User's Manual

11
OIL PASSAGES
Thoroughly clean all oil passages through the end cover
or end cover adapter. Inspect the passages with a wire
to be sure. Blow the loosened foreign matter out with air
pressure.
CYLINDER BLOCK UNLOADER BORES
Thoroughly clean the unloader bore on both sides of the
compressor cylinder block. Make certain not to scratch
or gouge the air pressure sealing surfaces of the bores
during the cleaning process.
INSPECTION OF PARTS
CYLINDER HEAD & VALVE BODY
1. Carefully inspect the cylinder head gasket surfaces for
deep gouges and nicks. If detected, the compressor
must be replaced.
2. Carefully inspect the valve body gasket surfaces for
deep gouges and nicks. Pay particular attention to
the metal gasket surface. A metal gasket (18) is used
between the valve body assembly and cylinder block.
This surface must be smooth and free of all but the
most minor scratching. If excessive marring or gouging
is detected, the compressor must be replaced.
3. Inspect the cylinder head for cracks or damage. With
the cylinder head and head gasket secured to the valve
body, apply shop air pressure to one of the coolant
ports with all others plugged, and check for leakage by
applying a soap solution to the exterior of the head. If
leakage is detected in the cylinder head casting, replace
the compressor.
END COVER OR END COVER ADAPTER
Check for cracks and external damage. Check the crankshaft
main bearing surface in the end cover or end cover adapter,
check for excessive wear and fl at spots and replace the end
cover if necessary. Check for galling of the oil port threads
and replace the end cover or end cover adapter if necessary.
Minor thread chasing is permitted but do not “recut” the
threads if they are badly damaged.
CYLINDER BLOCK
1. Check the cylinder head gasket surface on the cylinder
block for nicks, gouges, and marring. A metal gasket
is used to seal the cylinder head to the cylinder block.
This surface must be smooth and free of all but the most
minor scratching. If excessive marring or gouging is
detected, the compressor must be replaced.
4. Repeat step 3 for the second inlet check valve
assembly.
5. Remove the two 10mm x 25mm discharge valve bolts
(9) that secure the discharge check valve components.
Remove the spacer sleeve (10), holder (11) and
discharge valve (12).
6. Repeat step 5 for the second discharge valve
assembly.
CRANKCASE COVER
1. Remove the four cap screws (28) securing the
crankcase cover (29). Using a soft mallet, gently tap the
crankcase cover (29) to break the gasket seal. Scrape
off any gasket material (27) from the crankcase and
bottom cover or adapter.
2. Repeat step 1 for the second crankcase cover.
END COVER OR END COVER ADAPTER
1. Remove the cap screws (31) that secure the rear end
cover or end cover adapter to the crankcase.
Note: Some compressor models use four cap
screws while others use a combination of cap
screws and studs.
2. Remove the rear end cover or end cover adapter from
the crankcase. Remove the o-ring seal (30) from the
end cover if so equipped.
CLEANING OF PARTS
GENERAL
All parts should be cleaned in a good commercial grade of
solvent and dried prior to inspection.
CYLINDER HEAD
1. Carefully remove all gasket material adhering to the
cylinder head, valve body assembly and cylinder block.
Make certain not to deeply scratch or mar the gasket
surfaces. Pay particular attention to the gasket surfaces
of the aluminum head.
2. Remove carbon deposits from the discharge and inlet
cavities of the cylinder head and valve body assembly.
Make certain the inlet and discharge ports of the valve
body assembly are open and clear.
3. Remove rust and scale from the cooling cavities and
passages in the head and valve body assembly and
use shop air to clear debris from the passages.
4. Make certain the unloader air passages and coolant
passages through the valve body are open and clear
of contamination.
5. Check the threads in all cylinder head ports for galling.
Minor chasing is permitted.