CF90 AIREND OVERHAUL MANUAL

PRODUCT CODE HJ

Portable Power
P.O. Box 868
501 Sanford Ave
Mocksville, N.C. 27028
www.portablepower.irco.com

Manual # 22259444 (3/03)

AIREND DISASSEMBLY
(Refer to Figure 1 for the following steps) 3. Separate the adapter (G) from the gear
case housing by removing screws (E).
1. Place the airend assembly on a clean
work surface. Position the airend in a
vertical position with the drive shaft end
up.
2. Remove the screw (C) and remove the
hex bearing from the shaft.

Figure 1

(Refer to figure 2 for the following steps.) 8. Remove locknut (H) from drive gear (N).
4. Remove screws (A & B) and separate 9. Set the drive gear from the gear case.
the seal/bearing housing (D) from the
10. Remove wear sleeve (K) and o-ring (F)
gear case housing (V).
from drive gear shaft.
5. Remove and discard o ring (S), double
11. Remove bearings (J) from the drive
element seal (G) and single element
gear. Remove the inner race of bearing
seal (E).
(Q) from the drive gear.
6. Remove and discard bearing (Q) from
12. Remove screws (U) and set the gear
the gear case housing.
case housing (V) from the airend.
7. Remove screws (M) and bearing
retainers (L) from seal /bearing housing.

Manual # 22259444 (3/03)

 Figure 2

(Refer to figure 3 for the following steps).

13. Remove locknut (D) from the male rotor
shaft.
14. Remove the driven gear from the male
rotor shaft with a gear puller. Secure
the puller arms to the gear with a c-
clamp. The gear may jump once it
loosens from the shaft. Wear gloves
and be alert during this operation.
15. Remove screws (E) and dowel pin (H) to
set the front bearing housing from the
airend. Figure 3
16. Remove check valve ball (B) from front
bearing housing. See figure 4. 20. Rotate the airend assembly to a vertical
position with the drive shaft down. Rest
17. Remove oiler assembly (F) from front the assembly on 4-inch thick wooden
bearing housing. blocks so that the rotor housing is
18. Remove screw and washer (A & B) from supported and the rotors are free of the
the front bearing housing. blocks.
19. Remove and discard bearings (C & G) (Refer to figure 4 for the following steps).
from the front bearing housing. 21. Remove discharge bearing cover (A5)
by removing screws (A6).
22. Remove wave springs (Q & R).

Manual # 22259444 (3/03)

23. Remove locknuts (U & V) from the male
and female rotor shafts.
24. Remove bearing nut spacers (S & T)
from male and female rotor shafts.
25. Press the male and female rotors (C)
free of the bearings.
26. Set the rotor housing (Y) free of the
male and female rotors.
Figure 4
INSPECT PARTS
Inspect all parts previously disassembled for
wear and damage to determiner their
serviceability. Make sure all internal oil
passages clear and free of debris.
Always use new gaskets, o-rings, bearings
and seals when reassembling airend. All
wear parts and instructions are included in
Ingersoll-Rand overhaul kits.
Manual # 22259444 (3/03)
27. Remove the tapered roller bearings (N &
P) from the rotor housing.
28. Remove shims (E-M) from male and
female rotor shafts.
29. Remove inner bearing races (C & G)
from the intake end of the male and
female rotors. (Refer to figure 3).
DISCHARGE END CLEARANCE
SHIMMING PROCEDURE
Before reassembling of the airend, it is
necessary to record certain measurements
to determine the amount of shims required
for proper discharge end clearances on the
male and female rotors.
1. Measure the thickness of the rotor
housing where the tapered roller
bearings outer races rest. Record a
measurement for the each rotor. Step
A.
2. Determine the bearing standoff
dimension from the male and female
tapered roller bearings and record. Step
B. Position each bearing on a hard flat
surface with the outer race up. Rotate
the outer race several times to seat the
race on the cone. Measure the distance
from the top of the outer race to the
inner race shoulder with a depth
micrometer. See figure A.
Figure A
3. Add the dimensions from steps A & B
for each rotor. Step C.
STEP MALE
A Rotor housing
thickness
B Bearing
standoff
C Add A + B
D Rotor spacer
height
E Subtract (D-C)
F End clearance
G Shims Req’d
ADD E + F
AIREND REASSEMBLY
1. Position the rotor housing in a vertical
position with the drive end up.
2. Place inlet end bearing races (C & G in
figure 3) in an oven and heat to 300°F
(149°C) for maximum of 30 minutes.
3. Place male and female rotors into
housing.
4. Remove bearing races from oven and
seat on respective rotor shafts. USE
PROPER GLOVES TO HANDLE HOT
RACES.
Manual # 22259444 (3/03)
4. Measure the height of the rotor spacer.
Record a measurement for the male and
female rotor. Step D.
5. Subtract D from C for both the male and
female. Step E.
6. The allowable discharge end clearance
is .0015 to .0025 inches. Use .002
inches discharge end clearance for the
male and female rotors. Step F.
7. Add the numbers from steps E & F.
This is the thickness of shims to install
on the respective rotor shaft to obtain
the required discharge end clearances.
8. Assemble the correct thickness of shims
and install on each rotor.
MALE SPEC FEMALE FEMALE SPEC
1.155 -1.159 1.155 -1.159
.088 -.100 .049 -.060
1.243 -1.259 .1.204 - 1.219
1.222 -1.226 1.182 -1.186
.017 - .037 .018 - .037
.0015-.0025 .0015-.0025
.0185 - .0395 .0195 - .0395
5. Apply a small bead of Loctite® 242
around half of the outer race of the inlet
bearings (C & G, figure 3) and install
each in the front bearing housing.
6. Install check valve ball (B, figure 4) into
the front bearing housing using a small
amount of grease to hold it In place.
7. Apply a thin layer of Loctite® 515 or 573
to the mating surface of the rotor
housing.
8. Position front bearing housing (A, figure
4) into position on the rotor housing (Y,
figure 4).
9. Tap 2 dowel pins (D, figure 4) into front
bearing housing and rotor housing.
10. Apply a drop of Loctite® 242 to the
threads of each screw (E, figure 3) and
install in the front bearing housing.
Torque screws to 38-lbs. ft.
11. Apply a drop of Loctite® 242 to the
threads of screw (A, figure 3) and install
with washer in the front bearing housing
to secure the bearings. Torque screw to
38-lbs. ft.
12. Apply a drop of Loctite® 242 to the
threads of the gear oiler assembly and
install in front bearing housing. Position
so that holes in tube are directed toward
gears.
13. Rotate airend 180° and rest inlet end of
rotor housing on 4-inch wooden blocks.
Discharge end should be up.
14. Assure calculated shims on each rotor.
15. Heat Tapered roller bearings for male
and female rotors in oven at 225°F
(107°C) for 30 minutes.
16. Apply anti-seize compound on rotor
shafts in bearing area and place
bearings on respective rotor shafts.
USE PROPER GLOVES TO HANDLE
HOT BEARINGS.
17. Install bearing nut spacer on each rotor.
18. Apply 3 drops of Loctite® 222 or 932 on
the rotor threads and install the locknut.
Torque the locknut to 160-lbs. ft.
19. Place wave springs in respective
bearing bores.
20. Install a thin layer of Loctite® 515 or 573
to the rear bearing housing flange face.
21. Install rear bearing cover into place and
install 2 screws on opposite ends of the
plate. Tighten screws to evenly bring
cover onto flange face of the rear
bearing housing.
22. Install remaining screws in cover plate
and torque to 38-lbs. ft.
23. Check discharge end clearances with a
feeler gauge for the male and female
rotors. Rotate the rotors to help seat
bearings before taking measurements.
If measurements are within .0015 to
.0025 specification, proceed with
Manual # 22259444 (3/03)
reassembly. If not, disassemble and
adjust shims. Add shims to increase
end clearance and subtract shims to
reduce end clearance.
REASSEMBLY OF THE DRIVE GEAR
24. Heat gear bearings and inner race to
300°F (149°C) for 30 minutes.
25. Place the gear bearing inner race on the
gear. USE PROPER GLOVES TO
HANDLE HOT BEARING.
26. Place the bearings on the drive gear
shaft. USE PROPER GLOVES TO
HANDLE HOT BEARING.
27. Apply 3 drops of Loctite® 222 or 932 on
the rotor threads and install the locknut.
Torque the locknut to 160-lbs. ft.
28. Install o-ring and wear sleeve on drive
gear shaft.
29. Apply A thin layer of Loctite® 222 on the
outside diameter of the single element
(E) and double element (G) seals.
Press seals into seal/bearing housing
(D).
30. Apply small amount of grease onto and
between the seals.
31. Apply a drop of Loctite® 242 on each of
the 3 screws and loosely install the 3
bearing retainers and screws into the
seal/bearing housing.
32. Slide gear shaft into seal/bearing
housing.
33. Torque the 3 retainer screws to 8-lbs. ft.
34. Place the heated bearing inner race on
the drive gear. USE PROPER GLOVES
TO HANDLE HOT BEARING.
35. Install key in keyway on male rotor
shaft.
36. Heat driven gear to 300°F (149°C) for
30 minutes.
37. Install the heated gear onto the male
rotor shaft. USE PROPER GLOVES TO
HANDLE HOT BEARING.
38. Apply 3 drops of Loctite® 222 or 932 on
the rotor threads and install the locknut.
CLEAN-UP OF AIREND SYSTEM
Torque the locknut to 219-lbs. ft.
Once the airend has been overhauled, the
39. Apply a thin layer of Loctite® 515 or 573
following clean-up procedure is required
front bearing housing flange.
before installation of the airend back into its
40. Position the gear case onto the front package.
bearing housing.
1. Drain the entire airend oil system
41. Tap dowel pin into housings. Apply a and flush the separator tank.
drop of Loctite® 242 on each of the
2. Remove the old oil and air filter
screws and install the screws into the
elements, clean canisters and install
gear case and torque to 38-lbs. ft.
new elements.
42. Apply a small bead of Loctite® 242
3. Flush all manifolds, pipes and/or
around half of the outer race of the drive
hoses from the oil filter outlet to the
gear bearing (Q, figure 2) and install in
airend. If necessary, remove
the gear case housing (V, figure 2).
components, flush with clean 10W
43. Install o-ring into groove of seal/bearing compressor oil and reinstall.
housing using a small amount of grease
Note: It is critical that the small oil supply
to hold it in place during assembly.
lines connecting to the airend receive
44. Guide the seal/bearing housing special attention.
assembly into position on the gear case.
4. Check condition of all compressor
45. Apply a drop of Loctite® 242 to each air and oil hoses and replace if
screw and install them into the either inner or outer surface is
seal/bearing housing and torque to 38- visually damaged.
lbs. ft.
5. Upon installation, take every
46. Apply a drop of Loctite® 242 to each precaution to prevent foreign
screw and install them to attach adapter material from entering airend.
to seal/bearing housing and torque to
6. When setting the airend into position
38-lbs. ft.
for bolting to the engine, care must
47. Install key in drive shaft. be taken to ensure proper
alignment.
48. Slide hex bearing onto drive shaft as far
as it will go, small diameter first. 7. Refill system with approved
lubricant.
49. Rotate the bearing and shaft by hand
and check for interference. If 8. Pour one gallon of oil into the airend
interference is found, back off the hex intake to aid lubrication on initial
bearing until there is clearance. start-up.
50. Apply a drop of Loctite® 242 to the hex
bearing screw and torque to 18-lbs. ft.

DRIVE COUPLING INSTALLATION

1. Apply a drop of Loctite® 242 to each
screw and attach the drive coupling to
the engine flywheel. Torque screws to
31-lbs.ft.

Manual # 22259444 (3/03)

Manual # 22259444 (3/03)