C80 Element Overhaul PDF

 

Main tenance e & Overhaul Manual Maintenanc 1

General Ge neral inf orm ation

C80 Overhaul Overhaul Instruct ion Printed Matter Number

:

2946 1722 00

 Appl  Ap pl ic abl e to

:

Compressors with C80 elements

Preliminary Operations:

:

 –

Safety Safety Instructi ons

:

General

Persons Required

:

1

Special Tools

:

C80 overhaul kit, Torque wrench, Overhaul stand, Induction heater, Adjustable induction heater

Consumables

:

Loctite 243, Loctite 641, oil, cleaning product

2

Document overview

This document describes the following: 1 

General information............................................................ information.............................................................................................................................. ................................................................................................ .............................. 1 

2 

Document overview............................................................ overview.............................................................................................................................. ................................................................................................ .............................. 1 

3 

Safety first ....................................................................................................................................................... ..................................................................................... ..................................................................................... ................... 2 

4 

Parts overview overvie w ............................................................................................................... ................................................................................................................................................................... .................................................... 3 

5 

6 

4.1 

Element overhaul kit k it (2901 1959 00) ......................................................................................................................... ........................................................... .............................................................. 3 

4.2 

Other necessary parts ..................................... ....................................................................................................... .......................................................................................................... ........................................ 3 

Tools overview ................................................................................................................................................ .............................................................................. ..................................................................................... ................... 4  5.1 

C80 Overhaul kit (2230 0108 00) ............................................................................................................................... ................................................................. .............................................................. 4 

5.2 

Other tools ............................................................................................................................................... ............................................................................. .................................................................................... .................. 5 

Overhaul ............................................................................................................................................... ............................................................................. ............................................................................................... ............................. 6  6.1 

6.1.1 

Element housing ............................................................... ................................................................................................................................. .................................................................................... .................. 6 

6.1.2 

Female rotor and female rotor bearings ............................................................................................................... ................................................ ............................................................... 9 

6.1.3 

Male rotor and male rotor bearings ..................................................................................................................... ........................................................ ............................................................. 12 

6.1.4 

Inner races of the b bearing earing at the inlet side .......................................................................................................... ......................................................... ................................................. 14 

6.2 

Cleaning and inspection ......................................................................................... ....................... ................................................................................................................... ................................................. 15 

6.2.1 

Male and female rotors ....................................................................................................................................... ...................................................................................................................... ................. 15 

6.2.2 

Element housing and outlet o utlet flange ..................................................................................................................... ......................................................... ............................................................ 15 

6.3 

7 

Dismantling ........................................................................................................................ ................................................................................................................................................................ ........................................ 6 

Reassembly ............................................................................................................................................................. ...................................................................................................................... ....................................... 15 

6.3.1 

Inner races of the roller bearings at the inlet side of the male and female rotors................................................ 15 

6.3.2 

Bearings at the outlet side of the female rotor .................................................................................................... 17 

6.3.3 

Bearing at outlet ou tlet side of male rotor ..................................................................................................................... ......................................................... ............................................................ 20 

6.3.4 

Bearings at the outlet side of the male rotor ....................................................................................................... 21 

6.3.5 

Spacer at the outlet side of the male rotor .......................................................................................................... ......................................................... ................................................. 22 

Packing .................................................................................................... ...................................................................................................................................................................... ........................................................................ ...... 26 

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Safety fety fir st Sa

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3

Parts Pa rts overvi ew

3.1

Element overh aul kit (290 (2901 1 195 1959 9 00)

Kit content: Part number

Descripti De scripti on

Quantity

0508 1108 00

Bearing

1

0508 1100 46

Bearing

1

0211 1323 00

Cap screw

1

1616 7202 00

Washer

1

1616 6915 00

Oil nozzle

1

0211 1322 00

Cap screw

1

0301 2335 00

Washer M8

1

0147 1364 03

Bolt M10x35 M10x35  

6

0147 1365 03

Bolt M10x40

2

0101 1951 40

Dowel pin

1

0504 0200 14

Ball bearing

2

1616 7426 00

Bearing

1

Note: this is a bearing which can only be ordered from Atlas Copco.

3.2 3.2

0504 0200 54

Bearing

1

0147 1368 03

Hexagon bolt

1

0295 3107 00

Nut

1

0147 1326 03

Hexagon bolt M8x30

6

0663 2106 70

O-ring

1

0663 7139 00

O-ring

1

0663 2112 18

O-ring

1

0663 2106 67

O-ring

1

1616 6267 20

Spacer

1

Other necessary parts

  Fine sandpaper

•

  Loctite 243

•

  Loctite 641

•

  Cleaning product

•

  Oil

•

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4 4.1

Tools overview C80 Overh aul ki t (2230 0108 00)

  Blocking tool (1630 0929 28)

•

  Inner race press tool (1630 0929 29)

•

  SKF lock nut socket (TMFS6)

•

  Threaded rod M10

•

  Small bearing

•

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4.2 4.2

Other tools

  Thickness gauge foil 0.04mm

•

  nut M10

•

  Torque wrench

•

  Overhaul stand

•

  Induction heater:

•

  2908 0048 00 (50Hz)

•

  2908 0048 01 (60Hz)

•

  Adjustable induction heater

•

  2230 0102 00 (50Hz)

•

  2230 0103 00 (60Hz)

•

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5

Overhaul

5.1

Dismantling

5.1.1 5.1 .1

1.

Element hou sin g

Connect the element with its outlet flange to the overhaul stand (inlet side upwards) (A).

 A

2.

Remove the fixation washer (A) and bolt (B) of the outer races.

B

 A

3.

Remove the fixation washer (A) and bolt (B) of the oil spray nozzle.

 A

B

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4.

Remove the oil spray nozzle (A).

5.

Change position of the element – outlet side upwards.

 A

6.

Unscrew 6 bolts (A) and remove the male & female rotor end cap (B).  A B

7.

Change position of the element – inlet side upwards and unscrew 8 bolts of the outlet flange (A).

 A  A

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8.

Disconnect the housing of the element (A) from the outlet flange (B).

 A

B

9.

Change position of the element – outlet side upwards .

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5.1. 5.1.2 2

1.

Fe Female male rotor and and female roto r bearings

Place the lock nut socket (A) on the lock nut of the female rotor (B).

 A

B

2.

Block the rotors (A) with the locking tool (B).  A

B

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3.

Unscrew and remove the nut of the female rotor (A).

 A

4.

Screw in the M10 bolt (A) for the protection of the female rotor.  A

5.

Place a pulley puller (A) and push through the female rotor (B).

 A

B

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Support the female rotor to prevent it from falling!  

 A

6.

Remove the female rotor outlet bearings (A).

 A

If needed you can use pulley puller (B).

B

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5.1. 5.1.3 3

1.

Male rotor and male rotor bearings bearings

Unscrew the fixation bolt of the male rotor (A) and remove the washer (B) (use the blocking tool to prevent the rotor from rotation).

 A

B

2.

Screw in the fixation bolt for the protection of the male rotor (A).

 A

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3.

Use the pulley puller and the blocking tool (A) to press out the male rotor (B). Support the male rotor to prevent it from falling!  falling!    A

B

4.

Remove spacer (A) from male rotor outlet side.

 A

5.

Remove the male rotor outlet bearings (A).

 A

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5.1. 5.1.4 4

Inner races of the bearing at the inlet side

Note:

The overh overhaul aul procedure procedure does not for foresee esee metal shells for the disman dismantling tling of the inner races of the roller roller be bearings arings due to high cost and very short life time.

1.

2.

Position the rope of the adjustable induction heater (A) around the inner race of the inlet bearing of the male rotor (B).

 A B

Heat up the bearing inner race (A) until it can be removed from the shaft of the element by hand.  A

 Al way ways s u se heat h eat r esi stin st in g gloves during all operation with the inductio n heate heater! r!

3.

4.

Position the rope (A) of the adjustable induction heater around the inner race of the inlet bearing of the female rotor (B).

 A B

Heat up the bearing inner race (A) until it can be removed from the shaft of the element by hand.

 A

5.

Clean up the shafts of the rotors (A).

 A

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5.2 5.2

Cleaning Cle aning and inspectio n

5.2.1 5.2 .1

Male and female rot or s

1.

Clean the rotors

2.

Inspect both rotors for scratches and other damage

If the condition of the rotors is doubtful, replace the element.

5.2. 5.2.2 2 1. 2.

Eleme Element nt housin g and outl et flange

Clean element housing the outlet flange Inspect housing and outlet flange for scratches sc ratches and other damage

If the condition of the housing and/or outlet flange is doubtful, replace the element.

5.3

Reassembly

5.3. 5.3.1 1

1.

Inner races of the roller bearings at at the inlet side of the male male a and nd female roto rs

Take a new female rotor roller bearing (0508 1100 46) (A) from the kit.

 A

2.

Heat up the inner race of the bearing (A) with the induction heater up to 120°C.  Al way ways s u se heat h eat r esi stin st in g gloves during all operation

 A

with the inductio n heate heater! r! Overheating of the inner Overheating race can cause deformation or change the material property so that the bearing will not be suitable for use.

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3.

Take a brush and put some Loctite 641 on the inner race seat of the female rotor shaft. Closed circle around the shaft.

4.

Install the inner race of the bearing (A) on the shaft of the female rotor. Hold the inner race in place till cooled down sufficiently

5.

Take a new male rotor roller bearing (0508 1108 00) (A) from the kit.

 A

 A

6.

7.

8.

Heat up the inner race of the bearing (A) with the induction heater up to 120°C.

 A

Take a brush and put some Loctite 641 on the inner race seat of the male rotor shaft.

 A

Install the inner race of the bearing on the shaft of the male rotor. Hold the inner-race in place till cooled down sufficiently.

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5.3. 5.3.2 2

Bearings at the outlet side of the female rotor

Take the roller bearing 1616742600 and the ball bearing 0504020054 from the kit and install them iinto nto the outlet flange of the element. This roller b earing earing i s an AIRT AIRTEC EC be bearing aring which only can be o rdered from Atl as Copco. Pa Pay y attention to the position of the bearings.

1.

Take 2 pieced of thickness gauge foil of 0.04mm (A).

 A

2.

Position the female rotor (A) in the housing and support the rotor (for example by hydraulic pump). In

B

between the female rotor and the housing head plane position 2 pieces of thickness gauge foil (B).  A

During next steps continuously check position rotor and gauge foils. This determines head clearance!

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B

 

3.

Take roller bearing (1616 7426 00) and position the inner race (A) over female rotor shaft. Position the inner race press tool (B) over this bearing.

B

 A

4.

5.

Position standard nut socket (size 30) (A) and a small bearing (B) on the inner race tool (C) and then insert the threaded rod with the nut on it (D).

D

B

Torque the nut to press the inner race over the rotor shaft till the inner race tool touches the housing.

 A C

The inner race tool will limit the t he depth the inner race is pressed over the rotor shaft.

6.

Press the outer race of the bearing (1616 7426 00) (A) in the housing with the inner race tool (B) and a similar set up as the inner race.

 A

B

7.

Take the bearing (0504 0200 54) (A) and heat this up to 120°C (position sensor on inner race of bearing).

8.

Place this bearing in the housing over the rotor (B). Hold the bearing down till it is cooled off.

 A

B

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Check the po sition bea Check bearing. ring. The side with broad inner race should be upwards (A).  A

9.

Take the new lock nut (A) of the female rotor from the overhaul kit and apply Loctite 243 on it.

 A

Do not apply big quantity of the Loctite 243, since this can cause change of the female rotor gap duri ng exploitation of the overhauled element.  element. 

Chamfer (A) should always be turned downwards!  A

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10. Install the nut (A) on the female rotor (B) and tighten it with the torque value of 4 Nm.  Nm.   A

B

11. Remove the thickness gauge foils (A).  A

5.3. 5.3.3 3

Bearing at outlet side of male rotor

Spacer at the outlet side of the male rotor 1.

Install spacer (A) on the shaft of the male rotor (B). Reuse the old spacer or machine the spacer (1616 6267 20) to the required thickness to achieve perfect head clearance.

 A

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B

 

5.3. 5.3.4 4

1.

Bearings at the outlet side of the male rotor

Take two ball bearings (0504 0200 14) (A) from the kit and install them into the outlet flange of the element. Pa Pay y attention to the posit ion of the bearings!

 A

Mark spacer on below Mark drawing.

 A

2.

Place washer on top of the bearings (A) - Male outlet washer used as tool.

3.

Position standard nut cap (size 30) (B) and a small bearing (C) on top of the washer.

4.

Put the nut on the rod (D) and put them through bearing / nut / washer / male outlet bearings.

D

C B

 A

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5.

Take the male rotor (A) and catch the threaded hole of the rotor at the outlet side by the threaded rod.

6.

Block the rotor (A) with the blocking tool (B).

B

 A

7.

Press the bearings on the shaft of the male rotor by the tightening of the nut.

8.

Proceed until the bearings are completely pressed on the shaft.  Ap pl ied to rq rque ue s ho houl ul d n ot be more them 15 Nm during this operation

9.

B

 A

 A

Take new bolt from the overhaul kit (A), put the male shaft washer (B) on it and apply the Loctite 243.

10. Tighten the bolt of the male shaft (A). Required to rque – 46Nm.

5.3. 5.3.5 5 1.

Space Spacerr at the outlet side of the male rotor

Remove old O-ring (A) of the female cap (B) and replace it with a new one from the overhaul kit (C).

 A

C

B

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2.

Remove old O-ring (A) of the male cap (B) and replace it with a new one from the overhaul kit (B).

C  A

B

3.

Install the male cap (A) into the outlet flange and tighten the bolts (B) by applying 23 Nm torque. Nm  torque.

 A

B

4.

Install the female cap into the outlet flange and tighten the bolts by applying 23 Nm torque. Nm  torque.

 A

B

5.

Change position of the element – outlet side downwards.

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6.

Remove old O-ring (0663 2106 70) (A) at the outlet flange of the housing and replace it with a new one from the overhaul kit (B).

B  A

Note: Do not forget about small O-ring (0663 2106 67) of the oil injection

C

hole (C).

7.

Insert the rotors into the housing of the element.

8.

Tighten all 8 bolts (A) of the outlet flange by applying 46 Nm torque. Nm  torque.

 A

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9.

Install the outer race of the roller bearing (0508 1100 46) (A) at the inlet side of the female rotor.

 A

10. Install the outer race of the roller bearing (0508 1108 00) (A) at the inlet side of the male rotor.

 A

11. Take new bolt (A) from the overhaul kit, put the washer on it and apply the Loctite 243. 12. Tighten XXX bolt by applying 39 Nm torque. Nm  torque.

 A

13. Install new oil spray nozzle (A) from the overhaul kit.

 A

14. Take new bolt from the overhaul kit, put the washer on it and apply the Loctite 243. 15. Tighten the bolt by applying 39 Nm torque. Nm  torque.  A  A

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6

Packing

1.

Oil the element.

2.

Cover the shaft with greased paper.

3.

Cover the element outlet with tape.

4.

Remove the element from the overhaul stand.

5.

Cover the element with tape.

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