Service Manual Part 2
Contents
1. 0 13 mm spacing B 2nd side therefore B RFM2 RFM3 0 37 mm 0 13 mm 0 24 mm C23556277_EN 11 2009 Rev 0 To set the spacing B of the rotor to the side cover on the second side to the target value of 0 15 to 0 18 mm shim rings have to be used with a strength of 0 06 to 009 mm NOTE The shim rings that came with the delivery feature the following thickness 0 05 0 08 0 13 0 25 mm Example A shim ring with a thickness X2 of 0 08 mm is used The spacing B1 Spacing 2nd side after shim ring installation is therefore reduced by 0 08 mm and is therefore set to B1 B X2 0 24 mm 0 08 mm 0 16 mm This corresponds with the target range e Unscrew second bearing cover and reinstall it on the side cover with the determined shim rings e Measure axial float Fixed Free Float FFF Fixed Free Float and check whether the float falls into the target area Target value Fixed Free Float 0 19 to 0 35 mm 35 6 6 4 Final work e Turn compressor around the connecting flanges 1 must point upwards Tape cover connecting flanges to prevent that dirt or something similar enter the compressor e Check flexibility of the separating valve Slowly turn shaft in the specified rotation direc tion see arrow 2 and listen whether you can hear 6 clicking sounds with a full turn of the shaft The clicking occurs the the separating valves hit the casing when the separa2. hydraulic motor with screws 8 4xM12 or 2xM14 spring washers 7 and washers 6 into the threaded drill holes of the drive cover and tighten with the specified torque Tightening torque M12 8 8 52 Nm 38 4 Ibf ft M14 8 8 80 Nm 59 Ibf ft e Reinstall finger guard onto the drive cover e Install connecting lines of the hydraulic motor on the vehicle C23556277_EN 11 2009 Rev 0 4 Safety labels Sticker in compliance with ISO European market QQ A A L oa WP 22 Read and follow the safety notes and oper ating instructions before starting operation Pressurized air outlet direction of flow Burn hazard Hot surface Keep out Wear hearing protection WARNING No breathable air Sticker in compliance with ANSI North American market with product sul Oy Hot surface Can cause severe injury Do not touch Allow to cool before servicing Rotating fan blade Can cause severe injury Lockout Tagout machine Before using read manual supplied PC80150394 Do not operate without guard in place Disconnect power before servicing Discharge A DANGER Discharge air Can contain carbon monoxide or other contaminants Will cause severe injury or death Do not breathe this air High pressure air Can cause severe injury or death Relieve pressure before removing filler plugs caps fittings or c
3. information Maintenance information The operating instructions must be read prior to starting the compressor The operating instructions must be read prior to starting the compressor To avoid corrosion let the compressor run for about 15 minutes after any cleaning work To avoid corrosion let the compressor run for about 15 minutes after any cleaning work Clean intake filters weekly in case of high dust level shorten the intervals between cleaning Clean intake filters weekly in case of high dust level shorten the intervals between cleaning Machine no Machine no ED ingersou rand QP noeros Rand e Apply service notice in the for the operator local language version e Attach the second maintenance instruction where it can be clearly seen e g in the driver s cab e Enter machine no with waterproof pen 23 5 initial commissioning 5 1 General The first start of operation of the compressor kit takes place at the site of the system installer It includes the rotation direction control and a test run with pressure test If in exceptional cases the first start of operation is carried out by the customer the following work has to be carried out Rotation direction control When look onto the compressor drive shaft the compressor step must turn corresponding to the arrow marking on the compressor casing see Chapter 3 3 1 Compressor drive
4. must fall in to the range of 0 49 to 0 59 mm C23556277_EN 11 2009 Rev 0 Example Measured free float FFM 0 540 mm oe V e Install bearing cover 2 on one side with screws M8x20 1 onto the side cover 3 at this time do not insert shim rings 4 yet Tightening torque M8x20 10 9 28 Nm 20 7 Ibf ft SD EY e Remaining axial tolerance RFM1 Remaining Float Measured as previously described Record measured value Example Remaining float measured RFM1 0 320 mm The difference between free float and the remain ing float is the fixed float minimal spacing A between rotor and side cover A FFM RFM1 33 The float should fall into the range between 0 150 to 0 180 mm and can be adjusted by respective shim rings between bearing cover and side cov er NOTE The use of shim rings increases the spacing between the bearing cover and the side cover the minimal spacing between the rotor and the side cover is therefore reduced by the same val ue Example Spacing A 0 54 0 32 mm 0 22 mm To set the spacing between the rotor and the side cover to the target value of 0 15 to 0 18 mm you therefore need to use shim rings with a total thickness of 0 04 to 0 07 mm NOTE Select shim rings so that the required thickness is achieved with the least number of shim rings No more than 3 shim rings should be used on one bearing
5. plate for the articulated shaft in accordance with accident prevention regulations if necessary 19 SV120 H kit only e Loosen screws 2 4 pieces at the drive cover 1 of the compressor and take of finger guard 3 e Unscrew setscrew 3 of a hub 1 of the flexible coupling Slide hub over feather key 2 onto the drive shaft and fasten with headless pin initially only tighten headless pin into a finger tight posi tion 20 e Slide the second hub 2 of the flexible coupling onto the shaft 1 of the hydraulic motor and tighten headless pin 4 into a finger tight posi tion e Tentatively install the hydraulic motor with screws M12 7 spring washers 6 and washers 5 on the drive cover 3 of the compressor e Measure space between the two hubs e f the measured space between the does not match the target value of 4 mm move the hub s respectively and tighten the headless pins NOTE The two hubs should be pushed onto the shafts approximately the same length of the way e Uninstall the hydraulic motor again from the compressor covering C23556277_EN 11 2009 Rev 0 e Place coupling sleeve 2 onto the hub of the compressor drive shaft 4 and install hydraulic motor 1 again onto the drive cover 3 at the same time push hub 5 onto the shaft of the hydraulic motor into the coupling sleeve 2 Cross wise screw
6. prior to working on or cleaning the compressor If a pressure washer is used make sure to keep a distance of at least 0 5 m 1 7 ft While cleaning the outside and the inside with pressurized air ensure that flying dust is not breathed in remove more extensive accumula tion of dust by washing the outside and the inside or by wiping it off with a moist rag CAUTION Do not use cleaning products solutions with a high PH level strong alkaline solution corrosion hazard Always rinse with clean water after wards 26 6 6 Repair work 6 6 1 De installation dismantling e Deinstall the compressor from the vehicle and place on a work bench WARNING Do not hold lift the compressor by the plastic covers that are attached to the sides e Loosen fastening screws of the fastening plate or the footers and take off fastening plate footers e Only SV120 D Loosen the headless pin 2 for the fastening of the overload coupling 1 or the drive flange and pull of overload coupling with inner ring 5 or drive flange from the the compressor drive shaft 4 Take feather key 3 out of the groove in the compressor shaft C23556277_EN 11 2009 Rev 0 e Only SV120 H Loosen fastening screws 8 and together with spring washers 7 and disc washers 6 take them off the hydraulic drive 1 Take hydraulic drive off the drive cover 3 and pu
7. rotation speed The rotational speed range of the rotary valve com pressor stated in the technical data must not be exceeded or undercut Reliable rotational speed range of the rotary valve compressor Work See Section SV120 e Rotation direction control 3 3 1 Min 1000 min rpm e Test run 5 2 Max 1800 min rpm NOTE WARNING The further operation of the completed compres Ensure that the compressor is only operated sor exclusively falls under the responsibility of the within its permissible rotational speed range operator WARNING It is absolutely necessary to adhere to the operating values of the rotary valve compressor specified in Chapter 1 6 Technical data of SV120 rotary valve compressor 5 2 Test run WARNING Prior to the test run check all safety relevant screw connections for a tight fit Vehicle motors with EDC control must potential ly be re parameterized prior to the start of oper ations The rotation direction the rotational soeed and the flawless function of the safety equipment must be checked during the test run Only start compressor without any load Never go into operation against a potentially existing counter pressure 24 5 3 Switching Compressor Off CAUTION Do not turn compressor off if there is counter pressure If there is counter pressure take appropriate measures to reduce pressure before turning co
8. bear ings and the shaft seals will also be replaced dur ing the repair NOTE The required replacement parts come together in one repair kit which can be obtained as a replace ment part from GHH RAND or through authorized service partners The tools that are required to carry out the repair work are listed in Chapter 6 7 WARNING The continued operation of the compressor with worn separation valves may damage the rotor and the compressor casing this in turn will lead to an increased wear and tear a shortened lifespan of new separation valves An insufficient or neglected cleaning of the parts that are to be reinstalled can also lead to an increased wear and tear and therefore to a pre mature failure of the compressor In conjunction with broken separation valves the following additional work must be carried out Cleaning of the air filter replacement of the air filter cartridge Cleaning of the intake and pressure lines Check and potentially replacement of safety and non return valve C23556277_EN 11 2009 Rev 0 25 6 5 Preparatory work Prior to the dismantling of the compressor from the vehicle or the reinstallation of the compressor on the vehicle the compressor as well as the area surrounding the vehicle must be cleaned to prevent the entry of dirt foreign particles into the compres sor WARNING Compressor and pressure line become hot Let parts cool down
9. cover The shim rings that came with the delivery feature the following thickness 0 05 0 08 0 13 0 25 mm D D Example A shim ring with a thickness X1 of 0 05 mm is used The spacing A1 Spacing 1st side after shim ring installation is therefore reduced by 0 05 mm and is therefore set to A1 A X1 0 22 mm 0 05 mm 0 17 mm This corresponds with the target range 34 e Loosen screws 1 and take off bearing cover 2 Reinstall bearing cover with the determined shim ring s 4 on the side cover 3 The remaining float RFM2 after the installation of the bearing cover and the shim ring s is increased by the implemented thickness of the shim rings RFM2 RFM1 A1 Example Remaining float RFM1 previously 0 32 mm utilized shim ring thickness X1 0 05 mm remaining float RFM2 RFM2 0 32 mm 0 05 mm 0 37 mm C23556277_EN 11 2009 Rev 0 e Install second bearing cover on the opposite side without shim rings tighten fastening screws with specified torque Tightening torque M8x20 10 9 28 Nm 20 7 Ibf ft e Measure and record remaining axial float of the rotor shaft after installation of the second bearing cover RFM3 The difference from RFM2 without installed bear ing cover and the measured value for RFM3 is the minimal spacing between rotor and second bear ing cover B B RFM2 RFM3 Example value float RFM2 0 37 mm measured float RFM3
10. diately thereafter pull it off the rotor shaft while wearing an appropriate protective glove Dispose of bearing ring e Carefully clean rotor e Take off bearing cover from both side covers Loosen screws 1 and bearing cover 2 as well as shim ring s 8 from the side cover 4 Dispose of dismantled shim rings 29 e Remove and dispose of rotary shaft seal 1 from the two bearing covers 2 e Remove and dispose of exterior bearing ring including rolling element 1 as well as rotary shaft seal 2 from the two side covers 3 e Carefully clean compressor casing rotor as well as side cover and bearing cover CAUTION An insufficient or neglected cleaning of the parts that are to be reinstalled can lead to an increased wear and tear and therefore to a premature failure of the compressor 30 6 6 2 Assembly installation e Insert rotary shaft seal 945 627 1 onto a re spective installation pin 3 and afterwards push it into the side cover 2 as shown e Fill inside space of the rotary shaft seal 1 see magnifying glass in side cover 2 with specified grease 3 Grease SV120 Bearing Grease C23556277_EN 11 2009 Rev 0 e Slide rotary shaft seal 930 42x6 1 onto a re spective installation pin 8 and then push it into the bearing lid 2 as shown e Fill interior room of th
11. e Install intake air filter with mounting on the vehi cle e Take off screw cap 2 at the rubber elbow piece 3 and screw in service gage 1 e Put rubber elbow piece onto the hose connector fitting on the air filter casing and fasten with hose clamp e Insert an included pipe piece on the other side of the rubber elbow piece and fasten with hose clamp Install pipe piece on the vehicle 5 i e Remove foil at the intake flange 3 of the com pressor Install hose connector fitting 1 and flange seal 2 with screws M10x40 5 spring washers 6 and nuts 7 onto the compressor 18 CAUTION Always insert screw head into slot on the com pressor as shown An incorrect installation can damage the compressor NOTE The intake side the intake fitting can be identi fied by the arrow marking 4 in the casing which points away from the flange on the respective side e Install intake line spiral hose in an as straight a line as possible on the vehicle and fasten the ends on the hose connector fitting as well as on the pipe piece using hose clamps NOTE Keep intake hose as short as possible shorten the hose if necessary e Install pressure line to the tank with safety and non return valve or combined safety and non return valve and if necessary also micro filter and relieve ball valve on the vehicle in accordance
12. e rotary shaft seal 1 in the bearing cover 2 with a specific grease 3 Grease SV120 Bearing Grease C23556277_EN 11 2009 Rev 0 e Place paper or similar 4 place into the compres sor casing 3 ensure that the entire length of the casing is covered with paper e Carefully place rotor 1 on the paper in the com pressor casing Ensure that the rotation direction of the rotor matches the arrow 2 on the casing if necessary place rotor in the casing in opposite direction CAUTION The fitted key slot in the shaft has sharp edges Wear appropriate protective gloves e Lift the rotor slightly and remove paper or similar with any traces Carefully put down rotor 31 e Insert O ring 2 on one side into the groove int he since cover 1 and carefully slide side cover with installed shaft seal 4 over the rotor shaft use a respective cone shaped sleeve Place side cover onto the alignment pins 3 on the casing and fasten to the casing with srews M8 5 Tightening torque M8x20 10 9 28 Nm 20 7 Ibf ft CAUTION Ensure that the seals are clean during the instal lation Side covers must reinstalled on the original cas ing side e On the other compressor side insert new sepa rating valves 1 into the grooves in the rotor 2 ensure at the same time that the slanted edge points to the casing and that the sharp edge points in rotor dir
13. ease must be ordered separately order number The address or telephone number for ordering replacement parts can be found on the last inside cover of this instruction 38 C23556277_EN 11 2009 Rev 0 Service GHH RAND Schraubenkompressoren GmbH Max Planck Ring 27 46049 Oberhausen Germany SILU Service Hotline Tel 49 208 99 94 177 Service Tel 49 208 99 94 170 Spare parts Tel 49 208 99 94 171 Fax 49 208 99 94 179 E Mail info_ghh rand irco com Internet www ghhrand com Printed in Germany Subject to changes of technical details compared to the information and illustrations of the Installation Instruction Areplication copying or translation even in parts is not permitted with out written consent GHH RAND Schraubenkompressoren GmbH Subject to revision without notice FR RAND Max Planck Ring 27 Printed in the Federal Republic of 46049 Oberhausen Germany Germany SILU Service Hotline ne Tel 49 208 99 94 177 Fax 49 208 99 94 179 A contribution to environmental protection IR This paper was made of 100 chlorine free Gi Ing er soll Rand bleached paper Industrial Technologies
14. ection see magnifying class 32 CAUTION Prior to inserting the separating valve into the rotor if necessary clean separating valve from attached dirt grease that are a result from touch ing them Only touch separating valves with clean fingers at the corners e Install second side cover as previously de scribed e Shrink fit new bearing inner rings onto the rotor shaft Warm bearing interior rings 1 to 120 C 248 F While wearing an appropriate pro tective glove quickly push bearing rings with the smooth side toward the the rotor until they sit flush 2 on the rotor shaft Wait a few seconds before letting so that the bearing ring will no longer be able to move e Insert bearing exterior ring 1 on both sides into the side cover 3 while carefully pushing the rolling elements onto the interior ring 2 C23556277_EN 11 2009 Rev 0 6 6 3 Measuring calibration of the bear ing float NOTE Only carry out float measuring with cold compres sor and grease free bearings e Screw measuring stand 1 into a threaded drill M10 2 for the side covers and place sensors of the dial gage 4 onto the end of the rotor shaft 3 e Push rotor shaft fully against the side cover on one side and set dial gage to zero e Push rotor shaft onto the other side until it sits flush on the side cover and record the value free float measured FFM the value
15. m pressor off CAUTION Do not turn vehicle motor off while power take off is running C23556277_EN 11 2009 Rev 0 6 Repair service 6 1 General GHH RAND points out that damage on the seal will void the warranty 6 2 Personnel and qualification The repair and service work on the compressor compressor kit described in this Chapter may only be carried out by trained or educated personnel who are familiar with the applicable safety regula tions The staff of the Service Center or of GHH RAND is also available to carry out this work 6 3 Safety Adhere to all safety instructions to prevent injuries and damage to the compressor compressor kit WARNING The rotor as well as the feather key groove may have sharp edges As a prevention against injuries caused by cuts wear protect gloves while carrying out respective work Turn vehicle motor off prior to work relating to the dismantling installation remove key and secure vehicle against rolling away use wedges CAUTION Ensure that no foreign parts enter the compres sor or remain in the compressor because this may damage destroy the compressor 6 4 Repair time and scope If it is determined during a scheduled inspection of the separation valves see Operating Instructions for SV120 D H that the separation valves must be replaced the compressor requires repair in addition to the separation valves the shaft
16. n the compressor CAUTION Only SV120 H When the hydraulic drive is reattached to the compressor the spacing of the hubs of the flex ible coupling must be checked again and set to the specified volume see Chapter 3 6 e Install intake and pressure line with new flange seals on the compressor CAUTION Only the non electricity conductive flange seals that come with the repair kit may be used on the compressor flanges risk of corrosion NOTE After the repair and the reattachment on the vehi cle the proper function of the compressor has to be checked and the connections have to be checked for leaks in a test run C23556277_EN 11 2009 Rev 0 6 7 Required tools The tools required for the service repair of the SV120 rotary valve compressor can be found in the following table Pos Name OO o y Installation pin 30 42 mm nstallation pin 40 62 mm Grease volume measuring device You can obtain these tools from GHH RAND if nec essary For that please contact GHH RAND ora GHH RAND service partner 37 7 Replacement parts and ordering The components required for the repair of the rotary valve compressor bearing separating valve sealings O rings and shim rings are combined in a special repair kit This kit includes all components that are required for a new bearing and or sealing including the replacement of the separating valves The required special gr
17. overs C23556277_EN 11 2009 Rev 0 Positioning of the stickers Position the safety and maintenance notices as follows e Read Operating Instructions 1 A In the driver s cab right next to the control of the power take off which starts the compressor e Exhaust air 2 B Look for optimal position in immediate proximity to drain line and pay atten tion to good visibility e Hot surface 3 C As close as possible next to the compressor casing the drain sound suppres sor and the drain line Do not affix directly to hot surface e Do not step here 4 As close as possible to the compressor casing so that it will not used as an unintended stepping platform e Wear hearing protection 5 Easily visible on the vehicle frame close to the installed compres sor e No breathable air 6 D On each line outlet of the system where exhaust air can be extracted e Rotating ventilation panel E At the plastic co vers and at the aluminum drive cover only hyd raulic drive of the compressor step e Pressurized air F If possible on any feature in the pressure line behind the non return valve NOTE The areas that are to receive the stickers must be completely free of grease and dust C23556277_EN 11 2009 Rev 0 GB Affix maintenance information in easily visible location Do not affix to hot surfaces The surface must be completely free of grease and dirt GHH RAND GHH RAND Maintenance
18. shaft off the alignment dowel pins 4 in the com pressor casing Remove and dispose of O rings 8 28 CAUTION When pulling the side cover off carefully place the rotor into the casing do not let it drop The surface of the casing drilling may otherwise get damaged NOTE During the subsequent reassembly install the side again on the respective side if necessary mark the side cover NOTE To loosen a tight fitting side cover you may use a rubber hammer to lightly tap against the side of the side cover The 2 cylinder pins 4 ensure that the side cov ers cannot be attached on the wrong side during the installation e Take off second side cover off the casing as described above e Pull out separating valve 1 total of 6 units out of the slots in the rotor 2 C23556277_EN 11 2009 Rev 0 e Carefully lift rotor 1 and insert paper or some thing similar 3 between the rotor and the casing 2 ensure that the paper covers the entire length of the casing e Carefully lift rotor take it out of the casino and place it on a clean surface Remove paper from the casing CAUTION When lifting the rotor out of back into the case ensure that the rotor does not touch the casing C23556277_EN 11 2009 Rev 0 e Briefly heat up the inner ring of the bearing 1 with a burner on both sides of the rotor shaft 2 and imme
19. t aside Pull coupling sleeve 2 off the hub 5 on the compressor shaft e Only SV120 H Loosen the two remaining fastening screws 4 of the drive covering 3 and pull the drive cover ing in longitudinal direction off the compressor e Only SV120 H Loosen headless pin 2 of the coupling hub 1 on the compressor shaft and pull coupling hub from the compressor shaft Take feather key 3 out of the groove in the com pressor shaft C23556277_EN 11 2009 Rev 0 e Only SV120 D Loosen fastening screws 1 and take them off the drive covering 3 together with disc washers 2 Pull drive covering from compressor in lon gitudinal direction of the shaft e Take off cover 1 on the side opposite to the drive Loosen screws 3 and take them off the cover together with disc washers 2 Pull cover from compressor in longitudinal direction of the shaft 27 e Unscrew headless pin 1 from the fan hub 4 and pull fan hub off the compressor shaft 3 together with installed fan wheel NOTE Due to the counterbore 2 in the rotor shaft it may not be possible to pull the fan hub off the shaft if the headless pin 1 is only slightly loos ened e Put compressor on the side with the connecting flanges e Loosen fastening screws 1 of the side cover 2 on one compressor side and carefully pull the side cover in longitudinal direction to the rotor
20. ting valves slide down from the rotor slots e Unscrew locking screw 3 on both compressor sides and through the opening pressure fit 8 cm of the specified grease while turning the shaft 4 to achieve an even filing of the ball bearing Grease SV120 Bearing Grease CAUTION Do not fill more than the specified amount of grease into the bearings because it may other wise lead to a failure of the bearing due to an excessive warming of the bearings Use a suit able measuring device to determine the exact filling amount of grease 36 e Fit locking screws with screw retention e g Loctife 243 Loxeal 55 03 or similar and screw them back into the bearing cover 5 e Insert fans with fan hubs 4 onto the shaft 3 on both sides and position them so that the headless pin 1 comes to rest on the counterbore 2 in the shaft when it is screwed into the fan hub Tighten headless pin e Install covers back into the original position orientation to the connection flanges see Chap ter 6 6 1 pay attention to the correct rotation direction at the free shaft end Do not screw in screws to attach the fastening plate or footers yet e Re insert feather key into the rotor shaft and install the drive flange overload coupling SV120 D or coupling hub SV120 H onto the compres sor shaft C23556277_EN 11 2009 Rev 0 e Install compressor on the vehicle and attach drive shaft or hydraulic drive o
21. with Chapter 3 5 WARNING The length of the pressure line from the compres sor to the safety valve may not exceed 1 meter It must be ensured that it is not possible for liq uids from the tank to enter the pressure line and to reach the compressor C23556277_EN 11 2009 Rev 0 e Remove foil at the pressure flange 3 of the compressor attach pipe connection flange 1 of the pressure line with flange seal 2 and fasten with screws 4 M10x40 spring washers 5 and nuts 6 on the pressure flange SV120 D kit only e Install overload coupling with shear bolt 1 op tional or drive flange on the compressor drive shaft 4 Slide component over the feather key 3 on the drive shaft and secure hexagon socket head bolt 2 C23556277_EN 11 2009 Rev 0 NOTE The inner ring 5 in the overload coupling 1 can be taken out and inserted the other way around A switching of the inside outside alignment ena bles the installation of the following DIN and SAE flanges on the coupling e DIN 100 6 e SAE 1100 e SAE 1310 e Screw in articulated shaft at the overload cou pling as well as on the power take off flange of the vehicle WARNING Follow the instructions in Chapter 3 3 4 for the installation of the articulated shaft The cardan joints 1 of the articulated shaft 2 must point into the same direction NOTE Provide cover
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