Hycomp Air Boosters, Руководство по установке и эксплуатации

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14. Reinstall the oil pump or oil pump cover per “Oil
Pump Replacement”.
COMPRESSOR ASSEMBLY
This is only a general outline of how to assemble a
Hycomp compressor. Certain speci
fi cs may apply to
your compressor that are not listed here. Contact an
authorized distributor or the factory for assistance on
assembling your compressor.
Compressor assembly is generally the opposite of
compressor disassembly. Before assembling, clean all
parts thoroughly and check surfaces for burrs, nicks,
dings or excessive wear patterns. Replace all O-rings
and gaskets that were removed during disassembly.
‘A’ - ‘E’ and ‘V’ Blocks:
If the crosshead piston and piston rod have been
disassembled, it will be necessary to reassemble them
fi rst.
Clamp the piston rod into tool P/N SA003 and
clamp this tool to a work surface. Apply 4 drops of
Loctite (Item #266) to end of bolt thread. Do not touch
threads with your hands as this will contaminate the
Loctite. Attach guide piston to piston rod. Torque bolt
to proper speci
fi cation.
CONNECTING ROD & CROSSHEAD PISTON
NOTICE: When replacing one crosshead piston or
connecting rod, the new part and remaining part must
both have the same part number. Differences may lead
to unbalanced conditions and excessive vibration.
1. To replace wrist pin bushings in connecting rod,
press the new bushing into the connecting rod and
hone to proper diameter. To replace wrist pin bearings,
heat connecting rod until the bearings slide easily into
hole. The side of the bearing with the part number
stamped on it should face out. The bearings should
go in until they are just
fl ush with the outside of the
connecting rod. Do not put bearings in too far as they
will block
fl ow from the oil passage through the center
of the connecting rod. Liberally grease bearings or
bushing with an appropriate assembly grease.
2. Place one snap ring into crosshead piston. Heat
the crosshead piston until the wrist pin slides easily
into piston. Slide the connecting rod into bottom of
crosshead piston until bearing/bushing is aligned with
wrist pin. Allow wrist pin to slide through connecting
rod and into other end of the crosshead piston. Put
the second snap ring in place. Allow the assembly to
cool. Repeat with second assembly.
3. After connecting rod and crosshead assembly
have cooled, place the split bearing halves into the
connecting rod halves, aligning the bearing tang with
the grooves in the connecting rod. Liberally coat the
bearing faces with grease.
4. Set the top of the connecting rod/crosshead
assembly over the crankshaft journal. Replace the
proper connecting rod cap, aligning the dots or numbers
on the connecting rod and cap so they are both on the
same side. Start the nuts onto the connecting rod bolts
and torque to proper tightness. Repeat with second
assembly. Do not allow crosshead piston to fall against
crankcase as this may damage the piston.
‘F’ Blocks:
Reinstall piston rods into crosshead piston.
Screw jam nut all the way up the lower thread of the
piston rod. Screw piston rod all the way into crosshead
piston and back out 3 full turns. The crosshead piston
has locking threads, so expect some resistance. Do
not tighten jam nut yet.
CROSSHEAD GUIDE
5. Replace the crosshead to crankcase gasket with
a new one.
6. Coat the inside of the crosshead guide cylinder
with oil. Lightly grease the outside of the crosshead
pistons.
7. Set the crosshead guide cylinder over the crosshead
pistons and slowly lower onto crankcase. Make certain
the crosshead guide pistons are started straight into
the bores of the crosshead guide cylinder to prevent
damage. Set crosshead guide cylinder onto crankcase
and hand tighten bolts.
8. Replace the oil packing box and new O-rings and
hand tighten bolts. Do not fully tighten bolts yet. Slide
the oil packings down the piston rod, being certain not
to damage the packing face or inner diameter. Replace
oil packing box gland and hand tighten bolts.
9. Fill the crankcase with the proper amount of oil.
Squirt oil onto the crankshaft bearings and connecting
rod bearings.
10. Re-install crankcase inspection plate with new
gaskets, and tighten to proper torque.
11. Rotate the crankshaft a few times and then
tighten crosshead guide cylinder cap screws to proper
torque. Rotate crankshaft again to insure smooth
movement.
A-E Blocks: Tighten the oil packing box bolts and gland
bolts to proper torque.