Maintenance & Overhaul Manual

1 General information

C80 Overhaul Instruction

Printed Matter Number : 2946 1722 00
Applicable to : Compressors with C80 elements
Preliminary Operations: : –
Safety Instructions : General
Persons Required : 1
Special Tools : C80 overhaul kit, Torque wrench, Overhaul stand, Induction heater, Adjustable induction
heater
Consumables : Loctite 243, Loctite 641, oil, cleaning product

2 Document overview

This document describes the following:

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

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

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

4 Parts overview ................................................................................................................................................................... 3

4.1 Element overhaul kit (2901 1959 00) ......................................................................................................................... 3

4.2 Other necessary parts ............................................................................................................................................... 3
5 Tools overview ................................................................................................................................................................... 4

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

5.2 Other tools ................................................................................................................................................................. 5
6 Overhaul ............................................................................................................................................................................ 6

6.1 Dismantling ................................................................................................................................................................ 6

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

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

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

6.1.4 Inner races of the bearing at the inlet side.......................................................................................................... 14

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

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

6.2.2 Element housing and outlet flange ..................................................................................................................... 15

6.3 Reassembly ............................................................................................................................................................. 15

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

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

6.3.3 Bearing at outlet side of male rotor ..................................................................................................................... 20

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

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

7 Packing ............................................................................................................................................................................ 26

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 Safety first

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3 Parts overview

3.1 Element overhaul kit (2901 1959 00)

Kit content:

Part number Description Quantity

0508 1108 00 Bearing 1

0508 1100 46 Bearing 1

0211 1323 00 Cap screw 1

1616 7202 00 Washer 1

1616 6915 00 Oil nozzle 1

0211 1322 00 Cap screw 1

0301 2335 00 Washer M8 1

0147 1364 03 Bolt M10x35 6

0147 1365 03 Bolt M10x40 2

0101 1951 40 Dowel pin 1

0504 0200 14 Ball bearing 2

1616 7426 00 Bearing 1

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

0504 0200 54 Bearing 1

0147 1368 03 Hexagon bolt 1

0295 3107 00 Nut 1

0147 1326 03 Hexagon bolt M8x30 6

0663 2106 70 O-ring 1

0663 7139 00 O-ring 1

0663 2112 18 O-ring 1

0663 2106 67 O-ring 1

1616 6267 20 Spacer 1

3.2 Other necessary parts

• Fine sandpaper
• Loctite 243
• Loctite 641
• Cleaning product
• Oil

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4 Tools overview

4.1 C80 Overhaul kit (2230 0108 00)

• Blocking tool (1630 0929 28)

• Inner race press tool (1630 0929 29)

• SKF lock nut socket (TMFS6)

• Threaded rod M10

• Small bearing

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4.2 Other tools
• Thickness gauge foil 0.04mm

• nut M10
• Torque wrench
• Overhaul stand
• Induction heater:
• 2908 0048 00 (50Hz)
• 2908 0048 01 (60Hz)
• Adjustable induction heater
• 2230 0102 00 (50Hz)
• 2230 0103 00 (60Hz)

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5 Overhaul

5.1 Dismantling

5.1.1 Element housing

1. Connect the element with its

outlet flange to the overhaul stand
(inlet side upwards) (A).

2. Remove the fixation washer (A) B

and bolt (B) of the outer races.

3. Remove the fixation washer (A)

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

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4. Remove the oil spray nozzle (A).

5. Change position of the element –

outlet side upwards.

6. Unscrew 6 bolts (A) and remove

the male & female rotor end cap
(B).
A
B

7. Change position of the element –

inlet side upwards and unscrew 8
bolts of the outlet flange (A).

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

9. Change position of the element –

outlet side upwards .

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5.1.2 Female rotor and female rotor bearings

1. Place the lock nut socket (A) on

the lock nut of the female rotor (B). A

2. Block the rotors (A) with the

locking tool (B).

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

4. Screw in the M10 bolt (A) for the

protection of the female rotor.
A

5. Place a pulley puller (A) and push A

through the female rotor (B).

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 Support the female rotor to
prevent it from falling!

6. Remove the female rotor outlet

bearings (A). A

If needed you can use pulley

puller (B).

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5.1.3 Male rotor and male rotor bearings

1. Unscrew the fixation bolt of the

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

2. Screw in the fixation bolt for the

protection of the male rotor (A).

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3. Use the pulley puller and the
blocking tool (A) to press out the
male rotor (B).

Support the male rotor to

prevent it from falling!

4. Remove spacer (A) from male

rotor outlet side.

5. Remove the male rotor outlet

bearings (A).

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5.1.4 Inner races of the bearing at the inlet side

Note: The overhaul procedure does not foresee metal shells for the dismantling of the inner races of the roller bearings due to high cost
and very short life time.

1. Position the rope of the adjustable

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

2. Heat up the bearing inner race (A)

until it can be removed from the
shaft of the element by hand.
A
Always use heat resisting
gloves during all operation
with the induction heater!

3. Position the rope (A) of the A

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

4. Heat up the bearing inner race (A)

until it can be removed from the
shaft of the element by hand.

5. Clean up the shafts of the rotors

(A).

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5.2 Cleaning and inspection

5.2.1 Male and female rotors

1. Clean the rotors

2. Inspect both rotors for scratches and other damage

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

5.2.2 Element housing and outlet flange

1. Clean element housing the outlet flange

2. Inspect housing and outlet flange for scratches and other damage

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

5.3 Reassembly

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

1. Take a new female rotor roller

bearing (0508 1100 46) (A) from
the kit.

2. Heat up the inner race of the

bearing (A) with the induction
heater up to 120°C.

Always use heat resisting A

gloves during all operation
with the induction heater!

Overheating of the inner

race can cause deformation
or change the material
property so that the bearing
will not be suitable for use.

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

4. Install the inner race of the

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

5. Take a new male rotor roller

bearing (0508 1108 00) (A) from
the kit.
A

6. Heat up the inner race of the

bearing (A) with the induction A
heater up to 120°C.

7. Take a brush and put some

Loctite 641 on the inner race seat
A
of the male rotor shaft.

8. Install the inner race of the

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

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5.3.2 Bearings at the outlet side of the female rotor
Take the roller bearing 1616742600 and the ball bearing 0504020054 from the kit and install them into the outlet flange of
the element.

This roller bearing is an AIRTEC bearing which only can be ordered from Atlas Copco.

Pay attention to the position of the bearings.

1. Take 2 pieced of thickness gauge

foil of 0.04mm (A).

2. Position the female rotor (A) in the

housing and support the rotor (for B B
example by hydraulic pump). In
between the female rotor and the
housing head plane position 2
pieces of thickness gauge foil (B).
A
During next steps
continuously check position
rotor and gauge foils. This
determines head clearance!

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

4. Position standard nut socket (size

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

5. Torque the nut to press the inner

A
race over the rotor shaft till the
inner race tool touches the C
housing.

The inner race tool will limit the

depth the inner race is pressed
over the rotor shaft.

6. Press the outer race of the

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

7. Take the bearing (0504 0200 54) A

(A) and heat this up to 120°C
(position sensor on inner race of
bearing).

8. Place this bearing in the housing

over the rotor (B). Hold the
B
bearing down till it is cooled off.

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 Check the position bearing.
The side with broad inner
race should be upwards (A).

9. Take the new lock nut (A) of the

female rotor from the overhaul kit A
and apply Loctite 243 on it.

Do not apply big quantity of

the Loctite 243, since this
can cause change of the
female rotor gap during
exploitation of the
overhauled element.

Chamfer (A) should always

be turned downwards!

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

11. Remove the thickness gauge foils

(A).
A

5.3.3 Bearing at outlet side of male rotor

Spacer at the outlet side of the male rotor

1. Install spacer (A) on the shaft of

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

A B

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5.3.4 Bearings at the outlet side of the male rotor

1. Take two ball bearings (0504 0200

14) (A) from the kit and install
them into the outlet flange of the
element.

Pay attention to the position

of the bearings! A

Mark spacer on below

drawing.

2. Place washer on top of the

bearings (A) - Male outlet washer
used as tool.

3. Position standard nut cap (size

D
30) (B) and a small bearing (C) on
top of the washer.

4. Put the nut on the rod (D) and put C

them through bearing / nut / B
washer / male outlet bearings.

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

6. Block the rotor (A) with the

blocking tool (B).

7. Press the bearings on the shaft of

the male rotor by the tightening of
the nut.

8. Proceed until the bearings are

completely pressed on the shaft.

B
Applied torque should not A
be more them 15 Nm during
this operation A

9. Take new bolt from the overhaul

kit (A), put the male shaft washer
(B) on it and apply the Loctite
243.

10. Tighten the bolt of the male shaft

(A). Required torque – 46Nm.

5.3.5 Spacer at the outlet side of the male rotor

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

C
B

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

3. Install the male cap (A) into the A

outlet flange and tighten the bolts
(B) by applying 23 Nm torque.

4. Install the female cap into the

outlet flange and tighten the bolts
by applying 23 Nm torque. A

5. Change position of the element –

outlet side downwards.

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

Note: Do not forget about small O-ring

(0663 2106 67) of the oil injection C
hole (C).

7. Insert the rotors into the housing

of the element.

8. Tighten all 8 bolts (A) of the outlet

flange by applying 46 Nm torque.

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

10. Install the outer race of the roller

bearing (0508 1108 00) (A) at the
inlet side of the male rotor.

11. Take new bolt (A) from the

overhaul kit, put the washer on it
and apply the Loctite 243.

12. Tighten XXX bolt by applying

39 Nm torque. A

13. Install new oil spray nozzle (A)

from the overhaul kit.

14. Take new bolt from the overhaul

kit, put the washer on it and apply
the Loctite 243.

15. Tighten the bolt by applying

39 Nm torque.
A

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6 Packing

1. Oil the element.

2. Cover the shaft with greased paper.

3. Cover the element outlet with tape.

4. Remove the element from the overhaul stand.

5. Cover the element with tape.

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