Service news

For internal use only

Installation of stage 2 long Mk II Priority : IV ECB AIF 1357/C1

on ZR 4 GAC : 48 Date : 17/07/2004
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1. Subject :

Installation of stage 2 long Mk II on ZR 4.

2. Modification :

A new stage 2 is introduced on new products and as service element.

3. Parts :

The regular stage 2 compressor element with part number 1616 5952 81 or 9825
0660 81, and the service stage with part number 2906 9000 80, are replaced by:

1616 6792 81

The teflon-free version of this compressor element 1616 5952 82 or 9825 0660
82, and the service stage with part number 2906 9000 81, are replaced by:

1616 6792 82

ZSS-GL
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4. Assembly.

I. Preparation of the element.

The preparation of the element can be carried out without any special
precautions for blocking the male rotor.

- Remove the protection bush

Attention: central bolt for pinion

fixation is with a left
hand thread

- Check the pinion, which you removed from the old element, on damages
and/or wear

- Heat up the pinion on a bearing heater till max. 100° C above ambient
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- Slide bush pn 1616 6453 00 over the male rotor shaft with the biggest
diameter in the direction of the axial bearing (see drwg below).
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- Slide the pinion over the shaft, WITH THE CHAMBER FACING AWAY
FROM THE AXIAL BEARING. You will hear a “click” when it makes contact
with the bush pn 1616 6453 00

Important: If ever the pinion gets stuck halfway on the shaft, remove it and
start the whole procedure again.
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- Refit the bolt previously used, to hold the protection bush. Use a new washer
pn 1616 6274 00. Prior to fitting the bolt, clean the thread with Loctite
7063. When installing the bolt, use Loctite 243.

- Torque the bolt with a torque of 150 Nm

- Use a 36 mm spanner to secure the washer while applying the torque.

REMEMBER: The bolt has LEFTHAND thread.

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II. Fixation of the element to the eccentric ring.

a. Eccentric ring with UNC thread.

Part number Description Qty

0144 3363 03 Bolt 1/2" UNC x 32 2

0144 3370 03 Bolt 1/2" UNC x 64 2

b. Eccentric ring with METRIC thread.

Part number Description Qty

0147 1402 03 Bolt M 12x35 2

0147 1408 03 Bolt M 12x65 2

The oil circuit connection, between the eccentric ring and the compressor
element has to be sealed off with seal disc pn 1621 0393 00 (2x) and O-ring pn
0663 7133 00 (2x).

III. Connection to the inlet and outlet flange.

The holes in the compressor casing have a metric thread now. Consequently the
connection bolts have to be changed.

a. HP inlet

Part number Description Qty

0147 1405 03 Bolt M12 x 50 2

0147 1408 03 Bolt M12 x 65 2
0266 2112 00 Nut M12 2

b. HP outlet

1. Units with serial number higher than ARP 605 000 or with AIF --- ---

Part number Description Qty

0211 1403 03 Bolt M12 x 40 4

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2. Older units (silencer directly bolted to the element)

Part number Description Qty

0147 1401 03 Bolt M12 x 30 4

IV. Adaptations to the water system.

a. Connection between the LP out and HP in.

- LP element = Mk II element

- Loosen coupling between pipe 1614 8446 00 and 1614 8434 00

(see fig. 4.A)
- Adjust the length of pipe 1614 8446 00 (shorten ± 35 mm)
- Apply cutting ring 0584 1021 00 on pipe 1614 8446 00
- Reconnect coupling
- Connect pipe 1614 8434 00 to the HP element by means of two bolts (0147
1413 03 (M12x90)). Use O-ring 0663 2107 86 between pipe and compressor
casing (see fig. 5.A)

- LP element = Mk I element

- Dismantle pipes 2255 2217 00 and 2255 2218 00 (see fig.1.A) when the HP
element was a Mk I. When the Hp element was a MkII, dismantle pipes 0070
0300 70 and 1614 8464 00 (see fig. 2.A).
- Assemble pipe 1614 8434 00 to the HP element by means of two bolts (0147
1413 03 (M12x90)). Use O-ring 0663 2107 86 between pipe and compressor
casing (see fig. 5.A)
- Assemble a straight pipe pn 0070 0300 70 (new one) in to the existing
coupling of the LP element. Use reduction pn 0584 1691 00, reduction nut
pn 0584 4091 00 and cutting ring 0584 1018 00 (see fig. 2.A)
- Connect pipe 1614 8434 00 with pipe 0070 0300 70 by means of the
following parts:
- Elbow body 0582 2000 15
- Reducing ring 0584 1681 00
- Reducing ring 0584 4081 00
- Cutting ring 0584 1018 00
- Cutting ring 0584 1021 00
- Nut 0584 3026 00
Adjust the length of the pipes if necessary
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b. Connection between HP outlet and the water outlet.

- Dismantle pipe 1614 8325 00 (see fig. 2.B / fig. 4.C)

- Assemble the following parts onto the water outlet of the HP element by
means of two bolts 0147 1413 03 and O-ring 0663 2107 86 between the pipe
and the compressor casing (see fig. 5.B):
- Flange 1614 8397 00
- Elbow 0560 0200 02
- Seal washer 0661 1000 30
- Nipple 1614 6841 00
- Adjust the length of pipe 1614 8339 00 (shorten ± 35 mm) (see fig. 5.C)
- Assemble the following parts onto pipe 1614 8339 00 (see fig. 5.C)
- Pipe coupling 0582 0535 00
- Seal washer 0661 1000 31
- Nipple 1614 8000 00
- Connect both parts by means of a hose (0070 8403 50) and the
corresponding hose clips (1079 3471 02)

V. Adaptations to the oil system.

a) Lubrication system:

- Disconnect pipe pn 1202 7123 00.

- Put plug pn 0584 1814 00 in the T-coupling and plug pn 0584 1810 00 in the
coupling at the gear casing side. Re-use the nuts of the old pipe.
- Disconnect pipe pn 2252 2186 43.
- Unscrew the plug out of the oil channel at the timing gear side of the new
element.
- Fit coupling pn 1079 5831 17. Seal off with seal washer pn 0661 1000 27.
- Screw elbow body pn 0582 200013 onto coupling pn 1079 5831 17 and seal
with O-ring pn 0663 2101 87.
- Connect elbow pn 0582 2000 13 with the existing T-coupling of 22 by means
of a straight pipe pn 0075 5551 39 (L-150).
- Use cutting ring pn 0584 1010 00 and nut pn 0584 3013 00 and new cutting
ring pn 0584 1010 00 at the T-coupling side.

b) Oil return to gear casing

For the oil return to the gear casing use pipe pn 1621 0388 00 and seal on
both sides with O-ring pn 0663 2107 81 and fix with two bolts pn 0147 1324
03 (M8x22).
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VI. Adaptations to the regulating system

- Disconnect the pipe (for balancing pressure) between the coupling and the
element (see fig. 8.A)
- Connect pipe 1621 0387 00 with pipe couplings 0580 0013 32 and seal
washers 0661 1000 25, onto the HP element for the balancing pressure (see
fig. 6.A).
- When the compressor is regulated by the elektronikon, then plug of the T-
coupling by means of plug 0584 1804 00. When the compressor is
electromechanically regulated, then put plug 0686 3716 01 and seal washer
0661 1000 25 in the throttle valve (see fig. 8.A)

VII. Check the backlash of the drive gears.

- Mark four points, equally spaced on drive coupling.

- Remove the balance piston cover.

- Take out the balancing piston by means of a magnet

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- Put a mark on the flat bar on pitch radius distance the pinion from the centre.
(See list of pitch diameters)

- Clamp the tool pn 2908 0057 80 on the head the fixation bolt of the
male timing gear
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- Put the measuring point of the puppy test gauge on the mark.

- Block the main shaft.

- Measure the backlash.

- Repeat this measurement at the other three points.

- The value measured should be within 0,1 and 0,45 mm with a maximum
difference of 0,1 mm.

- Reinstall balance piston and cover. Bolt torque 45 Nm.

List of pitch diameters.

Unit type Part number Pitch ∅

ZR 4-50/ZR 4-61 1202 6344 04 64.97
ZR 4-51/ZR 4-62 1202 6344 05 56.49
ZR 4-52 2254 1150 02 48.02
ZR 4-53/ZR 4 M 2252 5762 00 45.20
ZR 4-55/ZR 4-66 1202 6344 03 70.62
ZR 4-56/ZR 4-67/ZR 4 B 2254 1150 01 62.14
ZR 4-57/ZR 4 A 2253 8251 00 53.67
ZR 4-60 1202 6344 02 76.27
ZR 4-63 1202 6344 06 51.92
ZR 4-65 1202 6341 01 81.92
ZR 4 C 2254 9020 00 72.90
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Kit with parts needed for the first installation of a Stage 2 long Mk II on a old ZR 4.
Kit pn 2906 0617 00

Item Part number Part description Quantity

1 0663 2107 86 O-ring 1
2 1614 8397 00 Flange 1
3 0560 0200 02 Elbow 1
4 0661 1000 30 Seal washer 1
5 1614 6841 00 Nipple 1
6 1079 3471 02 Hose clip 2
7 0070 8403 50 Hose (300 mm) 1
8 1614 8000 00 Nipple 1
9 0661 1000 31 Seal washer 1
10 0582 0535 00 Pipe coupling 1
11 0584 3026 00 Nut 3
12 0582 0000 30 Straight coupling 1
13 0584 1021 00 Cutting ring 3
14 1621 0388 00 Pipe 1
15 1621 0393 00 Seal disc 2
16 0663 7133 00 O-ring 2
17 1621 0387 00 Pipe 1
18 0580 0013 32 Coupling 2
19 0661 1000 25 Seal washer 3
20 0582 2000 15 Elbow body 1
21 0584 1681 00 Reducing ring 1
22 0584 4081 00 Reducing ring 1
23 0584 1018 00 Cutting ring 1
24 1614 8434 00 Pipe 1
25 0584 1804 00 Plug 1
26 0686 3716 01 Plug 1

Note:
When this newer version (the longer version) of the stage 2 element is to be installed on
a compressor on which the stage 2 Mk I was still installed, then don’t forget to order the
kit mentioned in ECB AIF 1163/C1.
The part number for this kit, is pn 2906 0356 00
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