33 - 2
Compressor Unit
Dismantling and Assembly
When Dismantling
Note: Prior to dismantling the compressor unit, an area
should be cleared and cleaned so that each part can be laid
out in assembly order for inspection. Every precaution
should be taken to keep out dirt from oil passages or
exposed apertures. During the dismantling and assembly of
the unit certain operations will require the use of special
equipment to prevent damage to parts. Contact JCB Special
Products for information on these special tools. The tools
are referred to throughout the text by their item numbers,
see ‘Service Tools’ to identify the tool and item number.
It is assumed that the compressor has been removed from
the machine with coupling removed so that access is
available to the input shaft.
1 Working inside the bell-housing, unscrew 8 x M6
capscrews (Fig. 2 (2)) and remove the oil seal housing
(3) and bearing cover (12).
2 Remove the single outer seal (1), then drift out the two
inner seals (5, 7) and back-up washer (6) using service
tool (tool 19). Always use a new back-up washer with
new spiroseal lip seals.
3 Stand the unit on the engine mounting face. Take care
not to damage its locating spigot. Remove the 1/4”
BSP plug (Fig. 3 (15)) from the delivery end casing. Fit
sling pin L.H. (tool 14) and its washer into the vacated
hole, and sling pin R.H. (tool 11) into the M10 x 1.5 - 6H
hole on the opposite side of the casing.
4 Unscrew the 10 x M10 bolts (14, 16, 17) securing the
delivery end casing to the inlet/rotor casing. Using two
suitable levers, separate the delivery end casing/rotor
assembly from the inlet/rotor casing. Attach suitable
lifting gear and lift the rotor assembly clear, taking care
not to damage the tip seals along the periphery of the
rotors.
5 Secure fixture (tool 6) in a vice and lower the rotor
assembly into the fixture with the female shaft in the
clamping hole (Fig. 4). Clamp the shaft securely.
Remove the sling pins.
6 Check the delivery end clearance between the ends of
the rotors and the delivery end casing with a feeler
gauge. This is important as any excess clearance will
result in a loss of efficiency owing to air under pressure
finding its way back to the inlet/rotor casing. The
checking of clearances at this stage will, if they are
correct, prevent unnecessary work during re-assembly.
7 Release the lock-plate (Fig. 3 (2)) and remove the
retaining screw (1) and plate (3) from the fan spigot (4).
Remove the fan spigot.
8 Unscrew the eight capscrews (5) and remove the
bearing end caps (6, 24). Withdraw the spigot spacer
(21), oil thrower (19) and thrower spacer (18) from the
female rotor shaft. Extract the taper circlip (11) from the
bearing bore.
9 Release the locking plate (9) and remove the retaining
screw (8) and plate (10) from the male rotor shaft.
Extract the taper circlip (11) from the bearing bore.
10 Attach fixture (tool 1) with spacers and bolts to the
delivery end casing (Fig. 5). Fit long stud (plain end to
rotor shaft) in hole over male shaft and short stud over
female shaft. With nuts locked on their threaded ends,
alternately screw down the studs and draw the delivery
end casing and bearings clear of the rotors.
11 With the fixture still attached to the delivery end casing,
screw down the long stud so that its thread protrudes
sufficiently to attach extractor (tool 9), washer and two
nuts locked together. Screw the stud back up through
the plate until the bearing is pulled clear of the casing.
Repeat for the second bearing.
12 Remove circlips (Fig. 2 (9)) from the inlet bearing bores
and, using drift (tool 17), drive out the bearings.
13 Remove the coupling spacer (8) and inner bearings
track from the female rotor shaft using service tool (tool
12). Repeat for male shaft inner bearing track after
removing its circlip (11).
Section A
Attachments
9803/7130
Section A
33 - 2
Issue 1
Airmaster Compressor
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