Airends

AC20160-1327, Issue 2, June, 1994
OIL-INJECTED AIR-ENDS
REPAIR MANUAL
FOREWORD
! WARNING
1. Worldwide service and parts facilities are !
provided by CompAir BroomWade Distributors.
The service and parts departments at High ● The use of replacement parts or
Wycombe are available should any difficulty be lubricating oils not supplied or approved
experienced. by CompAir BroomWade may lead to
failures in service which would not be
2. It is essential to quote the MODEL and SERIAL covered by warranty.
numbers in all communications.
● Any unauthorised modifications or failure
3. The substitution of parts not manufactured or to maintain this equipment in accordance
approved by CompAir BroomWade can reduce with the maintenance instructions may
performance or service life and create potential make it unsafe. The use of replacement
mechanical or personnel hazards. parts not supplied or approved by
CompAir BroomWade may create
4. The right is reserved to modify the contents of hazardous conditions over which CompAir
this publication without notice and the data BroomWade has no control.
given is in no way binding on the
manufacturers. ● Such hazardous conditions may lead to
accidents that can be life threatening,
5. Where approximate figures are shown, specific cause substantial bodily injury or result in
details are available on request. damage to the equipment. CompAir
BroomWade can bear no responsibility for
equipment in which unapproved
WARRANTY replacement parts are included.
The conditions of the CompAir BroomWade Warranty

are set out in the company’s standard Conditions of
Sale available from the Distributor supplying the
machine.
i
AC20160-1327, Issue 2, June, 1994
CONTENTS
Chapter Title
1 Safety
2 SRM Air-ends
Dismantling and Assembly Procedures
3 SRM Air-ends
Tooling Diagrams
4 Cyclon Air-ends
Dismantling and Assembly Procedures
5 Cyclon Air-ends
Tooling Diagrams
ii
Safety
CHAPTER 1
SAFETY PRECAUTIONS
Contents
SAFETY
1. GENERAL
2. WARNINGS, CAUTIONS AND NOTES
2.1 Warnings
2.2 Cautions
2.3 Notes
3. GENERAL SAFETY PRECAUTIONS
4. MAINTENANCE PRECAUTIONS
Chapter 1, Page 1
CompAir BroomWade – Air-end Repair Manual
SAFETY
1. GENERAL 2. WARNINGS, CAUTIONS AND NOTES
Most accidents which occur during the operation

and maintenance of machinery are the result of 2.1 WARNINGS
failure to observe basic safety rules or precautions.
An accident can often be avoided by recognising a Warnings call attention to operations or procedures
situation that is potentially hazardous. involving specific hazards which could cause injury
or death and are identified by the following symbols
When handling, operating or carrying out on the unit and in the text of the manual.
maintenance on the unit, personnel must use safe
engineering practices and observe all relevant local
health and safety requirements and regulations.
The attention of users in the UK is drawn to the
Health and Safety at Work Act, 1974, and to the
! WARNING: RISK OF DANGER
Regulations of the Institution of Electrical

Engineers.
CompAir BroomWade cannot anticipate every

possible circumstance which might represent a WARNING: RISK OF ELECTRIC
potential hazard. The WARNINGS in this manual SHOCK
are therefore not all-inclusive. If the user employs
an operating procedure, an item of equipment or a
method of working which is not specifically
recommended by CompAir BroomWade he must
ensure that the unit will not be damaged or made ! WARNING: RISK OF HIGH
unsafe and that there is no risk to persons or PRESSURE
property.
WARNING: CONSULT MANUAL
2.2 Cautions
Incorrect operational procedures causing possible

damage to the compressor unit are identified by a
‘CAUTION’ in the text of this manual.
2.3 Notes
Methods to make the job easier and points which

require particular attention are identified by a
‘Note’ in the text of the manual
Chapter 1, Page 2
Safety
3. GENERAL SAFETY PRECAUTIONS Always use tools that are in good condition and be
sure you understand how to use them properly
When using cleaning solvents, local Health and before starting any service work. Use the correct
Safety regulations must be complied with. Provide tool for each job. Knowledge of the proper use of
good ventilation and use suitable protection such tools and their limitations, coupled with common
as a breathing filter mask, safety glasses, sense, can prevent many accidents.
protective apron and gloves.
Special service tools are available for some
Safety footwear should be compulsory in all specific jobs and should always be used when
workshops. Safety helmets must be worn if there recommended. This will save time and prevent
is any risk of falling objects. damage to components.
If using compressed air for cleaning purposes,

ensure safety regulations are complied with and 4. MAINTENANCE PRECAUTIONS
appropriate clothing and eye protection is worn.
When disposing of condensate, old oil, used filter
Never direct compressed air onto your skin or at elements and other parts and waste material of any
other people. kind make sure that there is no pollution of any
drain or natural water-course and that no burning
Never use compressed air to clean loose dirt from of waste take place which could cause pollution of
clothing. the air. Protect the environment by using only
approved methods of disposal.
Before releasing compressed air through a hose
make sure that the free end is held securely so that Use only CompAir BroomWade Genuine Parts.
it cannot whip and cause injury.
Bearing components must be matched with their
Avoid injury by using a hoist to lift heavy loads. boxed counterparts and not interchanged with
Check that all chains, hooks, shackles and slings other bearing assemblies.
are in good condition and are of the correct
capacity. They must be tested and approved Keep a written record of all maintenance and repair
according to local safety regulations. work carried out on the air end. The frequency and
nature of the work required over a period can
Cables, chains or ropes must never be applied reveal adverse operating conditions which should
directly to lifting eyes. Always use an appropriate be corrected.
shackle or hook, properly positioned. Arrange
lifting cables so that there are no sharp bends. Use only lubricating oils and greases approved by
CompAir BroomWade. Make sure that the selected
Use a spreader bar to avoid side loads on hooks, lubricants comply with all relevant safety
eyes and shackles. regulations, especially with regard to the risk of
explosion or fire and the possibility of
When a load is on a hoist stay clear of the danger decomposition or the generation of hazardous
area beneath and around it. Keep lifting gases.
acceleration and speed within safe limits and never
leave a load hanging on a hoist for longer than is Always clean up oil spills before and after
necessary. maintenance work.
A hoist should always be used to lift in a Make sure that all instructions concerning
perpendicular direction. If lifting at an angle cannot operation and maintenance are strictly followed
be avoided take precautions to prevent the load and that the complete unit, with all accessories and
swinging. This can achieved by using two hoists, safety devices, is kept in good running order.
each lifting at not more than 30˚ from the vertical.
Maintenance, overhaul and repair work must only
Note: This will reduce the safe working load be carried out by competent personnel under a
capacity of the hoists. qualified supervisor.
Chapter 1, Page 3
Never use a light source with an open flame to

inspect any part of the unit.
Only use lint free cloth when cleaning components

and ensure that hands, tools and work surfaces are
clean and free from sand, grit or other abrasive
particles.
After completion of repair or maintenance work

ensure that no tools, loose items or cloth are left on
or inside any part of the air end.
Do not use any flammable liquid to clean air pipes

or any components carrying a flow of air during
normal operation. If chlorinated hydrocarbon non-
flammable fluids are used for cleaning, safety
precautions must be taken against any toxic
vapours which may be released.
Do not use carbon tetrachloride
Precautions must be taken when using acids,

alkalis and chemical detergents for cleaning
machine parts and components. These materials
cause irritation and are corrosive to the skin, eyes,
nose and throat. Avoid splashes and wear suitable
protective clothing and goggles. Do not breath
mists. Ensure that water and soap are readily
available.
Chapter 1, Page 4
Dismantling & Assembly – SRM Air-end 63·75 x 1·5
CHAPTER 2
SRM AIR ENDS
DISMANTLING AND ASSEMBLY PROCEDURES
Contents
SRM AIR-ENDS – COMPRESSOR MODEL REFERENCE GUIDE
1. AIR-END 63·75 x 1·5 (C20453-70)
1.1 Dismantling Procedure
1.2 Assembly Procedure
2. AIR- END 86·7 x 1·54 (C20451-70)
2.1 Dismantling Procedure (Air-Ends to Serial No. L009/8480)
2.2 Assembly Procedure (Air-Ends to Serial No. L009/ 8480)
2.3 Dismantling Procedure (Air-Ends From Serial No. L009/8481)
2.4 Assembly Procedure (Air-Ends From Serial No. L009/8481)
3. AIR-END 102 X 1·65
3.1 Dismantling Procedure (C20434-40 & 87)
3.2 Assembly Procedure (C20434-40 & 87)
3.3 Dismantling Procedure (C20434-117)
3.4 Assembly Procedure (C20434-117)
4. AIR-END 102 X 1·8 (C20452-69)
5. AIR-END 127·5 X 1·65 (C20450-40)
6. AIR-END 178·5 X 1·65
6.1 Dismantling Procedure (C20438-90A)
6.2 Assembly Procedure (C20438-90A)
6.3 Dismantling Procedure (C20438-40)
6.4 Assembly Procedure (C20438-40)
7. GEARBOX C20438-1 (AIR-END 178.5 X 1.65 – C20438-40)
8. AIR END 204 X 1·65 (C20437-201)
9. GEARBOX C20437-4 (AIR-END 204 X 1·65 – C20437-201)
9.1 Dismantling Procedure Continued
Chapter 2, Page 1
FIGURES
FIG. 2.1 AIR-END 63·75 x 1·5 (C20453-70)
FIG. 2.2 AIR-END 86·7 x 1·54 (C20451-70 to Serial No. L009/8480)
FIG. 2.3 AIR-END 86·7 x 1·54 (C20451-70 From Serial No. L009/8481)
FIG. 2.4 AIR END 102 x 1·65 (C20434-40 & 87)
FIG. 2.5 AIR END 102 x 1·65 (C20434-117)
FIG. 2.6 AIR END Type 102 x 1·8 (C20452-69)
FIG. 2.7 AIR-END 127·5 x 1·65 (C20450-40)
FIG. 2.8 AIR-END 178·5 x 1·65 (C20438-90A)
FIG. 2.9 AIR-END 178·5 x 1·65 (C20438-40)
FIG. 2.10 GEARBOX C20438-1 (Air-end 178.5 x 1.65 – C20438-40)
FIG. 2.11 AIR END 204 x 1·65 (C20437-201)
FIG. 2.12 GEARBOX C20437-4 (Air-end 204 x 1·65 – C20437-201)
Chapter 2, Page 2
SRM AIR-ENDS – COMPRESSOR MODEL REFERENCE GUIDE
Compressor Air End Part No.
6007EA from F125/0101 63·75 x 1·5 C20453-70

6010EA from F126/0151
6010E from F070/0001

6015E from F071/0001
6015EA from F127/0201
6020E from F073/0001 86·7 x 1·54 C20451-70
6020EA from F128/0251
6025E from F075/0001
6025EA from F129/0301
6030EA from F130/0101
RA30 from F004/7001

RA40 from F002/7501
RX30 from F005/5501 102 x 1·65 C20434-40
RX40 from F003/5001
6030 from F076/0001
6040 from F078/0001
6050 from F079/0001 102 x 1·65 C20434-87
6020 from F072/0001

6025 from F074/0001
RBS15 from F094/0101 102 x 1·65 C20434-117
RBS20 from F095/0101
6040EA from F131/0151 102 x 1·8 C20452-69

6050EA from F132/0201
6060 from F080/0001 127·5 x 1·65 C20450-40

6075 from F081/0001
6100 from F082/0001 178·5 x 1·65 C20438-90A

6115 from F083/0001
6125 from F084/0001★ 178·5 x 1·65 C20438-40

6150 from F085/0001★
6180A from F086/0101▲

6180W from F090/0101▲ 204 x 1·65 C20437-201
6220A from F087/0101▲
6220W from F091/0101▲
★ ▲
Gearbox part no. C20438-1 Gearbox part no. C20437-4
Chapter 2, Page 3
1. AIR-END 63·75 x 1·5 (C20453-70)
! WARNING !
● Refer to the safety precautions in Chapter 1 before carrying out any of the following procedures
1.1 DISMANTLING PROCEDURE 5. Remove screws (15) and washers (16)

securing each of the end covers (14) to the
Note 1: It is assumed that all drive components, delivery bearing housing (17). Remove the
including shaft key, have been previously removed. covers and ‘O’ rings (12) and discard the
Removal and subsequent refitting of these ‘O’ rings. Using locknut spanner 288004,
components is described in the compressor Repair remove both male and female delivery bearing
Manual. retaining locknuts (13).
Note 2: Tooling diagrams are contained in 6. Position the delivery bearing housing/rotors
Chapter 3. assembly to a press. Using a suitable
mandrel, press out the male (7) and
1. Remove screws (20) and washers (21) female (18) rotors from the bearings (11),
securing the oilseal housing (3) to ensuring that each rotor is supported as it is
rotor casing (6). Using a soft drift, separate the released from the bearing. Remove shims (10)
seal housing. Remove and discard joint (4). from the delivery end of the rotor shafts.
Using a press and suitable mandrel, remove
and discard the single piece oil seal (2). 7. Using suitable pulling equipment or splitting as
necessary, remove the bearing inner rings
2. Using a strap wrench or equivalent tool, from the inlet end of both rotor shafts, and
remove the seal sleeve (1) from the drive shaft discard the rings.
and discard the sleeve.
8. Using a press and suitable mandrel, press out
3. Position the rotor locking fixture 288003 to a both matched pairs of bearings (11) from the
vice. Remove screws (23), (24) and delivery bearing housing (17), together with
washers (22) securing the delivery bearing the bearing spacer. The outer rings of the
housing (17) to rotor casing (6). Using a soft innermost pair of bearings will remain in the
drift, separate the bearing housing. Carefully housing. Using a suitable extractor, withdraw
withdraw the bearing housing/rotors assembly both outer rings. Discard the bearings.
from the rotor casing and position to the
locking fixture, ensuring the fixture key
engages with the male rotor shaft (7) keyway.
The two dowels (8) remain in the rotor casing. 1.2 Assembly Procedure
Remove and discard joint (9).
CAUTION: Clean all components thoroughly before
4. Using a press and suitable mandrels, press assembly.
out the male (5) and female (19) inlet end
bearings from the rotor casing and discard the
bearings.
Chapter 2, Page 4
1. Inspect all components retained for re-use for 6. To determine the depth of the female delivery
evidence of wear or damage, renewing as bearing inner race from the face of the
applicable. Responsibility for verifying that delivery bearing housing, first ensure the face
components are suitable for re-use rests with is clean. Position shim gauge (A) 288001 into
the repairer. Sound engineering practices the female bore to locate on the bearing inner
should be observed and advice sought if doubt race. Holding the gauge firmly in position,
exists. accurately measure with feeler gauges the
gap between gauge and housing face.
Remove burrs where necessary and ensure SUBTRACT the gap distance from the
joint faces are clean. Do not remove bearings measurement stamped on the gauge and note
from packaging until required or interchange the new figure. Remove gauge from housing.
bearings or spacers of a matched assembly
with parts of another assembly. 7. With rotors secured in locking fixture, position
shim gauge (B) 288002 to female rotor shaft
Thoroughly de-grease and clean all delivery end. Holding the gauge firmly in
components, ensuring that all oil galleries are position, accurately measure with feeler
clear, refitting plugs with Loctite 542. gauges the gap between gauge and rotor
face. ADD the gap distance to the
2. Separate the inner ring from the new male inlet measurement stamped on the gauge and note
bearing (5) and de-grease. Heat the inner ring the new figure. Remove gauge from shaft.
by induction or in an oven to 100 – 120° C and
then drop over the male rotor shaft (7), 8. SUBTRACT rotor shaft dimension from
ensuring that the ring is hard against the bearing housing dimension to obtain
shoulder. Allow to cool in air DO NOT USE difference. To this figure ADD the required
WATER. Repeat for the female inlet end clearance
bearing (19) and rotor (18). i.e. 0·05 – 0·10 mm (0·002" – 0·004"). This
new figure is the shim pack thickness to
3. De-grease outer race of new male inlet achieve the correct end clearance. Carefully
bearing (5). Apply Loctite 641 to the inlet measure shims (10) to obtain correct total
bearing bores of the rotor casing (6). Position thickness, and position to rotor shaft using a
bearing to press tool 288005 and press small amount of grease to retain.
bearing fully into housing. Repeat for female
inlet bearing (19) using press tool 288006. 9. Repeat procedures 6 to 8 for male bore and
shaft.
4. Position a matched pair of bearings and
spacer (11) to the delivery bearing press tool 10. Remove both covers (14) from delivery
288007. Press bearings into the male bore of bearing housing (17). Position two delivery
the delivery bearing housing (17), ensuring that bearing supports 288008 to press and place
the bearing is hard against inner shoulder of delivery bearing housing onto bearing
housing. Repeat for the female bore. supports.
5. Fit both end covers (14) to delivery bearing Note: During procedure 11, it is important to use
housing (17) and secure with screws (15) and two sets of feeler gauges to eliminate discrepancy
washers (16) torque loaded to 7 Nm (5 lbf.ft). due to bearing clearance.
Ensure that the inner races of the delivery
bearings revolve freely after securing the end 11. Position female rotor (18) to bearing housing
covers. bore and press into bearings (11) until
shims are hard against inner race. Rotate
rotor to ensure free running. Carefully check
clearance between rotor and housing face
with two sets of feeler gauges positioned
diametrically opposite each other. Clearance
should be within 0·05 – 0·10 mm
(0·002" – 0·004") tolerance.
Chapter 2, Page 5
FIG. 2.1 AIR-END 63·75 X 1·5 (C20453-70)
Chapter 2, Page 6
If clearance is not within limits, remove rotor 18. Fit the oil seal housing (3) to the rotor casing (6) with
and carry out necessary adjustments by a new joint (4), using mounting sleeve C11402/359/
adding or subtracting shims. 11. Secure housing to rotor casing with screws (20)
and washers (21) torque loaded to 11·7 Nm (8·6
Note: 'First time' accuracy is important when lbf.ft).
carrying out the procedures in item 11.
Note: Shaft seal mounting sleeves are obtainable from
12. Repeat procedure 11 for male rotor (7). CompAir BroomWade Parts Department, High Wycombe.
13. Position bearing housing/rotors assembly to 19. Pre-lubricate the rotors and bearings using the
rotor locking fixture in vice. Fit new recommended compressor oil, and turn the rotors by
locknuts (13) to delivery end of both rotors hand to ensure distribution.
and, using tube spanner 288004, torque load
to 34 Nm If the air-end is to be stored for more than fourteen
(25 lbf.ft). days, or in hostile conditions, spray approximately
10 cc of Astrolan DA362 Motorstor (or equivalent)
14. Fit delivery end covers (14) with new into the inlet port while turning the rotors slowly by
‘O’ rings (12), and secure with screws (15) hand, ensuring that all internal parts are covered.
and washers (16) torque loaded to 7 Nm Blank off inlet and discharge ports until ready for
(5 lbf.ft). use. All external machined surfaces should be
similarly protected against corrosion.
15. Position delivery bearing housing/rotors
assembly to rotor casing delivery end with a Note: Inhibitor provides a protected shelf life of 12
new joint (9), ensuring that weight is months.
supported as rotors enter casing. Locate
rotors into inlet end bearings and secure
bearing housing with screws (23), (24) and
washers (22), torque loaded to 28 Nm (21
lbf.ft).
16. Coat bore of new shaft seal sleeve (1) with

Loctite 932 and position to male rotor shaft (7)
against bearing inner ring. Remove all excess
Loctite immediately.
CAUTION: When fitting the oil seal during item 17,

it is important that the inner circumference is not
damaged or distorted in any way. The seal as
supplied is coated with a sealant; after pressing into
housing remove all traces of residual sealant from
internal surfaces of seal housing.
17. Using a suitable mandrel, press a new single

piece oil seal (2) into the seal housing (3).
Chapter 2, Page 7
2. AIR-END 86·7 X 1·54 (C20451-70)
! WARNING !
● Refer to the safety precautions in Chapter 1 before carrying out any of the following procedures.
2.1 Dismantling Procedure assembly from the rotor casing and position to
(Air-Ends to Serial No. L009/8480) the locking fixture, ensuring the fixture key
engages with the male rotor shaft keyway.
Note 1: It is assumed that all drive components, The two dowels (10) remain in the rotor
including shaft key, have been previously removed. casing. Open the tabs on both delivery end
Removal and subsequent refitting of these locking plates (20). Remove screws (19) and
components is described in the compressor Repair locking components (18).
Manual.
7. Position the delivery bearing housing/rotors
Note 2: Tooling diagrams are contained in assembly to the press. Using a suitable
Chapter 3. mandrel, press out male (9) and female (26)
rotors from bearings (13). Ensure that each
1. Remove bolts (33) and washers (34) securing rotor is supported as it is released from the
the oil seal housing (30) to inlet bearing bearing. Remove the shims (23) from the
housing (5). Using a soft drift, separate the delivery end of rotor shafts.
seal housing. The two dowels (28) remain in
the bearing housing. Remove the sleeve (35) 8. Using suitable pulling equipment or splitting as
and ‘O’ ring (2) from the drive shaft and necessary, remove the bearing inner rings
discard. Using a press and suitable mandrel, from the inlet end of both rotor shafts, and
remove the single piece oil seal (1) and discard rings.
discard. Remove the joint (3) and discard.
2. Remove circlip (29) securing the inner ring of both matched pairs of bearings (13) from the
the female inlet bearing (27) to the rotor shaft. delivery bearing housing, together with the
bearing spacer. The outer rings of the
3. Remove bolts (31) and washers (32) securing innermost pair of bearings will remain in the
the inlet bearing housing (5) to rotor housing. Using a suitable extractor, withdraw
casing (8). Using a soft drift, separate the inlet both outer rings. Discard bearings and rings.
bearing housing. The two dowels (7) remain in
the rotor casing. Remove joint (6) and discard.
4. Using a press and suitable mandrels, press 2.2 Assembly Procedure

out the male (4) and female (27) bearings (Air-Ends to Serial No. L009/ 8480)
from the inlet bearing housing (5) and discard.
5. Remove screws (16) and washers (17) assembly.
delivery bearing housing (12). Remove the 1. Inspect all components retained for re-use for
covers and ‘O’ rings (14). Discard ‘O’ rings. evidence of wear or damage, renewing as
applicable. Responsibility for verifying that
6. Position the rotor locking fixture 288018 to the components are suitable for re-use rests with
vice. Remove screws (21), (24) and the repairer. Sound engineering practices
washers (22) and (25) securing the delivery should be observed and advice sought if
bearing housing (12) to rotor casing (8). Using doubt exists.
a soft drift, separate the bearing housing.
Carefully withdraw the bearing housing/rotors
Chapter 2, Page 5
Remove burrs where necessary and ensure female bore to locate on the bearing inner
joint faces are clean. Do not remove bearings race. Holding the gauge firmly in position,
from packaging until required or interchange accurately measure with feeler gauges the
bearings or spacers of a matched assembly gap between gauge and housing face.
with parts from another assembly. SUBTRACT the gap distance from the
measurement stamped on the gauge and note
Thoroughly de-grease and clean all the new figure. Remove gauge from housing.
components, ensuring that all oil galleries are
clear, refitting plugs with Loctite 542. Lightly 8. With rotors secured in locking fixture, position
grease 'O' rings before fitting. shim gauge (B) 288017 to female rotor shaft
delivery end. Holding the gauge firmly in
2. Separate the inner ring from the new male inlet position, accurately measure with feeler
bearing (4) and de-grease. Apply Loctite gauges the gap between gauge and rotor
14486 to inlet bearing diameter of the male face. ADD the gap distance to the
rotor shaft (9). Heat the inner ring by induction measurement stamped on the gauge and note
or in an oven to 100 – 120° C and then drop the new figure. Remove gauge from shaft.
over the male rotor shaft, ensuring that the ring
is hard against the shoulder. Allow to cool in air 9. SUBTRACT rotor shaft dimension from
– DO NOT USE WATER. bearing housing dimension to obtain
difference. To this figure ADD the required
3. Separate the inner ring from the new female end clearance i.e. 0·05 – 0·10 (0·002" –
inlet bearing (27) and de-grease. Heat the 0·004"). This new figure is the shim pack
inner ring by induction or in an oven to thickness to achieve the correct end
100 – 120° C and then drop over the female clearance. Carefully measure shims (23) to
rotor shaft (26), ensuring that the ring is hard obtain correct total thickness, and position to
against the shoulder. Allow to cool in air – DO rotor shaft using a small amount of grease to
NOT USE WATER. retain.
4. De-grease outer race of new male inlet 10. Repeat procedures 7 to 9 for male bore and
bearing (4). Apply Loctite 641 to the bearing shaft.
bore of inlet bearing housing (5). Position
bearing to press tool 288019, and press 11. Remove both covers (15) from delivery
bearing fully into housing. Repeat for female bearing housing (12). Position two delivery
inlet bearing (27) using press tool 288020. bearing supports 288022 to press and place
delivery bearing housing onto bearing
5. Position a matched pair of bearings and supports.
spacer (13) to the delivery bearing press tool
288021. Press bearings into the male bore of Note: During procedure 12, it is important to use
the delivery bearing housing (12), ensuring that two sets of feeler gauges to eliminate discrepancy
bearing is hard against inner shoulder of due to bearing clearance.
housing. Repeat for the female bore.
12. Position female rotor (26) to bearing housing
6. Fit both end covers (15) to delivery bearing bore and press into bearings (13) until
housing (12) and secure with screws (16) and shims (23) are hard against inner race. Rotate
washers (17) torque loaded the to 7 Nm (5 rotor to ensure free running. Carefully check
lbf.ft). Ensure that the inner races of delivery clearance between rotor and housing face
bearings revolve freely after securing the end with two sets of feeler gauges positioned
covers. diametrically opposite each other. Clearance
should be within 0·05 – 0·10 mm
7. To determine the depth of the female delivery (0·002" – 0·004") tolerance.
bearing inner race from the face of the delivery
bearing housing, first ensure the face is clean. If clearance is not within limits, remove rotor
Position shim gauge (A) 288016 into the and carry out necessary rectification by adding
or subtracting shims.
Chapter 2, Page 6
FIG. 2.2 86·7 X 1·54 (C20451-70 TO SERIAL NO. L009/8480)
Chapter 2, Page 7
Note: 'First time' accuracy is important when Note: Shaft seal mounting sleeves are available
carrying out the procedures in item 12. from CompAir BroomWade Parts
Department, High Wycombe.
13. Repeat procedure 12 for male rotor (9).
22. Pre-lubricate the rotors and bearings using
14. Position bearing housing/rotors assembly to the recommended compressor oil, and turn
rotor locking fixture in vice. Fit the retaining the rotors by hand to ensure distribution.
plates (18), new locking plates (20), and
screws (19) to rotors at the delivery end. If the air-end is to be stored for more than
Torque load screws to 23 Nm (17 lbf.ft). Lock fourteen days, or in hostile conditions, spray
tabs against flats. approximately 10 cc of Astrolan DA362
Motorstor (or equivalent) into the inlet port
15. Fit delivery end covers (15) with new while turning the rotors slowly by hand,
‘O’ rings (14), and secure with screws (16) ensuring that all internal parts are covered.
and washers (17) torque loaded to 7 Nm (5 lbf Blank off inlet and discharge ports until ready
ft). for use. All external machined surfaces
should be similarly protected against
16. Position delivery bearing housing/rotors corrosion.
assembly to rotor casing delivery end with a
new joint (11), ensuring that weight is Note: Inhibitor provides a protected shelf life of 12
supported as rotors enter casing. Secure months.
bearing housing with bolts (21), (24) and
washers (22) and (25), torque loaded to 29
Nm (21 lbf.ft).
17. Using a new joint (6), fit the inlet bearing

housing (5) to rotor casing (8) and secure with
bolts (31) and washers (32) torque loaded to
29 Nm (21 lbf.ft).
18. Fit the circlip (29) to secure the inner ring of

the female inlet bearing (27). Fit a new
‘O’ ring (2) to the male rotor shaft (9). Place a
new joint (3) over dowels (28) in the inlet
bearing housing.

CAUTION: When fitting the single piece seal, it is

important that the inner circumference is not
supplied is coated with a sealant; after pressing
into housing remove all traces of residual sealant
from internal surfaces of seal housing.
20. Pass a new sleeve (35), internal taper end

first, over the male rotor shaft (9) and through
seal (1) until it is located against the bearing
and ‘O’ ring.
21. Fit the oil seal housing (30) to the inlet

bearing housing (5) using mounting sleeve
C11402/359/9. Secure with screws (33) and
washers (34) torque loaded to 12 Nm (9 lbf.ft).
Chapter 2, Page 8
! WARNING !
6. Position the rotor locking fixture 288018 to the

vice. Remove screws (21), (24) and
2.3 Dismantling Procedure washers (22) and (25) securing the delivery
(Air-Ends From Serial No. L009/8481) bearing housing (12) to rotor casing (8). Using
a soft drift, separate the bearing housing.
Note 1: It is assumed that all drive components, Carefully withdraw the bearing housing/rotors
including shaft key, have been previously removed. assembly from the rotor casing and position to
Removal and subsequent refitting of these the locking fixture, ensuring the fixture key
components is described in the compressor Repair engages with the male rotor shaft keyway.
Manual. The two dowels (10) remain in the rotor
casing. Open the tabs on both delivery end
Note 2: Tooling diagrams are contained in locking plates (20). Remove screws (19) and
Chapter 3. locking components (18).
1. Remove bolts (31) and washers (32) securing 7. Position the delivery bearing housing/rotors
the oil seal housing (30) to inlet bearing assembly to the press. Using a suitable
housing (5). Using a soft drift, separate the mandrel, press out male (9) and female (26)
seal housing. The two dowels (28) remain in rotors from bearings (13). Ensure that each
the bearing housing. Using a strap wrench or rotor is supported as it is released from the
equivalent tool, remove the seal sleeve (33) bearing. Remove the shims (23) from the
from the drive shaft and discard. Using a delivery end of rotor shafts.
press and suitable mandrel, remove the single
piece oil seal (1) and discard. Remove and 8. Using suitable pulling equipment or splitting as
discard the joint (2). necessary, remove the bearing inner rings
from the inlet end of both rotor shafts, and
2. Remove circlip (29) securing the inner ring of discard rings.
the female inlet bearing (27) to the rotor shaft.
3. Remove bolts (34) and washers (35) securing both matched pairs of bearings (13) from the
the inlet bearing housing (5) to rotor delivery bearing housing, together with the
casing (8). Using a soft drift, separate the inlet bearing spacer. The outer rings of the
bearing housing. The two dowels (7) remain in innermost pair of bearings will remain in the
the rotor casing. Remove joint (6) and discard. housing. Using a suitable extractor, withdraw
both outer rings. Discard bearings.
4. Using a press and suitable mandrels, press
out the male (3) and female (27) bearings
from the inlet bearing housing (5), taking care
not to damage the bearing spacer (4 ) behind 2.4 Assembly Procedure
the male bearing. Remove spacer (4) and (Air-Ends From Serial No. L009/8481)
retain. Discard bearings.
5. Remove screws (16) and washers (17) assembly.
delivery bearing housing (12). Remove the 1. Inspect all components retained for re-use for
covers and ‘O’ rings (14). Discard ‘O’ rings. evidence of wear or damage, renewing as
applicable. Responsibility for verifying that
components are suitable for re-use rests with
Chapter 2, Page 9
the repairer. Sound engineering practices the new figure. Remove gauge from housing.
should be observed and advice sought if
doubt exists. 8. With rotors secured in locking fixture, position
2. Separate the inner ring from the new male delivery end. Holding the gauge firmly in
inlet bearing (4) and de-grease. Apply Loctite position, accurately measure with feeler
14486 to inlet bearing diameter of the male gauges the gap between gauge and rotor
rotor shaft (9). Heat the inner ring by induction face. ADD the gap distance to the
or in an oven to 100 – 120° C and then drop measurement stamped on the gauge and note
over the male rotor shaft, ensuring that the the new figure. Remove gauge from shaft.
ring is hard against the shoulder. Allow to cool
in air – DO NOT USE WATER. 9. SUBTRACT rotor shaft dimension from
bearing housing dimension to obtain
3. Separate the inner ring from the new female difference. To this figure ADD the required end
inlet bearing (27) and de-grease. Heat the clearance i.e. 0·05 – 0·10 (0·002" – 0·004").
inner ring by induction or in an oven to This new figure is the shim pack thickness to
100 – 120° C and then drop over the female achieve the correct end clearance. Carefully
rotor shaft (26), ensuring that the ring is hard measure shims (23) to obtain correct total
against the shoulder. Allow to cool in air – DO thickness, and position to rotor shaft using a
NOT USE WATER. small amount of grease to retain.
4. Position spacer (4) to male bore of inlet 10. Repeat procedures 7 to 9 for male bore and
bearing housing (5). De-grease outer race of shaft.
new male inlet bearing (3). Apply an even coat
of Loctite 641 to the bearing bore of inlet 11. Remove both covers (15) from delivery
bearing housing (5). Position bearing to press bearing housing (12). Position two delivery
tool 288023, and press bearing fully into bearing supports 288022 to press and place
housing. Repeat for female inlet bearing (27) delivery bearing housing onto bearing
using press tool 288020. supports.
5. Position a matched pair of bearings and Note: During procedure 12, it is important to use
spacer (13) to the delivery bearing press tool two sets of feeler gauges to eliminate discrepancy
288021. Press bearings into the male bore of due to bearing clearance.
the delivery bearing housing (12), ensuring
that bearing is hard against inner shoulder of 12. Position female rotor (26) to bearing housing
housing. Repeat for the female bore. bore and press into bearings (13) until
shims (23) are hard against inner race. Rotate
6. Fit both end covers (15) to delivery bearing rotor to ensure free running. Carefully check
housing (12) and secure with screws (16) and clearance between rotor and housing face
washers (17) torque loaded the to 7 Nm with two sets of feeler gauges positioned
(5 lbf.ft). Ensure that the inner races of diametrically opposite each other. Clearance
delivery bearings revolve freely after securing should be within 0·05 – 0·10 mm
the end covers. (0·002" – 0·004") tolerance.
7. To determine the depth of the female delivery If clearance is not within limits, remove rotor
bearing inner race from the face of the and carry out necessary rectification by adding
delivery bearing housing, first ensure the face or subtracting shims.
is clean. Position shim gauge (A) 288016 into
the female bore to locate on the bearing inner Note: 'First time' accuracy is important when
race. Holding the gauge firmly in position, carrying out the procedures in item 12.
accurately measure with feeler gauges the
gap between gauge and housing face.
SUBTRACT the gap distance from the
measurement stamped on the gauge and note
Chapter 2, Page 10
FIG. 2.3 86·7 X 1·54 (C20451-70 FROM SERIAL NO. L009/8481)
Chapter 2, Page 11
13. Repeat procedure 12 for male rotor (9). 21. Fit the oil seal housing (30) to the inlet
bearing housing (5) using mounting sleeve
14. Position bearing housing/rotors assembly to C11402/359/9. Secure with screws (31) and
rotor locking fixture in vice. Fit the retaining washers (32) torque loaded to 12 Nm (9 lbf.ft).
screws (19) to rotors at the delivery end. Note: Shaft seal mounting sleeves are available
Torque load screws to 23 Nm (17 lbf.ft). Lock from CompAir BroomWade Parts Department, High
tabs against flats. Wycombe.
15. Fit delivery end covers (15) with new 22. Pre-lubricate the rotors and bearings using
‘O’ rings (14), and secure with screws (16) the recommended compressor oil, and turn
and washers (17) torque loaded to 7 Nm the rotors by hand to ensure distribution.
(5 lbf.ft).
If the air-end is to be stored for more than
16. Position delivery bearing housing/rotors fourteen days, or in hostile conditions, spray
assembly to rotor casing delivery end with a approximately 10 cc of Astrolan DA362
new joint (11), ensuring that weight is Motorstor (or equivalent) into the inlet port
supported as rotors enter casing. Secure while turning the rotors slowly by hand,
bearing housing with bolts (21), (24) and ensuring that all internal parts are covered.
washers (22) and (25), torque loaded to Blank off inlet and discharge ports until ready
29 Nm (21 lbf.ft). for use. All external machined surfaces
should be similarly protected against
17. Using a new joint (6), fit the inlet bearing corrosion.
bolts (34) and washers (35) torque loaded to Note: Inhibitor provides a protected shelf life of 12
29 Nm (21 lbf.ft). months.
18. Fit the circlip (29) to secure the inner ring of

the female inlet bearing (27). Place a new
joint (2) over dowels (28) in the inlet bearing
housing.
19. Coat the bore of a new shaft seal sleeve (33)

with Loctite 932 and position the sleeve to
male rotor shaft (9) against bearing inner ring.
Remove all excess Loctite immediately.

CAUTION: When fitting the single piece seal, it is

supplied is coated with a sealant; after pressing into
housing remove all traces of residual sealant from
internal surfaces of seal housing.
Chapter 2, Page 12
Dismantling & Assembly – SRM Air-end 102 x 1·65
3. AIR-END 102 X 1·65
! WARNING !
● RefertothesafetyprecautionsinChapter1beforecarryingoua
t nyotfhefolowingprocedures.
3.1 Dismantling Procedure (C20434-40 & 87) 7. Poso tintherotoolrcknigxfituretothevcie.

Removebotsl(34),(36a )nd(38a ),nd
Note1:Itisassumedthatad l rivecomponents, washers(35),(37a )nd(39s)ecurn igthe
includingshafkteyh
, avebeenpreviouslyremoved. devilerybearn ighousn ig(21to)rotor
Removaalndsubsequenrteftingoth fese casnig(6U ).snigasodstf,tfrieparae th
te
componentssidescrb i edn
ithecompressorRepari bearn i ghousn i gC . arefuylwtihdrawthe
Manua.l bearn i ghousn i g/rotorsassembylfromthe
rotocrasn i gandposo tintotheo l ckn
i gxfiture,
Note2:Toolingdiagramsarecontainedin ensuringthefixturekeyengageswiththemale
Chape3
tr. rotorshaftkeyway.Thetwodowels(9)remain
n
itherotorcasn i gO. penthetabsonboth
.1 Removecricp il s(2a)nd(28f)rommae land devileryendo l ckn i gpa l tes(19)R. emove
femae
lboresothfenie
lbtearn
ighousn ig(24). screws(20a )ndo l ckn i gcomponents(18)
and(19R ).emoveboh tcrcp
ils(12).
.2 Removepn
io
i nspacer(1f)rommae
lrotor
7
.()shtaf 8. Posoitnh tedevilerybean
righousnigr/ootrs
assembyltothepressU . sni gasutiabe
l
.3 Openthetabonthefemaleinlee t ndlocking mandrep,lressoum t ae l (7a
)ndfemae l (8)
pale
t(30P ).osoitnh
teroo
tlrcknig
xifu
tre roo
trsrfombean rigs(11E).nsurehtaetach
288040tothemae lrotor(7e),nsurni gthe rotosirsupportedasitrieel asedfromthe
fixturekeyengageswiththerotorkeyway, bearn i gR. emoveshm i s(23)fromthedevilery
aol wn i gaccesstothefemae lbearn i go
l ckn
ig endorofotsrhastf.
componentsR . emovescrew(31)andlocking
components(29a )nd(30R ). emovethe 9. Usnigsua tibelpunilgequpimenotsrpnitlgas
olcknixg
ifu
tre. necessaryr,emovethebearinginnerings
fromthen ie
letndobfothrotosrhaftsa,nd
.4 Removebostl(25)(,32a)nd dsican
rd
igs.
washers(26),(33s)ecurn igthen
ielbtearn
ig
housnig(24o tr)oo
tcrasnig(6U
).snigasotf .01 Usn i gapressandsutiabe lmandrep ,l ressout
dsrft,ieparatethen ielbtearn
ighousn igT.he bothmatchedparisobfearn i gs(11fr)omthe
twodowesl (5r)eman in
itherotocrasni g. devilerybearnighousnig(21to),gethew rth
i
Removeo jni t(4a
)nddsicard. themae l (10a
)ndfemae l (17b )aal nce
psitonsE.nsurebaa lncepsitonsarenot
.5 Usn i gapressandsutiabe lmandreslp,ress damageddurn i gremovaolb fearn i gsD. si card
outhemae l (3a
)ndfemae l (27b)earn
i gs ben
aig
rs.
fromthen ie
lbtearni ghousn
i g(24a)nd
dsciad
r.
.6 Removescrews(14)andwashers(15) 3.2 Assembly Procedure (C20434-40 & 87)

securn i gtheendcover(16t)odevilerybearnig
housn ig(21R). emovethecovearndo
jn
it(13). CAUTION:Cleanalcomponent
l sthoroughlybefore
Dsicaon
jd
ri.t assembyl.
.1 Inspecatclomponentsretan
i edfore-usefor
evidenceofwearordamage,renewingas
apcp
a
ilb
el.
Chapter 2, Page 13
Responsb ityilfovrerfyin
i gthactomponents distancefromthemeasuremensttampedon
aresuta
ibe
lfore-userestswth ithereparier. thegaugeandnotethenewfigure.Remove
Soundengn i eern i gpractci esshoud lbe gaugefromhousn i g.
observedandadvci esoughd fitoube
txsi ts.
.7 Wth irotorssecurednio
l ckn
i gxfiturep,osotin
Removeburrswherenecessaryandensure shmi gauge(B2 )88031tofemae lrotosrhaft
o
jn i ftacesarece
l anD . onortemovebearn i gs deliveryendH . oldingthegaugefirmlyin
frompackagn i gunreltiquriedon
irterchange postoi na,ccurateylmeasurewtihfeee lr
bearingsorspacersoa fmatchedassembly gaugesthegapbetweengaugeandrotor
wtihpartsfromanothea rssembyl. faceA . DDthegapdistancetothe
measurementstampedonthegaugeandnote
Thoroughylde-greaseandce l anal thenewfigureR . emovegaugefromshaft.
componentse,nsurn igthaa
o
g
tliae
lre
isare
celaren
ri,tifgpulgswh
tiLoce
ti542. .8 SUBTRACTrotorshafd t imensionfrom
bearn i ghousn i gdm i enso i ntoobtan
i
.2 Separatetheinneringfromthenewmaleinlet dfierenceT . othsifg
i ureADDtherequried
bearn i g(3a )ndde-greaseH . eathen i nern
ig endce l arance
byinductionorinanovento100–120 ° Cand e
.0
i.0
·5–01
·0mm(00 ·02–0 "0
·04T ").hsi
thendropovetrhemae lrotosrhaft(7), newfg i uresitheshm i packthci knessrequried
ensurn i gthathterni gsihardagan i sthte toache i vethecorece tndce l aranceC . arefuyl
shoulder.Allowtocoolinair–DONOTUSE measureshm i s(23o t)obatnicoreco tta
tl
WATERR . epeaftorthefemaleinlet thciknessa,ndposo tintorotosrhauftsn iga
beanrig(27a)ndroot(r8). smalmounotgfreasetoretan i.
.3 De-greaseouteraceon f ewmaleinlet 9. Repeatprocedures6to8formaleboreand

bearn i g(3A ). ppylLoctei641tothebearn ig .th
sa
f
boreohtfenielbtean righousnig(24P).osoitn
bearn i gtopresstoo2l88041a,ndpress .01 Poso tinbearn
i ghousn
i gandbearn
i gsupports
bearn i gfuyln i tohousn i gR. epeafo tfremael p
ote
rss.
nielbtean
rig(27u)snigpresso to2l88042.
Note:Duringprocedure11ist,importantouse
.4 Poso tinthemae lbaa lncepsiton(10n i)tothe twosetsofeeel rgaugestoem
il n
i atedsi crepancy
mae lboreoth fedevilerybearn i ghousn i g(21), duetobearn
i gce
l arance.
ensun rigcorecote
rina toitnP.osoitna
matchedpao ribfearn i gs(11t)othedevilery .11 Position female rotor (8) to bearing housing
bearn igpresstoo2l88043P .ressbearn igsn
ito bore and press into bearings (11) until
themaleboreotfhedeliverybearing shims (23) are hard against balance
housn ig(21e),nsurn igthabtearnigsihard piston (17). Rotate rotor to ensure free
agan i snitnesrhoud l eorhfousn i gR . epeafo
tr running. Carefully check clearance between
thefemae lbore. rotor and housing face with two sets of feeler
gauges positioned diametrically opposite
.5 Posto i ntwodevilerybearn
i gsupports288031 each other. Clearance should be within 0·05 –
tobenchandplacedeliverybearinghousingto 0·10 mm(0·002"–0·004")tolerance.
beanrig
supposrt.
cIfe
l arancesinow t th
in
im
l tsire
,moverotor
.6 Todeterminethedepthofthefemaledelivery andcarryoun t ecessaryrectifcationbyadding
baal ncepsi tonfromthefaceotfhedevil ery osrubra
tcnitg
shm
i s.
bearni ghousn i grfis,etnsurethefacesice
l an.
Posotinshm i gauge(A2 )88030n i tothe Note:F' irstimea' ccuracyisimportanw
t hen
femae lboretoo
l cateonthebaa l ncepsiton. caryn
i goutheproceduresn itiem11.
Hod lni gthegaugefrimyln ipostiona,ccurateyl
measurewithfeelergaugesthegapbetween .21 Repeaptrocedure11fom
r ae
lrotor(7).
gaugeandhousingface.SUBTRACTthegap
Chapter 2, Page 14
FIG. 2.4 AIR END 102 X 1·65 (C20434-40 & 87)
Chapter 2, Page 15
.3
1 Poso tinthebearn ighousn ig/rotorsassembyl
torotoolrckn igxfituren ivcieF.thtieretan in
ig
pa ltes(18n),ewo lckn igpa ltes(19a),nd
screws(20to )therotorsathedevileryend.
Torqueo l adthescrewsto57Nm(42b l f.t).
Loca ktbsaganih tsa
te
lfF
cstrcp
i.tils(12o
t)
bothbearn i ghousn i gbores.
.41 Fdtievileryendcover(16w ) tihnewo

jn
i t(13),
andsecurewtihscrews(14)andwashers(15)
o
trque oladedo
t285
·Nm(21bl)tf.
.51 Posoitndevilerybeanrighousnigr/oo trs

assemblytorotorcasingdeliveryendwitha
newo jnit(22e),nsurn igthaw t egihsit
supportedasrotorsentecrasn i gS. ecure
bearn ighousn igwth ibotsl(34),(36a)nd(38)
andwashers(35),(37a )nd(39t)o,rque
oladedo t285·Nm(21 bl)t.f
.61 Usn i ganewo jn

i t(4thtfi),en
ie
lbtearn
ig
housn ig(24to)rotocrasn ig(6a)ndsecure
wth
ibotsl (32a )ndwashers(33to )rqueo
l aded
o
2
t85
N
· m2 (.)b
tf1
l.f
1
7
. Fthtiefemae ln
ie
lbtearn igretan inig
pa l te(29)n,ewo l ckni gwasher(30)a,nd
screw(31to)femae lrotoernd(8P ).oso
tin
rotoo lrckn
igxfituretothemae lrotor(7),
ensuringthefixturekeyengageswiththerotor
keyway,thusallowingaccesstothefemale
bearn i go
l ckn i gcomponentsT . orqueo
l adthe
screwto57Nm(42b l f.L
t).ocktab.
.8
1 Fctricp
ils(2a)nd(28to)bothmae land
femae lboresothfen
ie
lbtearn
ighousn
ig(24).
.91 Pre-u
lbrciatetherotorsandbearnigsusn
igthe
recommendedcompressoroa ,li ndturnrotors
byhandtoensuredsitrb i uo
tin.
tIh
f eari-endsitobestoredformorethan
fourteendayso,n irhoste licondtionss,pray
approximately10ccofAstrolanDA362
Moo trsotr(oerquviaelni)othe
niep
ltort
whileturningtherotorsslowlybyhand,
ensun rigthan a
itlternaplartsarecovered.
Ba l nkon ife
latnddsichargeportsunre tli ady
foruseA .elxternam l achn i edsurfacesshoudl
besmi aliyrlproe
tce tdaganisctorosoin.
Note:Inhb
i tiop
rrovd
i esaprotectedshefileo1f2
monhts.
Chapter 2, Page 16
! WARNING !
● RefertothesafetyprecautionsinChapter1beforecarryingoua
t nyotfhefolowingprocedures
3.3 Dismantling Procedure (C20434-117) 6. Usn i gapressandsutiabe lmandreslp,ress

outhemae l (6a
)ndfemae l (28b
)earn
i gs
fromthen ie
lbtearni ghousn
i g(27a)nd
Note1:Itisassumedthatad l rivecomponents, dsciad
r.
includingshafkteyh
, avebeenpreviouslyremoved.
Removaalndsubsequenrteftingoth fese 7. Removescrews(17)andwashers(18)
componentssidescrb i edn
ithecompressorRepari securn i gtheendcover(19t)odevilerybearnig
Manua.l housn ig(24R). emovethecovearndo
jn
it(16).
Dsicaon
jd
ri.t
Note2:Toolingdiagramsarecontainedin
Chape3
tr. 8. Poso tintherotoolrcknigxfituretothevcie.
Removebotsl(43)(,45)(,47a),nd
.1 Removescrews(3)andwashers(4)securing washers(44),(46a)nd(48s)ecurn igthe
theo
sle
i ahlousn ig(5to)n
ie
lbtearn
ig devilerybearn ighousn ig(24to)rotor
housn i g(27S ).eparatetheseahlousn i gfrom casnig(9U ).snigasodstf,tfrieparae th
te
thebearn i ghousn i gR. emoveo jn i t(37a)nd bearn i ghousn i gC . arefuylwtihdrawthe
dsicardR . emovese leve(38a)ndO‘ rn
’ig(1) bearn i ghousn i g/rotorsassembylfromthe
fromthedrvi eshaa ftnddsi cardU
. sn i ga rotocrasn i gandposo tintotheo l ckn
i gxfiture,
pressandsutiabe lmandrer,lemovethesn i ge
l ensuringthefixturekeyengageswiththemale
peiceoslei a(l2a)nddsicard. rotorshafkteywayT . hetwodowels(12)
reman initherotorcasn i gO. penthetabson
.2 Removescrews(34)andwashers(35) bothdevileryendo l ckn i gpa l tes(22)R . emove
securni gthefemaeln
ie
letndcover(33t)o screws(23a)ndo lckn igcomponents(21)
n
ie
lbtearni ghousn
i g(27)a,ndremovethe and(22R ).emoveboh tcrcp
ils(15).
coveRr. emovetheO‘ r’n
ig(31a
)nddsicard.
9. Posoitnh tedevilerybeanrighousnigr/ootrs
.3 Openthetabonthefemaleinlee t ndlocking assembyltothepressU . sni gasutiabe
l
pale
t(36P ).osoitnh
teroo
tlrcknig
xifu
tre mandrep,lressoum t ae l (10a)ndfemae l (11)
288040tothemae lrotor(10e),nsurn
igthe rotorsfrombean rigs(14E).nsurethaetach
fixturekeyengageswiththerotorkeyway, rotosirsupportedasitriee l asedfromthe
aol wn i gaccesstothefemae lbearni go
l ckn
ig bearn i gR. emoveshm i s(26f)romthedevilery
componentsR . emovescrew(32)andlocking endorofo tsrhastf.
components(30a )nd(36)R . emovethe
olcknixg
ifu
tre. .01 Usnigsua tibelpunilgequpimenotsrpnitlgas
necessaryr,emovethebearinginnerings
.4 Removecricp il (29f)romfemae
lboreon
ife
lt fromthen ie
letndobfothrotosrhaftsa,nd
beanrighousnig(27). dsican
rd
igs.
.5 Removebotsl(39),(41a)ndwashers(40) .11 Usn i gapressandsutiabe lmandrep ,l ressout

and(42s)ecurn igthenie
lbtearnig bothmatchedparisobfearn i gs(14fr)omthe
housnig(27o t)roo
tcrasnig(9U).snigasotf devilerybearni ghousn i g(24to),gethew r th
i
dsrft,ieparatethen ielbtearnighousn igT.he themae l (13a)ndfemae l (20b )aa
l nce
twodowesl (8r)eman in
itherotocrasn
i g. psitonsE.nsurebaa lncepsitonsarenot
Removeo jn i t(7a
)nddsicard. damageddurn i gremovaolb fearn i gsD. si card
ben
aig
rs.
Chapter 2, Page 17
3.4 Assembly Procedure (C20434-117) .6 Todeterminethedepthofthefemaledelivery

baal ncepsi tonfromthefaceotfhedevil ery
CAUTION:Cleanalcomponent
l sthoroughlybefore bearni ghousn i grfis,etnsurethefacesicel an.
assembyl. Posotinshm i gauge(A2 )88030n i tothe
femae lboretoo
l cateonthebaa l ncepsiton.
.1 Inspecatclomponentsretan
i edfore-usefor Hod lni gthegaugefrimyln iposto i n,
evidenceofwearordamage,renewingas accuratelymeasurewithfeelergaugesthe
apcp
a
ilb
el. gapbetweengaugeandhousingface.
SUBTRACTthegapdistancefromthe
Responsb ityilfovrerfyin
i gthactomponents measurementstampedonthegaugeandnote
aresuta
ibe
lfore-userestswth ithereparier. thenewfigure.Removegaugefromhousing.
Soundengn i eern i gpractci esshoud lbe
observedandadvci esoughd fitoube
txsi ts. .7 Wth irotorssecurednio
l ckn
i gxfiturep,osotin
shmi gauge(B2 )88031tofemae lrotosrhaft
Removeburrswherenecessaryandensure deliveryendH . oldingthegaugefirmlyin
o
jn i ftacesarece
l anD . onortemovebearn i gs postoi na,ccurateylmeasurewtihfeee lr
frompackagn i gunreltiquriedon
irterchange gaugesthegapbetweengaugeandrotor
bearingsorspacersoa fmatchedassembly faceA . DDthegapdistancetothe
wtihpartsfromanothea rssembyl. measurementstampedonthegaugeandnote
thenewfigureR . emovegaugefromshaft.
Thoroughylde-greaseandce l anal
componentse,nsurn igthaa
o
g
tliae
lre
isare .8 SUBTRACTrotorshafd t imensionfrom
celaren
ri,tifgpulgswh
tiLoce
ti542. b earing housing dimension to obtain
.2 Separatetheinnerringfromthenewmale end clearance i.e. 0·05 – 0·10 (0·002"-
n
ielbtearn i g(6a )ndde-greaseH . eathen
i ner 0·004"). This new figure is the shim pack
ringbyinductionorinanovento100–120 °C thciknesstoache i vethecorecetnd
andthendropovetrhemae lrotosrhaft(10), cel aranceC . arefuylmeasureshm i s(26to
)
ensurn i gthathterni gsihardagani sthte oba tnicorecotta
thlciknessa,ndposoitno
t
shoulder.Allowtocoolinair–DONOTUSE rotosrhau ftsn i gasmaalmounotgfreaseto
WATERR . epeaftorthefemaleinlet n.ae
itr
beanrig(28a)ndroo
t(1
r1).
.9 Repeatprocedures6to8formaleboreand
.3 De-greaseouteraceon f ewmaleinlet .th
sa
f
bearn i g(6A ). ppylLoctei641tothebearn ig
boreohtfenielbtean righousnig(24P).osoitn .01 Poso tinbearn
i ghousn
i gandbearn
i gsupports
bearn i gtopresstoo2l88041a,ndpress p
ote
rss.
bearn i gfuyln i tohousn i gR. epeafo tfremael
nielbtean
rig(28u)snigpressoto 2l88042. Note:Duringprocedure11ist,importantouse
twosetsofeeel rgaugestoem
il n
i atedsi crepancy
.4 Poso tinthemae lbaalncepsiton(13n i)tothe duetobearn
i gce
l arance.
maleboreotfhedeliverybearing
housnig(24e),nsunrigcoreo
ce
trina toitn. .11 Posoitne
fmaelroo tr(11o t)bean righousnig
Poso tinamatchedpao ribfearn i gs(14to )the boreandpressn itobearn igs(14u)nlti
devilerybearn i gpresstoo2l88043P . ress shmi s(26a )rehardagan isbtaalnce
bearn i gsni tothemae lboreotfhedevil ery psio
tn(20R
).oa te
troo to
te
rnsurerfee
bearn ighousn ig(24e),nsurn igthabtearn igsi runningC . arefulycheckclearancebetween
hardagan i sn
itnesrhoud l eo rhfousn i g. rotorandhousingfacewithtwosetsofeeler
Repeaftorthefemae lbore. gaugesposo tinedda i metrciaylopposte ieach
otherC.el aranceshoud lbewtihni0·05–0·10
.5 Posto i ntwodevilerybearn
i gsupports288031 mm(00 ·02–
0"0
·04o te")lrance.
tobenchandplacedeliverybearinghousing
o
tbean
rigsupporst.
Chapter 2, Page 18
FIG. 2.5 AIR END 102 X 1·65 (C20434-117)
Chapter 2, Page 19
cIfe
l arancesinow t th
in
im
l tsire
,moverotor
andcarryoun t ecessaryrectifcationbyadding
osrubra
tcnitg
shm
i s.
Note:F' irstimea' ccuracyisimportanw

t hen
caryn
i goutheproceduresn itiem11.
.21 Repeaptrocedure11fom
r ae
lrotor(11).
.3
1 Posoitnbean righousnigr/oo trsassembylo
t
rotoo
lrcknigxfituren ivcieF.thtieretan in
ig
palets(21n),ewolcknigpale ts(22a),nd
screws(23t)otherotorsathedevileryend.
Torqueo l adthescrewsto57Nm(42b l f.t).
Loca ktbsaganialfsF
sctrcp
.itls(15o
tb)oh
t
bearn ighousn igbores.
.41 Fdtievileryendcover(19w ) tihnewo

jn
i t(16),
andsecurewithscrews(17)andwashers(18)
o
trque oladedo
t285
·Nm(21bl)tf.
.51 Posoitndevilerybean righousnigr/ootrs

assemblytorotorcasingdeliveryendwitha
newo jn i t(25e
),nsurni gthaw
t egi hsit
supportedasrotorsentecrasn i gS . ecure
bean righousnigwthibotsl(43)(,45)(,47a)nd
washers(44),(46a )nd(48to ),rqueo ladedto
28N
5·m .)2
t(b
f.l1
f
.61 Usn i ganewo jni t(7thf)i,en

ie
lbtearn ig
housn ig(27to )rotocrasn ig(9a)ndsecure
whtibostl(39)(,41a)ndwashers(40a)nd(42)
o
trque oladedo t285 ·Nm(21 bl)tf.
1
7
. Fthtiefemae lnie
lbtearn igretan in
ig
pa l te(30)n,ewo l ckni gwasher(36)a,nd
screw(32o t)e
fmaelroo ternd(11P ).osoitn
rotoo lrckn
igxfituretothemae lrotor(10),
ensuringthefixturekeyengageswiththerotor
keyway,thusallowingaccesstothefemale
bearn i gol ckn i gcomponentsT . orqueo
l adthe
screwto57Nm(42b l f.L
t).ocktab.
.8
1 Fctricp
il(29to)femae
lboreothfen
ie
lt
beanrighousnig(27).
.91 FatinewO‘ ’rn

i g(31t)othefemae ln
ie letnd
cover(33a )ndposo tintothen
ie
lbtearn ig
housn i g(27)S . ecurecovew r tihscrews(34)
andwashers(35)torqueloadedto16Nm
.)tf.b
fl1
2(
.02 FatinewO ‘ r’n

i g(1to )themae lrotor
sha(tf10F )a
.n
tiewseleve(38ni),e trnatlper
endrfisot,vethreshausoftiltn
icltiated
aganish ttebean rigandO ‘nri’g.
Chapter 2, Page 20
4. AIR-END 102 X 1·8 (C20452-69)
! WARNING !
4.1 Dismantling Procedure 5. Using a press and suitable mandrels, press

Note 1: It is assumed that all drive components, from the inlet bearing housing (7) and discard.
including shaft key, have been previously removed.
Removal and subsequent refitting of these 6. Remove screws (18) and washers (19)
components is described in the compressor Repair securing each of the end covers (17) to
Manual. delivery bearing housing (23). Remove the
covers and ‘O’ rings (16). Discard ‘O’ rings.
Note 2: Tooling diagrams are contained in
Chapter 3. 7. Position the rotor locking fixture to the vice.
Remove bolts (37) and (39), nuts (41), and
1. Remove screws (35) and washers (36) washers (38), (40) and (42) securing the
securing the oil seal housing (2) to inlet delivery bearing housing (23) to rotor
bearing housing (7). Separate the seal casing (10). Using a soft drift, separate the
housing from the bearing housing. Remove bearing housing. Carefully withdraw the
‘O’ ring (5) from the seal housing and discard. bearing housing/rotors assembly from rotor
Remove sleeve (1) and ‘O’ ring (6) from the casing and position to the locking fixture,
drive shaft and discard. Using a press and ensuring that the fixture key engages with the
suitable mandrel, remove the single piece oil male rotor shaft keyway. The two dowels (13)
seal (34) and discard. remain in the rotor casing. Open the tabs on
both delivery end locking plates (21). Remove
2. Remove screws (29) and washers (30) screws (22) and locking components (20)
securing the female inlet end cover (31) to and (21).
inlet bearing housing (7), and remove the
cover. Remove ‘O’ ring (32) and discard. 8. Position the delivery bearing housing/rotors
assembly to the press. Using a suitable
3. Open the tab on the female inlet end locking mandrel, press out male (11) and female (12)
plate (27). Position the rotor locking fixture rotors from bearings (15). Ensure that each
288040 to male rotor (11), ensuring that the rotor is supported as it is released from the
fixture key engages with the rotor keyway, bearing. Remove shims (14) from the delivery
allowing access to the female bearing locking end of rotor shafts.
components. Remove screw (28) and locking
components (26) and (27). Remove the 9. Using suitable pulling equipment or splitting as
locking fixture. necessary, remove the bearing inner rings
from the inlet end of both rotor shafts, and
4. Remove bolts (3) and washers (4) securing discard rings.
the inlet bearing housing (7) to rotor
casing (10). Using a soft drift, separate the 10. Using a press and suitable mandrel, press out
inlet bearing housing. The two dowels (9) both matched pairs of bearings (15) from
remain in the rotor casing. Remove joint (8) delivery bearing housing (23), together with
and discard. the bearing spacer. The outer rings of the
innermost pair of bearings will remain in the
housing. Using a suitable extractor, withdraw
both outer rings. Discard bearings.
Chapter 2, Page 21
4.2 Assembly Procedure 6. Fit both end covers (17) to delivery bearing
housing and secure with screws (18) and
CAUTION: Clean all components thoroughly before washers (19) torque loaded to 16 Nm
assembly. (21 lbf.ft). Ensure that the inner races of
delivery bearings revolve freely after securing
1. Inspect all components retained for re-use for the end covers.
evidence of wear or damage, renewing as
applicable. 7. To determine the depth of the female delivery
bearing inner race from the face of the
Responsibility for verifying that components delivery bearing housing, first ensure the face
are suitable for re-use rests with the repairer. is clean. Position shim gauge (A) 288038 into
Sound engineering practices should be the female bore to locate on the bearing inner
observed and advice sought if doubt exists. race. Holding the gauge firmly in position,
Remove burrs where necessary and ensure gap between gauge and housing face.
joint faces are clean. Do not remove bearings SUBTRACT the gap distance from the
from packaging until required or interchange measurement stamped on the gauge and note
bearings or spacers of a matched assembly the new figure. Remove gauge from housing.
with parts from another assembly.
8. With rotors secured in locking fixture, position
Thoroughly de-grease and clean all shim gauge (B) 288039 to female rotor shaft
components, ensuring that all oil galleries are delivery end. Holding the gauge firmly in
clear, refitting plugs with Loctite 542. position, accurately measure with feeler
gauges the gap between gauge and rotor
2. Separate the inner ring from the new male inlet face. ADD the gap distance to the
bearing (33) and de-grease. Apply Loctite measurement stamped on the gauge and note
14486 to inlet bearing diameter of the male the new figure. Remove gauge from shaft.
rotor shaft (11). Heat the inner ring by
induction or in an oven to 100 – 120° C and 9. SUBTRACT rotor shaft dimension from
then drop over the male rotor shaft, ensuring bearing housing dimension to obtain
that the ring is hard against the shoulder. Allow difference. To this figure ADD the required
to cool in air – DO NOT USE WATER. end clearance i.e. 0·05 – 0·10 mm
(0·002" – 0·004"). This new figure is the shim
3. Separate the inner ring from the new female pack thickness required to achieve the correct
inlet bearing (25) and de-grease. Heat the end clearance. Carefully measure shims (14)
inner ring by induction or in an oven to to obtain correct total thickness, and position
100 – 120° C and then drop over the female to rotor shaft using a small amount of grease
rotor shaft (12), ensuring that the ring is hard to retain.
against the shoulder. Allow to cool in air – DO
NOT USE WATER. 10. Repeat procedures 7 to 9 for male bore and
shaft.
4. De-grease outer race of new male inlet
bearing (33). Apply Loctite 641 to the bearing 11. Remove both covers (17) from delivery
bore of inlet bearing housing (7). Position bearing housing (23). Position two delivery
bearing to press tool 288041, and press bearing supports 288044 to the press, and
bearing fully into housing. Repeat for female place delivery bearing housing onto bearing
inlet bearing (25) using press tool 288042. supports.
5. Position a matched pair of bearings and Note: During procedure 12, it is important to use
spacer (15) to the delivery bearing press tool two sets of feeler gauges to eliminate discrepancy
288043. Press bearings into the male bore of due to bearing clearance.
the delivery bearing housing (23), ensuring that
bearing is hard against inner shoulder of
housing. Repeat for the female bore.
Chapter 2, Page 22
FIG. 2.6 AIR END TYPE 102 X 1·8 (C20452-69)
Chapter 2, Page 23
12. Position female rotor (12) to bearing housing 19. Fit a new ‘O’ ring (32) to the female inlet end
bore and press into bearings (15) until cover (31) and position to the inlet bearing
shims (14) are hard against inner race. Rotate housing (7). Secure cover with screws (29)
rotor to ensure free running. Carefully check and washers (30) torque loaded to 16 Nm
clearance between rotor and housing face (12 lbf.ft).
with two sets of feeler gauges positioned
diametrically opposite each other. Clearance 20. Fit a new ‘O’ ring (6) to the male rotor
should be within 0·05 – 0·10 mm shaft (11). Fit a new sleeve (1), internal taper
(0·002" – 0·004") tolerance. end first, over the shaft until it is located
against the bearing and ‘O’ ring.
If clearance is not within limits, remove rotor
and carry out necessary rectification by adding CAUTION: When fitting the single piece seal during
or subtracting shims. procedure 21, it is important that the inner
circumference is not damaged or distorted in any
Note: 'First time' accuracy is important when way. The seal as supplied is coated with a sealant;
carrying out the procedures in item 12. after pressing into housing remove all traces of
residual sealant from internal surfaces of seal
13. Repeat procedure 12 for male rotor (11). housing.
14. Position bearing housing/rotors assembly to 21. Using a suitable mandrel, press a new single
rotor locking fixture in vice. Fit retaining piece oil seal (34) into the seal housing (2).
screws (22) to the rotors at the delivery end. 22. Fit a new ‘O’ ring (5) to the oil seal
Torque load screws to 45 Nm (33 lbf.ft). Lock housing (2), position to inlet bearing
tabs against flats. housing (7) and secure with screws (35) and
washers (36) torque loaded to 16 Nm
15. Fit delivery end covers (17) with new (12 lbf.ft).
‘O’ rings (16), and secure with screws (18)
and washers (19) torque loaded to 16 Nm (12 23. Pre-lubricate the rotors and bearings using the
lbf.ft). recommended compressor oil, and turn rotors
by hand to ensure distribution.
assembly to rotor casing (10) delivery end with If the air-end is to be stored for more than
a new joint (24), ensuring that weight is fourteen days, or in hostile conditions, spray
supported as rotors enter casing. Secure approximately 10 cc of Astrolan DA362
bearing housing (23) with bolts (37), (39) and Motorstor (or equivalent) into the inlet port
washers (38), (40) torque loaded to 29 Nm while turning the rotors slowly by hand,
(21 lbf.ft). Fit nuts (41) and washers (42) to ensuring that all internal parts are covered.
studs and secure. Blank off inlet and discharge ports until ready
for use. All external machined surfaces should
17. Using a new joint (8), fit the inlet bearing be similarly protected against corrosion.
housing (7) to the rotor casing (10) and secure
with bolts (3) and washers (4) torque loaded to Note: Inhibitor provides a protected shelf life of 12
29 Nm (21 lbf.ft). months.
18. Fit the female inlet bearing retaining

plate (26), new locking washer (27), and
screw (28) to female rotor end (12). Position
rotor locking fixture to the male rotor (11),
ensuring the fixture key engages with the rotor
keyway, thus allowing access to the female
bearing locking components. Torque load the
screw to 57 Nm (42 lbf.ft). Lock tab against
flats.
Chapter 2, Page 24
5. AIR-END 127·5 X 1·65 (C20450-40)
! WARNING !
5.1 Dismantling Procedure 6. Position the rotor locking fixture to the vice.
Remove bolts (31) and (33), nut (35), and
Note 1: It is assumed that all drive components, washers (32), (34) and (36) securing the
including shaft key, have been previously removed. delivery bearing housing (11) to rotor
Removal and subsequent refitting of these casing (7). Using a soft drift, separate the
components is described in the compressor Repair bearing housing. Carefully withdraw the
Manual. bearing housing/rotors assembly from the
rotor casing and position to the locking fixture,
Note 2: Tooling diagrams are contained in ensuring the fixture key engages with the male
Chapter 3. rotor shaft keyway. The two dowels (9) remain
in the rotor casing. Open the tabs on both
1. Remove circlips (2) and (25) from male and delivery end locking plates (19). Remove
female bores of the inlet bearing housing (4). screws (20) and locking components (18)
and (19).
2. Open the tab on the female inlet end locking
plate (28). Position the rotor locking fixture 7. Position the delivery bearing housing/rotors
288054 to the male rotor (8), ensuring the assembly to the press. Using a suitable
fixture key engages with the rotor keyway, mandrel, press out male (8) and female (23)
allowing access to the female bearing locking rotors from bearings (13). Ensure that each
components. Remove screw (27) and locking rotor is supported as it is released from the
components (26) and (28). Remove the bearing. Remove shims (22) from the delivery
locking fixture. end of rotor shafts.
3. Remove bolts (29) and washers (30) securing 8. Using suitable pulling equipment or splitting as
the inlet bearing housing (4) to rotor necessary, remove the bearing inner rings
casing (7). Using a soft drift, separate the inlet from the inlet end of both rotor shafts, and
bearing housing. The two dowels (5) remain in discard rings.
the rotor casing. Remove joint (6) and discard.
4. Using a press and suitable mandrels, press both matched pairs of bearings (13) from the
out the male (3) and female (24) bearings delivery bearing housing (11), together with
from the inlet bearing housing (4) and discard. the male (12) and female (21) balance
pistons. Ensure balance pistons are not
5. Remove screws (14) and washers (15) damaged during removal of bearings. Discard
securing each of the end covers (17) to the bearings.
delivery bearing housing (11). Remove the
Chapter 2, Page 25
5.2 Assembly Procedure 5. Fit both end covers (17) to delivery bearing
housing (11) and secure with screws (14) and
CAUTION: Clean all components thoroughly before washers (15) torque loaded to 28·5 Nm
assembly. (21 lbf.ft). Ensure that the inner races of the
1. Inspect all components retained for re-use for the end covers.
applicable. 6. To determine the depth of the female delivery
balance piston from the face of the delivery
Responsibility for verifying that components bearing housing, first ensure the face is clean.
are suitable for re-use rests with the repairer. Position shim gauge (A) 288052 into the
Sound engineering practices should be female bore to locate on the balance piston.
observed and advice sought if doubt exists. Holding the gauge firmly in position,
Remove burrs where necessary and ensure gap between gauge and housing face.
joint faces are clean. Do not remove bearings SUBTRACT the gap distance from the
from packaging until required or interchange measurement stamped on the gauge and note
bearings or spacers of a matched assembly the new figure. Remove gauge from housing.
with parts from another assembly.
7. With rotors secured in locking fixture, position
Thoroughly de-grease and clean all shim gauge (B) 288053 to female rotor shaft
components, ensuring that all oil galleries are delivery end. Holding the gauge firmly in
clear, refitting plugs with Loctite 542. position, accurately measure with feeler
gauges the gap between gauge and rotor
2. Separate the inner ring from the new male inlet face. ADD the gap distance to the
bearing (3) and de-grease. Heat the inner ring measurement stamped on the gauge and note
by induction or in an oven to 100 – 120° C and the new figure. Remove gauge from shaft.
then drop over the male rotor shaft (8),
ensuring that the ring is hard against the 8. SUBTRACT rotor shaft dimension from
shoulder. Allow to cool in air – DO NOT USE bearing housing dimension to obtain
WATER. Repeat for the female inlet difference. To this figure ADD the required
bearing (24) and rotor (23). end clearance i.e. 0·05 – 0·10 mm (0·002" –
0·004"). This new figure is the shim pack
3. De-grease outer race of new male inlet thickness to achieve the correct end
bearing (3). Apply Loctite 641 to the bearing clearance. Carefully measure shims (22) to
bore of the inlet bearing housing (4). Position obtain correct total thickness, and position to
bearing to press tool 288055, and press rotor shaft using a small amount of grease to
bearing fully into housing. Repeat for female retain.
inlet bearing (24) using press tool 288056.
9. Repeat procedures 6 to 8 for male bore and
4. Position the male balance piston (12) into the shaft.
male bore of delivery bearing housing (11),
ensuring correct orientation. Position a 10. Remove both covers (17) from delivery
matched pair of bearings (13) to the delivery bearing housing (11). Position two delivery
bearing press tool 288057. Press bearings into bearing supports 288058 to press and place
the male bore of delivery bearing housing (11), delivery bearing housing onto bearing
ensuring that bearing is hard against inner supports.
shoulder of housing. Repeat for the female
bore. Note: During procedure 11, it is important to use
two sets of feeler gauges to eliminate discrepancy
due to bearing clearance.
Chapter 2, Page 26
FIG. 2.7 AIR-END 127·5 X 1·65 (C20450-40)
Chapter 2, Page 27
11. Position female rotor (23) to bearing housing 16. Using a new joint (6), fit the inlet bearing
bore and press into bearings (13) until housing (4) to the rotor casing (7) and secure
shims (22) are hard against balance with bolts (29) and washers (30) torque loaded
piston (21). Rotate rotor to ensure free to 56 Nm (42 lbf.ft).
running. Carefully check clearance between
rotor and housing face with two sets of feeler 17. Fit the female inlet bearing retaining
gauges positioned diametrically opposite plate (26), new locking washer (28), and
each other. Clearance should be within 0·05 – screw (27) to female rotor end (23). Position
0·10 mm (0·002" – 0·004") tolerance. rotor locking fixture to the male rotor (8),
If clearance is not within limits, remove rotor keyway, allowing access to the female bearing
and carry out necessary rectification by adding locking components. Torque load the screw to
or subtracting shims. 97·5 Nm (72 lbf.ft). Lock tab.
Note: 'First time' accuracy is important when 18. Fit circlips (2) and (25) to both male and
carrying out the procedures in item 11. female bores of the inlet bearing housing (4).
12. Repeat procedure 11 for male rotor (8). 19. Pre-lubricate the rotors and bearings using the
recommended compressor oil, and turn rotors
13. Position bearing housing/rotors assembly to by hand to ensure distribution.
rotor locking fixture in vice. Fit the retaining
plates (18), new locking plates (19), and If the air end is to be stored for more than
screws (20) to the rotors at the delivery end. fourteen days, or in hostile conditions, spray
Torque load the screws to 97·5 Nm (72 lbf.ft). approximately 10 cc of Astrolan DA362
Lock tabs against flats.. Motorstor (or equivalent) into the inlet port
while turning the rotors slowly by hand,
14. Fit delivery end covers (17) with new ensuring that all internal parts are covered.
‘O’ rings (16), and secure with screws (14) Blank off inlet and discharge ports until ready
and washers (15) torque loaded to 28·5 Nm for use. All external machined surfaces should
(21 lbf.ft). be similarly protected against corrosion.
15. Position delivery bearing housing/rotors Note: Inhibitor provides a protected shelf life of 12
assembly to rotor casing delivery end with a months.
new joint (10), ensuring that weight is
supported as rotors enter casing. Secure
bearing housing with bolts (31), (33) and
washers (32), (34), torque loaded to 56 Nm
(42 lbf.ft). Fit nut (35) and washer (36) to stud
and secure.
Chapter 2, Page 28
6. AIR-END 178·5 X 1·65
! WARNING !
6.1 Dismantling Procedure (C20438-90A) 6. Using a press and suitable mandrels, press
Note 1: It is assumed that the bellhousing and all
drive components, including shaft key, have been 7. Remove screws (13) and washers (14)
previously removed. Removal and subsequent securing each of the end covers (15) to the
refitting of these components is described in the delivery bearing housing (19). Remove the
compressor Repair Manual. covers and ‘O’ rings (12). Discard ‘O’ rings.
Note 2: Tooling diagrams are contained in 8. Position the rotor locking fixture to the vice.
Chapter 3. Remove bolts (40), nuts (42), and
washers (41) and (43) securing the delivery
1. Remove screws (35) and washers (36) bearing housing (19) to rotor casing (7). Using
securing the oil seal housing (33) to inlet a soft drift, separate the bearing housing.
bearing housing (4). Separate the seal Carefully withdraw the bearing housing/rotors
housing from the bearing housing. Remove assembly from the rotor casing and position to
joint (33) and discard. Remove sleeve (37) the locking fixture, ensuring the fixture key
and ‘O’ ring (2) from the drive shaft and engages with the male rotor shaft keyway.
discard. Using a press and suitable mandrel, The two dowels (9) remain in the rotor casing.
remove the single piece oil seal (1) and Open the tabs on both delivery end locking
discard. plates (17). Remove screws (16) and locking
components (17) and (18).
2. Remove screws (31) and washers (32)
securing the female inlet end cover (30) to the 9. Position the delivery bearing housing/rotors
inlet bearing housing (4), and remove the assembly to the press. Using a suitable
cover. Remove joint (29) and discard. mandrel, press out male (8) and female (23)
rotors from bearings (11). Ensure that each
3. Remove the circlip (25) from female bore of rotor is supported as it is released from the
the inlet bearing housing (4). bearing. Remove shims (22) from the delivery
end of the rotor shafts.
4. Open the tab on the female inlet end locking
plate (27). Position the rotor locking fixture 10. Using suitable pulling equipment or splitting as
288068 to male rotor (8), ensuring the fixture necessary, remove the bearing inner rings
key engages with the rotor keyway, allowing from the inlet end of both rotor shafts, and
access to the female bearing locking discard rings.
components. Remove screw (28) and locking
components. Remove the locking fixture. 11. Using a press and suitable mandrel, press out
both matched pairs of bearings (11) from the
5. Remove bolts (38) and washers (39) securing delivery bearing housing (19), together with
the inlet bearing housing (4) to rotor the male (10) and female (20) balance
casing (7). Using a soft drift, separate the inlet pistons. Ensure balance pistons are not
bearing housing. The two dowels (6) remain in damaged during removal of bearings. Discard
the rotor casing. Remove joint (5) and discard. bearings.
Chapter 2, Page 29
6.2 Assembly Procedure (C20438-90A) 6. To determine the depth of the female delivery
balance piston from the face of the delivery
CAUTION: Clean all components thoroughly before bearing housing, first ensure the face is clean.
assembly. Position shim gauge (A) 288066 into the
female bore to locate on the balance piston.
1. Inspect all components retained for re-use for Holding the gauge firmly in position,
evidence of wear or damage, renewing as accurately measure with feeler gauges the
applicable. gap between gauge and housing face.
SUBTRACT the gap distance from the
Responsibility for verifying that components measurement stamped on the gauge and note
are suitable for re-use rests with the repairer. the new figure. Remove gauge from housing.
Sound engineering practices should be
observed and advice sought if doubt exists. 7. With rotors secured in locking fixture, position
Remove burrs where necessary and ensure delivery end. Holding the gauge firmly in
joint faces are clean. Do not remove bearings position, accurately measure with feeler
from packaging until required or interchange gauges the gap between gauge and rotor
bearings or spacers of a matched assembly face. ADD the gap distance to the
with parts from another assembly. measurement stamped on the gauge and note
the new figure. Remove gauge from shaft.
Thoroughly de-grease and clean all
components, ensuring that all oil galleries are 8. SUBTRACT rotor shaft dimension from
clear, refitting plugs with Loctite 542. bearing housing dimension to obtain
2. Separate the inner ring from the new male inlet end clearance i.e. 0·05 – 0·10 (0·002" –
bearing (3) and de-grease. Heat the inner ring 0·004"). This new figure is the shim pack
by induction or in an oven to 100 – 120° C and thickness to achieve the correct end
then drop over the male rotor shaft (8), clearance. Carefully measure shims (22) to
ensuring that the ring is hard against the obtain correct total thickness, and position to
shoulder. Allow to cool in air – DO NOT USE rotor shaft using a small amount of grease to
WATER. Repeat for the female inlet retain.
bearing (24) and rotor (23).
9. Repeat procedures 6 to 8 for male bore and
3. De-grease outer race of new male inlet shaft.
bearing (3). Apply Loctite 641 to the bearing
bore of the inlet bearing housing (4). Position 10. Remove both covers (15) from delivery
bearing to press tool 288069, and press bearing housing (19). Position two delivery
bearing fully into housing. Repeat for female bearing supports 288072 to press and place
inlet bearing (24) using press tool 288070. delivery bearing housing onto bearing
supports.
4. Position the male balance piston (10) into the
male bore of the delivery bearing housing (19), Note: During procedure 11, it is important to use
ensuring correct orientation. Position a two sets of feeler gauges to eliminate discrepancy
matched pair of bearings (11) to the delivery due to bearing clearance.
bearing press tool 288071. Press bearings into
the male bore of the delivery bearing 11. Position female rotor (23) to bearing housing
housing (19), ensuring that bearing is hard bore and press into bearings (11) until
against inner shoulder of housing. Repeat for shims (22) are hard against balance
the female bore. piston (20). Rotate rotor to ensure free
running. Carefully check clearance between
5. Fit both end covers (15) to delivery bearing rotor and housing face with two sets of feeler
housing (19) and secure with screws (13) and gauges positioned diametrically opposite
washers (14) torque loaded to 40·7 Nm each other. Clearance should be within 0·05 –
(30 lbf.ft). Ensure that the inner races of the 0·10 mm (0·002" – 0·004") tolerance.
the end covers.
Chapter 2, Page 30
FIG. 2.8 AIR-END 178·5 X 1·65 (C20438-90A)
Chapter 2, Page 31
If clearance is not within limits, remove rotor 19. Position female inlet end cover (30) to inlet
and carry out necessary rectification by adding bearing housing (4) with a new joint (29) and
or subtracting shims. secure cover with screws (31) and
washers (32) torque loaded to 16 Nm
Note: 'First time' accuracy is important when (12 lbf.ft).
carrying out the procedures in item 11.
20. Fit a new ‘O’ ring (2) to the male rotor
12. Repeat procedure 11 for male rotor (8). shaft (8). Fit a new sleeve (37), internal taper
end first, over the shaft until it is located
13. Position bearing housing/rotors assembly to against the bearing and ‘O’ ring.
rotor locking fixture in vice. Fit the retaining
plates (18), new locking plates (17), and 21. Using a suitable mandrel, press a new single
screws (16) to the rotors at the delivery end. piece oil seal (1) into the seal housing (34).
Torque load the screws to 135·6 Nm
(100 lbf.ft). Lock tabs against flats. CAUTION: When fitting the single piece seal, it is
14. Fit delivery end covers (15) with new damaged or distorted in any way. The seal as
‘O’ rings (12), and secure with screws (13) supplied is coated with a sealant; after pressing into
and washers (14) torque loaded to 40·7 Nm housing remove all traces of residual sealant from
(30 lbf.ft). internal surfaces of seal housing.
15. Position delivery bearing housing/rotors 22. Position seal housing (34) to inlet bearing
assembly to rotor casing delivery end with a housing (4) with a new joint (33), and secure
new joint (21), ensuring that weight is with screws (35) and washers (36) torque
supported as rotors enter casing. Secure loaded to 58 Nm (43 lbf.ft).
bearing housing (19) with bolts (40) and
washers (41), torque loaded to 135·6 Nm 23. Pre-lubricate the rotors and bearings using the
(100 lbf.ft). Fit nuts (42) and washers (43) to recommended compressor oil, and turn rotors
studs and secure. by hand to ensure distribution.
16. Using a new joint (5), fit the inlet bearing If the air end is to be stored for more than
housing (4) to rotor casing (7) and secure with fourteen days, or in hostile conditions, spray
bolts (38) and washers (39) torque loaded to approximately 10 cc of Astrolan DA362
108·5 Nm (80 lbf.ft). Motorstor (or equivalent) into the inlet port
17. Fit the female inlet bearing retaining ensuring that all internal parts are covered.
plate (26), new locking plate (27), and Blank off inlet and discharge ports until ready
screw (28) to female rotor end (23). Position for use. All external machined surfaces should
rotor locking fixture to the male rotor (8), be similarly protected against corrosion.
keyway, allowing access to the female bearing Note: Inhibitor provides a protected shelf life of 12
locking components. Torque load the screw to months.
135·6 Nm (100 lbf.ft). Lock tab against flat.
18. Fit circlip (25) to female bore of the inlet

bearing housing (4).
Chapter 2, Page 32
! WARNING !
6.3 Dismantling Procedure (C20438-40) 7. Position the rotor locking fixture to the vice.
Remove bolts (32), nuts (34), and washers
Note 1: It is assumed that all drive components, (33) and (35) securing the delivery bearing
including shaft key, have been previously removed. housing (19) to rotor casing (7). Using a soft
Removal and subsequent refitting of these drift, separate the bearing housing. Carefully
components is described in the compressor Repair withdraw the bearing housing/rotors assembly
Manual. from the rotor casing and position to the
locking fixture, ensuring the fixture key
Note 2: Tooling diagrams are contained in engages with the male rotor shaft keyway.
Chapter 3. The two dowels (9) remain in the rotor casing.
Open the tabs on both delivery end locking
1. Remove circlips (2) and (25) from male and plates (16). Remove screws (15) and locking
female bores of the inlet bearing housing (4). components (16) and (17).
2. Remove pinion spacer (1) from male rotor 8. Position the delivery bearing housing/rotors
shaft (8). assembly to the press. Using a suitable
mandrel, press out male (8) and female (23)
3. Open the tab on the female inlet end locking rotors from bearings (11). Ensure that each
plate (27). Position the rotor locking fixture rotor is supported as it is released from the
288068 to the male rotor, ensuring the fixture bearing. Remove shims (22) from the delivery
key engages with the rotor keyway, allowing end of rotor shafts.
access to the female bearing locking
components. Remove screw (28) and locking 9. Using suitable pulling equipment or splitting as
components (26) and (27). Remove the necessary, remove the bearing inner rings
locking fixture. from the inlet end of both rotor shafts, and
discard rings.
4. Remove bolts (29), (30) and washers (31)
securing the inlet bearing housing (4) to rotor 10. Using a press and suitable mandrel, press out
casing (7). Using a soft drift, separate the inlet both matched pairs of bearings (11) from the
bearing housing. The two dowels (6) remain in delivery bearing housing (19), together with
the rotor casing. Remove the joint (5) and the male (10) and female (20) balance
discard. pistons. Ensure balance pistons are not
damaged during removal of bearings. Discard
Note: When carrying out item 6.3.5, the outer race bearings.
of the gearbox shaft support bearing (36) remains in
the housing. It is only removed as part of the
gearbox refurbishment – see the appropriate
section in the relevant repair manual. 6.4 Assembly Procedure (C20438-40)
5. Using a press and suitable mandrels, press CAUTION: Clean all components thoroughly before
out the male (3) and female (24) bearings assembly.
1. Inspect all components retained for re-use for
6. Remove screws (12) and washers (13) evidence of wear or damage, renewing as
securing each of the end covers (14) to the applicable.
delivery bearing housing (19). Remove the
Chapter 2, Page 33
Responsibility for verifying that components 6. To determine the depth of the female delivery
are suitable for re-use rests with the repairer. balance piston from the face of the delivery
Sound engineering practices should be bearing housing, first ensure the face is clean.
observed and advice sought if doubt exists. Position shim gauge (A) 288066 into the
female bore to locate on the balance piston.
Remove burrs where necessary and ensure Holding the gauge firmly in position,
joint faces are clean. Do not remove bearings accurately measure with feeler gauges the
from packaging until required or interchange gap between gauge and housing face.
bearings or spacers of a matched assembly SUBTRACT the gap distance from the
with parts from another assembly. measurement stamped on the gauge and note
the new figure. Remove gauge from housing.
components, ensuring that all oil galleries are 7. With rotors secured in locking fixture, position
clear, refitting plugs with Loctite 542. shim gauge (B) 288067 to female rotor shaft
delivery end. Holding the gauge firmly in
2. Separate the inner ring from the new male position, accurately measure with feeler
inlet bearing (3) and de-grease. Heat the inner gauges the gap between gauge and rotor
ring by induction or in an oven to 100 – 120° C face. ADD the gap distance to the
and then drop over the male rotor shaft (8), measurement stamped on the gauge and note
ensuring that the ring is hard against the the new figure. Remove gauge from shaft.
shoulder. Allow to cool in air – DO NOT USE
WATER. Repeat for the female inlet 8. SUBTRACT rotor shaft dimension from
bearing (24) and rotor (23). bearing housing dimension to obtain
3. De-grease outer race of new male inlet end clearance i.e. 0·05 – 0·10 mm (0·002" –
bearing (3). Apply Loctite 641 to the bearing 0·004"). This new figure is the shim pack
bore of the inlet bearing housing (4). Position thickness to achieve the correct end
bearing to press tool 288069, and press clearance. Carefully measure shims (22) to
bearing fully into housing. Repeat for female obtain correct total thickness, and position to
inlet bearing (24) using press tool 288070. rotor shaft using a small amount of grease to
retain.
4. Position the male balance piston (10) into the
male bore of the delivery bearing 9. Repeat procedures 6 to 8 for male bore and
housing (19), ensuring correct orientation. shaft.
Position a matched pair of bearings (11) to the
delivery bearing press tool 288071. Press 10. Remove both covers (14) from delivery
bearings into the male bore of the delivery bearing housing (19). Position two delivery
bearing housing (19), ensuring that bearing is bearing supports 288072 to press and place
hard against inner shoulder of housing. delivery bearing housing onto bearing
Repeat for the female bore. supports.
5. Fit both end covers (14) to delivery bearing Note: During procedure 11, it is important to use
housing (19) and secure with screws (12) and two sets of feeler gauges to eliminate
washers (13) torque loaded to 40·7 Nm discrepancy due to bearing clearance.
(30 lbf.ft). Ensure that the inner races of the
delivery bearings revolve freely after securing 11. Position female rotor (23) to bearing housing
the end covers. bore and press into bearings (11) until
shims (22) are hard against balance
piston (20). Rotate rotor to ensure free running.
Carefully check clearance between rotor and
housing face with two sets of feeler gauges
positioned diametrically opposite each other.
Clearance should be within 0·05 – 0·10 mm
(0·002" – 0·004") tolerance.
Chapter 2, Page 34
FIG. 2.9 AIR-END 178·5 X 1·65 (C20438-40)
Chapter 2, Page 35
If clearance is not within limits, remove rotor 19. Pre-lubricate the rotors and bearings using the
and carry out necessary rectification by adding recommended compressor oil, and turn rotors
or subtracting shims. by hand to ensure distribution.
Note: 'First time' accuracy is important when If the air end is to be stored for more than
carrying out the procedures in item 11. fourteen days, or in hostile conditions, spray
approximately 10 cc of Astrolan DA362
12. Repeat procedure 11 for male rotor (8). Motorstor (or equivalent) into the inlet port
13. Position bearing housing/rotors assembly to ensuring that all internal parts are covered.
rotor locking fixture in vice. Fit the retaining Blank off inlet and discharge ports until ready
plates (17), new locking plates (16), and for use. All external machined surfaces should
screws (15) to the rotors at the delivery end. be similarly protected against corrosion.
Torque load the screws to 135·6 Nm
(100 lbf.ft). Lock tabs against flats. Note: Inhibitor provides a protected shelf life of 12
months.
14. Fit delivery end covers (14) with new ‘O’
rings (18), and secure with screws (12) and
washers (13) torque loaded to 40·7 Nm
(30 lbf.ft).

assembly to rotor casing (7) delivery end with
a new joint (21), ensuring that weight is
supported as rotors enter casing. Secure
bearing housing with bolts (32) and
washers (33), torque loaded to 135·6 Nm
(100 lbf.ft). Fit nuts (34) and washers (35) to
studs and secure.

bolts (29), (30) and washers (31) torque
loaded to 108·5 Nm (80 lbf.ft).
17. Fit the female inlet bearing retaining

plate (26), new locking plate (27), and
screw (28) to female rotor end (23). Position
rotor locking fixture to the male rotor (8),
keyway, allowing access to the female bearing
locking components. Torque load the screw to
135·6 Nm (100 lbf.ft). Lock tab against flat.
18. Fit circlips (2) and (25) to both male and

female bores of the inlet bearing housing (4).
Chapter 2, Page 36
Dismantling & Assembly – Gearbox C20438-1
7. GEARBOX C20438-1 (AIR-END 178.5 X 1.65 – C20438-40)
! WARNING !
7.1 Dismantling Procedure Note: The gear spacer (13) is sized to a particular
gear ratio (some ratios do not have a spacer). If it is
Note: The gearbox must still be secure to the air- intended to change the ratio during assembly,
end assembly or, alternatively the air-end must be reference should be made to the relevant parts list
available when re-assembling the gearbox. It is to ensure the correct spacer is fitted. This is also
assumed that the drive coupling and shaft key have applicable to the air-end pinion spacer (see relevant
previously been removed. Removal and Air-end Section).
subsequent re-fitting of these components is
described in the compressor Repair Manual. 6. Invert shaft (27) in the press and, using
suitable tooling, press the shaft through
Note 2: Tooling diagrams are contained in bearing (3) inner race.
Chapter 3.
7. Using suitable pulling equipment, remove
1. Remove plug (5) and bonded washer (6) from bearing (8) outer race from the air-end inlet
gear casing (4), and fit an M20 eyebolt. bearing housing.
2. Sling the gearbox from a crane to the eyebolt. 8. Remove screws (26) and washers (25)
Remove bolts (12), (21) and washers (11) and securing seal housing (24) to gear case (4).
(22) securing the gearbox to inlet bearing Using two of the screws (26) in the tapped
housing. jacking holes, remove seal housing (24).
Using suitable mandrel, remove and discard
CAUTION: When the gear casing (4) is separated the single piece oil seal (28). Remove and
from the inlet bearing housing within the gearbox, discard ‘O’ ring (1). Carefully remove shims
the shaft (27) and gear (23) assembly is not (2) from the gearbox and retain as a set for re-
positively retained within the gear casing (4). Steps use.
should be taken to ensure that the shaft/gear
assembly does not fall out when the gearbox is Note: It is important that the original shim pack is
craned from the air-end. kept as a complete set.
3. Separate the gearbox from the air-end using a 9. Using a suitable mandrel, remove bearing (3)
soft drift as necessary. Remove and discard outer race from gearcase (4), and discard the
joint (15). bearing.
4. Withdraw the shaft/gear assembly from 10. Remove the gear spray (16), coupling (17),
bearing (3) outer race and seal (28). Remove copper washer (18), oil restrictor (20), and
screw (10), locking plate (14), and retaining copper washer (19) from the gearcase (4).
plate (9) from the shaft (27).
5. Position the shaft/gear assembly to a press

with the small taper roller bearing (8)
uppermost. Using a suitable mandrel, press
the shaft (27) through the gear (23) and
bearing (8) inner race. Discard the bearing (8)
but retain the distance piece (7) and gear
spacer (13).
Chapter 2, Page 37

5. Apply Loctite 641 to the gearbox bearing (8)
CAUTION: Clean all components thoroughly before bore of the air-end inlet bearing housing.
assembly. Position the outer race of bearing (8) to the
inlet bearing housing and press home with
1. Inspect all components retained for re-use for tool 288076.
applicable. CAUTION: For the next stage of assembly it is
desirable to have the air-end assembly orientated
Responsibility for verifying that components vertically such that the air-end drive pinion is
are suitable for re-use rests with the repairer. uppermost. Ideally the air-end must be secured to a
Sound engineering practices should be fixture or dedicated clamp. In all cases the air-end
observed and advice sought if doubt exists. must be secure and safely restrained.
Remove burrs where necessary and ensure 6. Position the shaft/gear assembly to the air-end
joint faces are clean. Do not remove bearings and inlet bearing housing to engage both
from their packaging until required. Do not halves of bearing (8) and both drive gears.
interchange bearings or spaces of a matched
assembly with parts from another assembly. 7. Fit coupling (17) with copper washer (18) to
the gear casing (4) using Loctite 270. Ensure
Thoroughly degrease and clean all that the oil jet of the gear spray (16) is clear by
components, ensuring that all oil galleries are blowing through with compressed air. Position
clear. Re-fit plugs with Loctite 542. the gear spray (16) to coupling (17), ensuring
the blade is correctly located against gear
2. Fit gear spacer (13) (if applicable) and shaft casing (4), and secure. Lightly oil the main
key to shaft. Apply Loctite Super Clean Safety bore of gear casing (4).
Cleaner (or equivalent) to the gear diameter of
shaft (27), and the bore of gear (23). Allow the 8. Position a new joint (15) to the air-end inlet
cleaner to evaporate thoroughly. bearing housing, using two M16 studs to aid
alignment. Secure the gear casing (4) using
Apply Loctite 14486 to the shaft and key, screws (12), (21) and washer (11) and (22)
spreading it evenly with a brush. Position the torque loaded to 109 Nm (80 1bf.ft).
unheated gear to the shaft, gear face
identification ring facing the shaft shoulder, and 9. Position the outer race of bearing (3) to gear
press home to spacer (13) or the shaft casing bore (4) and press to meet the inner
shoulder if a spacer is not required. Remove race, using tool 288078.
any excess Loctite.
10. Position the original shim pack (2) (retained
3. Fit distance piece (7) to shaft (27). Position the as a set during disassembly) to the top face of
inner race of bearing (8), correctly orientated, bearing (3). Fit the seal housing (24), without
to the shaft and press home to the distance seal (28) or ‘O’ ring (1), to the gear casing (4)
piece using press tool 288077. Fit retaining and secure using screws (26) and washers
plate (9), ensuring that pin is correctly located. (25) torque loaded to 58 Nm (43 1bf.ft).
Fit new locking plate (14), and screw (10) to
the shaft end. Torque load the screw to 136 11. Position lifting tool 288080 to shaft (27) to rest
Nm (100 1bf.ft). Lock tab against flat. on the seal housing (24). Lock the tool to shaft
with the locking screw, position in the shaft
4. Invert shaft (27) in the press so that the gear keyway. Position a dial test indicator (DTI),
and bearing (8) are downward. Position mounted on a magnetic base, to the shaft end,
bearing (3) inner race, correctly orientated, to to allow checking of shaft end float.
the shaft and press home using press tool
288079.
Chapter 2, Page 38
FIG. 2.10 GEARBOX C20438-1 (AIR-END 178.5 X 1.65 – C20438-40)
Chapter 2, Page 39
Using the cam levers of the lifting tool, pull the

shaft upwards and measure maximum end
float. The shaft end float should be within
tolerance 0·013mm (0·0005") to 0·064mm
(0·0025"). If end float is outside these limits,
adjust shim pack thickness accordingly and
then re-check. Remove the DTI and lifting tool.
12. Remove seal housing (24). Using a suitable

mandrel, press a new single piece oil seal (28)
into seal housing (24).
Note: When fitting the single piece seal it is

supplied is coated with a sealant; after
pressing into the housing remove all traces of
residual sealant from the internal surfaces of
the seal housing.
13. Fit ‘O’ ring (1) to seal housing (24) and fit the
housing to gearbox, securing with screws (26)
and washers (25) torque loaded to 58 Nm
(43 1bf.ft)
14. Ensure the oil restrictor plug (20) is clear by

blowing through with compressed air. Fit the
restrictor plug and copper washer (19), to
gearbox .
15. Remove the eyebolt from gearbox and fit

plug (5) and washer (6).
If the gearbox and air-end are to be stored for

more than fourteen days, or in hostile
conditions, spray approximately 10 cc of
Astrolan DA32 Motorstor (or equivalent)
through the eyebolt hole while slowly turning
the gearbox shaft by hand.
All external machined surfaces should be also

be protected against corrosion.
Chapter 2, Page 40
8. AIR END 204 x 1·65 (C20437-201)
! WARNING !
● Refer to the safety precautions in Chapter 1 before proceeding with any of the following procedures.
8.1 Dismantling Procedure male and female rotors at approximately every

1/4 turn of each removal screw, progressively
Note !: It is assumed that the bellhousing, gearbox, jack housing/bearings from rotors. Remove
and all drive components, including the shaft key, tooling. Using two M12 eyebolts, remove
have been previously removed. Removal and bearing housing (13) ensuring balance
subsequent re-fitting of these components is pistons (9) (19) do not foul rotor shafts.
described in the compressor Repair Manual. Remove joint (7) and discard.
Note 2: Tooling diagrams are contained in 7. Using suitable tooling, remove delivery
Chapter 3. bearings (18) and balance pistons (9) (19)
from bearing housing (13). Ensure the balance
1. Open the tabs of locking plate (43). Remove pistons are not damaged during removal.
screws (42) and locking plate (43) securing Discard the bearings.
gear spray (29). Remove the gear spray and
joint (41). Discard the joint. Remove pinion 8. Using an M16 eyebolt, carefully remove each
spacer (30). rotor (6) (22) in turn. Remove rotor seal
sleeves (8) and shims (20).
2. Open the tabs of locking plate (28) at the inlet
end of female rotor shaft (22). Remove Note: One face of each sleeve is marked male or
screws (27) and locking components (26) (28). female.
3. Remove the screws (16) and washers (17) 9. Using suitable pulling equipment or splitting as
securing the delivery end cover (32). Remove necessary, remove the bearing inner rings
the cover and joint (31). Discard the joint. from the inlet end of the rotor shafts. Discard
Remove disc springs (15) and bearing the rings.
spacers (14).
10. Remove screws (36) and washers (37)
4. Using two M12 eyebolts in delivery housing securing cover (38) to rotor casing. Remove
end face (13), position air end vertically on to cover and joint (35). Discard joint.
suitable supports (e.g. two 6”x6” blocks) under
the inlet end. 11. Using the two M20 eyebolts in the inlet flange,
position rotor casing/inlet bearing housing to
5. Position the rotor locking plate 288101 to the horizontal. Remove the screws (39) and
rotors and secure using screws (27). Open washers (40) securing the inlet bearing
tabs on both delivery end locking plates (12). housing (3) to the rotor casing (5). Using
Remove the screws (11) and locking jacking screws separate the casings. The two
components (10) (12). Remove rotor locking dowels (23) remain in the rotor casing.
plate. Remove and discard the joint (4).
6. Remove screws (33) and washers (34) 12. Remove the inlet bearing circlips (2) (24).
securing delivery bearing housing (13). Screw Using suitable tooling, remove the male (1)
rotor pads 288103 into the delivery end of and female (25) bearings from the inlet
both rotors. Fit rotor removal plate 288102 to bearing housing (3). Discard the bearings.
the delivery bearing housing (13) and secure
using cover screws (16). Alternating between
Chapter 2, Page 41
8.2 Assembly Procedure 7. Using an M16 eyebolt, carefully lower each

rotor (6) (22) into the rotor casing in turn,
CAUTION: Clean all components thoroughly before ensuring inlet bearings engage correctly.
assembly.
8. Ensuring correct orientation, position the male
1 Inspect all components retained for re-use for balance piston (9) into the male bore of the
evidence of wear or damage, renewing as delivery bearing housing (13). Fit a pair of
applicable. delivery bearings (18), ensuring correct ‘face
to face’ orientation, into delivery bearing
Responsibility for verifying that components housing using tool 288104. Repeat for the
are suitable for re-use rests with the repairer. female bore.
Sound engineering practices should be
observed and advice sought if doubt exists. 9. Fit bearing spacers (14) to each bore of the
delivery bearing housing (13), followed by
Remove burrs where necessary and ensure each disc spring (15). Fit end cover (32) with
joint faces are clean. Do not remove bearings joint (31) and secure with screws (16) and
from their packaging until required. Do not washers (17) progressively torque loaded to
interchange bearings or spacers of a matched 98Nm (72 lbf. ft).
assembly with parts from another assembly.
10. To determine the depth of the male delivery
Thoroughly degrease and clean all balance piston from the face of the delivery
components, except bearings, ensuring that all bearing housing, first ensure the face is clean.
oil galleries are clear, and re-fitting plugs with Position the shim gauge 288108 into the male
Loctite 542. Lightly grease ‘O’ rings before bore to locate on the balance piston. Holding
fitting. the gauge firmly in position, accurately
measure with feeler gauges the gap between
2. Separate the inner ring from the new male inlet the gauge and the housing face. SUBTRACT
bearing (1) and degrease. Heat the inner ring the gap distance from the measurement
by induction or in an oven to 100-120°C and stamped on the gauge and note the new
then drop over the male rotor shaft (6), figure. Remove the gauge from the housing.
ensuring that the ring is hard against the
shoulder. Allow to cool in air – DO NOT USE 11. Accurately measure the length of the male
WATER. Repeat for the female inlet seal sleeve (8). SUBTRACT the sleeve
bearing (25) and rotor (22). dimension from the bearing housing
dimension to obtain the difference. To this
3. Degrease the outer race of a new male inlet figure ADD the required end clearance i.e.
bearing (1). Apply an even coat of Loctite 641 0·05-0·10mm (0·002”-0·004”). This new figure
to the bearing bore of the inlet bearing is the shim pack thickness required to achieve
housing (3). Position the bearing to tool the correct end clearance. Carefully measure
288106 and fit the bearing fully into the shims (20) to obtain the correct total
housing. Repeat for the female inlet thickness. Position the seal sleeve (8) to the
bearing (25) using tool 288107. male rotor (6), followed by the shims using a
small amount of grease to retain.
4. Fit circlips (2) (24) to the male and female
bearing bores of the inlet bearing housing (3). 12. Repeat procedures 10-11 for the female bore
and shaft (22).
housing (3) to the rotor casing (5) and secure 13. Remove delivery end cover (32), disc
with screws (39) and washers (40) torque springs (15), and bearing spacers (14). Using
loaded to 98Nm (72 lbf. ft). suitable tooling, carefully remove delivery
bearings (18) and balance pistons (9) (19)
6. Using two M12 eyebolts in delivery housing from bearing housing (13). Ensure the balance
and face (13), position rotor casing/bearing pistons are not damaged during removal.
housing onto suitable supports (e.g. two 6”x6” Identify each bearing pair as either male or
blocks) under the inlet end. female, and store as a pair until required.
Chapter 2, Page 42
FIG. 2.11 AIR END 204 X 1·65 (C20437-201)
Chapter 2, Page 43
14. Using two M12 eyebolts, fit delivery bearing The clearance should be within 0·05-0·10mm
housing (13) to rotor casing (5) with joint (7). (0·002”-0·004”) tolerance. If the clearance is
Secure housing using four equally spaced not within limits, remove the rotor and carry
screws only. out any necessary rectification by adding or
subtracting shims.
15. Ensuring correct orientation, position male
balance piston (9) into the male bore of the Note: ‘First time’ accuracy is important when
delivery bearing housing (13), over the rotor carrying out the procedures in item 17.
shaft. Position one of the male bearing
pair (18), correctly orientated, to the male bore 18. Carefully lower bearing housing/rotors into
of the bearing housing. Using tool 288104, fit rotor casing, ensuring inlet bearings engage
bearing into housing and over rotor shaft until correctly. Secure bearing housing to rotor
tool engages shaft. Remove tooling. casing using screws (33) and washers (34)
torque loaded to 98Nm (72 lbf. ft). Bend up
Position second bearing of male pair to tabs of locking plates (12) against flats.
bearing housing, ensuring ‘face to face’
orientation with installed bearing. Using tool 19. Fit bearing spacers (14), disc springs (15),
288104, fit bearing into housing and over rotor joint (31), and end cover (32). Secure end
shaft until sleeve (8), shims (20), and balance cover screws (16) and washers (17) torque
piston (9) are hard against the inner race of loaded to 98Nm (72 lbf. ft).
bearing (18). Remove tooling.
20. Fit cover (38) to rotor casing (5) with joint (35)
Combining clamp 288105 with plate of tool and secure with screws (36) and washers (37)
288104, and using two screws (16) to secure torque loaded to 57Nm (42 lbf. ft).
clamp, ensure bearing outer races are hard
against shoulder of housing. Repeat 21. Using two M20 eyebolts in the inlet flange,
procedure for female bore and rotor shaft. position the air end to the horizontal. Fit
retaining plate (26) and locking plate (28) to
16. Position the rotor locking plate 288101 to the female rotor shaft (22) and secure using
rotors at inlet end and secure using screws (27) torque loaded to 57Nm (42 lbf. ft).
screws (27). Fit retaining plates (10) and
locking plates (12) to rotor shafts and secure 22. Fit gear spray (29) with joint (41) and secure
using screws (11) torque loaded to 98Nm (72 using screws (42) and locking plate (43)
lbf. ft). DO NOT BEND UP TABS. Remove torque loaded to 98Nm (72 lbf. ft). Lock tabs
tooling. against flats.
Note: During procedure 17 it is important to use two 23. Pre-lubricate the rotors and bearings using the
sets of feeler gauges to eliminate any discrepancy specified compressor oil, and turn the rotors
due to bearing clearance. by hand to ensure distribution. If the air end is
to be stored for more than fourteen days, or in
17. Remove screws and washers securing hostile conditions, spray approximately 10cc
delivery bearing housing (13) to rotor of Astrolan DA362 Motorstor (or equivalent)
casing (5). Using two M12 eyebolts in delivery into the inlet port while turning the rotors
bearing housing end face, carefully withdraw slowly by hand, ensuring that all internal parts
housing/rotors from rotor casing sufficiently to are covered. Blank off inlet and discharge
allow measurement of the delivery end ports until ready for use. All external machined
clearance. Carefully check the clearance surfaces should be similarly protected against
between each rotor and the housing face with corrosion.
two sets of feeler gauges positioned
diametrically opposite each other. Note: Inhibitor provides a protected shelf life of 12
months.
Chapter 2, Page 44
9. GEARBOX C20437-4 (AIR-END 204 x 1·65 – C20437-201)
! WARNING !
9.1 Dismantling Procedure 9.2 Assembly Procedure
Note 1: It is assumed that the gearbox has been CAUTION: Clean all components thoroughly before
removed from the air-end assembly and the drive assembly.
coupling and shaft key have been removed from the
gearbox shaft. 1 Inspect all components retained for re-use for
Note 2: Tooling diagrams are contained in Chapter applicable.
3.
Responsibility for verifying that components
1. Remove the plug (3) and bonded seal (4) from are suitable for re-use rests with the repairer.
the gear casing (1) and fit a M20 eyebolt. Sound engineering practices should be
Using suitable lifting gear, move the gearbox observed and advice sought if doubt exists.
assembly to a bench , gear uppermost.
Remove burrs where necessary and ensure
2. Open tabs of locking plate (8). Remove joint faces are clean. Do not remove bearings
screws (9) and locking components (7) from their packaging until required. Do not
and (8). Using suitable pulling equipment interchange bearings or spacers of a matched
remove gear (5) and key (6). assembly with parts from another assembly.
3. Invert gearbox so that the seal housing (17) is Thoroughly degrease and clean all
uppermost. Remove screws (20) and components, except bearings, ensuring that
washers (21) securing the seal housing. all oil galleries are clear, and re-fitting plugs
Remove the seal housing and using a suitable with Loctite 542. Lightly grease ‘O’ rings
mandrel remove and discard the single piece before fitting.
oil seal (19). Remove and discard the ‘O’
ring (16). Note: Check that orientation is correct when fitting
bearings in item 2.
4. Withdraw shaft/bearing assembly from the
gear casing (1). Press the shaft (18) through 2. Position the inner race of bearing (13) on the
the bearings (12) and (13) and spacers (2) shaft (18) and press on to the shoulder using
and (11). Retain the spacers and shims (10). tool 288109. Select shims (10),
Discard the bearings. 0·50mm (0·020”) total thickness, and position
against bearing inner race. Fit the outer race
5. Remove the oil restrictor plug (14) and copper of bearing (13). Position inner (11) and
washer (15). outer (2) spacers to bearing (13).
Fit the outer race of bearing (12) followed by

the inner race using tool 288109 against the
spacer (11).
Chapter 2, Page 45
3. Enter the shaft/bearing assembly into the gear 8. Invert gearbox and place on suitable supports.
casing, resting against the shoulder. Fit the Fit key (6) to shaft (18). Apply Loctite Super
seal housing (17), without the ‘O’ ring or seal, Clean Safety Cleaner (or equivalent) to the
to the gear casing and secure using shaft and bore of the gear. Allow the cleaner
screws (20) and washers (21). Progressively to evaporate then heat the gear by induction
tighten to 30Nm (22 lbf.ft). or in an oven to 100-110°C.
4. Tap down the shaft to take up any end float. Apply Loctite 14486 to the shaft and key,
Position a dial test indicator, mounted on a spreading it evenly with a brush. Position the
magnetic base, to the end of the shaft and gear on the shaft with the gear face
using a M20 eyebolt pull the shaft upwards and identification ring facing the bearing (12) and
measure the maximum end float. The end float fit against the inner race. Remove excess
should be between 0·013mm (0·0005") and Loctite.
0·064mm (0·0025").
9. Fit retaining plate (7) with locking plate (8) and
If the measured end float is outside these secure using screws (9) torque loaded to 54
limits, disassemble the shaft from the bearings, Nm (40 lbf.ft). Lock tabs against flats.
adjust the shims and repeat the procedures in
items 2 and 3. Ensure that the inner race of 10. Remove the eyebolt from the gearbox. Fit
bearing (13) is fully supported when removing plug (3) with bonded seal (4) to gear
the shaft. casting (1).
Note: ‘First time’ accuracy is important when

carrying out the procedures in items 2 and 3.
5. When the correct end float has been achieved

remove the seal housing (17) and using a
suitable mandrel press a new single piece oil
seal (19) into the seal housing (17).
Note 1: It is important that the new seal is not

damaged or distorted in any way.
Note 2: The seal as supplied is coated with a

sealant. Ensure all traces of sealant are removed
from the internal surfaces of the seal housing after
fitting the seal.
6. Fit a new ‘O’ ring (16) to the seal housing and

fit the housing to the gearbox securing with
screws (20) and washers (21). Progressively
tighten to 30 Nm (22 lbf.ft).
7. Ensure the oil restrictor plug (14) is clear by

blowing through with compressed air. Fit the
restrictor plug to the gearbox with copper
washer (15).
Chapter 2, Page 46
FIG. 2.12 GEARBOX C20437-4 (AIR-END 204 X 1·65 – C20437-201)
Chapter 2, Page 47
Tooling Diagrams – SRM Air-ends
CHAPTER 3
SRM AIR-ENDS TOOLING DIAGRAMS
Contents
FIG. 3.1 MALE INLET BEARING OUTER RACE PRESS TOOLS
FIG. 3.2 FEMALE INLET BEARING OUTER RACE PRESS TOOLS
FIG. 3.3 DELIVERY BEARING PRESS TOOLS
FIG. 3.4 SHIM GAUGES A
FIG. 3.5 SHIM GAUGES B
FIG. 3.6 DELIVERY BEARING SUPPORTS
FIG. 3.7 ROTOR LOCKING FIXTURE 288003
FIG. 3.12 LOCKNUT SPANNER 288004
FIG. 3.13 GEARBOX BEARING PRESS TOOLS
FIG. 3.14 GEARBOX SHAFTLIFTING TOOL 288080
FIG. 3.15 ROTOR LOCKING PLATE 288101
FIG. 3.16 ROTOR REMOVAL PLATE AND SCREWS 288102
FIG. 3.17 ROTOR REMOVAL PAD 288103
FIG. 3.18 BEARING ASSEMBLY PLATE 288104
FIG. 3.19 DELIVERY BEARING CLAMP 288105
FIG. 3.20 GEARBOX BEARING ASSEMBLY TOOL 288109
Chapter 3, Page 1
FIG. 3.1 MALE INLET BEARING OUTER RACE PRESS TOOLS
Chapter 3, Page 2
FIG. 3.2 FEMALE INLET BEARING OUTER RACE PRESS TOOLS
Chapter 3, Page 3
FIG. 3.3 DELIVERY BEARING PRESS TOOLS
Chapter 3, Page 4
FIG. 3.4 SHIM GAUGES A
Chapter 3, Page 5
FIG. 3.5 SHIM GAUGES B
Chapter 3, Page 6
FIG. 3.6 DELIVERY BEARING SUPPORTS
Chapter 3, Page 7
Chapter 3, Page 8
Chapter 3, Page 9
Chapter 3, Page 10
Chapter 3, Page 11
Chapter 3, Page 12
FIG. 3.12 LOCKNUT SPANNER 288004
Chapter 3, Page 13
FIG. 3.13 GEARBOX BEARING PRESS TOOLS
Chapter 3, Page 14
FIG. 3.14 GEARBOX SHAFT LIFTING TOOL 288080
Chapter 3, Page 15
FIG. 3.15 ROTOR LOCKING PLATE 288101
Chapter 3, Page 16
FIG. 3.16 ROTOR REMOVAL PLATE AND SCREWS 288102
Chapter 3, Page 17
FIG. 3.17 ROTOR REMOVAL PAD 288103
Chapter 3, Page 18
FIG. 3.18 BEARING ASSEMBLY PLATE 288104
Chapter 3, Page 19
FIG. 3.19 DELIVERY BEARING CLAMP 288105
FIG. 3.20 GEARBOX BEARING ASSEMBLY TOOL 288109
Chapter 3, Page 20
Dismantling & Assembly – Cyclon 1 Air-end
CHAPTER 4
CYCLON AIR-ENDS
DISASSEMBLY & ASSEMBLY PROCEDURES
Contents
CYCLON AIR-ENDS – COMPRESSOR MODEL REFERENCE GUIDE

1. CYCLON 1 AIR-END (C20461-40)
1.1 Dismantling Procedure, Basic Air–end
1.2 Assembly Procedure, Basic Air-end
2.1 Dismantling Procedure, Basic Air–End
5. GEARBOX C20465-1 (CYCLON 4 AIR-END 105 X 2·3 – C20465-40)
5.1 Dismantling Procedure, Gearbox from Gearbox Adaptor/Air-end
5.2 Dismantling Procedure, Gearbox Adaptor from Air-end
5.4 Assembly Procedure, Gearbox to Gearbox Adaptor/Air-end
7.3 Assembly Procedure, Gearbox Adaptor to Air-end
Continued
Chapter 4, Page 1
FIGURES
FIG. 4.1 CYCLON 1 AIR-END (55 X 1·8 C20461-40)
FIG. 4.2 CYCLON 1 – TORQUE TIGHTENING SEQUENCE, BEARING HOUSING & COVER
FIG. 4.3 CYCLON 1 – TORQUE TIGHTENING SEQUENCE, DRIVE END COVER PLAT
FIG. 4.8 CYCLON 3 – TORQUE TIGHTENING SEQUENCE
FIG. 4.11 GEARBOX C20465-1 (Cyclon 4 Air-end 105 x 2·3 – C20465-40)
FIG. 4.12 GEARBOX C20465-1 – TORQUE TIGHTENING SEQUENCE
Chapter 4, Page 2
CYCLON AIR-ENDS – COMPRESSOR MODEL REFERENCE GUIDE
Compressor Air-end Part No., Drive arrangement

Basic Air-end
6005N to 6015N Cyclon 1 – 55 x 1·8 C20461-40 belt
6020N; 6025N Cyclon 2 – 74 x 1·8 C20463-40 belt
6040N; 6050N Cyclon 3 – 90 x 2·3 C20464-40 belt
6060N; 6075N Cyclon 4 – 105 x 2·3 C20465-40 direct drive or

Gearbox C20465-1 gear drive
6100N; 6125N; 6150N Cyclon 5 – 135 x 2·3 C20466-40 direct drive or

6180N; 6220N Cyclon 6 – 165 x 2·3 C20467-40 direct drive or

Note: Cyclon air-ends are also supplied to other compressor manufacturers who may utilise other drive
arrangements.
Chapter 4, Page 3
! WARNING !
1.1 Dismantling Procedure, Basic Air–end 6. Transfer bearing housing/rotor assembly to

suitable securely mounted fixture and support
on bearing housing joint face with rotors
Note 1: Before commencing this procedure hanging down. Fit rotor locking fixture
preliminary dismantling must include removal of all (Chapter 5, Fig.5.1) to prevent rotors from
drive components, including shaft key. turning.
Note 2: Annotations in brackets refer to Fig. 4.1. CAUTION: In operations 7, 8, 9 and 10 below it is
essential for safety reasons that bearing nuts are
Note 3: Tooling diagrams are contained in not disengaged from the threads until rotors are
Chapter 5. properly supported. Shaft/bearing tolerances may
make it possible for rotors to pull clear of bearings
1. Mount air-end securely, preferably in suitable under weight alone with consequent risk of injury.
rotating jig, with drive end uppermost.
7. Apply heat locally to bearing nut (6) on male
2. Remove screws and washers from drive end rotor shaft (3) to weaken assembly sealant.
cover plate (16) and remove cover. Remove This can be achieved by heating a suitable
gasket and discard. mild steel tube and placing it over shaft to rest
on bearing nut. Allow nut to absorb heat for
3. Remove circlip (13) from female rotor shaft. 2-3 minutes. Use special socket (Chapter 5,
Rotate jig to bring delivery end uppermost. Fig. 5.2) and pneumatic impact wrench to
slacken bearing nut on male rotor shaft (LH
4. Remove screws/spring washers from delivery thread). Do not remove nut.
end bearing housing cover (7) and remove
cover. 8. Repeat operation 7 on female rotor shaft (10)
using special socket (Chapter 5, Fig. 5.2) to
Remove screws, capscrew and washers from slacken bearing nut (8) on female rotor shaft
delivery end bearing housing (4). Separate (RH thread). Do not remove nut. Remove
bearing housing from rotor casing, using rotor locking fixture.
jacking screws in threaded holes.
9. Support male rotor securely and remove
5. Fit extended eyebolts in jacking holes of bearing nut from male rotor shaft. If
bearing housing. Attach lifting tackle and lift necessary, use suitable mandrel to press out
bearing housing and rotors clear of rotor male rotor shaft from delivery end bearings.
casing (2). Inner races of both drive end
bearings will be withdrawn with rotors. 10 Repeat operation 9 for female rotor shaft. Set
aside both rotors.
Chapter 4, Page 4
11. Lift out inner races of both rotor taper roller 3. Apply Loctite ‘Activator T’ to both roller
bearings (5) and (9). bearing bores in rotor casing, covering whole
circumference. Allow to dry for at least 2
12. Use suitable puller to remove outer bearing minutes.
races from both rotor bearing bores.
4. Select new roller bearings (1) and (11), and
13. Remove circlip (12) from inlet end of rotor use suitable solvent to clean external surface
casing (if fitted). only of both outer races. Re-wrap bearing
cages and inner races for protection and set
Support rotor casing (2) on wood blocks under aside.
inlet end. Use suitable tool to tap out outer
races of both roller bearings (1) and (11) from 5. Apply even coating of Loctite 641 to both
casing. bearing bores in rotor casing and using
suitable mandrels press in both roller bearing
Note: Drive end oil seal (15) and male rotor outer outer races. Clean off excess Loctite. Remove
roller bearing race will be removed together. rotor casing from press. If relevant, fit circlip
(12) in female rotor bearing bore.
14. Use split collar and suitable puller to remove
inner race of roller bearing from female rotor 6. Mount delivery end bearing housing (4) under
shaft. Repeat for male rotor shaft using split press, cover joint face uppermost. Wipe clean
collar to remove bearing race and sleeve (14) bearing bores.
together.
7. Select new taper roller bearings, (5) and (9),
15. Carefully clean dismantled parts, removing all for both rotors and use suitable solvent to
traces of gasket material, inspect and set aside clean external surface only of outer races. Re-
ready for re-assembly. Discard all old bearing, wrap inner races for protection and set aside.
seals and gaskets.
8. Apply even coating of Loctite 641 to both
bearing bores in housing and using suitable
1.2 ASSEMBLY PROCEDURE, BASIC AIR-END mandrels press in both outer races to locate
firmly against abutments. Clean off excess
CAUTION: Clean all components thoroughly before Loctite.
assembly.
9. Transfer female rotor (10) to press, inlet end
1. Inspect all components retained for re-use for uppermost. Use suitable tube mandrel to
evidence of wear or damage, renewing as press inner race of roller bearing (11) on to
applicable. Responsibility for verifying that shaft to locate firmly against shoulder.
the repairer. Sound engineering practices 10. Place inner races of both taper roller bearings,
should be observed and advice sought if doubt (5) and (9), on suitable supports (refer to
exists. Chapter 5, Fig. 5.3 for guidance) and invert
bearing housing over them to locate in
Remove burrs where necessary and ensure position on outer races.
joint faces are clean. Do not remove bearings
from packaging until required or interchange 11. Carefully lower female rotor into bearing
bearings or spacers of a matched assembly housing. Press rotor shaft into inner race of
with parts of another assembly. taper roller bearing to leave gap between rotor
end face and bearing housing of 0.25mm
Thoroughly de-grease and clean all (0.010in).
clear. Refit plugs with Loctite 542. 12. Carefully lower male rotor (3) into bearing
housing, meshing with female rotor. Press
2. Mount rotor casing (2) under press, drive end rotor shaft into inner race of taper roller
uppermost. bearing to leave gap between rotor end face
and bearing housing of 0.25mm (0.010in).
Chapter 4, Page 5
12 13 14 15 16
11
10 3
8 7 6
Chapter 4, Page 6
13. Lift bearing housing/rotor assembly off fixture. Use two feeler gauges simultaneously on
Fit bearing nut (8) to female rotor shaft and opposite sides of rotor and check several
hand tighten (RH thread). Fit bearing nut (6) times that correct clearance is maintained,
to male rotor shaft and hand tighten (LH turning rotors by hand between checks.
thread).
Fit rotor locking fixture. Remove bearing nut
Lightly lubricate both bearings on both shafts from male rotor shaft and clean nut and shaft.
with clean compressor oil. Apply a coating of Loctite 641 to shaft thread,
abutment face of nut and face of bearing inner
14. Set final end clearance of female rotor as race. Re-fit nut to male rotor shaft and tighten
follows: to torque of 15Nm (11lb ft). Remove rotor
locking fixture.
CAUTION: Rotor end clearance is critical to air-end
performance. Take great care to set it accurately. 16. Spin rotors by hand to check freedom and
smooth rotation. Invert assembly to bring rotor
Support bearing housing/rotor assembly shafts uppermost. Lightly oil face of bearing
securely on inner face of bearing housing with housing under rotor end faces. Spin rotors by
rotors hanging vertically downwards. Fit rotor hand again to check freedom and smooth
locking fixture to prevent rotation. Use special rotation.
socket to tighten bearing nut on female rotor
shaft (RH thread) to draw shaft up into 17. Take inner race of male rotor drive end roller
bearing until gap between rotor end face and bearing (1) and wipe clean. Place in suitable
bearing housing is between 0.050mm and oven or on pole bar of induction heater and
0.025mm (0.002in and 0.001in). Remove rotor heat to 100oC – 120oC.
locking fixture.
18. Clean bearing diameter of male rotor shaft.
Use two feeler gauges simultaneously on Wear gloves to remove roller bearing inner
opposite sides of rotor and check several race from heat and place it immediately over
times that correct clearance is maintained, male rotor shaft to locate firmly with shoulder.
turning rotors by hand between checks. Allow to cool.
Fit rotor locking fixture. Remove bearing nut 19. Transfer rotor casing (2) to secure fixture,
from female rotor shaft and clean nut and mounting with rotor bores vertical and delivery
shaft. Apply a coating of Loctite 641 to shaft end uppermost. Check dowels in joint face are
thread, abutment face of nut and face of secure and undamaged. Place new gasket on
bearing inner race. Re-fit nut to female rotor joint face.
shaft and tighten to torque of 10Nm (7.5lb ft).
20. Invert bearing housing/rotor assembly and fit
15. Set final end clearance of male rotor as M8 extended eyebolts in threaded holes in
follows: flange of bearing housing. Attach lifting gear
and position rotors over rotor casing. Carefully
CAUTION: Rotor end clearance is critical to air-end lower until rotors are entered into bores.
performance. Take great care to set it accurately.
21. Lift gasket from joint face and position it
Support bearing housing/rotor assembly loosely near top of rotors. Continue carefully
securely on inner face of bearing housing with lowering rotors until almost fully home. When
rotors hanging vertically downwards. Fit rotor there is no further risk of damaging gasket,
locking fixture to prevent rotation. Use special replace gasket on joint face over dowels.
socket to tighten bearing nut on male rotor Lower rotors fully, making sure dowels are
shaft (LH thread) to draw shaft up into entered into bearing housing flange. Tap
bearing until gap between rotor end face and gently with soft mallet to close joint. Remove
bearing housing is between 0.050mm and lifting gear and eyebolts.
0.025mm (0.002in and 0.001in). Remove rotor
locking fixture.
Chapter 4, Page 7
2 6 4
4
2
8
1
5 5 7
3 7
3 1
22. Fit screws and washers and tighten 25. Fit circlip (13) to female rotor shaft. Lightly oil
progressively in sequence shown in Fig. 4.2 to roller bearings with clean compressor oil and
a torque of 28Nm (21lb ft). spin rotors by hand to distribute oil.
23. Fit new gasket to bearing housing joint face 26. Fit slave mounting sleeve over male rotor
and fit bearing housing cover (7). Fit screws shaft to cover keyway completely. Select new
and washers and tighten progressively in drive end oil seal (15). Carefully locate oil seal
sequence shown in Fig.4.2 to torque of 12Nm over sleeve and press into place to bring outer
(9lb ft). face of seal flush with rotor casing. Wipe off
excess sealant from round outer perimeter of
24. Invert assembly to bring drive end uppermost. seal. Remove slave sleeve.
Clean diameter of male rotor shaft and bore of
sleeve (14). Coat bore of sleeve lightly with Note: DO NOT lubricate either sleeve or seal
Loctite 932. Place sleeve over male rotor shaft during fitting.
with taper towards bearing to locate against
bearing inner race. Wipe off excess Loctite. CAUTION: Seal must not be pressed beyond flush
position as this might cause obstruction of oilway to
bearings.
Chapter 4, Page 8
27. Fit gasket and cover (16) to rotor casing.

Secure cover with screws and washers and
tighten progressively in sequence shown in
Fig.4.3 to torque of 12Nm (9lb ft).
Basic air-end is now ready to receive drive

components.
1
4
5 6
FIG. 4.3 CYCLON 1 – TORQUE TIGHTENING SEQUENCE, DRIVE END COVER PLATE
Chapter 4, Page 9
! WARNING !
2.1 Dismantling Procedure, Basic Air–End CAUTION: In operations 7, 8, 9 and 10 below it is

Note 1: Before commencing this procedure not disengaged from the threads until rotors are
preliminary dismantling must include removal of all properly supported. Shaft/bearing tolerances may
drive components, including shaft key. make it possible for rotors to pull clear of bearings
under weight alone with consequent risk of injury.
Note 2: Annotations in brackets refer to Fig. 4.4.
7. Apply heat locally to bearing nut (6) on male
Note 3: Tooling diagrams are contained in rotor shaft (3) to weaken assembly sealant.
Chapter 5. This can be achieved by heating a suitable
mild steel tube and placing it over shaft to rest
1. Mount air-end securely, preferably in suitable on bearing nut. Allow nut to absorb heat for
rotating jig, with drive end uppermost. 2-3 minutes. Use special socket (Chapter 5,
Fig. 5.2) and pneumatic impact wrench to
2. Remove screws and washers from drive end slacken bearing nut on male rotor shaft (LH
cover plate (16) and remove cover. Remove thread). Do not remove nut.
gasket and discard.
8. Repeat operation 7 on female rotor shaft (10)
3. Remove circlip (13) from female rotor shaft. using special socket (Chapter 5, Fig. 5.2) to
Rotate jig to bring delivery end uppermost. slacken bearing nut (8) on female rotor shaft
(RH thread). Do not remove nut. Remove
4. Remove screws/spring washers from delivery rotor locking fixture.
end bearing housing cover (7) and remove
cover. 9. Support male rotor securely and remove
bearing nut from male rotor shaft. If
Remove screws, capscrew and washers from necessary, use suitable mandrel to press out
delivery end bearing housing (4). Separate male rotor shaft from delivery end bearings.
bearing housing from rotor casing, using
jacking screws in threaded holes. 10 Repeat operation 9 for female rotor shaft. Set
aside both rotors.
5. Fit extended eyebolts in jacking holes of
bearing housing. Attach lifting tackle and lift 11. Lift out inner races of both rotor taper roller
bearing housing and rotors clear of rotor bearings (5) and (9).
casing (2). Inner races of both drive end
bearings will be withdrawn with rotors. 12. Use suitable puller to remove outer bearing
races from both rotor bearing bores.
6. Transfer bearing housing/rotor assembly to
suitable securely mounted fixture and support
on bearing housing joint face with rotors
hanging down. Fit rotor locking fixture
(Chapter 5, Fig.5.1) to prevent rotors from
turning.
Chapter 4, Page 7
13. Remove circlip (12) from inlet end of rotor 4. Select new roller bearings (1) and (11), and
casing (if fitted). use suitable solvent to clean external surface
only of both outer races. Re-wrap bearing
Support rotor casing (2) on wood blocks under cages and inner races for protection and set
inlet end. Use suitable tool to tap out outer aside.
races of both roller bearings (1) and (11) from
casing. 5. Apply even coating of Loctite 641 to both
bearing bores in rotor casing and using
Note: Drive end oil seal (15) and male rotor outer suitable mandrels press in both roller bearing
roller bearing race will be removed together. outer races. Clean off excess Loctite. Remove
rotor casing from press. If relevant, fit circlip
14. Use split collar and suitable puller to remove (12) in female rotor bearing bore.
inner race of roller bearing from female rotor
shaft. Repeat for male rotor shaft using split 6. Mount delivery end bearing housing (4) under
collar to remove bearing race and sleeve (14) press, cover joint face uppermost. Wipe clean
together. bearing bores.
15. Carefully clean dismantled parts, removing all 7. Select new taper roller bearings, (5) and (9),
traces of gasket material, inspect and set for both rotors and use suitable solvent to
aside ready for re-assembly. Discard all old clean external surface only of outer races. Re-
bearing, seals and gaskets. wrap inner races for protection and set aside.
8. Apply even coating of Loctite 641 to both

2.2 Assembly Procedure, Basic Air-end bearing bores in housing and using suitable
mandrels press in both outer races to locate
CAUTION: Clean all components thoroughly before firmly against abutments. Clean off excess
assembly. Loctite.
1. Inspect all components retained for re-use for 9. Transfer female rotor (10) to press, inlet end
evidence of wear or damage, renewing as uppermost. Use suitable tube mandrel to
applicable. Responsibility for verifying that press inner race of roller bearing (11) on to
components are suitable for re-use rests with shaft to locate firmly against shoulder.
the repairer. Sound engineering practices
should be observed and advice sought if doubt 10. Place inner races of both taper roller bearings,
exists. (5) and (9), on suitable supports (refer to
Chapter 5, Fig. 5.3 for guidance) and invert
Remove burrs where necessary and ensure bearing housing over them to locate in
joint faces are clean. Do not remove bearings position on outer races.
from packaging until required or interchange
bearings or spacers of a matched assembly 11. Carefully lower female rotor into bearing
with parts of another assembly. housing. Press rotor shaft into inner race of
taper roller bearing to leave gap between rotor
Thoroughly de-grease and clean all end face and bearing housing of 0.25mm
components, ensuring that all oil galleries are (0.010in).
clear. Refit plugs with Loctite 542.
12. Carefully lower male rotor (3) into bearing
2. Mount rotor casing (2) under press, drive end housing, meshing with female rotor. Press
uppermost. rotor shaft into inner race of taper roller
bearing to leave gap between rotor end face
3. Apply Loctite ‘Activator T’ to both roller bearing and bearing housing of 0.25mm (0.010in).
bores in rotor casing, covering whole
circumference. Allow to dry for at least 2
minutes.
Chapter 4, Page 8
13 14 15 16
1
12
2
11
3
10
5
9
8 7 6
Chapter 4, Page 9
13. Lift bearing housing/rotor assembly off fixture. Use two feeler gauges simultaneously on
Fit bearing nut (8) to female rotor shaft and opposite sides of rotor and check several
hand tighten (RH thread). Fit bearing nut (6) times that correct clearance is maintained,
to male rotor shaft and hand tighten (LH turning rotors by hand between checks.
thread).
Lightly lubricate both bearings on both shafts from male rotor shaft and clean nut and shaft.
with clean compressor oil. Apply a coating of Loctite 641 to shaft thread,
14. Set final end clearance of female rotor as race. Re-fit nut to male rotor shaft and tighten
follows: to torque of 15Nm (11lb ft). Remove rotor
locking fixture.
CAUTION: Rotor end clearance is critical to air-end
performance. Take great care to set it accurately. 16. Spin rotors by hand to check freedom and
Support bearing housing/rotor assembly shafts uppermost. Lightly oil face of bearing
securely on inner face of bearing housing with housing under rotor end faces. Spin rotors by
rotors hanging vertically downwards. Fit rotor hand again to check freedom and smooth
locking fixture to prevent rotation. Use special rotation.
socket to tighten bearing nut on female rotor
shaft (RH thread) to draw shaft up into 17. Take inner race of male rotor drive end roller
bearing until gap between rotor end face and bearing (1) and wipe clean. Place in suitable
bearing housing is between 0.050mm and oven or on pole bar of induction heater and
0.025mm (0.002in and 0.001in). Remove rotor heat to 100oC – 120oC.
locking fixture.
shaft. Apply a coating of Loctite 641 to shaft end uppermost. Check dowels in joint face are
thread, abutment face of nut and face of secure and undamaged. Place new gasket on
bearing inner race. Re-fit nut to female rotor joint face.
shaft and tighten to torque of 10Nm (7.5lb ft).
15. Set final end clearance of male rotor as M8 extended eyebolts in threaded holes in
follows: flange of bearing housing. Attach lifting gear
and position rotors over rotor casing. Carefully
CAUTION: Rotor end clearance is critical to air-end lower until rotors are entered into bores.
performance. Take great care to set it accurately.
21. Lift gasket from joint face and position it
Support bearing housing/rotor assembly loosely near top of rotors. Continue carefully
securely on inner face of bearing housing with lowering rotors until almost fully home. When
rotors hanging vertically downwards. Fit rotor there is no further risk of damaging gasket,
locking fixture to prevent rotation. Use special replace gasket on joint face over dowels.
socket to tighten bearing nut on male rotor Lower rotors fully, making sure dowels are
shaft (LH thread) to draw shaft up into entered into bearing housing flange. Tap
bearing until gap between rotor end face and gently with soft mallet to close joint. Remove
bearing housing is between 0.050mm and lifting gear and eyebolts.
0.025mm (0.002in and 0.001in). Remove rotor
locking fixture.
Chapter 4, Page 10
5
2
4
7
8
7 6
4 1 3
5 3 8
9
10
6 1
22. Fit screws and washers and tighten 25. Fit circlip (13) to female rotor shaft. Lightly oil
progressively in sequence shown in Fig. 4.5 to roller bearings with clean compressor oil and
a torque of 28Nm (21lb ft). spin rotors by hand to distribute oil.
23. Fit new gasket to bearing housing joint face 26. Fit slave mounting sleeve over male rotor
and fit bearing housing cover (7). Fit screws shaft to cover keyway completely. Select new
and washers and tighten progressively in drive end oil seal (15). Carefully locate oil seal
sequence shown in Fig.4.5 to torque of 12Nm over sleeve and press into place to bring outer
(9lb ft). face of seal flush with rotor casing. Wipe off
excess sealant from round outer perimeter of
24. Invert assembly to bring drive end uppermost. seal. Remove slave sleeve.
sleeve (14). Coat bore of sleeve lightly with Note: DO NOT lubricate either sleeve or seal
Loctite 932. Place sleeve over male rotor shaft during fitting.
with taper towards bearing to locate against
bearing inner race. Wipe off excess Loctite. CAUTION: Seal must not be pressed beyond flush
position as this might cause obstruction of oilway to
bearings.
Chapter 4, Page 11
27. Fit gasket and cover (16) to rotor casing.

Secure cover with screws and washers and
tighten progressively in sequence shown in
Fig.4.6 to torque of 12Nm (9lb ft).
Basic air-end is now ready to receive drive

components.
1
4
2
6 5
3 7
Fig. 4.6 CYCLON 2 – TORQUE TIGHTENING SEQUENCE, DRIVE END COVER PLATE
Chapter 4, Page 12
! WARNING !

not disengaged from the threads until rotors are
Note 1: Before commencing this procedure properly supported. Shaft/bearing tolerances may
preliminary dismantling must include removal of all make it possible for rotors to pull clear of bearings
drive components, including shaft key. under weight alone with consequent risk of injury.
Note 2: Annotations in brackets refer to Fig. 4.7. 6. Apply heat locally to bearing nut (6) on male
rotor shaft (3) to weaken assembly sealant.
Note 3: Tooling diagrams are contained in This can be achieved by heating a suitable
Chapter 5. mild steel tube and placing it over shaft to rest
on bearing nut. Allow nut to absorb heat for 2-
3 minutes. Use special socket (Chapter 5,
1. Mount air-end securely, preferably in suitable Fig. 5.2) and pneumatic impact wrench to
rotating jig, with drive end uppermost. slacken bearing nut on male rotor shaft (LH
thread). Do not remove nut.
2. Remove circlip (15) from female rotor shaft.
Rotate jig to bring delivery end uppermost. 7. Repeat operation 6 on female rotor shaft (12)
3. Remove screws/spring washers from delivery slacken bearing nut (9) on female rotor shaft
end bearing housing cover (7) and remove (RH thread). Do not remove nut. Remove
cover. rotor locking fixture.
Remove screws, capscrew and washers from 8. Support male rotor securely and remove
delivery end bearing housing (4). Separate bearing nut from male rotor shaft. If
bearing housing from rotor casing, using necessary, use suitable mandrel to press out
jacking screws in threaded holes. male rotor shaft from delivery end bearings.
4. Fit extended eyebolts in jacking holes of 9. Repeat operation 8 for female rotor shaft. Set
bearing housing. Attach lifting tackle and lift aside both rotors.
bearing housing and rotors clear of rotor
casing (2). Inner races of both drive end 10. Lift out inner race of male rotor taper roller
bearings will be withdrawn with rotors. bearing (5). Remove circlip (8) and spacer (9)
from female rotor bearing bore.
suitable securely mounted fixture and support 11. Use suitable puller to remove outer bearing
on bearing housing joint face with rotors race from male rotor bearing bore. Invert
hanging down. Fit rotor locking fixture bearing housing and use suitable mandrel to
(Chapter 5, Fig. 5.1) to prevent rotors from tap out matched taper roller bearings (11)
turning. from female rotor bearing bore.
Chapter 4, Page 13
12. Remove circlip (14) from inlet end of rotor 5. Apply even coating of Loctite 641 to both
casing (if fitted). bearing bores in rotor casing and using
Support rotor casing (2) on wood blocks under outer races. Clean off excess Loctite.
inlet end. Use suitable tool to tap out outer Remove rotor casing from press. If relevant,
races of both roller bearings (1) and (13) from fit circlip (14) in female rotor bearing bore.
casing.
6. Mount delivery end bearing housing (4) under
13. Use split collar and suitable puller to remove press, cover joint face uppermost. Wipe clean
inner race of roller bearing from female rotor bearing bores.
shaft. Repeat for male rotor shaft using split
collar to remove bearing race and sleeve (16) 7. Select new taper roller bearing (5) for male
together. rotor and use suitable solvent to clean
external surface only of outer race. Re-wrap
14. Carefully clean dismantled parts, removing all bearing cage and inner race for protection
traces of gasket material, inspect and set and set aside.
aside ready for re-assembly. Discard all old
bearing, seals and gaskets. 8. Apply even coating of Loctite 641 to male
rotor bearing bore only in bearing housing.
Use suitable mandrel to press in outer race of
3.2 Assembly Procedure, Basic Air-end male rotor taper roller bearing to locate firmly
against abutment. Clean off excess Loctite.
CAUTION: Clean all components thoroughly before 9. Select new matched pair of taper roller
assembly. bearings (11) and separating spacer for
female rotor. Use suitable solvent to clean
1. Inspect all components retained for re-use for external surfaces only of outer races. Use
evidence of wear or damage, renewing as suitable mandrel to press in both bearings,
applicable. Responsibility for verifying that complete with spacer between, into bearing
components are suitable for re-use rests with housing to locate firmly against abutment.
should be observed and advice sought if 10. Set pre-load of matched taper roller bearings
doubt exists. as follows:-
Remove burrs where necessary and ensure Fit circlip (8) into groove in bearing bore,
joint faces are clean. Do not remove bearings taper face outwards. Use slip gauges to
from packaging until required or interchange measure gap between circlip and outer race
bearings or spacers of a matched assembly of bearing. Remove circlip. Select spacer (10)
with parts of another assembly. from set of three which is next greater in
thickness than measured gap. Clean spacer
Thoroughly de-grease and clean all and fit into bearing bore to locate against
components, ensuring that all oil galleries are bearing outer race. Fit circlip into groove with
clear. Refit plugs with Loctite 542. taper face outwards.
2. Mount rotor casing (2) under press, drive end 11. Transfer female rotor (12) to press, inlet end
uppermost. uppermost. Press inner race of roller bearing
(13) on to drive end of rotor shaft to locate
3. Apply Loctite ‘Activator T’ to both roller firmly against shoulder.
bearing bores in rotor casing, covering whole
circumference. Allow to dry for at least 2 12. Place inner race of male rotor taper roller
minutes. bearing on suitable support under press and
position similar support for inner race of
4. Select new roller bearings (1) and (13) and female rotor taper roller bearings (refer to
use suitable solvent to clean external surface Chapter 5, Fig. 5.3 for guidance). Invert
only of both outer races. Re-wrap bearing bearing housing over the supports to locate in
cages and inner races for protection and set correct position.
aside.
Chapter 4, Page 14
14 15 16
13
2
12
11
10 9 8 7 6
Chapter 4, Page 15
13. Carefully lower female rotor into bearing Support bearing housing/rotor assembly
housing and use suitable mandrel to press securely on inner face of bearing housing,
rotor shaft into inner bearing race to leave with rotors hanging vertically downwards. Fit
gap between rotor end face and bearing rotor locking fixture to prevent rotation. Use
housing of 0.25mm (0.010in). Fit bearing nut special socket to tighten bearing nut on male
(9) and hand tighten (RH thread). rotor shaft (LH thread) to draw shaft up into
bearings until gap between rotor end face and
14. Fit M10 eyebolt into drive end of male rotor bearing housing is between 0.050mm and
shaft and attach lifting gear. Carefully lower 0.025mm (0.002in and 0.001in). Remove
male rotor shaft into bearing housing, rotor locking fixture.
meshing with female rotor. Remove eyebolt
and use suitable mandrel to press rotor shaft Use two feeler gauges simultaneously on
into inner bearing race to leave gap between opposite sides of rotor and check several
rotor end face and bearing housing of times that correct clearance is maintained,
0.25mm (0.010in). Fit bearing nut (6) and turning rotors by hand between checks.
hand tighten (LH thread).
Lightly lubricate bearings on both shafts with from male rotor shaft and clean nut and shaft.
clean compressor oil. Apply a coating of Loctite 641 to shaft thread,
abutment face of nut and face of bearing
15. Set final end clearance of female rotor as inner race. Re-fit nut to male rotor shaft and
follows: tighten to torque of 41Nm (30lb ft). Remove
rotor locking fixture.
CAUTION: Rotor end clearance is critical to air-
end performance. Take great care to set it 17. Spin rotors by hand to check freedom and
accurately. smooth rotation. Invert assembly to bring rotor
shafts uppermost. Lightly lubricate face of
Support bearing housing/rotor assembly bearing housing under rotor end faces with
securely, with rotors extending vertically clean compressor oil. Spin rotors by hand
upwards. Fit rotor locking fixture to prevent again to check freedom and smooth rotation.
rotation. Use special socket to tighten bearing
nut on female rotor shaft (RH thread) to draw 18. Take inner race of male rotor drive end roller
shaft down into bearings until gap between bearing (1) and wipe clean. Place in suitable
rotor end face and bearing housing is oven or on pole bar of induction heater and
between 0.050mm and 0.025mm (0.002in heat for 2 minutes at 100oC – 120oC.
and 0.001in). Remove rotor locking fixture.
shaft. Apply a coating of Loctite 641 to shaft end uppermost. Check dowels in joint face
thread, abutment face of nut and face of are secure and undamaged. Place new
bearing inner race. Re-fit nut to female rotor gasket on joint face.
shaft and tighten to torque of 27Nm (20lb.ft).
16. Set final end clearance of male rotor as extended eyebolts in threaded holes in flange
follows: of bearing housing. Attach lifting gear and
position rotors over rotor casing. Carefully
CAUTION: Rotor end clearance is critical to air- lower until rotors are entered into bores.
end performance. Take great care to set it
accurately.
Chapter 4, Page 16
22. Lift gasket from joint face and position it 25. Invert assembly to bring drive end uppermost.
loosely near top of rotors. Continue carefully Clean diameter of male rotor shaft and bore
lowering rotors until almost fully home. When of sleeve (16). Coat bore of sleeve lightly with
there is no further risk of damaging gasket, Loctite 932. Place sleeve over male rotor
replace gasket on joint face over dowels. shaft with taper towards bearing.and press on
Lower rotors fully, making sure dowels are to locate against roller bearing inner race.
entered into bearing housing flange. Tap
gently with soft mallet to close joint. Remove 26. Fit circlip (15) to female rotor shaft. Lightly oil
lifting gear and eyebolts. roller bearings with clean compressor oil and
spin rotors by hand to distribute oil.
23. Fit screws and washers and tighten
progressively in sequence shown in Fig. 4.8 Basic air-end is now ready to receive drive
to torque of 57Nm (42lb.ft). components.
24. Fit new gasket to joint face of bearing housing

and fit bearing housing cover or cover/outlet
(7). Fit screws and washers and tighten
progressively in sequence shown in Fig. 4.8
to torque of 29Nm (21lb.ft).
7
2
5
10 4
2
7
10
5 1 9
6 3 8
8 1
3 9 4 6
Chapter 4, Page 17
! WARNING !

on bearing nut. Allow nut to absorb heat for 2-
3 minutes. Use special socket (Chapter 5,
Chapter 4, Page 19
Support rotor casing (2) on wood blocks under outer races. Clean off excess Loctite.
inlet end. Use suitable tool to tap out outer Remove rotor casing from press. If relevant,
races of both roller bearings (1) and (13) from fit circlip (14) in female rotor bearing bore.
casing.
14. Carefully clean dismantled parts, removing all bearing cage and inner race for protection
traces of gasket material, inspect and set and set aside.
aside ready for re-assembly. Discard all old
bearing, seals and gaskets. 8. Apply even coating of Loctite 641 to male
rotor bearing bore only in bearing housing.
Use suitable mandrel to press in outer race of
4.2 Assembly Procedure, Basic Air-end male rotor taper roller bearing to locate firmly
against abutment. Clean off excess Loctite.
CAUTION: Clean all components thoroughly before 9. Select new matched pair of taper roller
assembly. bearings (11) and separating spacer for
1. Inspect all components retained for re-use for external surfaces only of outer races. Use
evidence of wear or damage, renewing as suitable mandrel to press in both bearings,
applicable. Responsibility for verifying that complete with spacer between, into bearing
components are suitable for re-use rests with housing to locate firmly against abutment.
should be observed and advice sought if 10. Set pre-load of matched taper roller bearings
doubt exists. as follows:-
Remove burrs where necessary and ensure Fit circlip (8) into groove in bearing bore,
joint faces are clean. Do not remove bearings taper face outwards. Use slip gauges to
from packaging until required or interchange measure gap between circlip and outer race
bearings or spacers of a matched assembly of bearing. Remove circlip. Select spacer (10)
with parts of another assembly. from set of three which is next greater in
thickness than measured gap. Clean spacer
Thoroughly de-grease and clean all and fit into bearing bore to locate against
components, ensuring that all oil galleries are bearing outer race. Fit circlip into groove with
clear. Refit plugs with Loctite 542. taper face outwards.
2. Mount rotor casing (2) under press, drive end 11. Transfer female rotor (12) to press, inlet end
uppermost. uppermost. Press inner race of roller bearing
(13) on to drive end of rotor shaft to locate
3. Apply Loctite ‘Activator T’ to both roller firmly against shoulder.
bearing bores in rotor casing, covering whole
circumference. Allow to dry for at least 2 12. Place inner race of male rotor taper roller
minutes. bearing on suitable support under press and
4. Select new roller bearings (1) and (13) and female rotor taper roller bearings (refer to
use suitable solvent to clean external surface Chapter 5, Fig. 5.3 for guidance). Invert
only of both outer races. Re-wrap bearing bearing housing over the supports to locate in
cages and inner races for protection and set correct position.
aside.
Chapter 4, Page 20
14 15 16
1
13
12
11
10 9 8 7 6
Chapter 4, Page 21
13. Carefully lower female rotor into bearing Support bearing housing/rotor assembly
housing and use suitable mandrel to press securely on inner face of bearing housing,
rotor shaft into inner bearing race to leave with rotors hanging vertically downwards. Fit
gap between rotor end face and bearing rotor locking fixture to prevent rotation. Use
housing of 0.25mm (0.010in). Fit bearing nut special socket to tighten bearing nut on male
(9) and hand tighten (RH thread). rotor shaft (LH thread) to draw shaft up into
bearings until gap between rotor end face and
14. Fit M10 eyebolt into drive end of male rotor bearing housing is between 0.050mm and
shaft and attach lifting gear. Carefully lower 0.025mm (0.002in and 0.001in). Remove
male rotor shaft into bearing housing, rotor locking fixture.
meshing with female rotor. Remove eyebolt
and use suitable mandrel to press rotor shaft Use two feeler gauges simultaneously on
into inner bearing race to leave gap between opposite sides of rotor and check several
rotor end face and bearing housing of times that correct clearance is maintained,
0.25mm (0.010in). Fit bearing nut (6) and turning rotors by hand between checks.
hand tighten (LH thread).
Lightly lubricate bearings on both shafts with from male rotor shaft and clean nut and shaft.
clean compressor oil. Apply a coating of Loctite 641 to shaft thread,
abutment face of nut and face of bearing
15. Set final end clearance of female rotor as inner race. Re-fit nut to male rotor shaft and
follows: tighten to torque of 41Nm (30lb ft). Remove
rotor locking fixture.
CAUTION: Rotor end clearance is critical to air-
end performance. Take great care to set it 17. Spin rotors by hand to check freedom and
accurately. smooth rotation. Invert assembly to bring rotor
shafts uppermost. Lightly lubricate face of
Support bearing housing/rotor assembly bearing housing under rotor end faces with
securely, with rotors extending vertically clean compressor oil. Spin rotors by hand
upwards. Fit rotor locking fixture to prevent again to check freedom and smooth rotation.
rotation. Use special socket to tighten bearing
nut on female rotor shaft (RH thread) to draw 18. Take inner race of male rotor drive end roller
shaft down into bearings until gap between bearing (1) and wipe clean. Place in suitable
rotor end face and bearing housing is oven or on pole bar of induction heater and
between 0.050mm and 0.025mm (0.002in heat for 2 minutes at 100oC – 120oC.
and 0.001in). Remove rotor locking fixture.
shaft. Apply a coating of Loctite 641 to shaft end uppermost. Check dowels in joint face
thread, abutment face of nut and face of are secure and undamaged. Place new
bearing inner race. Re-fit nut to female rotor gasket on joint face.
shaft and tighten to torque of 27Nm (20lb.ft).
16. Set final end clearance of male rotor as extended eyebolts in threaded holes in flange
follows: of bearing housing. Attach lifting gear and
position rotors over rotor casing. Carefully
CAUTION: Rotor end clearance is critical to air- lower until rotors are entered into bores.
end performance. Take great care to set it
accurately.
Chapter 4, Page 22
22. Lift gasket from joint face and position it 25. Invert assembly to bring drive end uppermost.
loosely near top of rotors. Continue carefully Clean diameter of male rotor shaft and bore
lowering rotors until almost fully home. When of sleeve (16). Coat bore of sleeve lightly with
there is no further risk of damaging gasket, Loctite 932. Place sleeve over male rotor
replace gasket on joint face over dowels. shaft with taper towards bearing.and press on
Lower rotors fully, making sure dowels are to locate against roller bearing inner race.
entered into bearing housing flange. Tap
gently with soft mallet to close joint. Remove 26. Fit circlip (15) to female rotor shaft. Lightly oil
lifting gear and eyebolts. roller bearings with clean compressor oil and
spin rotors by hand to distribute oil.
23. Fit screws and washers and tighten
progressively in sequence shown in Fig. 4.10 Basic air-end is now ready to receive drive
to torque of 57Nm (42lb.ft). components.
24. Fit new gasket to joint face of bearing housing

and fit bearing housing cover or cover/outlet
(7). Fit screws and washers and tighten
progressively in sequence shown in Fig.
4.10to torque of 29Nm (21lb.ft).
7
2
4
9 4
10
2
6
5 9
1
5 3 8
8 1
11
3 6
Chapter 4, Page 23
! WARNING !
Note: Use appropriate CompAir BroomWade 7. Invert gearbox and support on tall blocks. Use
gearbox overhaul kit. a soft drift to tap out shaft, bearings (31) (33),
inner spacer (32) and outer spacer (23) from
gearbox casing (1), together with inner shims
5.1 Dismantling Procedure, Gearbox from (22). Retain shims and spacers but discard
Gearbox Adaptor/Air-end bearings.
Note: Annotations in brackets refer to Fig. 4.11 Note: It is important that the original shim pack is
kept as a complete set.
1. Support gearbox/air-end assembly on wood
blocks under air-end. Attach lifting gear to 8. Use suitable mandrel to remove oil seal (27)
gearbox eyebolt and take weight without from housing (24). Discard seal.
lifting.
9. Remove plug and copper washer from
2. Remove bolts (3), (18) and washers (4) and gearbox casing. Remove taper pressure plug
(17) securing gearbox (1) to gearbox adaptor from casing.
(2). DO NOT remove 2 screws (10) securing
adaptor to air-end.
5.2 Dismantling Procedure, Gearbox Adaptor
3. Use soft mallet to separate gearbox from air- from Air-end
end adaptor, supporting gearbox with lifting
gear. Take care to avoid damage to gear 1. Bend down tabs on locking plate (20) and
teeth. Remove and discard joint (16). Transfer remove screws (21) and pinion retaining plate
gearbox to bench and support on blocks with (19). Discard locking plate.
gear uppermost.
2. Use suitable puller to remove pinion (14) from
4. Release tabs on locking plate (8). Remove air-end shaft. Remove key (13) from keyway.
screws (9), locking plate, and retaining plate Remove sleeve (12).
(7) from shaft (28). Discard locking plate.
3. Remove nut (34) on oil spray pipe (35) and
5. Use suitable puller to remove gear (5) from remove pipe. Remove pipe coupling (36) and
shaft. Remove key (6). Invert gearbox to bring copper washer (37).
coupling end uppermost. Remove drive
coupling and key if necessary. 4. Remove 2 screws (10) and washers (11)
securing adaptor to air-end. Use soft mallet to
6. Remove screws (26) and washers from oil separate adaptor from air-end and remove
seal housing (24). Remove housing and ‘O’ adaptor and gasket (15). Clean joint faces of
ring (25). Discard ‘O’ ring. Remove circlip (29) adaptor and air-end to remove all traces of
and spacer (30). gasket.
Chapter 4, Page 25
5.3 Assembly Procedure, Gearbox Adaptor to Sound engineering practices should be

Air-end observed and advice sought if doubt exists.
CAUTION: Clean all components thoroughly before Remove burrs where necessary and ensure
assembly. joint faces are clean. Do not remove bearings
from their packaging until required. Do not
1. Support air-end securely on wood blocks. interchange bearings or spaces of a matched
Check dowels are secure and undamaged. Fit assembly with parts from another assembly.
new gasket (15) over dowels.
Thoroughly degrease and clean all
2. Fit adaptor to air-end. Make sure gasket is not components, ensuring that all oil galleries are
damaged and dowels are fully entered in clear. Re-fit plugs with Loctite 542.
locating holes. Fit screws (10) and washers
(11) and tighten to secure. DO NOT fully 2. Support gearbox casing (1) on bench, resting
tighten at this stage. on tall blocks with oil seal face uppermost.
Check that oilways are clear. Fit plug and
3. Apply coating of Loctite 270 to threads of pipe copper washer to casing. Fit taper pressure
coupling (36) and fit coupling and copper plug to casing.
washer (37) to adaptor. Check holes in oil
spray pipe (35) are clear. Fit oil spray pipe to 3. Carefully wipe clean inner bearing spacer
pipe coupling, locating flattened end of pipe in (32), outer bearing spacer (23) and circlip
casting recess (38). Tighten nut (34) to secure spacer (30). Clean shaft (28) and lightly oil
pipe. DO NOT over-tighten. bearing diameter.
4. Fit sleeve (12) over air-end shaft with chamfer 4. Set end float of bearings as follows.
towards air-end. Make sure sleeve is located
firmly against bearing. Measure thickness of gear (5) through the
bore. Make up sleeve spacer to fit closely but
5. Place pinion (14) on pole bar of induction not tightly over gear diameter of shaft, spacer
heater and heat at 150oC for 6 minutes. Use length being measured thickness of gear plus
gloves to remove pinion from heater and fit to 1mm. Wall thickness of spacer should be at
air-end shaft with datum groove towards air- least 2·5mm and end faces should be flat and
end. Make sure pinion is located firmly against square with axis.
sleeve (12).
Assemble the following components to
6. Fit retaining plate (19) to shaft. Partly bend up gearbox shaft in the correct sequence:
tabs on new locking plate (20) and fit with
screws (21) to end of shaft. Secure pinion to New taper roller bearing (31) with wide face of
prevent rotation and tighten screws to torque inner track towards shaft shoulder. Use
of 57Nm (42lb.ft). Bend up tabs on locking suitable mandrel to press bearing fully home.
plate to secure screws.
Outer spacer (23).
Inner spacer (32).
5.4 Assembly Procedure, Gearbox to Gearbox
Inner shims (22)
Adaptor/Air-end
New taper roller bearing (33) with narrow face
CAUTION: Clean all components thoroughly before of inner track towards inner shims. Use
assembly. suitable mandrel to press bearing fully home.
1. Inspect all components retained for re-use for Note: Make up shim pack from new shims with
evidence of wear or damage, renewing as total thickness equal to the pack removed during
applicable. dismantling plus at least 0·1mm. It is important to
use sufficient shims to allow measurable end float
Responsibility for verifying that components on first trial with new bearings.
are suitable for re-use rests with the repairer.
Chapter 4, Page 26
38
2 35
34
34 35 36 37 2
1
33 2
3
32
31
30 4
5
29
6
28
7
8
9
22 10
27
26 11
25
12
24
23 13
21
20 14
19
18 17 16 15
FIG. 4.11 GEARBOX C20465-1 (CYCLON 4 AIR-END 105 X 2·3 – C20465-40)
Chapter 4, Page 27
Fit sleeve spacer over shaft. Fit gear retaining 7. Fit slave tapered sleeve to coupling end of
plate (7) and screws (9). Hold shaft securely shaft to cover keyway and butt up to seal
and tighten screws to torque of 57Nm (42lb.ft). diameter. Lightly grease new ‘O’ ring (25) and
fit to oil seal housing. Assemble oil seal
Use suitable mandrel to press shaft and housing to gearbox over slave sleeve.
bearing cluster into gearbox casing. Make Remove slave sleeve. Fit screws (26) and
sure outer spacer enters bore cleanly. Make washers and tighten in diagonal sequence to
sure outer track of bearing (33) locates firmly torque of 29Nm (21lb.ft).
against shoulder. Fit circlip spacer (30) and
circlip (29) with bevelled face towards coupling Note: Take great care when fitting the oil seal to
end of shaft. make sure that the seal lips are not damaged or
deformed.
Support gearbox casing on bench and use dial
test indicator to check end float of shaft within 8. Invert gearbox to bring gear end of shaft
bearings. Correct end float is between uppermost. Fit key (6) to keyway. Place gear
0·013mm and 0·064mm (0·0005in and (5) on pole bar of induction heater and heat at
0·0025in). 150oC for 6 minutes. Use gloves to remove
gear from heater and fit to shaft with datum
5. If end float is outside these limits dismantle groove towards bearings. Make sure gear is
shaft/bearing cluster from casing and adjust located firmly against bearing. Fit retaining
thickness of shim pack accordingly. Repeat plate (7), new locking plate (8) and screws
operation 4 as necessary until end float is (9). Tighten screws to torque of 57Nm
correct. Spin shaft by hand to check freedom (42lb.ft). Bend up tabs of locking plate to
and smooth rotation. Remove screws (9), secure screws.
retaining plate (7) and sleeve spacer.
9. Attach lifting gear to gearbox eyebolt and
6. Wipe clean oil seal housing (24). Select new transfer to air-end/adaptor assembly. Fit new
oil seal (27) and use a suitable mandrel to gasket (16) over dowels. Align dowels with
press seal into housing to locate firmly against location holes and carefully mate gearbox
shoulder. with adaptor, turning shaft slightly if
necessary to mesh gear and pinion. Take
Note: The seal is supplied with the outside care not to damage gasket.
diameter coated with a sealant. After pressing the
seal into place remove all traces of excess sealant 10. Fit screws (3, 18) and washers (4, 17) and
from the housing bore. tighten all screws in sequence shown in
Fig. 4.12 to a torque of 57Nm (42lb.ft). Turn
gearbox shaft by hand to check freedom and
smooth rotation.
Chapter 4, Page 28
5 9 6
8 11
3 4
2 1
10 14 7
Tighten screws in sequence

shown to torque of
5 9 6 57 Nm (42 lb.ft)
13 12
Chapter 4, Page 29
! WARNING !

2-3 minutes. Use special socket (Chapter 5,
Chapter 4, Page 31
Support rotor casing (2) on wood blocks under outer races. Clean off excess Loctite. Remove
inlet end. Use suitable tool to tap out outer rotor casing from press. If relevant, fit circlip
races of both roller bearings (1) and (13) from (14) in female rotor bearing bore.
casing.
14. Carefully clean dismantled parts, removing all bearing cage and inner race for protection and
traces of gasket material, inspect and set aside set aside.
ready for re-assembly. Discard all old bearing,
seals and gaskets. Note: In operations 8, 9, 12 and 13 below, fitting
taper roller bearings (5) and (11) and installing rotor
shafts (3) and (12) may be carried out using a
6.2 ASSEMBLY PROCEDURE, BASIC AIR-END hydraulic/pneumatic pulling tool and suitable
attachments. Details are available from Service
CAUTION: Clean all components thoroughly before Dept. at CompAir BroomWade, High Wycombe.
assembly.
8. Apply even coating of Loctite 641 to male rotor
1. Inspect all components retained for re-use for bearing bore only in bearing housing. Use
evidence of wear or damage, renewing as suitable mandrel to press in outer race of male
applicable. Responsibility for verifying that rotor taper roller bearing to locate firmly
components are suitable for re-use rests with against abutment. Clean off excess Loctite.
should be observed and advice sought if doubt 9. Select new matched pair of taper roller
exists. bearings (11) and separating spacer for
Remove burrs where necessary and ensure external surfaces only of outer races. Use
joint faces are clean. Do not remove bearings suitable mandrel to press in both bearings,
from packaging until required or interchange complete with spacer between, into bearing
bearings or spacers of a matched assembly housing to locate firmly against abutment.
with parts of another assembly.
10. Set pre-load of matched taper roller bearings
Thoroughly de-grease and clean all as follows.
clear. Refit plugs with Loctite 542. Fit circlip (8) into groove in bearing bore, taper
face outwards. Use slip gauges to measure
2. Mount rotor casing (2) under press, drive end gap between circlip and outer race of bearing.
uppermost. Remove circlip. Select spacer (10) from set of
three which is next greater in thickness than
3. Apply Loctite ‘Activator T’ to both roller bearing measured gap. Clean spacer and fit into
bores in rotor casing, covering whole bearing bore to locate against bearing outer
circumference. Allow to dry for at least 2 race. Fit circlip into groove with taper face
minutes. outwards.
4. Select new roller bearings (1) and (13) and use

suitable solvent to clean external surface only
of both outer races. Re-wrap bearing cages
and inner races for protection and set aside.
Chapter 4, Page 32
13 14 15 16
12
11
5
10
9 8 7 6
Chapter 4, Page 33
11. Place inner race of male rotor taper roller 15. Set final end clearance of male rotor as
bearing on suitable support under press and follows:
female rotor taper roller bearings (refer to CAUTION: Rotor end clearance is critical to air-end
Chapter 5, Fig. 5.3 for guidance). Invert performance. Take great care to set it accurately.
bearing housing over the supports to locate in
correct position. Support bearing housing/rotor assembly
securely on inner face of bearing housing, with
12. Fit M16 eyebolt into inlet end of female rotor rotors hanging vertically downwards. Fit rotor
shaft and attach lifting gear. Carefully lower locking fixture to prevent rotation. Use special
female rotor into bearing housing and use socket to tighten bearing nut on male rotor
suitable mandrel to press rotor shaft into inner shaft (LH thread) to draw shaft up into
bearing race to leave gap between rotor end bearings until gap between rotor end face and
face and bearing housing of 0.25mm (0.010in). bearing housing is between 0.050mm and
Fit bearing nut (9) and hand tighten (RH 0.025mm (0.002in and 0.001in). Remove rotor
thread). locking fixture.
13. Fit M16 eyebolt into inlet end of male rotor shaft Use two feeler gauges simultaneously on
and attach lifting gear. Carefully lower male opposite sides of rotor and check several
rotor into bearing housing, meshing with times that correct clearance is maintained,
female rotor. Remove eyebolt and use suitable turning rotors by hand between checks.
mandrel to press rotor shaft into inner bearing
race to leave gap between rotor end face and Fit rotor locking fixture. Remove bearing nut
bearing housing of 0.25mm (0.010in). Fit from male rotor shaft and clean nut and shaft.
bearing nut (6) and hand tighten (LH thread). Apply a coating of Loctite 641 to shaft thread,
Lightly lubricate bearings on both shafts with race. Re-fit nut to male rotor shaft and tighten
clean compressor oil. to torque of 41Nm (30lb ft). Remove rotor
locking fixture.
14. Set final end clearance of female rotor as
follows: 16. Spin rotors by hand to check freedom and
CAUTION: Rotor end clearance is critical to air-end shafts uppermost. Lightly lubricate face of
performance. Take great care to set it accurately. bearing housing under rotor end faces with
clean compressor oil. Spin rotors by hand
Support bearing housing/rotor assembly again to check freedom and smooth rotation.
securely, with rotors extending vertically
upwards. Fit rotor locking fixture to prevent 17. Take inner race of male rotor drive end roller
rotation. Use special socket to tighten bearing bearing (1) and wipe clean. Place in suitable
nut on female rotor shaft (RH thread) to draw oven or on pole bar of induction heater and
shaft down into bearings until gap between heat for 2 minutes at 100oC – 120oC.
rotor end face and bearing housing is between
0.050mm and 0.025mm (0.002in and 0.001in). 18. Clean bearing diameter of male rotor shaft.
Remove rotor locking fixture. Wear gloves to remove roller bearing inner
race from heat and place it immediately over
Use two feeler gauges simultaneously on male rotor shaft to locate firmly with shoulder.
opposite sides of rotor and check several Allow to cool.
times that correct clearance is maintained,
turning rotors by hand between checks. 19. Take inner race of female rotor drive end roller
bearing (13) and wipe clean. Place in suitable
Fit rotor locking fixture. Remove bearing nut oven or on pole bar of induction heater and
from female rotor shaft and clean nut and heat for 2 minutes at 100oC – 120oC.
shaft. Apply a coating of Loctite 641 to shaft
thread, abutment face of nut and face of
bearing inner race. Re-fit nut to female rotor
shaft and tighten to torque of 41Nm (30lb ft).
Chapter 4, Page 34
20. Clean bearing diameter of female rotor shaft. 24. Fit screws and washers to secure bearing
Wear gloves to remove roller bearing inner housing and tighten progressively in sequence
race from heat and place it immediately over shown in Fig. 4.14 to torque of 98Nm (72lb.ft).
female rotor shaft to locate firmly with
shoulder. Allow to cool. 25. Fit new gasket to joint face of bearing housing
and fit bearing housing cover (7). Fit screws
21. Transfer rotor casing (2) to secure fixture, and washers and tighten progressively in
mounting with rotor bores vertical and delivery sequence shown in Fig. 4.14 to torque of
end uppermost. Check dowels in joint face are 57Nm (42lb.ft).
secure and undamaged. Place new gasket on
joint face. 26. Invert assembly to bring drive end uppermost.
22. Invert bearing housing/rotor assembly and fit sleeve (16). Coat bore of sleeve lightly with
M12 extended eyebolts in threaded holes in Loctite 932. Place sleeve over male rotor shaft
flange of bearing housing. Attach lifting gear with taper towards bearing and press on to
and position rotors over rotor casing. Carefully locate against roller bearing inner race.
lower until rotors are entered into bores.
27. Fit circlip (15) to female rotor shaft. Lightly oil
23. Lift gasket from joint face and position it roller bearings with clean compressor oil and
loosely near top of rotors. Continue carefully spin rotors by hand to distribute oil.
lowering rotors until almost fully home. When
there is no further risk of damaging gasket, Basic air-end is now ready to receive drive
replace gasket on joint face over dowels. components.
Lower rotors fully, making sure dowels are
entered into bearing housing flange.
Tap gently with soft mallet to close joint.
Remove lifting gear and eyebolts.
7
2
4
9 4
10
2
6
5 9
1
5 3 8
8 1
11
3 6
Chapter 4, Page 35
! WARNING !
Gearbox Adaptor/Air-end bearings.
Note: Annotations in brackets refer to Fig. 4.15 Note: It is important that the original shim pack is
kept as a complete set.
1. Support gearbox/air-end assembly on wood
blocks under air-end. Attach lifting gear to 8. Use suitable mandrel to remove oil seal (27)
gearbox eyebolt and take weight without from housing (24). Discard seal.
lifting.
9. Remove plug and copper washer from
2. Remove bolts (3), (18) and washers (4) and gearbox casing. Remove taper pressure plugs
(17) securing gearbox (1) to gearbox adaptor from casing.
(2). DO NOT remove 3 nuts (10) securing
adaptor to air-end.
7.2 Dismantling Procedure, Gearbox Adaptor
3. Use soft mallet to separate gearbox from air- from Air-end
gear. Take care to avoid damage to gear 1. Bend down tabs on locking plate (20) and
teeth. Remove and discard joint (16). Transfer remove screws (21) and pinion retaining plate
gearbox to bench and support on blocks with (19). Discard locking plate.
gear uppermost.
4. Release tabs on locking plate (8). Remove air-end shaft. Remove key (13) from keyway.
screws (9), locking plate, and retaining plate Remove sleeve (12).
3. Remove nut (34) on oil spray pipe (35) and
5. Use suitable puller to remove gear (5) from remove pipe. Remove pipe coupling (36) and
shaft. Remove key (6). Invert gearbox to bring copper washer (37).
Chapter 4, Page 37
7.3 Assembly Procedure, Gearbox Adaptor to Sound engineering practices should be

Air-end observed and advice sought if doubt exists.
CAUTION: Clean all components thoroughly before Remove burrs where necessary and ensure
assembly. joint faces are clean. Do not remove bearings
from their packaging until required. Do not
1. Support air-end securely on wood blocks. interchange bearings or spaces of a matched
Check dowels are secure and undamaged. Fit assembly with parts from another assembly.
new gasket (15) over dowels.
Thoroughly degrease and clean all
2. Fit adaptor to air-end. Make sure gasket is not components, ensuring that all oil galleries are
damaged and dowels are fully entered in clear. Re-fit plugs with Loctite 542.
locating holes. Fit screws (10) and washers
(11) and tighten to secure. DO NOT fully 2. Support gearbox casing (1) on bench, resting
tighten at this stage. on tall blocks with oil seal face uppermost.
Check that oilways are clear. Fit plug and
3. Apply coating of Loctite 270 to threads of pipe copper washer to casing. Fit taper pressure
coupling (36) and fit coupling and copper plug to casing.
washer (37) to adaptor. Check holes in oil
spray pipe (35) are clear. Fit oil spray pipe to 3. Carefully wipe clean inner bearing spacer
pipe coupling, locating flattened end of pipe in (32), outer bearing spacer (23) and circlip
casting recess (38). Tighten nut (34) to secure spacer (30). Clean shaft (28) and lightly oil
pipe. DO NOT over-tighten. bearing diameter.
4. Fit sleeve (12) over air-end shaft with chamfer 4. Set end float of bearings as follows.
towards air-end. Make sure sleeve is located
firmly against bearing. Measure thickness of gear (5) through the
bore. Make up sleeve spacer to fit closely but
5. Place pinion (14) on pole bar of induction not tightly over gear diameter of shaft, spacer
heater and heat at 150oC for 6 minutes. Use length being measured thickness of gear plus
gloves to remove pinion from heater and fit to 1mm. Wall thickness of spacer should be at
air-end shaft with datum groove towards air- least 2·5mm and end faces should be flat and
end. Make sure pinion is located firmly against square with axis.
sleeve (12).
Assemble the following components to
6. Fit retaining plate (19) to shaft. Partly bend up gearbox shaft in the correct sequence:
tabs on new locking plate (20) and fit with
screws (21) to end of shaft. Secure pinion to New taper roller bearing (31) with wide face of
prevent rotation and tighten screws to torque inner track towards shaft shoulder. Use
of 98Nm (72lb.ft). Bend up tabs on locking suitable mandrel to press bearing fully home.
plate to secure screws.
Outer spacer (23).
Inner spacer (32).
7.4 Assembly Procedure, Gearbox to Gearbox
Inner shims (22)
Adaptor/Air-end
are suitable for re-use rests with the repairer.
Chapter 4, Page 38
36 37 2
2 35
38
35
34 34
33 1 2 3
32
4
31
5
30
6
29
7
8
22 9
28 27 10
26 11
25 12
24
23 13
21 14
20
19
18 17 16 15
Chapter 4, Page 39
and tighten screws to torque of 98Nm (72lb.ft). diameter. Lightly grease new ‘O’ ring (25) and
fit to oil seal housing. Assemble oil seal
Use suitable mandrel to press shaft and housing to gearbox over slave sleeve.
bearing cluster into gearbox casing. Make Remove slave sleeve. Fit screws (26) and
sure outer spacer enters bore cleanly. Make washers and tighten in diagonal sequence to
sure outer track of bearing (33) locates firmly torque of 57Nm (42lb.ft).
against shoulder. Fit circlip spacer (30) and
circlip (29) with bevelled face towards coupling Note: Take great care when fitting the oil seal to
end of shaft. make sure that the seal lips are not damaged or
deformed.
Support gearbox casing on bench and use dial
test indicator to check end float of shaft within 8. Invert gearbox to bring gear end of shaft
bearings. Correct end float is between uppermost. Fit key (6) to keyway. Place gear
0·013mm and 0·064mm (0·0005in and (5) on pole bar of induction heater and heat at
0·0025in). 150oC for 6 minutes. Use gloves to remove
gear from heater and fit to shaft with datum
5. If end float is outside these limits dismantle groove towards bearings. Make sure gear is
shaft/bearing cluster from casing and adjust located firmly against bearing. Fit retaining
thickness of shim pack accordingly. Repeat plate (7), new locking plate (8) and screws
operation 4 as necessary until end float is (9). Tighten screws to torque of 98Nm
correct. Spin shaft by hand to check freedom (72lb.ft). Bend up tabs of locking plate to
and smooth rotation. Remove screws (9), secure screws.
retaining plate (7) and sleeve spacer.
9. Attach lifting gear to gearbox eyebolt and
6. Wipe clean oil seal housing (24). Select new transfer to air-end/adaptor assembly. Fit new
oil seal (27) and use a suitable mandrel to gasket (16) over dowels. Align dowels with
press seal into housing to locate firmly against location holes and carefully mate gearbox
shoulder. with adaptor, turning shaft slightly if
necessary to mesh gear and pinion. Take
Note: The seal is supplied with the outside care not to damage gasket.
diameter coated with a sealant. After pressing the
seal into place remove all traces of excess sealant 10. Fit screws (3, 18) and washers (4, 17) and
from the housing bore. tighten all screws in sequence shown in
Fig. 4.16 to a torque of 98Nm (72lb.ft). Turn
smooth rotation.
Chapter 4, Page 40
9
5 6
13 4 12
15
3
8
11
1
2
10 14 7
Tighten screws in sequence shown to torque of 98 Nm (72 lb.ft)
Chapter 4, Page 41
! WARNING !

2-3 minutes. Use special socket (Chapter 5,
Chapter 4, Page 43
Support rotor casing (2) on wood blocks under outer races. Clean off excess Loctite. Remove
inlet end. Use suitable tool to tap out outer rotor casing from press. If relevant, fit circlip
races of both roller bearings (1) and (13) from (14) in female rotor bearing bore.
casing.
14. Carefully clean dismantled parts, removing all bearing cage and inner race for protection and
traces of gasket material, inspect and set aside set aside.
ready for re-assembly. Discard all old bearing,
seals and gaskets. Note: In operations 8, 9, 12 and 13 below, fitting
taper roller bearings (5) and (11) and installing rotor
shafts (3) and (12) may be carried out using a
8.2 Assembly Procedure, Basic Air-end hydraulic/pneumatic pulling tool and suitable
attachments. Details are available from Service
Dept. at CompAir BroomWade, High Wycombe.
assembly. 8. Apply even coating of Loctite 641 to male rotor
bearing bore only in bearing housing. Use
1. Inspect all components retained for re-use for suitable mandrel to press in outer race of male
evidence of wear or damage, renewing as rotor taper roller bearing to locate firmly
applicable. Responsibility for verifying that against abutment. Clean off excess Loctite.
the repairer. Sound engineering practices 9. Select new matched pair of taper roller
should be observed and advice sought if doubt bearings (11) and separating spacer for
exists. female rotor. Use suitable solvent to clean
external surfaces only of outer races. Use
Remove burrs where necessary and ensure suitable mandrel to press in both bearings,
joint faces are clean. Do not remove bearings complete with spacer between, into bearing
from packaging until required or interchange housing to locate firmly against abutment.
bearings or spacers of a matched assembly
with parts of another assembly. 10. Set pre-load of matched taper roller bearings
as follows.
components, ensuring that all oil galleries are Fit circlip (8) into groove in bearing bore, taper
clear. Refit plugs with Loctite 542. face outwards. Use slip gauges to measure
gap between circlip and outer race of bearing.
2. Mount rotor casing (2) under press, drive end Remove circlip. Select spacer (10) from set of
uppermost. three which is next greater in thickness than
measured gap. Clean spacer and fit into
3. Apply Loctite ‘Activator T’ to both roller bearing bearing bore to locate against bearing outer
bores in rotor casing, covering whole race. Fit circlip into groove with taper face
circumference. Allow to dry for at least 2 outwards.
minutes.
4. Select new roller bearings (1) and (13) and use

suitable solvent to clean external surface only
of both outer races. Re-wrap bearing cages
and inner races for protection and set aside.
Chapter 4, Page 44
14 15 16
1
13
12
11 4
10 5
9 8 7 6
Chapter 4, Page 45
11. Place inner race of male rotor taper roller 15. Set final end clearance of male rotor as
bearing on suitable support under press and follows:
female rotor taper roller bearings (refer to CAUTION: Rotor end clearance is critical to air-end
Chapter 5, Fig. 5.3 for guidance). Invert performance. Take great care to set it accurately.
bearing housing over the supports to locate in
correct position. Support bearing housing/rotor assembly
securely on inner face of bearing housing, with
12. Fit M16 eyebolt into inlet end of female rotor rotors hanging vertically downwards. Fit rotor
shaft and attach lifting gear. Carefully lower locking fixture to prevent rotation. Use special
female rotor into bearing housing and use socket to tighten bearing nut on male rotor
suitable mandrel to press rotor shaft into inner shaft (LH thread) to draw shaft up into
bearing race to leave gap between rotor end bearings until gap between rotor end face and
face and bearing housing of 0.25mm (0.010in). bearing housing is between 0.050mm and
Fit bearing nut (9) and hand tighten (RH 0.025mm (0.002in and 0.001in). Remove rotor
thread). locking fixture.
13. Fit M16 eyebolt into inlet end of male rotor shaft Use two feeler gauges simultaneously on
and attach lifting gear. Carefully lower male opposite sides of rotor and check several
rotor into bearing housing, meshing with times that correct clearance is maintained,
female rotor. Remove eyebolt and use suitable turning rotors by hand between checks.
mandrel to press rotor shaft into inner bearing
race to leave gap between rotor end face and Fit rotor locking fixture. Remove bearing nut
bearing housing of 0.25mm (0.010in). Fit from male rotor shaft and clean nut and shaft.
bearing nut (6) and hand tighten (LH thread). Apply a coating of Loctite 641 to shaft thread,
Lightly lubricate bearings on both shafts with race. Re-fit nut to male rotor shaft and tighten
clean compressor oil. to torque of 41Nm (30lb ft). Remove rotor
locking fixture.
14. Set final end clearance of female rotor as
follows: 16. Spin rotors by hand to check freedom and
CAUTION: Rotor end clearance is critical to air-end shafts uppermost. Lightly lubricate face of
performance. Take great care to set it accurately. bearing housing under rotor end faces with
clean compressor oil. Spin rotors by hand
Support bearing housing/rotor assembly again to check freedom and smooth rotation.
securely, with rotors extending vertically
upwards. Fit rotor locking fixture to prevent 17. Take inner race of male rotor drive end roller
rotation. Use special socket to tighten bearing bearing (1) and wipe clean. Place in suitable
nut on female rotor shaft (RH thread) to draw oven or on pole bar of induction heater and
shaft down into bearings until gap between heat for 2 minutes at 100oC – 120oC.
rotor end face and bearing housing is between
0.050mm and 0.025mm (0.002in and 0.001in). 18. Clean bearing diameter of male rotor shaft.
Remove rotor locking fixture. Wear gloves to remove roller bearing inner
race from heat and place it immediately over
Use two feeler gauges simultaneously on male rotor shaft to locate firmly with shoulder.
opposite sides of rotor and check several Allow to cool.
times that correct clearance is maintained,
turning rotors by hand between checks. 19. Take inner race of female rotor drive end roller
bearing (13) and wipe clean. Place in suitable
Fit rotor locking fixture. Remove bearing nut oven or on pole bar of induction heater and
from female rotor shaft and clean nut and heat for 2 minutes at 100oC – 120oC.
shaft. Apply a coating of Loctite 641 to shaft
thread, abutment face of nut and face of
bearing inner race. Re-fit nut to female rotor
shaft and tighten to torque of 41Nm (30lb ft).
Chapter 4, Page 46
20. Clean bearing diameter of female rotor shaft. 24. Fit screws and washers to secure bearing
Wear gloves to remove roller bearing inner housing and tighten progressively in sequence
race from heat and place it immediately over shown in Fig. 4.18 to torque of 245Nm (180lb.ft).
female rotor shaft to locate firmly with
shoulder. Allow to cool. 25. Fit new gasket to joint face of bearing housing
and fit bearing housing cover (7). Fit screws
21. Transfer rotor casing (2) to secure fixture, and washers and tighten progressively in
mounting with rotor bores vertical and delivery sequence shown in Fig. 4.18 to torque of
end uppermost. Check dowels in joint face are 98Nm (72lb.ft).
secure and undamaged. Place new gasket on
joint face. 26. Invert assembly to bring drive end uppermost.
22. Invert bearing housing/rotor assembly and fit sleeve (16). Coat bore of sleeve lightly with
M12 extended eyebolts in threaded holes in Loctite 932. Place sleeve over male rotor shaft
flange of bearing housing. Attach lifting gear with taper towards bearing and press on to
and position rotors over rotor casing. Carefully locate against roller bearing inner race.
lower until rotors are entered into bores.
27. Fit circlip (15) to female rotor shaft. Lightly oil
23. Lift gasket from joint face and position it roller bearings with clean compressor oil and
loosely near top of rotors. Continue carefully spin rotors by hand to distribute oil.
lowering rotors until almost fully home. When
there is no further risk of damaging gasket, Basic air-end is now ready to receive drive
replace gasket on joint face over dowels. components.
Lower rotors fully, making sure dowels are
entered into bearing housing flange.
Tap gently with soft mallet to close joint.
Remove lifting gear and eyebolts.
7
2
4
9 4
10
2
6
5 9
1
5 3 8
8 1
11
3 6
Chapter 4, Page 47
! WARNING !
bearings.
Gearbox Adaptor/Air-end
Note: It is important that the original shim pack is
Note: Annotations in brackets refer to Fig. 4.19 kept as a complete set.
1. Support gearbox/air-end assembly on wood 8. Use suitable mandrel to remove oil seal (27)
blocks under air-end. Attach lifting gear to from housing (24). Discard seal.
gearbox eyebolt and take weight without
lifting. 9. Remove plug and copper washer from
gearbox casing. Remove taper pressure
2. Remove bolts (3), (18) and washers (4) and plugs from casing.
(17) securing gearbox (1) to gearbox adaptor
(2). DO NOT remove 2 nuits (10) securing 10. Remove nut (34) on oil spray pipe (35) and
adaptor to air-end. remove pipe. Remove pipe coupling (36) and
copper washer (37).
3. Use soft mallet to separate gearbox from air-
gear. Take care to avoid damage to gear 9.2 Dismantling Procedure, Gearbox Adaptor
teeth. Remove and discard joint (16). Transfer
gearbox to bench and support on blocks with from Air-end
gear uppermost.
1. Bend down tabs on locking plate (20) and
4. Release tabs on locking plate (8). Remove remove screws (21) and pinion retaining plate
screws (9), locking plate, and retaining plate (19). Discard locking plate.
5. Use suitable puller to remove gear (5) from air-end shaft. Remove key (13) from keyway.
shaft. Remove key (6). Invert gearbox to bring Remove sleeve (12).
Chapter 4, Page 49
9.3 Assembly Procedure, Gearbox Adaptor to are suitable for re-use rests with the repairer.
Air-end Sound engineering practices should be
observed and advice sought if doubt exists.
assembly. Remove burrs where necessary and ensure
joint faces are clean. Do not remove bearings
1. Support air-end securely on wood blocks. from their packaging until required. Do not
Check dowels are secure and undamaged. Fit interchange bearings or spaces of a matched
new gasket (15) over dowels. assembly with parts from another assembly.
2. Fit adaptor to air-end. Make sure gasket is not Thoroughly degrease and clean all
damaged and dowels are fully entered in components, ensuring that all oil galleries are
locating holes. Fit screws (10) and washers clear. Re-fit plugs with Loctite 542.
(11) and tighten to secure. DO NOT fully
tighten at this stage. 2. Support gearbox casing (1) on bench, resting
on tall blocks with oil seal face uppermost.
3. Apply coating of Loctite 270 to threads of pipe Check that oilways are clear. Fit plug and
coupling (36) and fit coupling and copper copper washer to casing. Fit taper pressure
washer (37). Check holes in oil spray pipe (35) plug to casing.
are clear. Fit oil spray pipe to pipe coupling,
locating flattened end of pipe in casting recess 3. Carefully wipe clean inner bearing spacer
(38). Tighten nut (34) to secure pipe. DO NOT (32), outer bearing spacer (23) and circlip
over-tighten. spacer (30). Clean shaft (28) and lightly oil
bearing diameter.
4. Fit sleeve (12) over air-end shaft with chamfer
towards air-end. Make sure sleeve is located 4. Set end float of bearings as follows.
firmly against bearing.
Measure thickness of gear (5) through the
5. Place pinion (14) on pole bar of induction bore. Make up sleeve spacer to fit closely but
heater and heat at 150°C for 6 minutes. Use not tightly over gear diameter of shaft, spacer
gloves to remove pinion from heater and fit to length being measured thickness of gear plus
air-end shaft with datum groove towards air- 1mm. Wall thickness of spacer should be at
end. Make sure pinion is located firmly against least 2·5mm and end faces should be flat and
sleeve (12). square with axis.
6. Fit retaining plate (19) to shaft. Partly bend up Assemble the following components to
tabs on new locking plate (20) and fit with gearbox shaft in the correct sequence:
screws (21) to end of shaft. Secure pinion to
prevent rotation and tighten screws to torque New taper roller bearing (31) with wide face of
of 245Nm (180lb.ft). Bend up tabs on locking inner track towards shaft shoulder. Use
plate to secure screws. suitable mandrel to press bearing fully home.
Outer spacer (23).
9.4 Assembly Procedure, Gearbox to Gearbox Inner spacer (32).
Adaptor/Air-end Inner shims (22)

Chapter 4, Page 50
38
34 35
1 2 3
32
32
4
5
31
6
30 7
29 8
22
10
11
28 27
26
25
12
24
23
37
36
34
35
13
21
20
19 14
18 17 16 15
Chapter 4, Page 51
and tighten screws to torque of 245Nm diameter. Lightly grease new ‘O’ ring (25) and
(180lb.ft). fit to oil seal housing. Assemble oil seal
housing to gearbox over slave sleeve.
Use suitable mandrel to press shaft and Remove slave sleeve. Fit screws (26) and
bearing cluster into gearbox casing. Make washers and tighten in diagonal sequence to
sure outer spacer enters bore cleanly. Make torque of 98Nm (72lb.ft).
sure outer track of bearing (33) locates firmly
against shoulder. Fit circlip spacer (30) and Note: Take great care when fitting the oil seal to
circlip (29) with bevelled face towards coupling make sure that the seal lips are not damaged or
end of shaft. deformed.
Support gearbox casing on bench and use dial 8. Invert gearbox to bring gear end of shaft
test indicator to check end float of shaft within uppermost. Fit key (6) to keyway. Place gear
bearings. Correct end float is between (5) on pole bar of induction heater and heat at
0·013mm and 0·064mm (0·0005in and 150oC for 6 minutes. Use gloves to remove
0·0025in). gear from heater and fit to shaft with datum
groove towards bearings. Make sure gear is
5. If end float is outside these limits dismantle located firmly against bearing. Fit retaining
shaft/bearing cluster from casing and adjust plate (7), new locking plate (8) and screws
thickness of shim pack accordingly. Repeat (9). Tighten screws to torque of 245Nm
operation 4 as necessary until end float is (180lb.ft). Bend up tabs of locking plate to
correct. Spin shaft by hand to check freedom secure screws.
and smooth rotation. Remove screws (9),
retaining plate (7) and sleeve spacer. 9. Attach lifting gear to gearbox eyebolt and
transfer to air-end/adaptor assembly. Fit new
6. Wipe clean oil seal housing (24). Select new gasket (16) over dowels. Align dowels with
oil seal (27) and use a suitable mandrel to location holes and carefully mate gearbox
press seal into housing to locate firmly against with adaptor, turning shaft slightly if
shoulder. necessary to mesh gear and pinion. Take
care not to damage gasket.
Note: The seal is supplied with the outside
diameter coated with a sealant. After pressing the 10. Fit screws (3, 18) and washers (4, 17) and
seal into place remove all traces of excess sealant tighten all screws in sequence shown in
from the housing bore. Fig. 4.20 to a torque of 245Nm (180lb.ft). Turn
smooth rotation.
Chapter 4, Page 52
9
5 6
13 12
4
3
8 11
2 1
10 14 7
Tighten screws in sequence shown to torque of 245 Nm (180 lb.ft)
Chapter 4, Page 53
Tooling Diagrams – Cyclon Air-ends
CHAPTER 5
CYCLON AIR-END TOOLING DIAGRAMS
Contents
FIG. 5.1 ROTOR LOCKING FIXTURES – CRITICAL DIMENSIONS
FIG. 5.2 SPECIAL SOCKETS – CRITICAL DIMENSIONS
FIG. 5.3 DELIVERY END BEARING SUPPORTS
Chapter 5, Page 1
ØA
D
ØB
C
ØE
ØF
SCREW LOCATES
IN KEYWAY
Dim. in mm Dia. A Dia. B C D Dia. E Dia. F
Cyclon 1 23 36 55 57 55 8
Cyclon 2 31 41 74 68 70 10
Cyclon 3 32 43 90 80 76 11
Cyclon 4 42 43 105 96 83 11
Cyclon 5 54 60 135 124 96 17
Cyclon 6 72 76 165 134 140 19
FIG. 5.1 ROTOR LOCKING FIXTURES – CRITICAL DIMENSIONS
Chapter 5, Page 2
Tooling Diagrams – Cyclon Air-ends
ØD
ØE
C
B
DRILL AND TAP TO SUIT SHORT
SCREW FOR TORQUE WRENCH
FEMALE ROTOR
Dim. in mm A B C Dia. D Dia. E
Cyclon 1 35 30 3.8 25 37
Cyclon 2 44 38 4·8 35 50
Cyclon 3 44 39 4·8 42 60
Cyclon 4 45 39 4·8 49 68
Cyclon 5 50 41 5·8 65 85
Cyclon 6 50 41 6·8 75 95
MALE ROTOR
Dim. in mm A B C Dia. D Dia. E
Cyclon 1 36 30 4·8 35 51
Cyclon 2 38 31 4·8 49 64
Cyclon 3 44 35 5·8 62 81
Cyclon 4 48 38 5·8 65 86
Cyclon 5 54 43 6·8 80 100
Cyclon 6 64 50 7·8 99 120
FIG. 5.2 SPECIAL SOCKETS – CRITICAL DIMENSIONS
Chapter 5, Page 3
A
B
H
ØG
ØD
ØC
ØE
Dim. Cyclon 1 Cyclon 2 Cyclon 3 Cyclon 4 Cyclon 5 Cyclon 6
(mm) male female male female male female male female male female male female
A 50 58 106 116 108 98 109 87 90 76 114 91
B 2 2 5 6 3 8 41 21 6 12 6 14
ØC 62 46 76 62 100 62 110 72 136 90 168 110
ØD 49 31 65 47 84 42 95 50 86 60 120 70
ØE 30 23 45 32 54 32 60 38 68 50 81 62
F 30 30 35 57 38 32 40 38 25 25 32 32
ØG 46 30 60 42 75 N/A 82 N/A N/A N/A N/A N/A
H 3 2 5 3 3 N/A 4 N/A N/A N/A N/A N/A
FIG. 5.3 DELIVERY END BEARING SUPPORTS
Chapter 5, Page 4

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AC20160-1327, Issue 2, June, 1994

The conditions of the CompAir BroomWade Warranty

1. GENERAL 2. WARNINGS, CAUTIONS AND NOTES

Most accidents which occur during the operation

Regulations of the Institution of Electrical

CompAir BroomWade cannot anticipate every

WARNING: CONSULT MANUAL

Incorrect operational procedures causing possible

Methods to make the job easier and points which

If using compressed air for cleaning purposes,

Never use a light source with an open flame to

Only use lint free cloth when cleaning components

After completion of repair or maintenance work

Do not use any flammable liquid to clean air pipes

Do not use carbon tetrachloride

Precautions must be taken when using acids,

DISMANTLING AND ASSEMBLY PROCEDURES

SRM AIR-ENDS – COMPRESSOR MODEL REFERENCE GUIDE

Compressor Air End Part No.

6007EA from F125/0101 63·75 x 1·5 C20453-70

6010E from F070/0001

RA30 from F004/7001

6050 from F079/0001 102 x 1·65 C20434-87

6020 from F072/0001

6040EA from F131/0151 102 x 1·8 C20452-69

6060 from F080/0001 127·5 x 1·65 C20450-40

6100 from F082/0001 178·5 x 1·65 C20438-90A

6125 from F084/0001★ 178·5 x 1·65 C20438-40

6180A from F086/0101▲

DISMANTLING AND ASSEMBLY PROCEDURES

1. AIR-END 63·75 x 1·5 (C20453-70)

1.1 DISMANTLING PROCEDURE 5. Remove screws (15) and washers (16)

FIG. 2.1 AIR-END 63·75 X 1·5 (C20453-70)

16. Coat bore of new shaft seal sleeve (1) with

CAUTION: When fitting the oil seal during item 17,

17. Using a suitable mandrel, press a new single

2. AIR-END 86·7 X 1·54 (C20451-70)

4. Using a press and suitable mandrels, press 2.2 Assembly Procedure

FIG. 2.2 86·7 X 1·54 (C20451-70 TO SERIAL NO. L009/8480)

17. Using a new joint (6), fit the inlet bearing

18. Fit the circlip (29) to secure the inner ring of

19. Using a suitable mandrel, press a new single

CAUTION: When fitting the single piece seal, it is

20. Pass a new sleeve (35), internal taper end

21. Fit the oil seal housing (30) to the inlet

6. Position the rotor locking fixture 288018 to the

FIG. 2.3 86·7 X 1·54 (C20451-70 FROM SERIAL NO. L009/8481)

18. Fit the circlip (29) to secure the inner ring of

19. Coat the bore of a new shaft seal sleeve (33)

20. Using a suitable mandrel, press a new single

CAUTION: When fitting the single piece seal, it is

3. AIR-END 102 X 1·65

3.1 Dismantling Procedure (C20434-40 & 87) 7. Poso tintherotoolrcknigxfituretothevcie.

.6 Removescrews(14)andwashers(15) 3.2 Assembly Procedure (C20434-40 & 87)

.3 De-greaseouteraceon f ewmaleinlet 9. Repeatprocedures6to8formaleboreand

FIG. 2.4 AIR END 102 X 1·65 (C20434-40 & 87)

.41 Fdtievileryendcover(16w ) tihnewo

.51 Posoitndevilerybeanrighousnigr/oo trs

.61 Usn i ganewo jn