Atlas Copco C146 Element Overhaul
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Maintenance procedure 1. General information
C146 (M05) Element overhaul Printed Matter Number
:
2946 1270 00
Applicable to
:
Element C146 (M05)
Preliminary Operations
:
–
Safety Instructions
:
General
Persons Required
:
1
Special Tools
:
–
Consumables
:
–
2. Document overview This document describes the following: 1.
General information ....................................................................................................................................................1
2.
Document overview ....................................................................................................................................................1
3.
When? ........................................................................................................................................................................3
4.
Necessary Parts..........................................................................................................................................................3 Element overhaul kit PN 2901 1089 00..............................................................................................................................3 Shims .................................................................................................................................................................................4 Others ................................................................................................................................................................................4
5.
Necessary tools ..........................................................................................................................................................4 Tools specific for element overhaul....................................................................................................................................4 Others ................................................................................................................................................................................5
6.
Overhaul .....................................................................................................................................................................6 6.1.
Dismantling ............................................................................................................................................................6
Bearing retainers & wave springs ......................................................................................................................................6 Male rotor QJ bearing - Part 1............................................................................................................................................7 Male rotor QJ bearing - Part 2............................................................................................................................................8 Female rotor QJ bearing - Part 1 .......................................................................................................................................8 Female rotor QJ bearing - Part 2 .......................................................................................................................................9 Outlet housing & outer races NU bearings.........................................................................................................................9 Inner races NU bearings ..................................................................................................................................................10 Inner races NJ bearings ...................................................................................................................................................10 Inlet housing & outer races NJ bearings ..........................................................................................................................10 6.2.
Cleaning and inspection of components ..............................................................................................................11
Male and female rotor ......................................................................................................................................................11 Element inlet & outlet housing..........................................................................................................................................11 6.3.
Reassembly .........................................................................................................................................................11
Important remarks ............................................................................................................................................................11 Inlet bearing male & female .............................................................................................................................................11
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Mounting male & female rotor ..........................................................................................................................................13 Element outlet housing.....................................................................................................................................................14 Measuring clearances outlet bearing female rotor ...........................................................................................................14 Measuring clearances outlet bearing male rotor ..............................................................................................................17 Mounting outlet bearing male rotor ..................................................................................................................................17 Mounting outlet bearing female rotor ...............................................................................................................................19 Torque values for mounting .............................................................................................................................................19 Check female and male clearances .................................................................................................................................20 Mounting wave springs and bearing retainers..................................................................................................................20 7.
Packing .....................................................................................................................................................................20
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3. When? The element overhaul is recommended every 24 000 hrs.
4. Necessary Parts Element overhaul kit PN 2901 1089 00
Kit content:
Ring:
0663 2111 77 (1x)
Bearing:
0508 1310 00 (2x)
Bearing male:
0512 0510 13 (1x)
Bearing female:
0512 0510 12 (1x)
Wave spring set male:
1616 7148 00 (1x)
Wave spring set female:
1616 7149 00 (1x)
Clamping ring:
1616 7266 00 (1x)
Cap screw:
0147 1409 03 (1x)
Shim 0.025 mm male
Shim 0.025 mm female
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Shims Available shim thicknesses:
Male:
PN 1616 7144 01: 0.050 mm
PN 1616 7144 03: 0.020 mm
PN 1616 7144 04: 0.030 mm
Female:
PN 1616 7145 01: 0.050 mm
PN 1616 7145 03: 0.020 mm
PN 1616 7145 04: 0.030 mm
Note:
The shims are not included in the overhaul kit. It is recommended to have a number of shims in stock at the element overhaul area.
Others
Oil stone
Fine sandpaper
Loctite 641
Loctite 243
Cleaning product
Oil
Bearing grease
5. Necessary tools Tools specific for element overhaul
Overhaul stand:
Basic tool set for pulling operations:
Hydraulic pump + puller:
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2990 0428 80 + 4x bolts and 4x washers
2903 0100 02 (HP63)
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Accessory set:
2903 0100 01 (HP63)
Bearing puller set:
Bearing puller set:
2903 0100 08
Male QJ bearing part 1:
2903 0100 07 (QJ 214 O / 63-767)
Male QJ bearing part 2:
2903 0100 05 (QJ 214 I / 63-768)
Female QJ bearing part 1:
2903 0100 06 (QJ 212 O / 63-765)
Female QJ bearing part 2:
2903 0100 04 (QJ 212 I / 63-766)
Male and female QJ bearing:
2903 0100 03
Inner race male NU bearing:
9423 0032 83
Inner race female NU bearing:
9423 0033 04
Outer race male NU bearing:
2990 0310 00
Outer race female NU bearing:
2990 0310 00
Measuring set:
Dial gauge male:
9421 0040 65
Dial gauge female:
9421 0040 69
Zero plate male:
9421 0040 66
Zero plate female:
9421 0040 70
Others
Induction heater:
2908 0048 00 (50Hz)
2908 0048 01 (60Hz)
Lifting eye
2 x M16 for lifting the male and female rotor
3 x M12 for lifting the element
2 x M14 for lifting the element outlet housing
Slide hammer puller: 2990 0310 00
Torque wrench
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6. Overhaul 6.1.
Dismantling
1.
Fit the element with its inlet flange to the overhaul stand and the outlet side upwards.
2.
Secure with 4 bolts.
Bearing retainers & wave springs 1.
Unscrew the hold down bolts of both bearing retainers.
2.
Remove the bearing retainers
3.
Take out both sets of wave springs.
For the male rotor:
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For the female rotor:
1.
Lock male rotor with locking tool (9423 0031 63).
2.
Remove female washer.
Male rotor QJ bearing - Part 1 1.
Take the basic tool set for pulling operations.
2.
Take bearing puller set (2903 0100 07) in combination with tool (2903 0100 03).
3.
Place a washer to protect the rotor shaft.
4.
Place the shelves around the outer race of the male ball bearing.
5.
Place the ring over the shelves
6.
Place the puller and tear off the upper inner ring and outer race of the ball bearing.
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Male rotor QJ bearing - Part 2 1.
Place a washer to protect the rotor shaft.
2.
Place the tool (2903 0100 05) in combination with tool (2903 0100 03) around the lower inner race of the male ball bearing.
3.
Place the puller and tear off the lower inner ring of the ball bearing.
Female rotor QJ bearing - Part 1 1.
Take bearing puller set (2903 0100 06) in combination with tool (2903 0100 03).
2.
Place a washer to protect the rotor shaft.
3.
Place the shelves around the outer race of the female ball bearing.
4.
Place the ring over the shelves.
5.
Place the puller and tear off the upper inner ring and the outer ring of the ball bearing.
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Female rotor QJ bearing - Part 2 1.
Place a washer to protect the rotor shaft.
2.
Place the bearing puller set (2903 0100 04) in combination with tool (2903 0100 03) around the lower inner race of the female ball bearing.
3.
Place the puller and tear off the lower inner ring of the ball bearing.
Outlet housing & outer races NU bearings 1.
Provide the outlet housing with 2 lifting eyes (min. 125 kg).
2.
Remove the bolts that keep the inlet and outlet housing together.
3.
Vertically lift and remove the outlet housing.
4.
Break cage of both bearings and put pulling tool inside outlet bearing ring.
5.
Remove both outer races (male and female) from the element outlet housing.
6.
Use slide hammer puller.
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Inner races NU bearings 1.
Take bearing puller set inner race male NU bearing (9423 0032 83) and inner race female NU bearing (9423 0033 04).
2.
Place a washer to protect the rotor shaft.
3.
Mount the basic tool set (2903 0100 02).
4.
Remove the male and female NU bearing inner race.
Inner races NJ bearings To lift the rotors: 1.
Prepare a wooden pallet to place both rotors.
2.
Fit 2 lifting eyes.
3.
First lift the male rotor, take care to lift in line with the rotor axis.
4.
Do the same for the female rotor.
5.
Place a washer to protect the rotor shaft.
6.
Mount the basic tool set and remove male and female NJ bearing inner race.
Inlet housing & outer races NJ bearings 1.
Take out the outer races of the male and female NJ bearing.
2.
Use a slide hammer puller (2990 0310 00) if necessary.
3.
Remove the o-ring and both dowel pins.
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6.2.
Cleaning and inspection of components
Male and female rotor These rotors were put together as a set. Always keep the rotor set together, never mix with other sets!!
To optimise element efficiency: 1.
Clean the rotors.
2.
Inspect both rotors for scratches and other damage.
IF necessary: smooth down with fine sandpaper and/or an oil stone to the original surface. Do not take away too much material!!! If the condition of the rotors is doubtful REPLACE ELEMENT
Element inlet & outlet housing 1.
Clean inlet and outlet housing.
2.
Inspect housing for scratches and other damage. IF necessary: smooth down with fine sandpaper and/or an oil stone to the original surface. Do not take away too much material!!! If the condition of the in- or outlet housing is doubtful REPLACE ELEMENT
6.3.
Reassembly
Important remarks Male and female rotor are delivered as a set Always keep the set together! All bearings are delivered and bound together as a set Always keep the set together! Never directly hit on the new bearing races You can use the rings of the old bearings after cleaning them.
Inlet bearing male & female Outer race inlet bearing 1.
Take one of the NJ bearings (0508 1310 00).
2.
Remove the packing.
3.
Check the bearing for damages.
NJ bearings are delivered and bound together as a set Always keep the set together!
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4.
Fit the outer race on the female seat of the housing. Markings on top!
Bearing markings
Use tooling (9423 0031 36).
5.
Repeat for the outer race male inlet bearing
Inner race inlet bearing 1.
Take the male rotor.
2.
Inspect the rotor shaft for scratches or other damage.
3.
Degrease the rotor shaft.
4.
Degrease the bearing inner race.
5.
Heat the bearing inner race up to 120°.
6.
In the mean time, take a brush and put some Loctite 641 on the inner race seat of the rotor shaft.
7.
Put on heat resisting gloves and take the inner race.
8.
Position the hot inner race on the inlet side of the rotor shaft.
Note:
Mount the inner race in the right direction Raised border towards rotor body.
Note:
Make rotating moves with the inner race to spread the Loctite.
9.
Repeat for the inner race of the female inlet bearing.
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Mounting male & female rotor Male rotor 1.
Grease the inlet bearings.
2.
Oil the housing.
3.
Let the inner race cool down.
4.
Lift the male rotor at its outlet side.
5.
Oil the rotor.
6.
Carefully lower the rotor in the element housing while pressing the rotor softly in the direction of the arrow (see picture).
7.
When lowering the rotor, make sure the inner race of the bearing fits into the outer race.
Female rotor 1.
Let the inner race cool down.
2.
Lift the female rotor at its outlet side.
3.
Oil the rotor.
4.
Carefully lower the rotor in the element housing while pressing the rotor softly towards the male rotor.
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5.
When lowering the rotor, make sure the inner race of the bearing fits into the outer race.
Element outlet housing 1.
Grease the seal surface and place a new o-ring.
2.
Mount both dowel pins, use a plastic hammer.
3.
Lift the outlet bearing housing
4.
Shove the housing equally over the dowel pins.
Note: Make sure the O-ring stays in place.
5.
Tighten the 11 bolts. Start with a bolt next to a dowel pin and a torque of 5 Nm. Final torque for all the bolts is 46 Nm.
Measuring clearances outlet bearing female rotor NU Cylindrical roller bearings
NU Cylindrical roller bearings
Radial load
No axial load
Movable in axial direction
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QJ Four-point contact ball bearing
QJ Four-point contact ball bearing
Combined radial and axial load
Fixed in axial direction (clearance: 0.02 mm). Total rotor clearance depends on position of fixed ball bearing.
Total rotor clearance
Total rotor clearance = 0.04 – 0.08 mm The rotor clearance can be corrected with shims:
Increase shim thickness Increase rotor clearance.
Measuring female rotor clearance:
As the ball bearing on top of cylindrical bearing and the measurement is done WITHOUT cylindrical bearing:
Zero the gauge on zero plate (9421 0040 66).
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1.
Place the gauge (9421 0040 69) over the female rotor shaft.
2.
Lift the rotor.
3.
Read out the gauge with the rotor in lifted position.
4.
Write down this value and calculate the shim thickness as described below.
Calculating shim thickness Read out = 0 Difference between inner and outer ring = 0 Calculated shim thickness = Total rotor clearance – bearing clearance = 0.08 mm – 0.04 mm = 0.04
Read out > 0
Inner ring below outer ring Add shims Calculated shim thickness = Total rotor clearance – ball bearing clearance + measured value = 0.08 mm – 0.04 mm + measured value = 0.04 + measured value
read out < 0
Outer ring below inner ring Remove shims Calculated shim thickness = Total rotor clearance – ball bearing clearance – measured value = 0.08 mm – 0.04 mm – measured value = 0.04 – measured value
Create shim set 1.
Create a set of shims as close as possible to the calculated shim thickness with the following available shim sizes:
0.050 mm
0.030 mm
0.020 mm
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Measuring clearances outlet bearing male rotor Differences with female rotor
Difference with female rotor: Ball bearing on top of element housing Measure between the inner ring and the housing with tool (9421 0040 65) and use zero plate (9421 0040 70).
Mounting outlet bearing male rotor NU/QJ bearings are packed and bound together as a set (the 5 parts have 1 common set-number).
Always keep the set together! Mount the bearing in the same way as it is packed!!
1.
Take the NU/QJ outlet bearing for the male rotor and remove the packing.
2.
Check the bearing for damages.
3.
Take the inner race of the cylindrical bearing and heat it up to 110°.
4.
In the mean time, take a brush and put some Loctite 641 on the inner race seat of the rotor shaft.
5.
Put on heat resisting gloves and take the inner race. Position the hot inner race on the male rotor shaft.
Note:
Mount the inner race in the right direction Markings upwards. Make rotating moves with the inner race to spread the Loctite.
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6.
Let the inner race cool down.
7.
Take the outlet race of the cylindrical bearing and degrease the outer race.
8.
Put some Loctite 641 on the outside.
9.
Press the outer race of the cylinder bearing in the housing. If necessary, put the old clean bearing ring on top and use a plastic hammer.
Note:
Mount the outer race in the right direction Marked V points upwards
10. Assemble the correct shim set, as calculated before! 11. Check the thickness of the shim set and fit the shims over the rotor.
Note:
Do not switch the lower inner ring with the upper inner ring upper ring has complete markings on top. Mount the bearing set exactly in the same way as it was packed!
12. Warm up the lower inner ring of the roller bearing (110 °C). 13. Position the lower inner ring over the male rotor shaft.
14. Let the inner ring cool down. 15. Mount the roller bearing.
Note:
Mount the outer race in the right direction Marked V points upwards. Mount the bearing set exactly in the same way as it was packed!
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16. Warm up the upper ring (110 °C) and mount onto the male rotor shaft.
Overview male bearing
Mounting outlet bearing female rotor Repeat step 41 up to 56 for the female bearing.
Overview female bearing
Torque values for mounting
Mount washer on female rotor and torque bolt to 80 Nm.
Mount mounting bushing on male rotor and torque bolt to 80 Nm.
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Check female and male clearances 1.
Fix a lifting eye.
2.
Fix a gauge to the rotor.
3.
Zero the gauge on the rotor housing.
4.
Lift the rotor.
5.
Read out the rotor clearance.
Note:
6.
Total rotor clearance has to be between 0.04 – 0.08 mm for each rotor!
Remove the male washer with the lifting eyes.
Mounting wave springs and bearing retainers 1.
Position a set of new wave springs onto each bearing set.
2.
Fit the bearing retainer, position and torque the bolts. Use a torque of 78 Nm.
7. Packing 1.
Oil the element
2.
Cover the shafts with greased paper.
3.
Cover the element outlet with tape.
4.
Remove the element from the overhaul stand.
5.
Cover the element inlet with tape.
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C146 (M05) Element overhaul Printed Matter Number
:
2946 1270 00
Applicable to
:
Element C146 (M05)
Preliminary Operations
:
–
Safety Instructions
:
General
Persons Required
:
1
Special Tools
:
–
Consumables
:
–
2. Document overview This document describes the following: 1.
General information ....................................................................................................................................................1
2.
Document overview ....................................................................................................................................................1
3.
When? ........................................................................................................................................................................3
4.
Necessary Parts..........................................................................................................................................................3 Element overhaul kit PN 2901 1089 00..............................................................................................................................3 Shims .................................................................................................................................................................................4 Others ................................................................................................................................................................................4
5.
Necessary tools ..........................................................................................................................................................4 Tools specific for element overhaul....................................................................................................................................4 Others ................................................................................................................................................................................5
6.
Overhaul .....................................................................................................................................................................6 6.1.
Dismantling ............................................................................................................................................................6
Bearing retainers & wave springs ......................................................................................................................................6 Male rotor QJ bearing - Part 1............................................................................................................................................7 Male rotor QJ bearing - Part 2............................................................................................................................................8 Female rotor QJ bearing - Part 1 .......................................................................................................................................8 Female rotor QJ bearing - Part 2 .......................................................................................................................................9 Outlet housing & outer races NU bearings.........................................................................................................................9 Inner races NU bearings ..................................................................................................................................................10 Inner races NJ bearings ...................................................................................................................................................10 Inlet housing & outer races NJ bearings ..........................................................................................................................10 6.2.
Cleaning and inspection of components ..............................................................................................................11
Male and female rotor ......................................................................................................................................................11 Element inlet & outlet housing..........................................................................................................................................11 6.3.
Reassembly .........................................................................................................................................................11
Important remarks ............................................................................................................................................................11 Inlet bearing male & female .............................................................................................................................................11
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Mounting male & female rotor ..........................................................................................................................................13 Element outlet housing.....................................................................................................................................................14 Measuring clearances outlet bearing female rotor ...........................................................................................................14 Measuring clearances outlet bearing male rotor ..............................................................................................................17 Mounting outlet bearing male rotor ..................................................................................................................................17 Mounting outlet bearing female rotor ...............................................................................................................................19 Torque values for mounting .............................................................................................................................................19 Check female and male clearances .................................................................................................................................20 Mounting wave springs and bearing retainers..................................................................................................................20 7.
Packing .....................................................................................................................................................................20
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3. When? The element overhaul is recommended every 24 000 hrs.
4. Necessary Parts Element overhaul kit PN 2901 1089 00
Kit content:
Ring:
0663 2111 77 (1x)
Bearing:
0508 1310 00 (2x)
Bearing male:
0512 0510 13 (1x)
Bearing female:
0512 0510 12 (1x)
Wave spring set male:
1616 7148 00 (1x)
Wave spring set female:
1616 7149 00 (1x)
Clamping ring:
1616 7266 00 (1x)
Cap screw:
0147 1409 03 (1x)
Shim 0.025 mm male
Shim 0.025 mm female
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Shims Available shim thicknesses:
Male:
PN 1616 7144 01: 0.050 mm
PN 1616 7144 03: 0.020 mm
PN 1616 7144 04: 0.030 mm
Female:
PN 1616 7145 01: 0.050 mm
PN 1616 7145 03: 0.020 mm
PN 1616 7145 04: 0.030 mm
Note:
The shims are not included in the overhaul kit. It is recommended to have a number of shims in stock at the element overhaul area.
Others
Oil stone
Fine sandpaper
Loctite 641
Loctite 243
Cleaning product
Oil
Bearing grease
5. Necessary tools Tools specific for element overhaul
Overhaul stand:
Basic tool set for pulling operations:
Hydraulic pump + puller:
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2990 0428 80 + 4x bolts and 4x washers
2903 0100 02 (HP63)
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Accessory set:
2903 0100 01 (HP63)
Bearing puller set:
Bearing puller set:
2903 0100 08
Male QJ bearing part 1:
2903 0100 07 (QJ 214 O / 63-767)
Male QJ bearing part 2:
2903 0100 05 (QJ 214 I / 63-768)
Female QJ bearing part 1:
2903 0100 06 (QJ 212 O / 63-765)
Female QJ bearing part 2:
2903 0100 04 (QJ 212 I / 63-766)
Male and female QJ bearing:
2903 0100 03
Inner race male NU bearing:
9423 0032 83
Inner race female NU bearing:
9423 0033 04
Outer race male NU bearing:
2990 0310 00
Outer race female NU bearing:
2990 0310 00
Measuring set:
Dial gauge male:
9421 0040 65
Dial gauge female:
9421 0040 69
Zero plate male:
9421 0040 66
Zero plate female:
9421 0040 70
Others
Induction heater:
2908 0048 00 (50Hz)
2908 0048 01 (60Hz)
Lifting eye
2 x M16 for lifting the male and female rotor
3 x M12 for lifting the element
2 x M14 for lifting the element outlet housing
Slide hammer puller: 2990 0310 00
Torque wrench
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6. Overhaul 6.1.
Dismantling
1.
Fit the element with its inlet flange to the overhaul stand and the outlet side upwards.
2.
Secure with 4 bolts.
Bearing retainers & wave springs 1.
Unscrew the hold down bolts of both bearing retainers.
2.
Remove the bearing retainers
3.
Take out both sets of wave springs.
For the male rotor:
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For the female rotor:
1.
Lock male rotor with locking tool (9423 0031 63).
2.
Remove female washer.
Male rotor QJ bearing - Part 1 1.
Take the basic tool set for pulling operations.
2.
Take bearing puller set (2903 0100 07) in combination with tool (2903 0100 03).
3.
Place a washer to protect the rotor shaft.
4.
Place the shelves around the outer race of the male ball bearing.
5.
Place the ring over the shelves
6.
Place the puller and tear off the upper inner ring and outer race of the ball bearing.
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Male rotor QJ bearing - Part 2 1.
Place a washer to protect the rotor shaft.
2.
Place the tool (2903 0100 05) in combination with tool (2903 0100 03) around the lower inner race of the male ball bearing.
3.
Place the puller and tear off the lower inner ring of the ball bearing.
Female rotor QJ bearing - Part 1 1.
Take bearing puller set (2903 0100 06) in combination with tool (2903 0100 03).
2.
Place a washer to protect the rotor shaft.
3.
Place the shelves around the outer race of the female ball bearing.
4.
Place the ring over the shelves.
5.
Place the puller and tear off the upper inner ring and the outer ring of the ball bearing.
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Female rotor QJ bearing - Part 2 1.
Place a washer to protect the rotor shaft.
2.
Place the bearing puller set (2903 0100 04) in combination with tool (2903 0100 03) around the lower inner race of the female ball bearing.
3.
Place the puller and tear off the lower inner ring of the ball bearing.
Outlet housing & outer races NU bearings 1.
Provide the outlet housing with 2 lifting eyes (min. 125 kg).
2.
Remove the bolts that keep the inlet and outlet housing together.
3.
Vertically lift and remove the outlet housing.
4.
Break cage of both bearings and put pulling tool inside outlet bearing ring.
5.
Remove both outer races (male and female) from the element outlet housing.
6.
Use slide hammer puller.
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Inner races NU bearings 1.
Take bearing puller set inner race male NU bearing (9423 0032 83) and inner race female NU bearing (9423 0033 04).
2.
Place a washer to protect the rotor shaft.
3.
Mount the basic tool set (2903 0100 02).
4.
Remove the male and female NU bearing inner race.
Inner races NJ bearings To lift the rotors: 1.
Prepare a wooden pallet to place both rotors.
2.
Fit 2 lifting eyes.
3.
First lift the male rotor, take care to lift in line with the rotor axis.
4.
Do the same for the female rotor.
5.
Place a washer to protect the rotor shaft.
6.
Mount the basic tool set and remove male and female NJ bearing inner race.
Inlet housing & outer races NJ bearings 1.
Take out the outer races of the male and female NJ bearing.
2.
Use a slide hammer puller (2990 0310 00) if necessary.
3.
Remove the o-ring and both dowel pins.
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6.2.
Cleaning and inspection of components
Male and female rotor These rotors were put together as a set. Always keep the rotor set together, never mix with other sets!!
To optimise element efficiency: 1.
Clean the rotors.
2.
Inspect both rotors for scratches and other damage.
IF necessary: smooth down with fine sandpaper and/or an oil stone to the original surface. Do not take away too much material!!! If the condition of the rotors is doubtful REPLACE ELEMENT
Element inlet & outlet housing 1.
Clean inlet and outlet housing.
2.
Inspect housing for scratches and other damage. IF necessary: smooth down with fine sandpaper and/or an oil stone to the original surface. Do not take away too much material!!! If the condition of the in- or outlet housing is doubtful REPLACE ELEMENT
6.3.
Reassembly
Important remarks Male and female rotor are delivered as a set Always keep the set together! All bearings are delivered and bound together as a set Always keep the set together! Never directly hit on the new bearing races You can use the rings of the old bearings after cleaning them.
Inlet bearing male & female Outer race inlet bearing 1.
Take one of the NJ bearings (0508 1310 00).
2.
Remove the packing.
3.
Check the bearing for damages.
NJ bearings are delivered and bound together as a set Always keep the set together!
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4.
Fit the outer race on the female seat of the housing. Markings on top!
Bearing markings
Use tooling (9423 0031 36).
5.
Repeat for the outer race male inlet bearing
Inner race inlet bearing 1.
Take the male rotor.
2.
Inspect the rotor shaft for scratches or other damage.
3.
Degrease the rotor shaft.
4.
Degrease the bearing inner race.
5.
Heat the bearing inner race up to 120°.
6.
In the mean time, take a brush and put some Loctite 641 on the inner race seat of the rotor shaft.
7.
Put on heat resisting gloves and take the inner race.
8.
Position the hot inner race on the inlet side of the rotor shaft.
Note:
Mount the inner race in the right direction Raised border towards rotor body.
Note:
Make rotating moves with the inner race to spread the Loctite.
9.
Repeat for the inner race of the female inlet bearing.
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Mounting male & female rotor Male rotor 1.
Grease the inlet bearings.
2.
Oil the housing.
3.
Let the inner race cool down.
4.
Lift the male rotor at its outlet side.
5.
Oil the rotor.
6.
Carefully lower the rotor in the element housing while pressing the rotor softly in the direction of the arrow (see picture).
7.
When lowering the rotor, make sure the inner race of the bearing fits into the outer race.
Female rotor 1.
Let the inner race cool down.
2.
Lift the female rotor at its outlet side.
3.
Oil the rotor.
4.
Carefully lower the rotor in the element housing while pressing the rotor softly towards the male rotor.
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5.
When lowering the rotor, make sure the inner race of the bearing fits into the outer race.
Element outlet housing 1.
Grease the seal surface and place a new o-ring.
2.
Mount both dowel pins, use a plastic hammer.
3.
Lift the outlet bearing housing
4.
Shove the housing equally over the dowel pins.
Note: Make sure the O-ring stays in place.
5.
Tighten the 11 bolts. Start with a bolt next to a dowel pin and a torque of 5 Nm. Final torque for all the bolts is 46 Nm.
Measuring clearances outlet bearing female rotor NU Cylindrical roller bearings
NU Cylindrical roller bearings
Radial load
No axial load
Movable in axial direction
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QJ Four-point contact ball bearing
QJ Four-point contact ball bearing
Combined radial and axial load
Fixed in axial direction (clearance: 0.02 mm). Total rotor clearance depends on position of fixed ball bearing.
Total rotor clearance
Total rotor clearance = 0.04 – 0.08 mm The rotor clearance can be corrected with shims:
Increase shim thickness Increase rotor clearance.
Measuring female rotor clearance:
As the ball bearing on top of cylindrical bearing and the measurement is done WITHOUT cylindrical bearing:
Zero the gauge on zero plate (9421 0040 66).
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1.
Place the gauge (9421 0040 69) over the female rotor shaft.
2.
Lift the rotor.
3.
Read out the gauge with the rotor in lifted position.
4.
Write down this value and calculate the shim thickness as described below.
Calculating shim thickness Read out = 0 Difference between inner and outer ring = 0 Calculated shim thickness = Total rotor clearance – bearing clearance = 0.08 mm – 0.04 mm = 0.04
Read out > 0
Inner ring below outer ring Add shims Calculated shim thickness = Total rotor clearance – ball bearing clearance + measured value = 0.08 mm – 0.04 mm + measured value = 0.04 + measured value
read out < 0
Outer ring below inner ring Remove shims Calculated shim thickness = Total rotor clearance – ball bearing clearance – measured value = 0.08 mm – 0.04 mm – measured value = 0.04 – measured value
Create shim set 1.
Create a set of shims as close as possible to the calculated shim thickness with the following available shim sizes:
0.050 mm
0.030 mm
0.020 mm
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Measuring clearances outlet bearing male rotor Differences with female rotor
Difference with female rotor: Ball bearing on top of element housing Measure between the inner ring and the housing with tool (9421 0040 65) and use zero plate (9421 0040 70).
Mounting outlet bearing male rotor NU/QJ bearings are packed and bound together as a set (the 5 parts have 1 common set-number).
Always keep the set together! Mount the bearing in the same way as it is packed!!
1.
Take the NU/QJ outlet bearing for the male rotor and remove the packing.
2.
Check the bearing for damages.
3.
Take the inner race of the cylindrical bearing and heat it up to 110°.
4.
In the mean time, take a brush and put some Loctite 641 on the inner race seat of the rotor shaft.
5.
Put on heat resisting gloves and take the inner race. Position the hot inner race on the male rotor shaft.
Note:
Mount the inner race in the right direction Markings upwards. Make rotating moves with the inner race to spread the Loctite.
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6.
Let the inner race cool down.
7.
Take the outlet race of the cylindrical bearing and degrease the outer race.
8.
Put some Loctite 641 on the outside.
9.
Press the outer race of the cylinder bearing in the housing. If necessary, put the old clean bearing ring on top and use a plastic hammer.
Note:
Mount the outer race in the right direction Marked V points upwards
10. Assemble the correct shim set, as calculated before! 11. Check the thickness of the shim set and fit the shims over the rotor.
Note:
Do not switch the lower inner ring with the upper inner ring upper ring has complete markings on top. Mount the bearing set exactly in the same way as it was packed!
12. Warm up the lower inner ring of the roller bearing (110 °C). 13. Position the lower inner ring over the male rotor shaft.
14. Let the inner ring cool down. 15. Mount the roller bearing.
Note:
Mount the outer race in the right direction Marked V points upwards. Mount the bearing set exactly in the same way as it was packed!
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16. Warm up the upper ring (110 °C) and mount onto the male rotor shaft.
Overview male bearing
Mounting outlet bearing female rotor Repeat step 41 up to 56 for the female bearing.
Overview female bearing
Torque values for mounting
Mount washer on female rotor and torque bolt to 80 Nm.
Mount mounting bushing on male rotor and torque bolt to 80 Nm.
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Check female and male clearances 1.
Fix a lifting eye.
2.
Fix a gauge to the rotor.
3.
Zero the gauge on the rotor housing.
4.
Lift the rotor.
5.
Read out the rotor clearance.
Note:
6.
Total rotor clearance has to be between 0.04 – 0.08 mm for each rotor!
Remove the male washer with the lifting eyes.
Mounting wave springs and bearing retainers 1.
Position a set of new wave springs onto each bearing set.
2.
Fit the bearing retainer, position and torque the bolts. Use a torque of 78 Nm.
7. Packing 1.
Oil the element
2.
Cover the shafts with greased paper.
3.
Cover the element outlet with tape.
4.
Remove the element from the overhaul stand.
5.
Cover the element inlet with tape.
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