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Maintenance procedure

1. General information

C146 (M05) Element overhaul


Printed Matter Number

2946 1270 00

Applicable to

Element C146 (M05)

Preliminary Operations

Safety Instructions

General

Persons Required

Special Tools

Consumables

2. Document overview
This document describes the following:
1.

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

2.

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

3.

When? ........................................................................................................................................................................3

4.

Necessary Parts..........................................................................................................................................................3
Element overhaul kit PN 2901 1089 00..............................................................................................................................3
Shims .................................................................................................................................................................................4
Others ................................................................................................................................................................................4

5.

Necessary tools ..........................................................................................................................................................4


Tools specific for element overhaul....................................................................................................................................4
Others ................................................................................................................................................................................5

6.

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

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

Bearing retainers & wave springs ......................................................................................................................................6


Male rotor QJ bearing - Part 1............................................................................................................................................7
Male rotor QJ bearing - Part 2............................................................................................................................................8
Female rotor QJ bearing - Part 1 .......................................................................................................................................8
Female rotor QJ bearing - Part 2 .......................................................................................................................................9
Outlet housing & outer races NU bearings.........................................................................................................................9
Inner races NU bearings ..................................................................................................................................................10
Inner races NJ bearings ...................................................................................................................................................10
Inlet housing & outer races NJ bearings ..........................................................................................................................10
6.2.

Cleaning and inspection of components ..............................................................................................................11

Male and female rotor ......................................................................................................................................................11


Element inlet & outlet housing..........................................................................................................................................11
6.3.

Reassembly .........................................................................................................................................................11

Important remarks ............................................................................................................................................................11


Inlet bearing male & female .............................................................................................................................................11

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Mounting male & female rotor ..........................................................................................................................................13


Element outlet housing.....................................................................................................................................................14
Measuring clearances outlet bearing female rotor ...........................................................................................................14
Measuring clearances outlet bearing male rotor ..............................................................................................................17
Mounting outlet bearing male rotor ..................................................................................................................................17
Mounting outlet bearing female rotor ...............................................................................................................................19
Torque values for mounting .............................................................................................................................................19
Check female and male clearances .................................................................................................................................20
Mounting wave springs and bearing retainers..................................................................................................................20
7.

Packing .....................................................................................................................................................................20

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3. When?
The element overhaul is recommended every 24 000 hrs.

4. Necessary Parts
Element overhaul kit PN 2901 1089 00

Kit content:

Ring:

0663 2111 77 (1x)

Bearing:

0508 1310 00 (2x)

Bearing male:

0512 0510 13 (1x)

Bearing female:

0512 0510 12 (1x)

Wave spring set male:

1616 7148 00 (1x)

Wave spring set female:

1616 7149 00 (1x)

Clamping ring:

1616 7266 00 (1x)

Cap screw:

0147 1409 03 (1x)

Shim 0.025 mm male

Shim 0.025 mm female

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Shims
Available shim thicknesses:

Male:

PN 1616 7144 01: 0.050 mm

PN 1616 7144 03: 0.020 mm

PN 1616 7144 04: 0.030 mm

Female:

PN 1616 7145 01: 0.050 mm

PN 1616 7145 03: 0.020 mm

PN 1616 7145 04: 0.030 mm

Note:

The shims are not included in the


overhaul kit. It is recommended to have a
number of shims in stock at the element
overhaul area.

Others

Oil stone

Fine sandpaper

Loctite 641

Loctite 243

Cleaning product

Oil

Bearing grease

5. Necessary tools
Tools specific for element overhaul

Overhaul stand:

Basic tool set for pulling operations:

Hydraulic pump + puller:

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2990 0428 80 + 4x bolts and 4x washers

2903 0100 02 (HP63)

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Accessory set:

2903 0100 01 (HP63)

Bearing puller set:

Bearing puller set:

2903 0100 08

Male QJ bearing part 1:

2903 0100 07 (QJ 214 O / 63-767)

Male QJ bearing part 2:

2903 0100 05 (QJ 214 I / 63-768)

Female QJ bearing part 1:

2903 0100 06 (QJ 212 O / 63-765)

Female QJ bearing part 2:

2903 0100 04 (QJ 212 I / 63-766)

Male and female QJ bearing:

2903 0100 03

Inner race male NU bearing:

9423 0032 83

Inner race female NU bearing:

9423 0033 04

Outer race male NU bearing:

2990 0310 00

Outer race female NU bearing:

2990 0310 00

Measuring set:

Dial gauge male:

9421 0040 65

Dial gauge female:

9421 0040 69

Zero plate male:

9421 0040 66

Zero plate female:

9421 0040 70

Others

Induction heater:

2908 0048 00 (50Hz)

2908 0048 01 (60Hz)

Lifting eye

2 x M16 for lifting the male and female rotor

3 x M12 for lifting the element

2 x M14 for lifting the element outlet housing

Slide hammer puller: 2990 0310 00

Torque wrench

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6. Overhaul
6.1.

Dismantling

1.

Fit the element with its inlet


flange to the overhaul stand and
the outlet side upwards.

2.

Secure with 4 bolts.

Bearing retainers & wave springs


1.

Unscrew the hold down bolts of


both bearing retainers.

2.

Remove the bearing retainers

3.

Take out both sets of wave


springs.

For the male rotor:

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For the female rotor:

1.

Lock male rotor with locking tool


(9423 0031 63).

2.

Remove female washer.

Male rotor QJ bearing - Part 1


1.

Take the basic tool set for pulling


operations.

2.

Take bearing puller set (2903


0100 07) in combination with tool
(2903 0100 03).

3.

Place a washer to protect the


rotor shaft.

4.

Place the shelves around the


outer race of the male ball
bearing.

5.

Place the ring over the shelves

6.

Place the puller and tear off the


upper inner ring and outer race
of the ball bearing.

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Male rotor QJ bearing - Part 2


1.

Place a washer to protect the


rotor shaft.

2.

Place the tool (2903 0100 05) in


combination with tool (2903
0100 03) around the lower inner
race of the male ball bearing.

3.

Place the puller and tear off the


lower inner ring of the ball
bearing.

Female rotor QJ bearing - Part 1


1.

Take bearing puller set (2903


0100 06) in combination with tool
(2903 0100 03).

2.

Place a washer to protect the


rotor shaft.

3.

Place the shelves around the


outer race of the female ball
bearing.

4.

Place the ring over the shelves.

5.

Place the puller and tear off the


upper inner ring and the outer
ring of the ball bearing.

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Female rotor QJ bearing - Part 2


1.

Place a washer to protect the


rotor shaft.

2.

Place the bearing puller set


(2903 0100 04) in combination
with tool (2903 0100 03) around
the lower inner race of the
female ball bearing.

3.

Place the puller and tear off the


lower inner ring of the ball
bearing.

Outlet housing & outer races NU bearings


1.

Provide the outlet housing with 2


lifting eyes (min. 125 kg).

2.

Remove the bolts that keep the


inlet and outlet housing together.

3.

Vertically lift and remove the


outlet housing.

4.

Break cage of both bearings and


put pulling tool inside outlet
bearing ring.

5.

Remove both outer races (male


and female) from the element
outlet housing.

6.

Use slide hammer puller.

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Inner races NU bearings


1.

Take bearing puller set inner


race male NU bearing (9423
0032 83) and inner race female
NU bearing (9423 0033 04).

2.

Place a washer to protect the


rotor shaft.

3.

Mount the basic tool set (2903


0100 02).

4.

Remove the male and female


NU bearing inner race.

Inner races NJ bearings


To lift the rotors:
1.

Prepare a wooden pallet to place


both rotors.

2.

Fit 2 lifting eyes.

3.

First lift the male rotor, take care


to lift in line with the rotor axis.

4.

Do the same for the female


rotor.

5.

Place a washer to protect the


rotor shaft.

6.

Mount the basic tool set and


remove male and female NJ
bearing inner race.

Inlet housing & outer races NJ bearings


1.

Take out the outer races of the


male and female NJ bearing.

2.

Use a slide hammer puller (2990


0310 00) if necessary.

3.

Remove the o-ring and both


dowel pins.

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6.2.

Cleaning and inspection of components

Male and female rotor


These rotors were put together as a set. Always keep the rotor set together, never mix with other sets!!

To optimise element efficiency:


1.

Clean the rotors.

2.

Inspect both rotors for scratches


and other damage.

IF necessary: smooth down with fine sandpaper and/or an oil stone to the original surface.
Do not take away too much material!!!
If the condition of the rotors is doubtful REPLACE ELEMENT

Element inlet & outlet housing


1.

Clean inlet and outlet housing.

2.

Inspect housing for scratches and other damage.


IF necessary: smooth down with fine sandpaper and/or an oil stone to the original surface.
Do not take away too much material!!!
If the condition of the in- or outlet housing is doubtful REPLACE ELEMENT

6.3.

Reassembly

Important remarks
Male and female rotor are delivered as a set Always keep the set together!
All bearings are delivered and bound together as a set Always keep the set together!
Never directly hit on the new bearing races You can use the rings of the old bearings after cleaning them.

Inlet bearing male & female


Outer race inlet bearing
1.

Take one of the NJ bearings


(0508 1310 00).

2.

Remove the packing.

3.

Check the bearing for damages.

NJ bearings are delivered and


bound together as a set
Always keep the set together!

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4.

Fit the outer race on the female


seat of the housing. Markings on
top!

Bearing
markings

Use tooling (9423 0031 36).

5.

Repeat for the outer race male


inlet bearing

Inner race inlet bearing


1.

Take the male rotor.

2.

Inspect the rotor shaft for


scratches or other damage.

3.

Degrease the rotor shaft.

4.

Degrease the bearing inner race.

5.

Heat the bearing inner race up to


120.

6.

In the mean time, take a brush


and put some Loctite 641 on the
inner race seat of the rotor shaft.

7.

Put on heat resisting gloves and


take the inner race.

8.

Position the hot inner race on


the inlet side of the rotor shaft.

Note:

Mount the inner race in the right


direction Raised border towards
rotor body.

Note:

Make rotating moves with the


inner race to spread the Loctite.

9.

Repeat for the inner race of the


female inlet bearing.

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Mounting male & female rotor


Male rotor
1.

Grease the inlet bearings.

2.

Oil the housing.

3.

Let the inner race cool down.

4.

Lift the male rotor at its outlet


side.

5.

Oil the rotor.

6.

Carefully lower the rotor in the


element housing while pressing
the rotor softly in the direction of
the arrow (see picture).

7.

When lowering the rotor, make


sure the inner race of the
bearing fits into the outer race.

Female rotor
1.

Let the inner race cool down.

2.

Lift the female rotor at its outlet


side.

3.

Oil the rotor.

4.

Carefully lower the rotor in the


element housing while pressing
the rotor softly towards the male
rotor.

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5.

When lowering the rotor, make


sure the inner race of the
bearing fits into the outer race.

Element outlet housing


1.

Grease the seal surface and


place a new o-ring.

2.

Mount both dowel pins, use a


plastic hammer.

3.

Lift the outlet bearing housing

4.

Shove the housing equally over


the dowel pins.

Note: Make sure the O-ring stays in place.

5.

Tighten the 11 bolts. Start with a


bolt next to a dowel pin and a
torque of 5 Nm. Final torque for
all the bolts is 46 Nm.

Measuring clearances outlet bearing female rotor


NU Cylindrical roller bearings

NU Cylindrical roller bearings

Radial load

No axial load

Movable in axial direction

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QJ Four-point contact ball bearing

QJ Four-point contact ball bearing

Combined radial and axial load

Fixed in axial direction (clearance: 0.02 mm).


Total rotor clearance depends on position of fixed ball bearing.

Total rotor clearance

Total rotor clearance = 0.04 0.08 mm


The rotor clearance can be corrected with shims:

Increase shim thickness Increase rotor clearance.

Measuring female rotor clearance:

As the ball bearing on top of cylindrical bearing and the measurement is done WITHOUT cylindrical bearing:

Zero the gauge on zero plate (9421 0040 66).

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1.

Place the gauge (9421 0040 69)


over the female rotor shaft.

2.

Lift the rotor.

3.

Read out the gauge with the


rotor in lifted position.

4.

Write down this value and


calculate the shim thickness as
described below.

Calculating shim thickness


Read out = 0
Difference between inner and outer ring = 0
Calculated shim thickness
= Total rotor clearance bearing clearance
= 0.08 mm 0.04 mm
= 0.04

Read out > 0

Inner ring below outer ring


Add shims
Calculated shim thickness
= Total rotor clearance ball bearing clearance + measured value
= 0.08 mm 0.04 mm + measured value
= 0.04 + measured value

read out < 0

Outer ring below inner ring


Remove shims
Calculated shim thickness
= Total rotor clearance ball bearing clearance measured value
= 0.08 mm 0.04 mm measured value
= 0.04 measured value

Create shim set


1.

Create a set of shims as close


as possible to the calculated
shim thickness with the following
available shim sizes:

0.050 mm

0.030 mm

0.020 mm

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Measuring clearances outlet bearing male rotor


Differences with female rotor

Difference with female rotor:


Ball bearing on top of element housing
Measure between the inner ring and the housing with tool (9421 0040 65) and use zero plate (9421 0040 70).

Mounting outlet bearing male rotor


NU/QJ bearings are packed and bound together as a set (the 5 parts have 1 common set-number).

Always keep the set together!


Mount the bearing in the same way as it is packed!!

1.

Take the NU/QJ outlet bearing


for the male rotor and remove
the packing.

2.

Check the bearing for damages.

3.

Take the inner race of the


cylindrical bearing and heat it up
to 110.

4.

In the mean time, take a brush


and put some Loctite 641 on the
inner race seat of the rotor shaft.

5.

Put on heat resisting gloves and


take the inner race. Position the
hot inner race on the male rotor
shaft.

Note:

Mount the inner race in the right


direction Markings upwards.
Make rotating moves with the
inner race to spread the Loctite.

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6.

Let the inner race cool down.

7.

Take the outlet race of the


cylindrical bearing and degrease
the outer race.

8.

Put some Loctite 641 on the


outside.

9.

Press the outer race of the


cylinder bearing in the housing.
If necessary, put the old clean
bearing ring on top and use a
plastic hammer.

Note:

Mount the outer race in the right


direction Marked V points
upwards

10. Assemble the correct shim set,


as calculated before!
11. Check the thickness of the shim
set and fit the shims over the
rotor.

Note:

Do not switch the lower inner ring


with the upper inner ring upper
ring has complete markings on
top.
Mount the bearing set exactly in
the same way as it was packed!

12. Warm up the lower inner ring of


the roller bearing (110 C).
13. Position the lower inner ring over
the male rotor shaft.

14. Let the inner ring cool down.


15. Mount the roller bearing.

Note:

Mount the outer race in the right


direction Marked V points
upwards.
Mount the bearing set exactly in
the same way as it was packed!

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16. Warm up the upper ring (110 C)


and mount onto the male rotor
shaft.

Overview male bearing

Mounting outlet bearing female rotor


Repeat step 41 up to 56 for the female bearing.

Overview female bearing

Torque values for mounting

Mount washer on female rotor and torque bolt to 80 Nm.

Mount mounting bushing on male rotor and torque bolt to 80 Nm.

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Check female and male clearances


1.

Fix a lifting eye.

2.

Fix a gauge to the rotor.

3.

Zero the gauge on the rotor


housing.

4.

Lift the rotor.

5.

Read out the rotor clearance.

Note:

6.

Total rotor clearance has to be


between 0.04 0.08 mm for each
rotor!

Remove the male washer with


the lifting eyes.

Mounting wave springs and bearing retainers


1.

Position a set of new wave


springs onto each bearing set.

2.

Fit the bearing retainer, position


and torque the bolts. Use a
torque of 78 Nm.

7. Packing
1.

Oil the element

2.

Cover the shafts with greased paper.

3.

Cover the element outlet with tape.

4.

Remove the element from the overhaul stand.

5.

Cover the element inlet with tape.

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