CF90 AIREND OVERHAUL MANUAL

PRODUCT CODE HJ

Doosan Infracore Portable Power

1293 Glenway Drive
Statesville, N.C. 28625

www.doosanportablepower.com

Manual # 22259444 (5-2010)

AIREND DISASSEMBLY
(Refer to Figure 1 for the following steps) 3. Separate the adapter (G) from the gear
case housing by removing screws (E).
1. Place the airend assembly on a clean
work surface. Position the airend in a
vertical position with the drive shaft end
up.
2. Remove the screw (C) and remove the
hex bearing from the shaft.

Figure 1

(Refer to figure 2 for the following steps.) 8. Remove locknut (H) from drive gear (N).
4. Remove screws (A & B) and separate 9. Set the drive gear from the gear case.
the seal/bearing housing (D) from the
10. Remove wear sleeve (K) and o-ring (F)
gear case housing (V).
from drive gear shaft.
5. Remove and discard o ring (S), double
11. Remove bearings (J) from the drive
element seal (G) and single element
gear. Remove the inner race of bearing
seal (E).
(Q) from the drive gear.
6. Remove and discard bearing (Q) from
12. Remove screws (U) and set the gear
the gear case housing.
case housing (V) from the airend.
7. Remove screws (M) and bearing
retainers (L) from seal /bearing housing.

Manual # 22259444 (5-2010)

 Figure 2

(Refer to figure 3 for the following steps).

13. Remove locknut (D) from the male rotor
shaft.
14. Remove the driven gear from the male
rotor shaft with a gear puller. Secure
the puller arms to the gear with a c-
clamp. The gear may jump once it
loosens from the shaft. Wear gloves
and be alert during this operation.
15. Remove screws (E) and dowel pin (H) to
set the front bearing housing from the
airend. Figure 3
16. Remove check valve ball (B) from front
bearing housing. See figure 4. 20. Rotate the airend assembly to a vertical
position with the drive shaft down. Rest
17. Remove oiler assembly (F) from front the assembly on 4-inch thick wooden
bearing housing. blocks so that the rotor housing is
18. Remove screw and washer (A & B) from supported and the rotors are free of the
the front bearing housing. blocks.
19. Remove and discard bearings (C & G) (Refer to figure 4 for the following steps).
from the front bearing housing. 21. Remove discharge bearing cover (A5)
by removing screws (A6).
22. Remove wave springs (Q & R).

Manual # 22259444 (5-2010)

23. Remove locknuts (U & V) from the male 27. Remove the tapered roller bearings (N &
and female rotor shafts. P) from the rotor housing.
24. Remove bearing nut spacers (S & T) 28. Remove shims (E-M) from male and
from male and female rotor shafts. female rotor shafts.
25. Press the male and female rotors (C) 29. Remove inner bearing races (C & G)
free of the bearings. from the intake end of the male and
female rotors. (Refer to figure 3).
26. Set the rotor housing (Y) free of the
male and female rotors.

Figure 4

INSPECT PARTS DISCHARGE END CLEARANCE

SHIMMING PROCEDURE

Inspect all parts previously disassembled for

wear and damage to determiner their Before reassembling of the airend, it is
serviceability. Make sure all internal oil necessary to record certain measurements
passages clear and free of debris. to determine the amount of shims required
for proper discharge end clearances on the
male and female rotors.
Always use new gaskets, o-rings, bearings
1. Measure the thickness of the rotor
and seals when reassembling airend. All
housing where the tapered roller
wear parts and instructions are included in
bearings outer races rest. Record a
Ingersoll-Rand overhaul kits.
measurement for the each rotor. Step
A.

Manual # 22259444 (5-2010)

2. Determine the bearing standoff 4. Measure the height of the rotor spacer.
dimension from the male and female Record a measurement for the male and
tapered roller bearings and record. Step female rotor. Step D.
B. Position each bearing on a hard flat
5. Subtract D from C for both the male and
surface with the outer race up. Rotate
female. Step E.
the outer race several times to seat the
race on the cone. Measure the distance 6. The allowable discharge end clearance
from the top of the outer race to the is .0015 to .0025 inches. Use .002
inner race shoulder with a depth inches discharge end clearance for the
micrometer. See figure A. male and female rotors. Step F.
7. Add the numbers from steps E & F.
This is the thickness of shims to install
on the respective rotor shaft to obtain
the required discharge end clearances.
8. Assemble the correct thickness of shims
Figure A and install on each rotor.

3. Add the dimensions from steps A & B

for each rotor. Step C.

STEP MALE MALE SPEC FEMALE FEMALE SPEC

A Rotor housing 1.155 -1.159 1.155 -1.159
thickness
B Bearing .088 -.100 .049 -.060
standoff
C Add A + B 1.243 -1.259 .1.204 - 1.219
D Rotor spacer 1.222 -1.226 1.182 -1.186
height
E Subtract (D-C) .017 - .037 .018 - .037
F End clearance .0015-.0025 .0015-.0025
G Shims Req’d .0185 - .0395 .0195 - .0395
ADD E + F

AIREND REASSEMBLY 5. Apply a small bead of Loctite® 242

around half of the outer race of the inlet
1. Position the rotor housing in a vertical
bearings (C & G, figure 3) and install
position with the drive end up.
each in the front bearing housing.
2. Place inlet end bearing races (C & G in
6. Install check valve ball (B, figure 4) into
figure 3) in an oven and heat to 300°F
the front bearing housing using a small
(149°C) for maximum of 30 minutes.
amount of grease to hold it In place.
3. Place male and female rotors into
7. Apply a thin layer of Loctite® 515 or 573
housing.
to the mating surface of the rotor
4. Remove bearing races from oven and housing.
seat on respective rotor shafts. USE
8. Position front bearing housing (A, figure
PROPER GLOVES TO HANDLE HOT
4) into position on the rotor housing (Y,
RACES.
figure 4).

Manual # 22259444 (5-2010)

9. Tap 2 dowel pins (D, figure 4) into front reassembly. If not, disassemble and
bearing housing and rotor housing. adjust shims. Add shims to increase
end clearance and subtract shims to
10. Apply a drop of Loctite® 242 to the
reduce end clearance.
threads of each screw (E, figure 3) and
install in the front bearing housing.
Torque screws to 38-lbs. ft.
REASSEMBLY OF THE DRIVE GEAR
11. Apply a drop of Loctite® 242 to the
threads of screw (A, figure 3) and install
with washer in the front bearing housing 24. Heat gear bearings and inner race to
to secure the bearings. Torque screw to 300°F (149°C) for 30 minutes.
38-lbs. ft.
25. Place the gear bearing inner race on the
12. Apply a drop of Loctite® 242 to the gear. USE PROPER GLOVES TO
threads of the gear oiler assembly and HANDLE HOT BEARING.
install in front bearing housing. Position
so that holes in tube are directed toward 26. Place the bearings on the drive gear
shaft. USE PROPER GLOVES TO
gears.
HANDLE HOT BEARING.
13. Rotate airend 180° and rest inlet end of
rotor housing on 4-inch wooden blocks. 27. Apply 3 drops of Loctite® 222 or 932 on
the rotor threads and install the locknut.
Discharge end should be up.
Torque the locknut to 160-lbs. ft.
14. Assure calculated shims on each rotor.
28. Apply A thin layer of Loctite® 222 on the
15. Heat Tapered roller bearings for male outside diameter of the single element
and female rotors in oven at 225°F (E) and double element (G) seals.
(107°C) for 30 minutes. Press seals into seal/bearing housing
(D).
16. Apply anti-seize compound on rotor
shafts in bearing area and place 29. Apply small amount of grease onto and
bearings on respective rotor shafts. between the seals.
USE PROPER GLOVES TO HANDLE
30. Apply a drop of Loctite® 242 on each of
HOT BEARINGS.
the 3 screws and loosely install the 3
17. Install bearing nut spacer on each rotor. bearing retainers and screws into the
seal/bearing housing.
18. Apply 3 drops of Loctite® 222 or 932 on
the rotor threads and install the locknut. 31. Slide gear shaft into seal/bearing
Torque the locknut to 160-lbs. ft. housing.
19. Place wave springs in respective 32. Torque the 3 retainer screws to 8-lbs. ft.
bearing bores.
33. Place the heated bearing inner race on
20. Install a thin layer of Loctite® 515 or 573 the drive gear. USE PROPER GLOVES
to the rear bearing housing flange face. TO HANDLE HOT BEARING.
21. Install rear bearing cover into place and 34. Install key in keyway on male rotor
install 2 screws on opposite ends of the shaft.
plate. Tighten screws to evenly bring
cover onto flange face of the rear 35. Heat driven gear to 300°F (149°C) for
bearing housing. 30 minutes.
36. Install the heated gear onto the male
22. Install remaining screws in cover plate
and torque to 38-lbs. ft. rotor shaft. USE PROPER GLOVES TO
HANDLE HOT BEARING.
23. Check discharge end clearances with a
37. Apply 3 drops of Loctite® 222 or 932 on
feeler gauge for the male and female
rotors. Rotate the rotors to help seat the rotor threads and install the locknut.
bearings before taking measurements. Torque the locknut to 219-lbs. ft.
If measurements are within .0015 to
.0025 specification, proceed with

Manual # 22259444 (5-2010)

38. Apply a thin layer of Loctite® 515 or 573 CLEAN-UP OF AIREND SYSTEM
front bearing housing flange.
Once the airend has been overhauled, the
39. Position the gear case onto the front following clean-up procedure is required
bearing housing. before installation of the airend back into its
package.
40. Tap dowel pin into housings. Apply a
drop of Loctite® 242 on each of the 1. Drain the entire airend oil system
screws and install the screws into the and flush the separator tank.
gear case and torque to 38-lbs. ft.
2. Remove the old oil and air filter
41. Apply a small bead of Loctite® 242 elements, clean canisters and install
around half of the outer race of the drive new elements.
gear bearing (Q, figure 2) and install in
3. Flush all manifolds, pipes and/or
the gear case housing (V, figure 2).
hoses from the oil filter outlet to the
42. Install o-ring into groove of seal/bearing airend. If necessary, remove
housing using a small amount of grease components, flush with clean 10W
to hold it in place during assembly. compressor oil and reinstall.
43. Guide the seal/bearing housing Note: It is critical that the small oil supply
assembly into position on the gear case. lines connecting to the airend receive
special attention.
44. Apply a drop of Loctite® 242 to each
screw and install them into the 4. Check condition of all compressor
seal/bearing housing and torque to 38- air and oil hoses and replace if
lbs. ft. either inner or outer surface is
visually damaged.
45. Install o-ring and wear sleeve on drive
gear shaft. 5. Upon installation, take every
precaution to prevent foreign
46. Install key in drive shaft.
material from entering airend.
47. Slide hex bearing onto drive shaft as far
6. When setting the airend into position
as it will go, small diameter first.
for bolting to the engine, care must
48. Rotate the bearing and shaft by hand be taken to ensure proper
and check for interference. If alignment.
interference is found, back off the hex
7. Refill system with approved
bearing until there is clearance.
lubricant.
49. Apply a drop of Loctite® 242 to the hex
8. Pour one gallon of oil into the airend
bearing screw and torque to 18-lbs. ft.
intake to aid lubrication on initial
start-up.
DRIVE COUPLING INSTALLATION
1. Apply a drop of Loctite® 242 to each
screw and attach the drive coupling to
the engine flywheel. Torque screws to
31-lbs.ft.

Manual # 22259444 (5-2010)