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Dismantling the XRV127 compressor

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Dismantling the XRV127 compressor during overhaul

Compressor disassembly procedure

Safety precautions should be taken before disassembling the compressor.
1. Isolate the drive element.
2. Lower the pressure and purge the system.
3. Disconnect the drive element clutch from the compressor.
4. Place the vessel under the outlet end of the compressor to capture oil.
which may spill out of the hydraulic cylinder when the cylinder cover is removed or the crankcases are separated.
5. Check the reliability and performance of all lifting equipment, i.e. eye bolts, belts and clamps.

Remember that the compressor spool is under spring load and therefore, to avoid injury, the operator should check that the spring is not tensioned before disassembling. This can be done by checking that the spool is completely unloaded (the piston must be at its maximum distance towards the outlet) and that the liquid coefficient adjustment is at its minimum value (the Vi adjusting screw should be turned clockwise to its limit value).

Disconnect/remove any installed electrical equipment if it prevents further disassembly.

1. Place the vessel under the crankcase at the inlet end, remove the hexagonal plug from the bottom of the crankcase at the inlet end, and drain off the oil. (Figure 10)

Fig.11 Dismantling the xrv127 compressorFig.11 Dismantling the xrv127 compressor  

Removing the Vi indicator node

1. Loosen and remove the 2 mounting screws that secure the base plate and pull this plate out. (Figure 12)
2. You can then remove the bushing mounting ring by loosening the two splined installation screws and pulling it out of the barrel with a sliding stop. (Figure 13)
3. You can then remove the indicator and screw bushing. Remove the index post by removing the slotted mounting screw.

fig. 12. Base platefig. 12. Base plate figure 13. Sleeve mounting ringfigure 13. Sleeve mounting ring

Removing the intake shaft seal

4. Remove the intake shaft seal sleeve from the inlet (drive) shaft. Remove the 4 mounting screws (Figure 14) and remove the seal body. (Figure 15). Assemble the sealing ring of the seal body, the fixed seat must remain in the seal body.
5. Loosen the 3 screws without the head that secure the shaft seal to it. (Figure 16)
6. Carefully remove the shaft seal from the intake shaft. (Figure 17) Remove the fixed drive shaft seat and sealing ring from the seal body.

figure 14. Seal body mounting screwsfigure 14. Seal body mounting screws fig. 15. Sealing bodyfig. 15. Sealing body
fig. 16. Shaft seal fastening screwsfig. 16. Shaft seal fastening screws figure 17. Remove the shaft sealfigure 17. Remove the shaft seal

Reducer cover

7. Loosen the slotted mounting screws of the gearbox cover. (Figure 18)
8. Insert the M10 guide rod. (Figure 19)
9. Remove the gearbox cover that supports both the drive shaft and the gear. (Figure 20)
10. Assemble the sealing ring. (Figure 21)

figure 18. Slotted gearbox cover screwsfigure 18. Slotted gearbox cover screws figure 19. M10 guide rodfigure 19. M10 guide rod
figure 20. Reducer coverfigure 20. Reducer cover figure 21. Gearbox cover sealing ringfigure 21. Gearbox cover sealing ring

Removing the drive gear and its bushing

11. Remove the drive gear screw and the washer at the end of the rotor “dad”. (Figure 22)
12. Remove the drive gear from the “male” rotor using the XR12008J extraction tool. (Figure 23)
13. Remove the drive gear bush. (Figure 24)

figure 22. Drive gear screwfigure 22. Drive gear screw figure 23. Rotor drive gear “dad”figure 23. Rotor drive gear “dad”
figure 24. Drive gear bushfigure 24. Drive gear bush  

Removing the power control limit switch unit

14. Remove the two upper mounting screws (Figure 25) that secure the limit switch cover and remove the cover. (Figure 26) This will allow access to microswitches and potentiometers.
15. Remove the four slotted mounting screws that secure the cylinder end cover (Figure 27) and remove the drive spindle/limit switch. (Figure 28)

Some compressors have an LPI sensor, which is installed as an option instead of switches, and do not have a cylinder switch cover.

NOTE: The indicator spindle must release the mounting pin that moves along the screw slot in the spindle, so this unit must be in an axial position during shooting until the spindle releases the dowel. The LPI sensor is securely located inside the sensor; this unit must also be photographed axially. Be careful when removing the cover to avoid damaging the LPI sensor casing attached to the cover.

IMPORTANT - so that the screw slot that secures the mounting pin is marked for proper reassembly to avoid damage to the potentiometer.

figure 25. Limit switch cover mounting screwsfigure 25. Limit switch cover mounting screws figure 26. Limit switch coverfigure 26. Limit switch cover
figure 27. Slotted cylinder end cap screwsfigure 27. Slotted cylinder end cap screws figure 28. Drive spindle/limit switchfigure 28. Drive spindle/limit switch

Removing the drive drum

16. When the drive drum is fully unloaded, bend the tab on the spring washer back. Some XRV127 compressors do not have a lock plate. (Figure 29)
17. Loosen and remove the lock nut (Figure 30) and spring washers. (Figure 31)
18. The drive drum can then be removed using extraction tools. (Figure 32)

figure 29. Drive drum spring washer tabfigure 29. Drive drum spring washer tab figure 30. Drive drum lock nutfigure 30. Drive drum lock nut
figure 31. Drive drum spring washersfigure 31. Drive drum spring washers figure 32. Drive drumfigure 32. Drive drum

Removing the rotor end cover plate

19. Remove the 6 slotted installation screws. (Figure 33)
20. Loosen and remove the 6 slotted mounting screws that secure the rotor end cover plate. (Figures 34 and 35)
21. Remove the rotor end cover plate to gain access to the “dad” and “mom” rotors. (Figure 36)

figure 33. Rotor end cover plate installation screwsfigure 33. Rotor end cover plate installation screws figure 34. Rotor end cap plate mounting screwsfigure 34. Rotor end cap plate mounting screws
figure 35. Remove the rotor end cover plate mounting screwsfigure 35. Remove the rotor end cover plate mounting screws figure 36. Rotor end cover platefigure 36. Rotor end cover plate

Removing the rotor thrust cover

22. Locate and remove the “dad” and “mother” rotor stop covers using a suitable threaded rod as an extraction tool. (Figure 37)
23. Now there is access to the disc springs of the “dad” and “mom” rotors. (Figure 38)
24. Locate and assemble disc springs. (Figure 39)

Removing the “mom” spacer

25. Remove the “mom” spacer. (Figure 40)

figure 37. Rotor thrust coversfigure 37. Rotor thrust covers figure 38. Rotor disc springsfigure 38. Rotor disc springs
figure 39. Assemble disc springsfigure 39. Assemble disc springs figure 40. “Mom” spacerfigure 40. “Mom” spacer

Removing the discharge drum

There are 2 ways to fix the rotors if you want to tighten or loosen them
lock nuts:
1. Insert the nylon key between the rotors (through the channel at the inlet end).
2. Use a special XR12012J wrench mounted on the intake
rotor shaft “dad”. (Figure 43)

26. While the rotors are locked, release the spring washer (Figure 41) and remove the lock nut from the rotor “dad” using the XR12005J tool. (Figure 42)
27. Remove the discharge drum using a suitable M6 threaded rod as an extraction tool and remove the o-rings. (Figure 44)

figure 41. Rotor spring washer “dad”figure 41. Rotor spring washer “dad” figure 42. Rotor lock nut “dad”figure 42. Rotor lock nut “dad”
figure 43. XR12012J Wrenchfigure 43. XR12012J Wrench figure 44. O-ringsfigure 44. O-rings

28. Remove the discharge drum bushing together with the labyrinth insert using the XR12008J jack support. (Figures 45 and 46)

figure 45. Discharge drum bushing with labyrinth insertfigure 45. Discharge drum bushing with labyrinth insert figure 46. XR12008J Jack Supportfigure 46. XR12008J Jack Support

29. Disconnect both spring washers: “dad” and “mom”. (Figure 47) For these lock nuts, a special XR12006J wrench, shown in Figure 48, is made.
30. Remove the “dad” lock nut (Figure 49), remembering to stop the rotors from rotating in an appropriate way. (Figure 50)

figure 47. “dad” and “mom” spring washersfigure 47. “dad” and “mom” spring washers figure 48. XR12006J Special Wrenchfigure 48. XR12006J Special Wrench
figure 49. Remove the “dad” lock nut with a special keyfigure 49. Remove the “dad” lock nut with a special key figure 50. Stop the rotors from rotatingfigure 50. Stop the rotors from rotating

31. Remove the “mother” lock nut (Figure 51), then remove the “dad” and “mom” spring washers. It is now possible to remove the rotors from the compressor inlet end after removing the gearbox unit.

Removing the gearbox

32. Remove the two internal slotted mounting screws. (Figure 53)

figure 51. “Mom” counternutfigure 51. “Mom” counternut figure 52. Remove the spring washersfigure 52. Remove the spring washers
figure 53. Slotted mounting screwsfigure 53. Slotted mounting screws  

33. Loosen and remove only twelve external slotted mounting screws from the inlet end, leaving one adjacent to each of the two mounting pins. (Figure 54)
34. Using the XR12010J extraction tool (Figure 55), remove the mounting pins from the main crankcase, but do not remove them from the gearbox.
35. Screw two long M12 x 200 guide bars into the selected holes and secure with two nuts. (Figure 56)

figure 54. External gearbox mounting screwsfigure 54. External gearbox mounting screws figure 55. XR12010J Extraction Toolfigure 55. XR12010J Extraction Tool
figure 56. M12 x 200 guide rodsfigure 56. M12 x 200 guide rods  

36. Support the gearbox mass at the lifting point and remove the remaining splined mounting screws.
37. While loosening the hex nuts evenly along the guide bars, remove the reducer from the rotor body until the spool spring pressure is relieved. (Figure 57)

NOTE: Since the inner ring of the angular contact bearing is also removed, the guide rod support is important.

38. The reducer is completely removed with the spool stop, the sliding nut stop, the barrel with the sliding stop, the fixing screw and the washer. (Figure 58) Remove the spool spring.

figure 57. Reducer with spool stopfigure 57. Reducer with spool stop figure 58. Spool springfigure 58. Spool spring


39. The rotors can now be removed. (Figure 59) The XR12007J jack support is installed in the position of the rotor end cover plate (Figure 60), and the “mother” rotor is pressurized by a lifting screw. (Figure 61) The rotor will rotate because it is misaligned. (Figure 62)

figure 59. Rotorsfigure 59. Rotors figure 60. XR12007J Jack Supportfigure 60. XR12007J Jack Support
figure 61. Lifting screwfigure 61. Lifting screw figure 62. Rotorfigure 62. Rotor

Continue to apply pressure with these lifting screws until the rotors are completely out of the thrust bearings. You can then remove the rotor by hand. (Figure 63)
40. Repeat the same procedure with the “mom” rotor. (Figure 64)

Removing the spool

41. Pull the spool out through the rotor body. (Figure 65)

figure 63. Remove the rotor by handfigure 63. Remove the rotor by hand figure 64. Lifting screw pressure on the rotorfigure 64. Lifting screw pressure on the rotor
figure 65. Spoolfigure 65. Spool  

Angular contact bearings at the discharge end, cylindrical roller bearings and floating bushing

42. The angular contact bearings, (Figures 67 and 68), the outer treadmill and the cylindrical roller bearing holder (Figure 69) and the floating bushing (Figure 70) can then be removed from both sides (“male” and “female”) of the output cover.

figure 67. Angular contact bearingsfigure 67. Angular contact bearings figure 68. Angular contact bearingsfigure 68. Angular contact bearings
figure 69. Treadmill and cylindrical roller bearing holderfigure 69. Treadmill and cylindrical roller bearing holder figure 70. Floating bushingfigure 70. Floating bushing

Removing the gear

43. Support the gearbox cover horizontally, with the inlet shaft pointing downwards. Remove the mounting screw and bearing washer (Figure 71).
44. Press down on the shaft to push the inner ring of the cylindrical roller bearing, the intake shaft spacer, and the gear out of the intake shaft (Figure 72).

figure 71. Mounting screw and bearing washerfigure 71. Mounting screw and bearing washer figure 72. Inner bearing ring, intake shaft spacer and gearfigure 72. Inner bearing ring, intake shaft spacer and gear

45. You can then remove the gear bush.
46. The angular contact bearing can be removed by pressing on the intake shaft (Figure 73).

Removing the bearings from the crankcase at the inlet end

47. Remove the 3 cylindrical bearings after removing the fixing spline mounting screw and washer.

figure 73. Angular contact bearingfigure 73. Angular contact bearing  

Continuation (Assembling the compressor)