jurop CT EXTRAORDINARY User manual

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XT TR RA AO OR RD DI IN NA AR RY Y
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MA AI IN NT TE EN NA AN NC CE E M MA AN NU UA AL L
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RI IG GI IN NA AL L I IN NS ST TR RU UC CT TI IO ON NS S

E XTRAORDINARY MAINTENANCE MANUAL - CT
R
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0
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20-05-2016
2 / 20
Jurop
SpA
Via Cros ra n° 50
33082 Azzano D cimo, PN (Italia)
T
EL
.
+39
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434
636811
F
AX
.
+39
0
434
636812
http://www.jurop.it
-mail: [email protected]
201
6
–
Jurop
–
Azzano D cimo (PN)
R production, l ctronic storag and diss mination, v n partial, ar prohibit d.
Jurop r s rv s th right to modify th products d scrib d in this manual without prior notic .
Any product nam s m ntion d h r in ar th trad marks of th ir r sp ctiv own rs.

E XTRAORDINARY MAINTENANCE MANUAL - CT
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3 / 20
Jurop
SpA
Via Cros ra n° 50
33082 Azzano D cimo, PN (Italia)
T
EL
.
+39
0
434
636811
F
AX
.
+39
0
434
636812
http://www.jurop.it
-mail: [email protected]
I dex
1. Ge eral war i gs
pag. 4
1.1 Introduction 4
1.2 Spar part r qu st 4
2. Equipme t required
pag. 5
3. Safety a d accide t preve tio
pag. 5
4. Disma tli g of the pump
pag. 6
5. Assembli g of the pump
pag. 9

E XTRAORDINARY MAINTENANCE MANUAL - CT
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33082 Azzano D cimo, PN (Italia)
T
EL
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636811
F
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+39
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434
636812
http://www.jurop.it
-mail: [email protected]
1.1. I troductio
• Th CT compr ssor hav b n d sign d for long working tim s
without any particular maint nanc apart from th ordinary on lik
ch cking/filling-up of lubricants, cl aning of filt rs and similar
int rv ntions.
• Op ration abov th for s n t mp ratur limits, pr ssur
maximum limits, infiltration of for ign bodi s / m dia into th pump or
occasional malfunctioning d p nding from diff r nt caus s could
possibly mak it n c ssary th compl t dismantling of th pump for a
thoroughly cl aning and th r placing of w ar - off or damag d parts.
• Do r m mb r that th r pairing of th pump do s not r mov th
caus of th troubl / br akag its lf. In ord r to avoid furth r probl ms
it is n c ssary to d t rminat and r mov th caus .
• Oft n th caus s of th pump’s sizing or a too fast w ar-off ar to
b ascrib d to:
- Infiltration by liquids or solids;
- Faulty / not suffici nt lubrication;
- Ov r-h ating.
• In th Op rating Manual (s r lat d s ction of th manual) th r
ar a numb r of sugg stions / r comm ndations for a troubl -fr
functioning of th machin .
• Th h r und r d scrib d int rv ntions hav to b (th r for )
consid r d as ‘ xc ptional’ and hav to b carri d-out by skill d
p rsonn l disposing of an ad quat s t of tools.
• Approximat maint nanc work could possibly r sult in major
damag to th machin and cr at dang rous situations for th
op rators, as w ll.
• B low is a bri f d scription of th symbols us d in this manual.
If th s saf ty rul s ar not r sp ct d, op rators can
b injur d and th pump or oil rs damag d
r markably.
If th s saf ty rul s ar not r sp ct d, th pump or
syst m can b damag d.
Sugg stions for an nvironm nt fri ndly us of th
pump.
Us ful information for an asy usag and
maint nanc of th pump.
• Th graphic r pr s ntations and photographs contain d in this
manual ar th r to illustrat th product in th parts that mak it up
and in sp cific op rating phas s. Though th mod l shown in th
manual may diff r from th on purchas d, th op rating principl at
th bas of th illustrat d op rating phas is th sam .
• Compr ssor has to b fitt d with its own tag r porting th following
data: Mod l, S rial numb r, Y ar, Max sp d, Max pr ssur .
Fig. 1.1
1.2. Spare part request
• Us only ge ui e spare parts for maint nanc and r pairs. To
ord r spar parts, provid th following d tails:
EXAMPLE:
a) Th mod l of th compr ssor (s compr ssor tag): CT80
b) Th s rial numb r of th compr ssor (s compr ssor tag): K60001
c) A d scription of th parts (s parts list): PLUG G1/2
d) Th quantity (s parts list): n°2 pz
) Th cod numb r of th part (s parts list): 40267 016 03
• For th id ntification of th compon nt cod s, s th spar parts
list in th Installation, us and maint nanc manual of th pump.
1.
Ge eral war i gs
 



 




E XTRAORDINARY MAINTENANCE MANUAL - CT
R
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1
20-05-2016
5 / 20
Jurop
SpA
Via Cros ra n° 50
33082 Azzano D cimo, PN (Italia)
T
EL
.
+39
0
434
636811
F
AX
.
+39
0
434
636812
http://www.jurop.it
-mail: [email protected]
• B for starting th actual dismantling of th pump mak sur that
all n d d and appropriat tools ar at hand in ord r to avoid
damaging th parts sp cially during th r -ass mbling.
1. Ring-nut wr nch.
(cod. 1506000400)
2. B nch pull r mad of: plug ø 6x28, thr ad d bar M10x200
and h xagon dom d nut M12.
(cod. 1506000800)
3. G ar pull r.
(cod. 1506000900)
4. Plastic-tipp d rod for cov r fitting.
(cod. 1506001000)
5. Plastic-tipp d rod for s al-bushing fitting.
(cod. 1506001100)
6. Plastic-tipp d rod for Y-s al fitting.
(cod. 1506001200)
7. Plastic-tipp d rod for b arings fitting (CT80…130).
(cod. 1506001300)
8. Plastic sl v s with scr ws M6x12 for th fitting of th s als,
with 6 pcs scr w M8x16 and wash rs Ø24.
9. Ring-nut wr nch for M45 siz .
10. Adjustabl / load wr nch adjust d at 2 kgm.
11. M tal-sh t tk. 0,20 - 0,25 mm, n c ssary for timing
proc dur . Contact Jurop’s Aft r-Sal S rvic .
• Furth rmor :
- High-t mp ratur s lubricating gr as for continuous work at 150-
200° C (for mounting of s aling l m nts on th driv ax ). Contact
Jurop’s Aft r-sal s rvic ;
- High-t mp ratur s (250°C) s aling-glu of th normally us d typ
for s aling g arbox s and ngin lids;
- Rust prot cting min ral oil for th parts to b coupl d tog th r.
• Th Figur shows th various quipm nt n c ssary for th
maint nanc activiti s.
Fig. 2.1
• Us ad quat clothing (avoid ti s, loos sl v s, n cklac s and so
on) and suitabl prot ction quipm nts (glov s, prot ction glass s,
boots...).
• Lift th h avy compon nts by m ans of a suitabl winch:
Atte tio : lift the heavy compo e ts by mea s of
a suitable wi ch.
• During dismantling op ration pay att ntion to th position of th
diff r nt compon nts and r lat d d tails that will b us ful for th r -
ass mbling of th machin .
Atte tio : duri g disma tli g operatio pay
atte tio to the positio of the differe t compo e ts
a d related details that will be useful for the re-
assembli g of the machi e.
• This way th instructions of th manual will r sult much mor asy
to handl .
• To facilitat th maint nanc op ration w sugg st to consult th
spar parts list insid th installation, us and maint nanc manual of
th pump.
3. Safety a d accide t preve tio
2.
Equipme t required

E XTRAORDINARY MAINTENANCE MANUAL - CT
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33082 Azzano D cimo, PN (Italia)
T
EL
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434
636811
F
AX
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+39
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434
636812
http://www.jurop.it
-mail: [email protected]
• Cl an th outsid of th pump b for starting th actual
dismantling.
• Drain out th lubricating oil from both g arbox s s parat ly.
• R mov th driving shaft tab.
• R mov th front cov r and xtract th Y-s al. Put away th
spac r and th s g r ring. Pull-out and k p th cylindrical guiding
pins.
• R mov th r ar cov r.
Block the rotatio of the axes by mea s of soft
material (rubber or a crop of belt power
trasmissio ) i serted betwee the teeth.
• If th compr ssor is provid d with th ov rdriv unit:
- R mov th driving shaft tab.
- R mov th front flang (small) and xtract th Y-s al.
- R mov th front ov rdriv cov r with b aring support.
- Estract th b aring (21309 E/C3) using th tool no. 7.
- Pull-out th cylindrical guiding pins Ø10x20.
- Estract th ov rdriv driving shaft.
- R mov th ov rdriv housing.
- Estract th b aring (22207 E/C3) using th tool no.7.
- Pull-out th cylindrical guiding pins Ø10x25 (4 pcs).
- R mov th ov rdriv driv d g ar in th following ord r:
- Scr w M12.
- Saf ty wash r.
- G ar spac r.
- Driv d g ar.
- Tab.
- Bushing Spac r.
Fig. 4.1
Fig. 4.2
4.
Disma tli g of the pump

E XTRAORDINARY MAINTENANCE MANUAL - CT
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Jurop
SpA
Via Cros ra n° 50
33082 Azzano D cimo, PN (Italia)
T
EL
.
+39
0
434
636811
F
AX
.
+39
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434
636812
http://www.jurop.it
-mail: [email protected]
Fro t be ch assembly
• R mov th Y-s al bushing.
• Unscr w th ring-nuts and tak car to block th timing g ars by
m ans of a soft mat rial (rubb r) ins rt d b tw n th t th.
• R mov th spac rs and th splashing oil disc.
• R mov th axial adjusting plat s (6 pcs).
• R mov th front b nch:
- Unscr w th scr w M8 (10 pcs).
- Ins rt th xtracting tool no. 2 in th thr ad d hol s show d in th
pictur . R m mb r to ins rt 2 cylindrical pins Ø6x28.
- Scr w th two thr ad d rods at th sam tim to avoid crawlings.
- Pull-out th cylindrical guiding pins.
Support the housi g usi g a suitable wi ch.
Do ’t remove the seal-ri gs outer bushi gs! The
bushi gs are glued to the be ch.
Fig. 4.3
Rear be ch assembly
• Unscr w th scr ws M8 (6 pcs) that lock th timing g ars.
(Straight n th saf ty wash r).
• R mov th spac rs (2 pcs).
• Extract th timing g ars:
- Mount th sp cific xtractor (tool no. 3) in th timing g ars using 3
scr ws M10.
- Handl th cilindrical hamm r and hit th nd of th thr ad d rod
as shown by th arrow in th pictur .
• Unscr w th ring nuts M45 (2pcs).
• R mov th spac rs and th splashing oil disc.
• R mov th axial (6pcs) adjusting plat s.
• Extract th rotors using rubb r hamm r or a plastic tips hamm r.
Extract the rotors carefully i order to ot
damage their surfaces. Support the rotors duri g
the extracti g operatio .
• R mov th axial locking plat s (6 pcs).
• R mov th axial adjusting spac rs.
Ide tify a d do ot mix the axial adjusti g
spacers of the drived a d drivi g rotor. It is very
importa t to mou t the spacers i the origi al
positio duri g the assembly. To mix or i vert
the spacers do ot assure the axial alig me t of
the rotors.
• R mov th r ar b nch:
- Unscr w th scr ws M8 (10 pcs).
- Ins rt th xtracting tool no. 2 in th thr ad d hol s show d in th
pictur . R m mb r to ins rt 2 cylindrical pins Ø6x28.
- Scr w th two thr ad d rods at th sam tim to avoid crawlings.
- Pull-out th cylindrical guiding pins.
Fig. 4.4
Removi g of the seal-ri gs bushi g
• R mov th rings from th bushing.
• R mov th bushing using an hamm r and a flat crop of
alluminium or copp r.
• Hit th bushing in th thr availabl points.
It is importa t to keep the allumi ium crop
alig ed to the rotor to avoid to damage the
bushi g cor er.

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33082 Azzano D cimo, PN (Italia)
T
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+39
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434
636811
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AX
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+39
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434
636812
http://www.jurop.it
-mail: [email protected]
Fig. 4.5
Removi g of the beari gs.
• R mov th b arings from th b nch using th tool no. 7.
• Push th D=60mm tip of th tool throw th int rnal ring of th
b aring.
Do ot push the tool throw the rolls of the
beari g.
• R mov th b aring using an hamm r.
Do ot remove the seal-ri gs outer bushi gs!
The bushi gs are glued to the be ch.
Fig.4.6
• R mov all gask ts, O-rings and v nting plugs.
• Thoroughly cl an all th compon nts sp cially v ntual
incrustations on th rotors, housing & flang s.
• R mov car fully all th incrustations on th s al-ring bushing
using an iron scratch brush.
Avoid scratches a d similar damages o all fi e-
machi ed surfaces. Every modificatio o
dime sio s, fi ishi g etc. could result to faulty
fu ctio i g of the machi e. Replace all the parts
that are showi g wear-off, deformatio s or
similar damages.
• R mov gr as and similar lubricating m dia by m ans of
ad quat solv nts (mak sur that cast-iron & st l won’t b aff ct d
by th m) and finally wash all th parts with pr ssuriz d wat r.
• Similar cl aning proc dur to b us d on all th compon nts lik :
v nting plugs, ch ck valv s, inj ction l m nts, 4-way valv tc.
Use this extraordi ary mai te a ce for checki g
a d clea i g all vacuum-li e like: seco dary
shutoff valve, suctio filter, exhaust-sile cer etc.
Dispose of the spe t lubrica ts a d of the
washi g fluids accordi g to the e viro me t
protectio existi g prescriptio s.

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http://www.jurop.it
-mail: [email protected]
F
RONT BENCH
R
EAR BENCH
• Plac th b nch as shown in th sid pictur .
Fig. 5.1
Mou t the pump’s feet a d the lifti g ri gs as
origi ally received. The oil drai i g-groves must
be directed toward u der-part as show i the
side picture.
• Both flang s hav to b compl t with r lat d s al-rings corr ctly
glu d. Mak sur that said s als ar not siz d or damag d and ar
prop rly lodg d in th ir s ats, v n with th cast-iron surfac as shown
in th sid drawing. If not prop rly fix d don’t try to r -glu th m: if
n c ssary r plac th whol ass mbly.
Fig. 5.2
• Ins rt 2 plastic bushings (tool no. 8. Inn r dia. 50mm – Out r dia.
84,5mm) in th front b nch. Fast n th plastic bushing with scr ws
M8x16 (6 pcs) and wash rs Ø 24 (6 pcs).
• Mount th spac rs (2 pcs) and th s g r rings (2 pcs) in th r ar
b nch.
• Ups t both th b nchs.
Check the i tegrity of the here show bushi gs
a d seal-ri gs. Remove carefully all the
i crustatio s o the seal-ri g bushi g usi g a
iro scratch brush.
Replace all the parts with wear-off marks. The
seal-ri gs must ru i to their seats free from
fictio a d jam.
Fig. 5.3
Fig. 5.4
• R -fit th s al-rings in th ir s ats in both b nchs using high-
t mp ratur gr as as lubricant around th s ats. Us th r lat d
lastic-band (tool no. 5 - Fig. 5.4) for ins rting th bushing-ass mbly in
th flang lodgm nt.
• Front b nch: push said ass mbly until it r sts against th plastic
bushing on th bottom.
• R ar b nch: push said ass mbly until it r sts against th spac r
fast n d by th s g r ring.
Each couple of seal-ri gs must be faci g at 180°
as show here u der.
Mou t the bushi g with the 3x45° chamfer faced
to the top (upward directed)
• Ins rt no. 10 Viton OR 108 in th s ats on th machin d sid of
ach flang ass mbly in th scr w’s bor s. Th O-rings hav to b
lightly push d in to grant th ir lodgm nt also by v rtical positioning of
th flang . Should b n c ssary: us a rubb r hamm r and pushing-
pad to ins rt th O-rings.
5.
Assembli g of the pump
SURFACES
TO
BE
KEPT EVEN

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Jurop
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T
EL
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+39
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434
636811
F
AX
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+39
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434
636812
http://www.jurop.it
-mail: [email protected]
Fig. 5.5
Fig. 5.6
Fig. 5.7
Fig. 5.8
Assembli g of the fro t be ch
The pump’s rotatio directio will determi ate
which side of the housi g the fro t be ch
assembly has to be mou ted. The temperature
co trol feeler seat must face upwards a d the
i jectio -slots are i dicati g which o e is the
exhaust port.
Fig. 5.9
• Onc id ntifi d th housing’s sid facing th front b nch
ass mbly, ins rt th pins Ø10x35 (4 pcs) in th housing’s s ats and
apply an v n & thin coat of high-t mp ratur s (250°C) s aling-glu .
Clea all the surfaces a d check for eve tual
damages / scratches before assembli g.
Make sure of this prior coupli g a d/or
assembli g.
• Car ful c nt r th b nch in th guiding pins.
• Mak sur that th draining slots ar facing downwards.
• Tight n th scr ws M8x30 (10 pcs) fixing th flang to th
housing.
• Cl an th s aling-glu r siduals insid th housing.