is a numbered checklist that mirrors the assembly sequence. It lists every operation from mounting the housing in the rebuild stand to filling the gear case with oil and greasing the upper bearing. This checklist is useful as a quality control document during a rebuild, because it forces the technician to verify each stage before moving to the next.

Bearing preload is treated as a critical process in this manual. The section on setting spindle bearing preload rolling torque explains how to use the adjustment locking ring tool, the input pinion tool and a dial type torque wrench to measure rolling torque through the spindle. The manual states the minimum rolling torque required and describes how to strike the inner race to stabilize the reading. It also warns about the consequences of insufficient preload, including race spinning, locknut wear and eventual endplay in the spindle assembly.

For maintenance planning, the manual includes mean time between service, maintenance and failure tables for light, normal and heavy duty applications. It also gives the average time to remove the rotary head from the rig and the average time to rebuild it. These tables are useful for scheduling and for understanding how duty severity affects rebuild intervals. The preventative maintenance section recommends checking preload every 2,000 hours and inspecting the magnetic drain plug at each oil change.

The Atlas Copco DM45 DM50 DML Rotary Head Rebuild Manual covers the full range of torque values needed during assembly, with separate tables in foot pounds and newton meters for SAE Grade 5 and Grade 8 fasteners, both dry and lubricated. Head markings for Grade 5 and Grade 8 capscrews are illustrated so the correct torque row can be selected. There is also a safety wire installation section with examples, which is important for the intermediate shaft plate and other lock-wired components.

This manual is intended for maintenance personnel who are already familiar with heavy equipment repair and have access to the special tools listed in the Required Tools section. Many of the procedures depend on the Tophead Rework Tools Kit 57512469, the rotary head working stand 57788051 and an induction heater or oil bath capable of reaching the temperatures specified for shrink fits. The rebuild sequence is written around those tools, so the manual is most useful when the recommended equipment is available.

Because the manual is specific to the spur gear rotary head used on DM45, DM50 and DML drills, it is not a generic gearbox rebuild guide. The part numbers, tolerances and procedures are tied to this rotary head assembly. The rebuild kit numbers and bare housing number are listed, so the correct replacement parts can be identified before the rebuild begins. The manual also includes the proper bearing oil seal orientation, with the lip pointing toward the pressure side and the spring facing the inside of the cavity.

What This Manual Enables You to Do

With the Atlas Copco DM45 DM50 DML Rotary Head Rebuild Manual, a technician can disassemble a spur gear rotary head down to the housing, inspect and replace bearings and gears, and reassemble the unit with correct fits, preload and torque values. It supports the full rebuild, including pulling the main gear from the spindle, removing and reinstalling the spindle, shrink fitting the output gear and intermediate gear assembly, and setting final bearing preload. It also covers the lower seal housing, upper seal housing, wear sleeve and swivel packing assembly.

Having the correct procedures and specifications matters because the rotary head is a precision assembly. Incorrect shrink fit temperatures, wrong preload or missed lock wiring can lead to premature bearing failure, oil leaks or spindle damage. This manual gives the exact values and sequences needed to avoid those outcomes and to bring the rotary head back to a reliable working condition.

IMAGES PREVIEW

The manual is delivered as an instant PDF download. There is no shipping and no waiting. It can be viewed on any device and printed for use in the workshop. The page layout makes it practical to print only the sections needed for a specific rebuild stage, or to print the entire manual and keep it with the rebuild stand.