Cf90 Airend Overhaul Manual Product Code HJ [PDF]

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CF90 AIREND OVERHAUL MANUAL PRODUCT CODE HJ



Portable Power P.O. Box 868 501 Sanford Ave Mocksville, N.C. 27028 www.portablepower.irco.com



Manual # 22259444 (3/03)



AIREND DISASSEMBLY (Refer to Figure 1 for the following steps)



3. Separate the adapter (G) from the gear case housing by removing screws (E).



1. Place the airend assembly on a clean work surface. Position the airend in a vertical position with the drive shaft end up. 2. Remove the screw (C) and remove the hex bearing from the shaft.



Figure 1



(Refer to figure 2 for the following steps.)



8. Remove locknut (H) from drive gear (N).



4. Remove screws (A & B) and separate the seal/bearing housing (D) from the gear case housing (V).



9. Set the drive gear from the gear case.



5. Remove and discard o ring (S), double element seal (G) and single element seal (E). 6. Remove and discard bearing (Q) from the gear case housing. 7. Remove screws (M) and bearing retainers (L) from seal /bearing housing.



Manual # 22259444 (3/03)



10. Remove wear sleeve (K) and o-ring (F) from drive gear shaft. 11. Remove bearings (J) from the drive gear. Remove the inner race of bearing (Q) from the drive gear. 12. Remove screws (U) and set the gear case housing (V) from the airend.



Figure 2 (Refer to figure 3 for the following steps). 13. Remove locknut (D) from the male rotor shaft. 14. Remove the driven gear from the male rotor shaft with a gear puller. Secure the puller arms to the gear with a cclamp. The gear may jump once it loosens from the shaft. Wear gloves and be alert during this operation. 15. Remove screws (E) and dowel pin (H) to set the front bearing housing from the airend. 16. Remove check valve ball (B) from front bearing housing. See figure 4. 17. Remove oiler assembly (F) from front bearing housing. 18. Remove screw and washer (A & B) from the front bearing housing. 19. Remove and discard bearings (C & G) from the front bearing housing.



Figure 3 20. Rotate the airend assembly to a vertical position with the drive shaft down. Rest the assembly on 4-inch thick wooden blocks so that the rotor housing is supported and the rotors are free of the blocks. (Refer to figure 4 for the following steps). 21. Remove discharge bearing cover (A5) by removing screws (A6). 22. Remove wave springs (Q & R).



Manual # 22259444 (3/03)



23. Remove locknuts (U & V) from the male and female rotor shafts.



27. Remove the tapered roller bearings (N & P) from the rotor housing.



24. Remove bearing nut spacers (S & T) from male and female rotor shafts.



28. Remove shims (E-M) from male and female rotor shafts.



25. Press the male and female rotors (C) free of the bearings.



29. Remove inner bearing races (C & G) from the intake end of the male and female rotors. (Refer to figure 3).



26. Set the rotor housing (Y) free of the male and female rotors.



Figure 4 INSPECT PARTS



Inspect all parts previously disassembled for wear and damage to determiner their serviceability. Make sure all internal oil passages clear and free of debris.



Always use new gaskets, o-rings, bearings and seals when reassembling airend. All wear parts and instructions are included in Ingersoll-Rand overhaul kits.



Manual # 22259444 (3/03)



DISCHARGE END CLEARANCE SHIMMING PROCEDURE



Before reassembling of the airend, it is necessary to record certain measurements to determine the amount of shims required for proper discharge end clearances on the male and female rotors. 1. Measure the thickness of the rotor housing where the tapered roller bearings outer races rest. Record a measurement for the each rotor. Step A.



2. Determine the bearing standoff dimension from the male and female tapered roller bearings and record. Step B. Position each bearing on a hard flat surface with the outer race up. Rotate the outer race several times to seat the race on the cone. Measure the distance from the top of the outer race to the inner race shoulder with a depth micrometer. See figure A.



4. Measure the height of the rotor spacer. Record a measurement for the male and female rotor. Step D. 5. Subtract D from C for both the male and female. Step E. 6. The allowable discharge end clearance is .0015 to .0025 inches. Use .002 inches discharge end clearance for the male and female rotors. Step F. 7. Add the numbers from steps E & F. This is the thickness of shims to install on the respective rotor shaft to obtain the required discharge end clearances. 8. Assemble the correct thickness of shims and install on each rotor.



Figure A 3. Add the dimensions from steps A & B for each rotor. Step C.



STEP A



Rotor housing thickness



B



Bearing standoff



C



MALE



MALE SPEC



FEMALE



FEMALE SPEC



1.155 -1.159



1.155 -1.159



.088 -.100



.049 -.060



Add A + B



1.243 -1.259



.1.204 - 1.219



D



Rotor spacer height



1.222 -1.226



1.182 -1.186



E



Subtract (D-C)



.017 - .037



.018 - .037



F



End clearance



.0015-.0025



.0015-.0025



G



Shims Req’d



.0185 - .0395



.0195 - .0395



ADD E + F AIREND REASSEMBLY 1. Position the rotor housing in a vertical position with the drive end up. 2. Place inlet end bearing races (C & G in figure 3) in an oven and heat to 300°F (149°C) for maximum of 30 minutes. 3. Place male and female rotors into housing. 4. Remove bearing races from oven and seat on respective rotor shafts. USE PROPER GLOVES TO HANDLE HOT RACES.



Manual # 22259444 (3/03)



5. Apply a small bead of Loctite® 242 around half of the outer race of the inlet bearings (C & G, figure 3) and install each in the front bearing housing. 6. Install check valve ball (B, figure 4) into the front bearing housing using a small amount of grease to hold it In place. 7. Apply a thin layer of Loctite® 515 or 573 to the mating surface of the rotor housing. 8. Position front bearing housing (A, figure 4) into position on the rotor housing (Y, figure 4).



9. Tap 2 dowel pins (D, figure 4) into front bearing housing and rotor housing. 10. Apply a drop of Loctite® 242 to the threads of each screw (E, figure 3) and install in the front bearing housing. Torque screws to 38-lbs. ft. 11. Apply a drop of Loctite® 242 to the threads of screw (A, figure 3) and install with washer in the front bearing housing to secure the bearings. Torque screw to 38-lbs. ft. 12. Apply a drop of Loctite® 242 to the threads of the gear oiler assembly and install in front bearing housing. Position so that holes in tube are directed toward gears. 13. Rotate airend 180° and rest inlet end of rotor housing on 4-inch wooden blocks. Discharge end should be up. 14. Assure calculated shims on each rotor. 15. Heat Tapered roller bearings for male and female rotors in oven at 225°F (107°C) for 30 minutes. 16. Apply anti-seize compound on rotor shafts in bearing area and place bearings on respective rotor shafts. USE PROPER GLOVES TO HANDLE HOT BEARINGS. 17. Install bearing nut spacer on each rotor.



reassembly. If not, disassemble and adjust shims. Add shims to increase end clearance and subtract shims to reduce end clearance.



REASSEMBLY OF THE DRIVE GEAR



24. Heat gear bearings and inner race to 300°F (149°C) for 30 minutes. 25. Place the gear bearing inner race on the gear. USE PROPER GLOVES TO HANDLE HOT BEARING. 26. Place the bearings on the drive gear shaft. USE PROPER GLOVES TO HANDLE HOT BEARING. 27. Apply 3 drops of Loctite® 222 or 932 on the rotor threads and install the locknut. Torque the locknut to 160-lbs. ft. 28. Install o-ring and wear sleeve on drive gear shaft. 29. Apply A thin layer of Loctite® 222 on the outside diameter of the single element (E) and double element (G) seals. Press seals into seal/bearing housing (D). 30. Apply small amount of grease onto and between the seals.



18. Apply 3 drops of Loctite® 222 or 932 on the rotor threads and install the locknut. Torque the locknut to 160-lbs. ft.



31. Apply a drop of Loctite® 242 on each of the 3 screws and loosely install the 3 bearing retainers and screws into the seal/bearing housing.



19. Place wave springs in respective bearing bores.



32. Slide gear shaft into seal/bearing housing.



20. Install a thin layer of Loctite® 515 or 573 to the rear bearing housing flange face.



33. Torque the 3 retainer screws to 8-lbs. ft.



21. Install rear bearing cover into place and install 2 screws on opposite ends of the plate. Tighten screws to evenly bring cover onto flange face of the rear bearing housing. 22. Install remaining screws in cover plate and torque to 38-lbs. ft. 23. Check discharge end clearances with a feeler gauge for the male and female rotors. Rotate the rotors to help seat bearings before taking measurements. If measurements are within .0015 to .0025 specification, proceed with



Manual # 22259444 (3/03)



34. Place the heated bearing inner race on the drive gear. USE PROPER GLOVES TO HANDLE HOT BEARING. 35. Install key in keyway on male rotor shaft. 36. Heat driven gear to 300°F (149°C) for 30 minutes. 37. Install the heated gear onto the male rotor shaft. USE PROPER GLOVES TO HANDLE HOT BEARING.



38. Apply 3 drops of Loctite® 222 or 932 on the rotor threads and install the locknut. Torque the locknut to 219-lbs. ft. 39. Apply a thin layer of Loctite® 515 or 573 front bearing housing flange. 40. Position the gear case onto the front bearing housing. 41. Tap dowel pin into housings. Apply a drop of Loctite® 242 on each of the screws and install the screws into the gear case and torque to 38-lbs. ft. 42. Apply a small bead of Loctite® 242 around half of the outer race of the drive gear bearing (Q, figure 2) and install in the gear case housing (V, figure 2). 43. Install o-ring into groove of seal/bearing housing using a small amount of grease to hold it in place during assembly. 44. Guide the seal/bearing housing assembly into position on the gear case. 45. Apply a drop of Loctite® 242 to each screw and install them into the seal/bearing housing and torque to 38lbs. ft. 46. Apply a drop of Loctite® 242 to each screw and install them to attach adapter to seal/bearing housing and torque to 38-lbs. ft.



CLEAN-UP OF AIREND SYSTEM Once the airend has been overhauled, the following clean-up procedure is required before installation of the airend back into its package. 1.



Drain the entire airend oil system and flush the separator tank.



2.



Remove the old oil and air filter elements, clean canisters and install new elements.



3.



Flush all manifolds, pipes and/or hoses from the oil filter outlet to the airend. If necessary, remove components, flush with clean 10W compressor oil and reinstall.



Note: It is critical that the small oil supply lines connecting to the airend receive special attention. 4.



Check condition of all compressor air and oil hoses and replace if either inner or outer surface is visually damaged.



5.



Upon installation, take every precaution to prevent foreign material from entering airend.



6.



When setting the airend into position for bolting to the engine, care must be taken to ensure proper alignment.



7.



Refill system with approved lubricant.



8.



Pour one gallon of oil into the airend intake to aid lubrication on initial start-up.



47. Install key in drive shaft. 48. Slide hex bearing onto drive shaft as far as it will go, small diameter first. 49. Rotate the bearing and shaft by hand and check for interference. If interference is found, back off the hex bearing until there is clearance. 50. Apply a drop of Loctite® 242 to the hex bearing screw and torque to 18-lbs. ft.



DRIVE COUPLING INSTALLATION 1. Apply a drop of Loctite® 242 to each screw and attach the drive coupling to the engine flywheel. Torque screws to 31-lbs.ft.



Manual # 22259444 (3/03)



Manual # 22259444 (3/03)