Repair Manual

EK175NG, EK175NK
Air Ends

GB DL071AA - 06/2007
CompAir Contents

Repair Manual

EK175NG, EK175NK
Air Ends

GB DL071AA - 06/2007

DL071AA 3
Contents CompAir

Contents
1 Introduction............................................................................................. 5
1.1 Foreword...........................................................................................................5
1.2 Scope................................................................................................................5
2 Safety Procedures.................................................................................10
2.1 General............................................................................................................10
2.2 Warnings, Cautions and Notes.......................................................................10
2.3 Safety Precautions..........................................................................................11
2.4 Maintenance Precautions................................................................................11
2.5 Precautions In The Event Of Fire...................................................................12
3 Dismantling............................................................................................ 13
3.1 Remove Delivery End Cover..........................................................................13
3.2 Remove Delivery End Locknuts.....................................................................13
3.3 Remove Bell-Housing....................................................................................15
3.4 Remove Drive Gears......................................................................................17
3.5 Remove Inlet Bearing Housing......................................................................18
3.6 Remove Rotors...............................................................................................18
3.7 Remove Bearing Inner Rings.........................................................................21
3.8 Repair Kits......................................................................................................21
4 Assembly - Prepare Inlet End - EK175NG...........................................22
4.1 Prepare Inlet Casing........................................................................................22
5 Assembly - Prepare Inlet End - EK175NK..........................................23
5.1 Prepare Inlet Casing........................................................................................23
6 Assembly - Install Rotors.....................................................................28
6.1 Mount Rotor Casing On Fixture.....................................................................28
6.2 Prepare Rotor Casing......................................................................................28
6.3 Install Rotors...................................................................................................29
7 Assembly - Fit Inlet End Components - EK175NG.............................31
7.1 Fit Inlet Bearing Inner Rings..........................................................................31
7.2 Fit Inlet Bearing Housing...............................................................................31
7.3 Assemble Inlet Bearings.................................................................................32
7.4 Fit Gear Pinion................................................................................................35
7.5 Pre-Assemble Drive Gear Shaft.....................................................................36
7.6 Fit Bell-Housing.............................................................................................39
7.7 Fit Shaft Oil Seal............................................................................................41
8 Assembly - Fit Inlet End Components - EK175NK.............................43
8.1 Fit Inlet Bearing Inner Rings . . . . . . . . . . . . . . . . . . . . . 43
8.2 Fit Oil Seal Inner Ring . . . . . . . . . . . . . . . . . . . . . . . . 43
8.3 Fit Inlet Bearing Cover . . . . . . . . . . . . . . . . . . . . . . . . 44
8.4 Fit Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9 Assembly - Delivery End . . . . . . . . . . . . . . . . . . . . . . . 47
9.1 Fit Shaft Locking Tool . . . . . . . . . . . . . . . . . . . . . . . . 47
9.2 Fit Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.3 Fit Angular Contact Bearings . . . . . . . . . . . . . . . . . . . . 49
9.4 Set Delivery End Clearances . . . . . . . . . . . . . . . . . . . . 52
9.5 Fit Delivery End Cover . . . . . . . . . . . . . . . . . . . . . . . . 55
10 Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.1 Air End Repair Kit - EK175NG . . . . . . . . . . . . . . . . . . . . 57
10.2 Shaft Oil Seal Kit - EK175NG . . . . . . . . . . . . . . . . . . . . 57
10.3 Air End Repair Kit - EK175NK . . . . . . . . . . . . . . . . . . . . 58
10.4 Shaft Oil Seal Kit - EK175NK . . . . . . . . . . . . . . . . . . . . 58

4 DL071AA
 Comp
1 Introduction
1.1 Foreword
1.1.1 These compressors are intended for compressing
atmospheric air and are not suitable for
compressing any other gas. They are designed
and manufactured to give optimum performance,
with long life and reliability.
1.1.2 This manual is intended for use by CompAir -
approved service personnel and gives all the
information necessary to dismantle and
re-assemble the compressor unit safely and
effectively.
1.1.3 Servicing facilities and the supply of genuine
replacement parts are provided through a
worldwide network of CompAir Distributors,
backed up by the Service and Parts departments at
Redditch. If replacement parts are needed, the
local Distributor should be contacted in the first
instance.
DL071
Introduction
1.1.4 The information given in this manual was correct
at the time of printing but modifications to parts
and procedures may be made without notice which
could affect the procedures described in this
manual. Before undertaking any work, the user is
advised to contact the local CompAir Distributor
who is supplied with revised and up-dated
information.
1.1.5 In any communication concerning the
compressor it is essential to quote the
MODEL and SERIAL NUMBER.
1.2 Scope
1.2.1 This manual is for use in the repair of
EK175NG/EK175NK air ends with serial
numbers 3013 11 06 (production month
November 2006) onwards only.
5
6

1 Introductio
12 11 10 9 8 7 6 5 4 3 2 1

138 109 Tropfen

H Schnitt A- A 2 H

102 133 126 101 104 109 119 110 117

200 103
127 132

125
123 127
G G

127
B 107
1
Fig 1.1 - EK175NG Air End - Sectional

114

118
F 134 05
F
120 108

124
127
131 136 137

E E

A
A B
X 1
1
122 2 Tropfen
D
D
121

+0,01 128
- 0,01
0

128
138
C 115 127 130 111 105 112 113
C
134 Ansicht X Anzugsmomente
Torque

B-B Verbindungselement
Zyl-Schraube M12
Pos
127
Anzugsmoment Nm
86
138 04

Doppelnippel 1 1/2-16UN 129 25

1
einkleben mit (glue with) Loctite 245 (Pos.139)
B
02 aufkleben mit (glue with) Loctite 496 (Pos.140) B
einkleben mit (glue with) Loctite 620 (Pos.141)
Maßstab: 1:5

134
Tolerierun g Rauhtiefe Rz Gewicht:
DIN 7167 Reihe 2 Rohteil- Nr. Auftr. -Nr.
Allgemeintoleranzen DIN 3141
ISO 2768-mH
Fertigteil Nr. Werkstoff
135 Datum Name
Gezeichnet 02.05.2003 Federmann
Bezeichnung Document description
Kontrolliert 02.05.2003 Thomes
Zusammenstellzeichnung
EK175NG Assembly
Norm

Abt Copyright reserved

.

134 137 129 Übersetzungen; Ident.-Nr. siehe Verdichterliste A11917074 05

04
9462-008-07
9462-047-06
14.03.07 Fed
20.12.06 Fed
Schutzvermerk nach
DIN 34 beachten
Klass. -Nr. UA Spr Codestelle

A
A Ratio; ID. according to Air End List A11917074 03
02
9462_026_06
9462_009_06
28.08.06 Fed
10.03.06 Fed
Material- Nr.
A11918074
Blatt/Blätter

1 /1
01 9462_010_04 19.03.04 Fed Drucklufttechnik GmbH A1

Comp
12 11 10 9 Status AM-Nr. Datum Name Enstanden aus: Ersatz für: Ersetzt durch:
DL071

8 7 6 5 4 3 2 1
Comp Introduction

102
127
126
109

200 148 134

126
123 134 138 107
127 132 127
111 117
134 130 110
115 119
128
109
103 129

127 137 127

124 108
116
114 101 113
126
120112
118 122 128
133
121

137
131
104
126

134 125 136

134

138
138

105
SM 1353

Fig 1.2 - EK175NG Air End - General Arrangement

Item Part No. Description Item Part No. Description

101 A11920174 Rotor Housing 121 A93147560 Circlip +
102 A11920374 Bearing Housing 122 A93196120 O-Ring +
103 A11920574 Bell Housing 123 A11922374 Safety Disc *
104 A11921174 Male Rotor 124 A93161120 Key +
105 A11921374 Female Rotor 125 A93161090 Key *
107 A11922074 Delivery End Cover 126 A93159760 Cylind.Pin
108 A11922174 Safety Plate * 127 A93040870 Cylind.Screw *
109 A93570290 Cylind.Roller Bearing * 128 A93060520 Locking Screw *
110 A93570300 Angular Contact Bearing * 129 A11375774 Double Nipple
111 A93575110 Cylindrical Roller Bearing * 130 A93573640 Spacer *
112 A93573810 Cylindrical Roller Bearing * 131 A93636060 Name Plate
113 A93570310 Angular Contact Bearing * 132 A93196130 O-Ring *
114 A93570360 Taper Roller Bearing * 133 A93196140 O-Ring *
115 A93570370 Taper Roller Bearing * 134 A93060450 Locking Screw *
116 A93574920 Locknut * 135 A93060490 Locking Screw *
117 A93570980 Locknut * 136 A93060480 Locking Screw *
118 A93220100 Shaft Seal.Ring + 137 A93060460 Locking Screw *
119 A93321370 Shim Disk PS 138 A93343350 Expander
120 A11922274 Inner Ring + 200 A11919574 Gear Set

Key to Figs. 1.1 and 1.2

* Part of Air End Repair Kit Nr. A11926174. + Part of Air End Oil Seal Kit Nr. A11926274.

DL071 7
8

1 Introductio
12 11 10 9 8 7 6 5 4 3 2 1

133 104 109 119 117 2 Tropfen

01 101
H 123 Schnitt A-A 110 132 H
103
134 138 128
109

127
118

120
G
G

107
Fig 1.3 - EK175NK Air End - Sectional

108
F F

131 136

127
124
137
B 122
E
E

A A 120
X

121 116
2 Tropfen

D B D
111

138

128
134
0,04 ` 0,01
Schnitt B-B 125 126
01
C 01
105 113
112 C

Ansicht X Anzugsmomente
Torque
Verbindungselement Pos Anzugsmoment Nm
Zyl-Schraube M12 127 86
Doppelnippel 1 1/2-16UN 129 25

einkleben mit (glue with) Loctite 245 (Pos.139)

B aufkleben mit (glue with) Loctite 496 (Pos.140) B
einkleben mit (glue with) Loctite 620 (Pos.141)

134 137 129

Nut positionieren 135 Tolerierung
DIN 7167
Rauhtiefe Rz
Reihe 2
Maßstab: 1
Gewicht: 195
Rohteil- Nr. Auftr. -Nr.

Deckscheiben bündig mit Planfäche Allgemeintoleranzen DIN 3141

ISO 2768-mH Fertigteil Nr. Werkstoff
Datum
Name Bezeichnung/ Document description

Ident.-Nr. siehe Verdichterliste A11917074

Comp
Gezeichnet 17.10.2003
Kontrolliert
Federmann
24.02.2004 Thomes
Zusammenstellzeichnung
DL071

ID. according to Air End List A11917074 Norm

EK175NK Assembly Drawing
Abt. Copyright reserved
Schutzvermerk nach Klass. -Nr. UA Spr Codestelle
DIN 34 beachten
A Material- Nr. Blatt/Blätter A
CompAir 1 /1
Drucklufttechnik GmbH A1
01 9462_21_04 05.07.04 Fed
A11917
12 11 10 9 Status AM-Nr. Datum Name Enstanden aus: Ersatz für: Ersetzt durch:

8 7 6 5 4 3 2 1
A11917574.idw
Comp Introduction

134
138 107
132 127

117
110
119
128
109
129
137 127
108
116
101 113
112
128
133 135

137
131
104

124 136

109 138
138
120
122
123 105
103 134

126 116

118
121 125

138
SM 1366
134
138 126
127

Fig 1.4 - EK175NK Air End - General Arrangement

Item Part No. Description Item Part No. Description

101 A11920174 Rotor Housing 122 A93196120 O-Ring +
103 A11920774 Inlet Cover 123 A11922674 Cover, Male Rotor
104 A11921574 Male Rotor 124 A93161120 Key +
105 A11921374 Female Rotor 125 A11922774 Cover, Female Rotor
107 A11922074 Delivery End Cover 126 A93159760 Cylind.Pin
108 A11922174 Safety Plate * 127 A93040870 Cylind.Screw *
109 A93570290 Cylind.Roller Bearing * 128 A93060520 Locking Screw *
110 A93570300 Angular Contact Bearing * 129 A11375774 Double Nipple
111 A93575110 Cylind.Roller Bearing * 131 A93636060 Name Plate
112 A93573810 Cylind.Roller Bearing * 132 A93196130 O-Ring *
113 A93570310 Angular Contact Bearing * 133 A93196140 O-Ring *
116 A93574920 Locknut * 134 A93060450 Locking Screw *
117 A93570980 Locknut * 135 A93060490 Locking Screw *
118 A93220100 Shaft Seal.Ring + 136 A93060480 Locking Screw *
119 A93321370 Shim Disk Ps 137 A93060460 Locking Screw *
120 A11922574 Inner Ring + 138 A93343350 Expander
121 A93147560 Circlip +

Key to Figs. 1.3 and 1.4

* Part of Air End Repair Kit Nr. A11929174. + Part of Air End Oil Seal Kit Nr. A11929274.

DL071 9
 2 Safety Comp

2 Safety Procedures
2.1 General 2.2 Warnings, Cautions and Notes
2.1.1 Most accidents which occur during the operation 2.2.1 Warnings
and maintenance of machinery are the result of
failure to observe basic safety rules or precautions. Warnings call attention to operations or procedures
An accident can often be avoided by recognising a involving specific hazards which could cause
situation that is potentially hazardous. injury or death and are identified by the following
symbols on the unit and in the text of the manual.
2.1.2 When handling, operating or carrying out
maintenance on the unit, personnel must use safe
engineering practices and observe all relevant
local health and safety requirements and WARNING: RISK OF DANGER
regulations. The attention of users in the UK is
drawn to the Health and Safety at Work Act,
1974, the Regulations of the Institution of
Electrical Engineers and the Pressure Systems and
Transportable Gas Container Regulations 1989. WARNING: RISK OF ELECTRIC
SHOCK
2.1.3 CompAir cannot anticipate every possible
circumstance which might represent a potential
hazard. The WARNINGS in this manual are
therefore not all-inclusive. If the user employs an WARNING: RISK OF HOT
operating procedure, an item of equipment or a SURFACES
method of working which is not specifically
recommended by CompAir he must ensure that the
unit will not be damaged or made unsafe and that
there is no risk to persons or property. WARNING: CONSULT MANUAL
2.1.4 The standard builds of all CompAir products are
not intended for use in either explosive or
potentially explosive atmospheres as defined in
Directive 94/9/EC. An explosive atmosphere is a
WARNING: RISK OF HIGH
mixture with air, under atmospheric conditions, of
PRESSURE
flammable gases, vapours, hazes or dust in which,
after ignition has occurred, combustion propagates
to the entire unburned mixture and may cause a 2.2.2 Cautions
hazard. A potentially explosive atmosphere is an
atmosphere which could become explosive due to Incorrect operational procedures causing
local conditions. possible damage to the compressor unit are
identified by a 'Caution’ in the text of this
2.1.5 Failure to observe the precautions given under manual.
‘Safety Procedures’ may be considered dangerous
practice or misuse of the compressor unit. 2.2.3 Notes
Methods to make the job easier and points which
require particular attention are identified by a
‘Note’ in the text of this manual.

1 DL071
 Comp
2.3 Safety Precautions
2.3.1 When using cleaning solvents, local Health and
Safety regulations must be complied with. Provide
good ventilation and use suitable protection such
as a breathing filter mask, safety glasses,
protective apron and gloves.
2.3.2 Safety footwear should be compulsory in all
workshops. Safety helmets must be worn if
there is any risk of falling objects.
2.3.3 If using compressed air for cleaning purposes,
ensure safety regulations are complied with and
appropriate clothing and eye protection is worn.
2.3.4 Never direct compressed air onto your skin or at
other people.
2.3.5 Never use compressed air to clean loose dirt
from clothing.
2.3.6 Before releasing compressed air through a
hose make sure that the free end is held
securely so that it cannot whip and cause
injury.
2.3.7 Avoid injury by using a hoist to lift heavy loads.
Check that all chains, hooks, shackles and slings
are in good condition and are of the correct
capacity. They must be tested and approved
according to local safety regulations.
2.3.8 Cables, chains or ropes must never be applied
directly to lifting eyes. Always use an appropriate
shackle or hook, properly positioned. Arrange
lifting cables so that there are no sharp bends.
2.3.9 Use a spreader bar to avoid side loads on
hooks, eyes and shackles.
2.3.10 When a load is on a hoist, stay clear of the danger
area beneath and around it. Keep lifting
acceleration and speed within safe limits and never
leave a load hanging on a hoist for longer than is
necessary.
2.3.11 A hoist should always be used to lift in a
perpendicular direction. If lifting at an angle
cannot be avoided take precautions to prevent the
load swinging. This can be achieved by using two
hoists, each lifting at not more than 30° from the
vertical.
Note: This will reduce the safe working load
capacity of the hoists.
2.3.12 Always use tools that are in good condition and be
sure you understand how to use them properly
before starting any service work. Use the correct
tool for each job. Knowledge of the
DL071
Safety Procedures
proper use of tools and their limitations,
coupled with common sense, can prevent
many accidents.
2.3.13 Special service tools are available for some
specific jobs and should always be used when
recommended. This will save time and prevent
damage to components.
2.4 Maintenance Precautions.
2.4.1 When disposing of condensate, old oil, used filter
elements and other parts and waste material of any
kind make sure that there is no pollution of any
drain or natural water-course and that no burning
of waste take place which could cause pollution of
the air. Protect the environment by using only
approved methods of disposal.
2.4.2 Use only CompAir Genuine Parts.
2.4.3 Bearing components must be matched with their
boxed counterparts and not interchanged with
other bearing assemblies.
2.4.4 Keep a written record of all maintenance and
repair work carried out on the air end. The
frequency and nature of the work required over a
period can reveal adverse operating conditions
which should be corrected.
2.4.5 Use only lubricating oils and greases approved
by CompAir. Make sure that the selected
lubricants comply with all relevant safety
regulations, especially with regard to the risk of
explosion or fire and the possibility of
decomposition or the generation of hazardous
gases.
2.4.6 Always clean up oil spills before and after
maintenance work.
2.4.7 Make sure that all instructions concerning
operation and maintenance are strictly followed
and that the complete unit, with all accessories
and safety devices, is kept in good running
order.
2.4.8 Maintenance, overhaul and repair work must
only be carried out by competent personnel
under a qualified supervisor.
2.4.9 Never use a light source with an open flame to
inspect any part of the unit.
2.4.10 Only use lint free cloth when cleaning
components and ensure that hands, tools and work
surfaces are clean and free from sand, grit or other
abrasive particles.
1
 2 Safety Comp

2.4.11 After completion of repair or maintenance work

ensure that no tools, loose items or cloth are left 2.5 Precautions In The Event Of Fire
on or inside any part of the air end. 2.5.1 Use extreme caution when handling
2.4.12 Do not use any flammable liquid to clean air pipes components that have been subjected to
or any components carrying a flow of air during fire or very high temperatures. Some
normal operation. If chlorinated hydrocarbon non- components may contain fluoroelastomer
flammable fluids are used for cleaning, safety materials which decompose under these
precautions must be taken against any toxic conditions to form highly corrosive residues. Skin
vapours which may be released. contact can cause painful and penetrating burns
resulting in permanent skin and tissue damage.
2.4.13 Do not use carbon tetrachloride
2.4.14 Precautions must be taken when using acids,
alkalis and chemical detergents for cleaning
machine parts and components. These materials
cause irritation and are corrosive to the skin, eyes,
nose and throat. Avoid splashes and wear suitable
protective clothing and goggles. Do not breath
mists. Ensure that water and soap are readily
available.
2.4.15 When disposing of condensate, old oil, used filter
elements and other parts and waste material of any
kind make sure that there is no pollution of any
drain or natural water-course and that no burning
of waste takes place which could cause pollution
of the air. Protect the environment by using only
approved methods of disposal.

1 DL071
 Comp Dismantling

3 Dismantling
Note: Item numbers in brackets refer to Figs. 3.1.3 Unscrew and remove the capscrews M12x40
1.1, 1.2, 1.3, 1.4 in Chapter 1. (127) securing the delivery end cover (107) and
remove the cover.
3.1 Remove Delivery End Cover
SM 1368
3.1.1 Mount the air end on a rotating assembly
fixture with drive end uppermost.
Note: Position a drip tray under the assembly
fixture to catch any oil from the air end during
dismantling.
SM 1376

Fig. 3.3 - Removing Delivery End Cover

3.2 Remove Delivery End Locknuts

3.2.1 Unscrew capscrew M12x40 (127) and
disassemble safety plate (108). (The safety
plate prevents rotation of the outer rings of
Fig. 3.1 - Air End Mounted on both axial bearings).
Assembly Fixture
SM 1252

3.1.2 Fit the shaft locking tool on the drive shaft

end.

Fig. 3.4 - Removing Safety Plate

Fig. 3.2 - Shaft Locking Tool Fitted on

Drive Shaft

SM 1162

DL071 1
 3 Comp

3.2.2 Unscrew locking screw G1 ½" (128) and 3.2.3 Release the locking screw in the shaft locknut
remove thermostatic valve. (116) of the female rotor.
Warning: Thermostatic valve insert SM 1310
is under spring tension.

Fig. 3.6 - Removing Locking Screw from

Female Rotor Locknut

3.2.4 Ensure that the shaft locking tool is positioned so

that it prevents the drive shaft from turning.
SM 1163

SM 1386
Fig. 3.7 - Ensure Shaft is Locked Securely

3.2.5 Loosen the shaft lock nut (116) on the female

rotor using a special spanner, then unscrew and
remove locknut.

Fig. 3.5 - Removing Thermostatic

Valve

SM 1308

Fig. 3.8 - Removing Female Rotor Locknut

1 DL071
 Comp Dismantling

3.2.6 Release the locking screw in the shaft locknut 3.3.3 Remove the two dowel pins (126) from the
(117) of the male rotor. bell housing (103) using a special tool.
3.2.7 Loosen and unscrew the locknut (117) using a SM 1164
special spanner.

SM 1311

Fig. 3.9 - Removing Male Rotor Locknut

3.3 Remove Bell-Housing

3.3.1 Turn the air end on the rotating fixture through
180° so that the drive shaft is now uppermost.
3.3.2 Remove shaft locking tool.

SM 1251

Fig. 3.10 - Removing Shaft Locking Tool Fig. 3.11 - Removing Dowel Pins

DL071 1
 3 Comp

3.3.4 Unscrew and remove the capscrews M12x 40 3.3.6 Screw eye bolts into the bell housing in
(127) securing the bell housing. diagonally opposite positions as shown.
SM 1352

SM 1181

Fig. 3.14 - Fitting Eyebolts

3.3.7 Carefully lift off the bell housing (103) using

suitable lifting tackle.
SM 1182

Fig. 3.12 - Removing Bell-housing

Capscrews

3.3.5 Remove the key from drive shaft.

SM 1165

Fig. 3.15 - Lifting Off Bell-housing

Fig. 3.13 - Removing Drive Key

1 DL071
 Comp Dismantling

3.4 Remove Drive Gears 3.4.3 Unscrew capscrew (127) and remove safety disc
3.4.1 The drive shaft of the gear (200) can now be (123).
lifted off. SM 1334

SM 1332

Fig. 3.16 - Drive Gear Shaft

3.4.2 Remove the outer ring of the taper roller bearing

(115) and the waved spring washers
(130) below.
Fig. 3.18 - Removing Safety Disc
from Male Rotor

3.4.4 Screw an M12 capscrew into the centre

tapping of the male rotor (104). Install the
gear-puller and remove the pinion (200).
SM 1342

Fig. 3.17 - Drive Gear Shaft Bearing

Outer Ring

SM 1330

Fig. 3.19 - Removing Male Rotor

Drive Pinion

DL071 1
 3 Comp

3.5 Remove Inlet Bearing Housing 3.5.3 Loosen the inlet bearing housing (102) with the
3.5.1 Remove the two dowel pins (126) from the help of a screw driver and remove the inlet bearing
inlet bearing housing (102) using a special housing.
tool. SM 1338

SM 1335

Fig. 3.22 - Loosening Inlet Bearing Housing

3.6 Remove Rotors

3.6.1 Turn the air end on the rotating fixture 180° so that
the delivery end is now uppermost.
3.6.2 Install hydraulic press fixture (part No.:
80285274) . Secure with 8 bolts.
SM 1363
Fig. 3.20 - Removing Dowel Pins from
Inlet End

3.5.2 Unscrew and remove the capscrews M12x40

(127).

Fig. 3.23 - Installing Hydraulic Press

Fixture

Fig. 3.21 - Removing Inlet Bearing Housing

Capscrews

SM 1337

1 DL071
 Comp Dismantling

3.6.3 Screw an M12 capscrew into the centre
tapping of the female rotor.
3.6.5 Turn the air end on the rotating fixture so that the
inlet end is now uppermost.
3.6.6 Using the hydraulic press, press the male
rotor (104) out of the rotor casing.
3.6.7 Screw an eyebolt into the centre tapping of the
male rotor, attach lifting tackle and carefully
remove the male rotor.

SM 1381

SM 1166
Fig. 3.24 - Capscrew Fitted to Female Rotor

3.6.4 Assemble hydraulic cylinder on the male rotor

side.
SM 1380

Fig. 3.26 - Lifting Out Male Rotor

Fig. 3.25 - Hydraulic Cylinder Fitted to

Male Rotor Side

DL071 1
 3 Comp

3.6.8 Turn the air end on the rotating fixture 180° again 3.6.9 Again, turn the air end on the rotating fixture
and assemble hydraulic cylinder on the female 180°.
rotor side.
3.6.10 Using the hydraulic press, press the female
SM 1379 rotor (105) out of the rotor casing.
3.6.11 Screw an eyebolt into the centre tapping of the
female rotor, attach lifting tackle and carefully
remove the female rotor.

SM 1382

Fig. 3.27 - Hydraulic Cylinder Fitted to

Female Rotor Side

Fig. 3.28 - Removing Female Rotor

3.6.12 Rotate the air end 180°.

3.6.13 Dismantle hydraulic press fixture and remove the
pressed out delivery end bearings.

2 DL071
 Comp Dismantling

3.7 Remove Bearing Inner Rings 3.8 Repair Kits

3.7.1 Hold a guide pin between vise jaws as shown. 3.8.1 Use only genuine repair kits from CompAir for
Suspend each rotor from a crane and lower the refurbishment of the EK175NG and NK air ends.
centre tapping over the guide pin . Warm the inner Details of the kits are given at the back of this
rings evenly until they drop off. publication.
Note: Turn the rotor continually to avoid Air end EK175NG:
overheating.
A11926174 Air end EK175NK:
Warning: Ensure the existing legal safety
instructions covering working with welding A11929174
sets are complied with.
Warning: Use safety clothing, safety
gloves and safety glasses.

SM 1384

Fig. 3.29 - Removing Bearing Inner Rings

3.7.2 After completing the dismantling of the air

end, all parts must be cleaned thoroughly.
3.7.3 Carefully remove any carbon deposits from the
rotor profiles using a very fine cleaning pad
(support the rotor on vee blocks). Polish out any
marks from small foreign particles on the rotors.
3.7.4 Polish flange faces of the housing parts.
3.7.5 Counterbore all threaded holes to remove any
burrs and run a tap down the tapped holes in
the face to clean up the threads.

DL071 2
 4 Assembly - Prepare Inlet End - Comp

4 Assembly - Prepare Inlet End - EK175NG

4.1 Prepare Inlet Casing 4.1.4 Polish the flange face of the inlet bearing
Note: Item numbers in brackets refer to figs. housing (102) using an oilstone and clean it
1.1 and 1.2 in Chapter 1. using a degreaser spray.

4.1.1 Carefully clean the bearing seats of the inlet

bearing housing (102) using a degreaser spray.
4.1.2 Within the bearing bores, check that the oil
feed ports to the male and female inlet
bearings are clear and unobstructed.

SM 1254

SM 1256
Fig. 4.3 - Cleaning Flange Face

Fig. 4.1 - Cleaning Housing Bores

2 DL071
Comp Assembly - Prepare Inlet End - 5

4.1.3 Apply some LOCTITE 620 on the seat of the male

rotor inlet bearing only (outer ring will be
glued in).

Caution: Do not apply LOCTITE 620 on

the seat of the female rotor inlet bearing.

SM 1255

Fig. 4.2 - Applying LOCTITE 620

DL071 2
 4 Assembly - Prepare Inlet End - Comp

5 Assembly - Prepare Inlet End - EK175NK

5.1 Prepare Inlet Casing
Note: Item numbers in brackets refer to figs.
1.3 and 1.4 in Chapter 1.
5.1.1 Polish the flange face of the inlet cover (103)
using an oilstone and clean it using a degreaser
spray. Also clean and degrease the bearing seats.
5.1.2 Within the bearing bores, check that the oil
feed ports to the male and female inlet
5.1.4 Using a suitable drift, carefully drive the
cylindrical roller bearing (111) into the inlet
cover.
Note: Ensure the outer ring sits firmly against the
shoulder of the bearing housing.
SM 1259

bearings are clear and unobstructed.

SM 1257
Fig. 5.1 - Polishing Inlet Cover

5.1.3 Position the cylindrical roller bearing NU208

(111) on the female rotor side and push it
carefully into the bearing seat.

SM 1258

Fig. 5.3 - Fitting Female Cylind. Roller

Bearing

Fig. 5.2 - Positioning Female Cylind. Roller

Bearing

2 DL071
 5 Assembly - Prepare Inlet End -
5.1.5 Do the same for the cylindrical roller bearing 5.1.6
(109) on the male rotor side. Position the bearing
and, using a suitable drift, carefully drive the
bearing into the inlet cover.
SM 1260
5.1.7
Fig. 5.4 - Fitting Male Cylind. Roller Bearing
2 DL071
Comp
Using a degreaser spray, carefully clean the
housing bores of the inlet cover again (in
preparation for fitting the cover discs).
SM 1263
Fig. 5.5 - Cleaning Housing Bores
Carefully clean the outer diameter of the cover
disk (125) of the female rotor using a degreaser
spray.
SM 1179
Fig. 5.6 - Cleaning Female Rotor
Cover Disc
 Comp Assembly - Prepare Inlet End - 5

5.1.8 Apply some LOCTITE 620 on the outer diameter

of the cover disk (125) and position the cover
disk (125) on the female rotor side.
Note: Check that the notch for the oil drain is
aligned as shown.

SM 1375

SM 1374
Fig. 5.9 - Female Bearing
Cover Disc In Position

Note: Check that the cover disk sits firmly. The

cover disk (125) should not protrude above the
face of the inlet cover (103).

Fig. 5.7 - Positioning Female Rotor

Cover Disc

5.1.9 Using a suitable drift, carefully drive the cover

disk (125) into the bore of the inlet cover.

SM 1262
Fig. 5.8 - Fitting Female Bearing
Cover Disc

DL071 2
 5 Assembly - Prepare Inlet End - Comp

5.1.10 Carefully clean the cover disk (123) of the male
rotor using a degreaser spray. Apply some
LOCTITE 620 on the outer diameter of the cover
disk (123).
5.1.12 Using a suitable drift, carefully drive the cover
disk (123) into the bore of the inlet cover.
Note: Check that the cover disk sits firmly. The
cover disk (123) should not protrude above the
face of the inlet cover (103).

SM 1264
SM 1180
Fig. 5.12 - Fitting Male Rotor Cover Disc
Fig. 5.10 - Preparing Male Rotor Cover Disc

5.1.11 Position the cover disk (123) on the male rotor side as
shown (check the position of the notch for the oil
drain).

SM 1264
Fig. 5.11 - Positioning Male Rotor
Cover Disc

2 DL071
 Comp Assembly - Prepare Inlet End - 5

5.1.13 Carefully remove any excess LOCTITE.

Caution: Note the hardening time of

LOCTITE 620. LOCTITE 620 is an
anaerobic hardening adhesive. The
adhesive joint is ready for handling after
60 minutes, final strength reached after 24
hours.

SM 1297
Fig. 5.13 - Removing Excess LOCTITE

DL071 2
 6 Assembly - Install Comp

6 Assembly - Install Rotors

Note: Item numbers in brackets refer to figs.
1.1, 1.2, 1.3 and 1.4 in Chapter 1.
6.1 Mount Rotor Casing On Fixture
6.1.1 Mount the rotor casing (101) on a rotating
assembly fixture.
6.2 Prepare Rotor Casing
6.2.1 Turn the rotor casing on the rotating fixture
through 180° so that the inlet end is now
uppermost. Polish the flange face and the
delivery end face of the rotor casing using an
oilstone and clean them using a degreaser spray.

SM 1347
SM 1296

Fig. 6.1 - Air End and Assembly Fixture

6.1.2 Secure the rotor casing on the assembly Fig. 6.3 - Rotor Casing
fixture.

6.2.2 Apply some general purpose grease (e.g. Renolit

Duraplex EP2) into the O-ring groove of the rotor
casing for ease of assembly of the O-ring.

Fig. 6.2 - Securing Rotor SM 1385

Casing Fig. 6.4 - Applying Grease
SM 1339

2 DL071
 Comp Assembly - Install Rotors

6.2.3 Install the O-ring (133) into its groove. The 6.3.2 Remove any burrs on the delivery end face of the
previously applied grease should hold the O- male rotor with an oilstone ( to allow correct
ring in the groove when the inlet bearing delivery end clearance adjustment).
housing is assembled later.

SM 1295
Fig. 6.5 - Fitting 'O'-Ring

6.3 Install Rotors

SM 1168
6.3.1 Screw an eye bolt into the centre tapping of the Fig. 6.7 - Polishing Male Rotor
male rotor (104) and suspend it from a crane.
Clean the male rotor using a degreaser spray.
6.3.3 Carefully lower the male rotor into the rotor
SM 1294
casing.

SM 1287

Fig. 6.6 - Cleaning Male Rotor

Fig. 6.8 - Positioning Male Rotor

DL071 2
 6 Assembly - Install Comp

6.3.4 In the same way, clean and degrease the female 6.3.6 Remove eye bolts from both rotors.
rotor (105) and remove any burrs from the
SM 1292
delivery end face.

SM 1169
Fig. 6.9 - Polishing Female Rotor

Fig. 6.11 - Remove Eyebolts

6.3.5 Carefully lower the female rotor (105) into the rotor
casing. Be aware that the rotor will turn as it
engages with the male rotor.

Caution: Be careful not to damage the

profile of the rotors
SM 1291

Fig. 6.10 - Positioning Female Rotor

3 DL071
 Comp Assembly - Fit Inlet End Components - EK175NG

7 Assembly - Fit Inlet End Components - EK175NG

Note: Item numbers in brackets refer to figs. 7.2 Fit Inlet Bearing Housing
1.1 and 1.2 in Chapter 1.
7.2.1 Carefully lower the inlet bearing housing
(102) into position on the rotor casing.
7.1 Fit Inlet Bearing Inner Rings
SM 1336
7.1.1 Heat the inner rings of the inlet end cylindrical
roller bearings (109) and (111) to a temperature of
120°C (max 125°C = 257°F) using an oven or
induction heater.

Warning: Hot components. Use safety

gloves.
7.1.2 Carefully slide the inner rings onto male and
female rotor shafts, ensuring they are tight
against their respective shoulders.
SM 1293

Fig. 7.2 - Positioning Inlet Bearing Housing

Fig. 7.1 - Fitting Bearing Inner Rings

DL071 3
 7 Assembly - Fit Inlet End Components - Comp

7.2.2 Drive in the two dowel pins (126) using a

copper hammer to position the inlet bearing
housing on the rotor casing.
7.2.3 Screw in the six cap screws and tighten
crosswise (Torque: 86 Nm).
SM 1333
7.3 Assemble Inlet Bearings
7.3.1 Position the cylindrical roller bearing (111)
onto the female rotor shaft.

SM 1324
Fig. 7.4 - Positioning Female Roller Bearing

Fig. 7.3 - Fitting Inlet Bearing Housing

3 DL071
 Comp Assembly - Fit Inlet End Components - EK175NG

7.3.2 Position the cylindrical roller bearing (109) 7.3.3 Do the same for the cylindrical roller bearing
onto the male rotor shaft. Using a suitable (111) on the female rotor side.
drift, carefully drive the bearing into the
bearing housing. SM 1323

Note: Ensure the outer ring sits firmly against the

shoulder of the bearing housing.

Caution: Do not damage the

rolling elements or bearing races
SM 1326

Fig. 7.6 - Fitting Female Cylind. Roller

Bearing

7.3.4 Fit the waved washers (130) on the female

rotor side.

SM 1325

Fig. 7.5 - Fitting Male Roller Bearing

Fig. 7.7 - Fitting Waved Washers

DL071 3
 7 Assembly - Fit Inlet End Components -
7.3.5 Position the outer ring of the taper roller
bearing (115) onto the female rotor shaft.
Caution: Ensure the outer ring is correctly
orientated.
Fig. 7.8 - Positioning Female Taper Roller
Bearing Outer Ring
SM 1322
3 DL071
Comp
7.3.6 Tap the outer ring of the taper roller bearing
(115) into the bore of the inlet bearing housing
with the careful use of a copper hammer.
Caution: Drive the outer ring only to a
position where it slightly touches the
previously assembled waved washers.
This outer ring (relocatable in the bore) is
automatically adjusted when the drive
shaft (200) and bell housing (103) are
assembled.
SM 1318
Fig. 7.9 - Fitting Female Taper Roller
Bearing Outer Ring
 Comp Assembly - Fit Inlet End Components - EK175NG

7.4 Fit Gear Pinion 7.4.3 Apply some grease onto the male rotor shaft end
7.4.1 Carefully drive the key (125) into the keyway of for ease of pinion assembly.
the male rotor shaft using a copper hammer. SM 1321

SM 1319

Fig. 7.12 - Applying Grease

7.4.4 Heat the pinion of the drive gear (200) to a

Fig. 7.10 - Fitting Drive Key temperature of 120 to max.125°C (257°F) in an
oven or by using an induction heater.

Warning: Hot components. Use safety

7.4.2 Apply some LOCTITE 245 (screw locking) to gloves.
the centre tapping of the male rotor.
7.4.5 Fit the pinion onto the shaft end of the male rotor.
SM 1320 Ensure the pinion sits firmly against the shaft
shoulder.
SM 1316

Fig. 7.11 - Applying LOCTITE 245

Fig. 7.13 - Fitting Drive Pinion

DL071 3
 7 Assembly - Fit Inlet End Components - Comp

7.4.6 Position the safety disk (123) on the pinion and
secure with a cap screw (127). Ensure rotors
cannot turn and tighten capscrew to 86 Nm.
SM 1317
7.5.3 Turn the drive shaft so that the drive end is
now uppermost.
Caution: Ensure that the drive shaft is
not standing on the cage of the
previously assembled taper roller
bearing. Support the shaft underneath
the pinion.

SM 1171

Fig. 7.14 - Fitting Safety Disc

7.5 Pre-Assemble Drive Gear Shaft

7.5.1 Heat the taper roller bearing (115) to a
temperature of 120 to max. max. 125°C (257°F)
in an oven or by using an induction heater.

Warning: Hot components. Use safety

gloves.
7.5.2 Fit the taper roller bearing (115) onto the non-
drive shaft end of the drive gear (200).
Ensure the bearing is oriented correctly when
fitting and sits firmly against the shoulder.

SM 1265

Fig. 7.16 - Drive Gear Shaft

Fig. 7.15 - Fitting Taper Roller Bearing

(Non-Drive End)

3 DL071
 Comp Assembly - Fit Inlet End Components - EK175NG
7.5.4 Heat the bigger taper roller bearing (114) to a
temperature of 120 max. 125°C (257°F) in an
oven or by using an induction heater.
Warning: Hot components. Use safety
gloves.
7.5.5 Fit the taper roller bearing (114) onto the drive
shaft end of the gear (200). Ensure the taper roller
bearing is oriented correctly when fitting and sits
firmly against the shoulder.
SM 1172
Fig. 7.17 - Fitting Taper Roller Bearing
(Drive End)
DL071
7.5.6 Fit inner ring of drive shaft oil seal as follows:-
a) Ensure helix orientation is appropriate for the
direction of rotation of the drive shaft. The helix
orientation must always tend to screw the oil back
into the air end. The helix orientation for the
EK175NG (right-handed) is opposite to that for
the EK175NK
(left-handed).
SM 1369
Fig. 7.18 - Correct Helix Orientaion
b) Fit the O-ring (122) into the groove of the
inner ring (120) of the shaft seal.
SM 1373
Fig. 7.19. - Positioning 'O'-ring in
Inner Ring of Shaft Oil Seal
3
7 Assembly - Fit Inlet End Components - Comp

c) Apply some grease to the O-ring of the inner
ring for ease of assembly.
e) Drive the inner ring (120) of the shaft seal onto
the shaft end of the gear shaft with the careful use
of a hammer and drift. Ensure that this inner ring
is seated firmly against the inner ring of the taper
roller bearing (114).

SM 1372
Fig. 7.20. - Applying Grease

d) Position the inner ring (120) of the shaft seal on

the drive end of the gear shaft.
Note: Check that the locating slot of the inner ring
(120) is aligned with the keyway in the shaft.

SM 1185

SM 1266

Fig. 7.22 - Fitting Inner Ring of

Shaft Oil Seal

Fig. 7.21 - Positioning Inner Ring of

Shaft Oil Seal

3 DL071
 Comp Assembly - Fit Inlet End Components - EK175NG

7.5.7 Position the drive shaft of the gear (200) onto the 7.6.2 Clean the flange face of the bell housing using a
already assembled outer ring of the taper roller degreaser spray and an oil stone.
bearing (115).
SM 1175
SM 1331

Fig. 7.25 - Polishing Face of Bell-Housing

7.6.3 Apply some grease onto the seat of the taper

Fig. 7.23 - Drive Shaft in Position roller bearing (to hold the outer ring of the
bearing in position during assembly).

7.6 Fit Bell-Housing

7.6.1 Screw locking screws (134) into the bell housing
(103) as shown, and tighten. Check that oil
injection port (Dia.: 1.5 mm) and oil feed port to
drive shaft inlet bearing are clear and
unobstructed.

SM 1176
Fig. 7.26 - Applying Grease

SM 1173

Fig. 7.24 - Fitting Locking Screws

DL071 3
 7 Assembly - Fit Inlet End Components - Comp

7.6.4 Fit the outer ring of the taper roller bearing
(114) into the bell housing bore.
7.6.7 Screw in two cap screws on each side of the bell
housing (127) and lightly tighten them crosswise.
Do not completely tighten these 4 screws; the
flange faces must be relocatable for assembly of
dowel pins.

SM 1177

Fig. 7.27 - Fitting Outer Ring of Taper

SM 1349
Roller Bearing

7.6.5 Screw two eye bolts into the bell housing

(103) as shown and attach lifting tackle.
7.6.6 Carefully lower the bell housing (103) onto the
rotor casing.
SM 1348

Fig. 7.29 - Fitting 4 "Holding" Screws

Fig. 7.28 - Lowering Bell-Housing

into Position

4 DL071
 Comp Assembly - Fit Inlet End Components - EK175NG

7.6.8 Drive in the two dowel pins (126), to accurately

locate the bell housing (103) on the rotor casing 7.7 Fit Shaft Oil Seal
(101). 7.7.1 Apply some grease onto the O-Rings (outer
diameter) and onto the rear sealing lip for ease of
assembly of the shaft seal ring (118).
SM 1300

Fig. 7.32 - Applying Grease to 'O'-Rings

and Rear Sealing Lip

7.7.2 Fill the space between dust lip and outer

sealing lip to half its depth with a high
SM 1351 temperature grease.
Fig. 7.30 - Driving In Dowel Pins

7.6.9 Screw in remaining cap screws (127) and

tighten these (and the 4 fitted previously)
cross-wise to a torque of 86 Nm.

SM 1352

SM 1301

Fig. 7.33 - Applying Grease Between Dust

Lip and Sealing Lip

Fig. 7.31 - Securing Capscrews

DL071 4
 7 Assembly - Fit Inlet End Components - Comp

7.7.3 Carefully fit the shaft seal ring (118) onto the 7.7.5 Fit the circlip (121) into the groove in the bell
drive shaft end . housing bore.
Caution: Do not damage the sealing lips
SM 1186

Fig. 7.36 - Fitting Circlip

7.7.6 Carefully drive the key (124) into the key way on
the shaft end using a copper hammer.
SM 1253

SM 1302
Fig. 7.34 - Positioning Shaft Seal Ring

7.7.4 Drive the shaft seal ring (118) into the bore with
the careful use of a hammer and drift. Ensure that
the seal ring is seated firmly against the shoulder
in the bell housing bore.
Fig. 7.37 - Fitting Drive Key
SM 1187

Fig. 7.35 - Fitting Shaft Seal Ring

4 DL071
 Comp Assembly - Fit Inlet End Components - EK175NK
8 Assembly - Fit Inlet End Components - EK175NK
Note: Item numbers in brackets refer to figs.
1.3 and 1.4 in Chapter 1.
8.1 Fit Inlet Bearing Inner Rings
8.1.1 Heat the inner rings of the inlet end cylindrical
roller bearings (109) and (111) to a temperature of
120°C (max 125°C = 257°F) using an oven or
induction heater.
Warning: Hot components. Use safety
gloves.
8.1.2 Carefully slide the inner rings onto male and
female rotor shafts, ensuring they are tight
against their respective shoulders.
SM 1293
Fig. 8.1 - Fitting Bearing Inner Rings
DL071
8.2 Fit Oil Seal Inner Ring
8.2.1 Ensure helix orientation on the new inner ring is
correct for the direction of rotation of the drive
shaft. The helix orientation must always tend to
screw the oil back into the air end. The helix
orientation for the EK175NG
(right-handed) is opposite to that for the
EK175NK (left-handed).
SM 1370
Fig. 8.2 - Correct Helix Orientation
8.2.2 Fit the O-ring (122) into the groove of the
inner ring (120) of the shaft seal.
SM 1373
Fig. 8.3. - Positioning 'O'-ring in
Inner Ring of Shaft Oil Seal
4
 8 Assembly - Fit Inlet End Components - Comp

8.2.3 Apply some grease to the O-ring of the inner

ring for ease of assembly. 8.3 Fit Inlet Bearing Cover
8.3.1 Screw two eye bolts into the inlet cover (103)
and attach lifting tackle.
8.3.2 Carefully lower the inlet cover onto the rotor
casing.

SM 1364

SM 1372
Fig. 8.4 - Applying Grease

8.2.4 Position the inner ring (120) on the male rotor

shaft end. Check that the locating slot of the inner
ring is aligned with the keyway in the shaft.
8.2.5 Drive the inner ring onto the male rotor shaft
end with the careful use of a hammer and drift.
Ensure that the inner ring sits firmly against the
inner ring of the bearing.
SM 1377

Fig. 8.6 - Positioning Inlet Bearing Cover

Fig. 8.5 - Fitting Oil Seal Inner Ring

4 DL071
 Comp Assembly - Fit Inlet End Components - EK175NK

8.3.3 With the help of a copper hammer, drive in the two

dowel pins (126) to accurately position the inlet 8.4 Fit Shaft Oil Seal
cover on the rotor casing. 8.4.1 Apply some grease onto the O-rings (outer dia.)
and onto the rear sealing lip for ease of assembly
of the shaft seal ring (118).
SM 1300

Fig. 8.7 - Fitting Dowel Pins

Fig. 8.9 - Applying Grease to 'O'-Rings and
Rear Sealing Lip

8.3.4 Screw in the cap screws M12x40 (127) and

SM 1367
tighten cross-wise to a torque of 86 Nm.
8.4.2 Fill the space between dust lip and outer
sealing lip to half its depth with a high
temperature grease.

SM 1365
Fig. 8.8 - Securing Inlet Bearing Cover

SM 1301

Fig. 8.10 - Applying Grease Between Dust

Lip and Sealing Lip

DL071 4
 8 Assembly - Fit Inlet End Components - Comp

8.4.3 Fit the shaft seal ring (118) onto the male 8.4.5 Fit the circlip (121) into the groove of the inlet
rotor shaft end. cover bore.
Caution: Do not damage the sealing lips. SM 1327
8.4.4 Drive the shaft seal ring into the bore with the
careful use of a hammer and drift. Ensure that the
seal ring is seated firmly against the shoulder in
the inlet cover.
SM 1329

Fig. 8.12 - Fitting Circlip

8.4.6 Carefully drive the key (124) into the keyway on

the shaft end using a copper hammer.
Fig. 8.11 - Fitting Shaft Oil SM 1328
Seal

Fig. 8.13 - Fitting Drive Key

4 DL071
 Comp Assembly - Delivery End

9 Assembly - Delivery End

Note: Item numbers in brackets refer to figs. 9.2 Fit Roller Bearings
1.1, 1.2, 1.3 and 1.4 in Chapter 1.
9.2.1 Heat the inner ring of the delivery end
9.1 Fit Shaft Locking Tool cylindrical roller bearing (109) of the male
rotor to a temperature of 120 -125°C (248 -
9.1.1 Fit the shaft locking tool on the drive shaft 257°F).
end.
Warning: Hot components. Use safety
SM 1251 gloves.
9.2.2 Carefully slide the inner ring onto the male
rotor, ensuring it is tight against the shaft
shoulder.

Fig. 9.1 - Fitting Shaft Locking Tool

SM 1267

9.1.2 Turn the air end on the rotating fixture through

180° so that the delivery end is now uppermost.

Fig. 9.2 - Positioning Male Cylind. Roller

Bearing Inner Ring

DL071 4
 9 Assembly - Delivery Comp

9.2.3 Heat the inner ring of the female rotor 9.2.6 Position the cylindrical roller bearing (109)
cylindrical roller bearing (112) to a onto the male rotor shaft.
temperature of 120 -125°C (248 - 257°F).
SM 1270
Warning: Hot components. Use safety
gloves.
9.2.4 Carefully slide the inner ring onto the shaft end
of the female rotor. Ensure the inner ring sits
firmly against the shaft shoulder. Let the
assembled inner rings cool down for 5 minutes
minimum.
SM 1268

Fig. 9.5 - Positioning Male Cylind. Roller

Bearing Outer Race

Fig. 9.3 - Positioning Female Cylind. Roller

Bearing Inner Ring

9.2.5 Position the cylindrical roller bearing (112)

onto the female rotor shaft.
SM 1269

Fig. 9.4 - Positioning Female Cylind. Roller

Bearing Outer Race

4 DL071
 Comp Assembly - Delivery End

9.2.7 Using a suitable drift, carefully drive the two

delivery end bearings into the rotor casing. 9.3 Fit Angular Contact Bearings
Ensure the outer ring sits firmly against the 9.3.1 Position the spacer ring (119) on the male
shoulder of the casing. rotor shaft as shown.
Caution: Do not damage the
rolling elements or bearing races.

SM 1271

SM 1281
Fig. 9.6 - Fitting Roller Bearings Fig. 9.7 - Positioning Spacer Ring

DL071 4
 9 Assembly - Delivery Comp

9.3.2 Heat the angular contact bearing (110) of the 9.3.6 Ensure that the bearing locating slots are
male rotor to a temperature of 120 -125°C (248 - aligned correctly to accept the lug on the
257°F). safety plate. It may be advisable to
temporarily position the plate to check.
Warning: Hot components. Use safety
gloves. SM 1371

9.3.3 Carefully slide the angular contact bearing onto

the male rotor shaft. Ensure the bearing outer
ring sits firmly against the shoulder of the casing.

SM 1279

Fig. 9.10 - Checking Alignment of Bearing

Locating Slots

9.3.7 Apply some LOCTITE 245 to the threaded

hole of the safety plate.
SM 1303

Fig. 9.8 - Fitting Male Angular Contact

Bearing

9.3.4 Heat the angular contact bearing (113) of the

female rotor to a temperature of 120 -125°C (248
- 257°F).

Warning: Hot components. Use safety

gloves.
9.3.5 Carefully slide the angular contact bearing
onto the female rotor shaft. Ensure the bearing
outer ring sits firmly against the shoulder of
the casing. Fig. 9.11 - Applying LOCTITE
for Safety Plate
SM 1280

Fig. 9.9 - Fitting Female Angular Contact

Bearing

5 DL071
 Comp Assembly - Delivery End

9.3.8 Apply some LOCTITE 245 to the external 9.3.9 Fit the shaft locknut (116) of the female rotor,
threads at the delivery end of the male and ensuring that the polished contact face is against
female rotor shafts. the bearing, and hand-tighten.
SM 1305

SM 1304
Fig. 9.12 - Applying LOCTITE
to External Threads

Fig. 9.13 - Positioning Female Shaft

Locknut

DL071 5
 9 Assembly - Delivery Comp

9.3.10 Do the same with the locknut (117) of the

male rotor shaft. 9.4 Set Delivery End Clearances
9.4.1 Position the shaft locking tool previously fitted at
the end of the drive shaft so that it locks the shaft
securely.

SM 1343
Fig. 9.15 - Securing Shaft Locking Tool

9.4.2 Using a special spanner, pre-tighten the locknut of

the male rotor by turning the locknut a quarter of
a turn only. Do not completely tighten the
locknut; the delivery end clearance still needs to be
SM 1306 adjusted as detailed in the next few steps.
Fig. 9.14 - Positioning Male Shaft Locknut

SM 1307

5 DL071
Comp Assembly - Delivery End

Fig. 9.16 - Pre-tightening Male Locknut

DL071 5
 9 Assembly - Delivery Comp

9.4.3 Pre-tighten the female rotor locknut - a 9.4.5 Screw an eyebolt into the centre tapping of the
quarter of a turn only - in the same way. female rotor.
9.4.6 Position the locknut spanner on the female
rotor locknut.
9.4.7 Position a dial gauge on the face of the casing with
probe tip on the end of the female rotor shaft.

SM 1308

Fig. 9.17 - Pre-tightening Female Locknut

9.4.4 Tighten the locking screws of both shaft

locknuts using an Allen key.
SM 1309
SM 1344
Fig. 9.19 - Dial Gauge Positioned on
Female Rotor Shaft

9.4.8 Attach lifting tackle or use a lever through the

eyebolt as shown to lift the female rotor.
9.4.9 Carefully adjust the delivery end clearance of the
female rotor to the required figure by tightening
the locknut.
Delivery End Clearance: 0.03 - 0.05 mm
9.4.10 Lift the rotor to measure the delivery end
clearance. Avoid values smaller than 0.03 mm as
correction is then more difficult.

SM 1361

Fig. 9.18 - Tightening Locking Screws

Fig. 9.20 - Checking Female Delivery End

Clearance

5 DL071
 Comp Assembly - Delivery End

9.4.11 Follow the same steps to adjust the delivery end 9.4.13 Check the rotors turn freely by turning the drive
clearance of the male rotor. shaft backwards and forwards with the help of
Delivery End Clearance: 0.03 - 0.05 mm the shaft locking tool.
SM 1362

Fig. 9.21 - Checking Male Delivery End SM 1383

Clearance Fig. 9.23 - Checking Rotors Turn Freely

9.4.14 Screw in and tighten the double nipple (129) - oil

9.4.12 Position the safety plate (108), making sure that its
filter connection (torque: 25 Nm).
lug locates correctly in the slots of both angular
contact bearings. Secure with a cap screw (127).
SM 1312

Fig. 9.22 - Fitting Safety Plate

SM 1354

Fig. 9.24 - Fitting Nipple for Oil Filter

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 9 Assembly - Delivery Comp

9.5 Fit Delivery End Cover 9.5.3 Polish the flange face of the rotor casing using an
9.5.1 Apply some grease into the O-ring groove of the oilstone and clean it using a degreaser spray.
delivery end cover (107) for ease of assembly of SM 1313
the O-ring.
SM 1314

Fig. 9.27 - Polishing Face of Rotor Casing

9.5.4 Carefully lower the delivery end cover (107)

into position on the rotor casing.

Caution: Do not damage the O-ring.

Fig. 9.25 - Applying Grease to
'O'-Ring Groove SM 1341

9.5.2 Install the O-ring (132) into its groove. The

previously applied grease should hold the O-
ring in the groove when the delivery end cover
is assembled later.
SM 1315

Fig. 9.28 - Positioning Delivery End Cover

Fig. 9.26 - Fitting O-Ring

5 DL071
 Comp Assembly - Delivery End

9.5.5 Screw in the capscrews (127) and torque

tighten crosswise to 86 Nm.
SM 1340

7 2
3 6
5
1 8 4

Fig. 9.29 - Securing Delivery End Cover

9.5.6 Finally screw in all the locking screws - Pos.

(128), (134), (135), (136) and (137) in
accordance with:-
figs. 1.1 & 1.2 (EK175NG) and
figs. 1.3 & 1.4 (EK175NK).

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Comp Repair Kits

10 Repair Kits
10.1 Air End Repair Kit - EK175NG

A11926174 - Air End Repair Kit - EK175NG

Item Part No. Description Quant

108 A11922174 Safety Plate (Against Rotation) 1
109 A93570290 Cylind.Roll.Bearing 2
110 A93570300 Angular Contact Bearing 1
111 A93575110 Cylindrical Roller Bearing 1
112 A93573810 Cylindrical Roller Bearing 1
113 A93570310 Angular Contact Bearing 1
114 A93570360 Taper Roller Bearing 1
115 A93570370 Taper Roller Bearing 1
116 A93574920 Locknut 1
117 A93570980 Locknut 1
123 A11922374 Safety Disk 1
125 A93161090 Key 1
127 A93040870 Cylind.Screw 25
128 A93060520 Locking Screw 2
130 A93573640 Spacer 4
132 A93196130 O-Ring 1
133 A93196140 O-Ring 1
134 A93060450 Locking Screw 7
135 A93060490 Locking Screw 2
136 A93060480 Locking Screw 2
137 A93060460 Locking Screw 3
1000 A11926274 Air End Shaft Seal Kit 1
1001 A92190200 Ergo 4052 Threadlocking Medium Blue 10g 1

10.2 Shaft Oil Seal Kit - EK175NG

A11926274 - Shaft Oil Seal Kit - EK175NG

Item Part No. Description Quant

118 A93220100 Shaft Seal Ring 1
120 A11922274 Inner Ring 1
121 A93147560 Circlip 1
122 A93196120 O-Ring 1
124 A93161120 Key 1
150 A13012774 Breather (Shaft Sealing) 1

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10 Repair Comp

10.3 Air End Repair Kit - EK175NK

A11929174 - Air End Repair Kit - EK175NK

Item Part No. Description Quant

108 A11922174 Safety Plate (Against Rotation) 1
109 A93570290 Cylind.Roll.Bearing 2
110 A93570300 Angular Contact Bearing 1
111 A93575110 Cylindrical Roller Bearing 1
112 A93573810 Cylindrical Roller Bearing 1
113 A93570310 Angular Contact Bearing 1
116 A93574920 Locknut 1
117 A93570980 Locknut 1
127 A93040870 Cylind.Screw 19
128 A93060520 Locking Screw 2
132 A93196130 O-Ring 1
133 A93196140 O-Ring 1
134 A93060450 Locking Screw 3
135 A93060490 Locking Screw 2
136 A93060480 Locking Screw 2
137 A93060460 Locking Screw 3
1000 A11929274 Air End Shaft Seal Kit 1
1001 A92190200 Ergo 4052 Threadlocking Medium Blue 10g 1

10.4 Shaft Oil Seal Kit - EK175NK

A11929274 - Shaft Oil Seal Kit - EK175NK

Item Part No. Description Quant

118 A93220100 Shaft Seal Ring 1
120 A11922274 Inner Ring 1
121 A93147560 Circlip 1
122 A93196120 O-Ring 1
124 A93161120 Key 1
150 A130112774 Breather (Shaft Sealing) 1

5 DL071