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12.4 AIR COMPRESSOR ASSEMBLY
(P/N 18- -00052)
Prior to the assembly of the air compressor, make sure
that all parts are correct, clean, and free of oil, as this is
an oil-less air compressor. All references to right and left
are made when viewing the compressor from the
cylinder head end.
Installing the Components:
a. Place the motor shaft spacer on the motor shaft and
slide it as far as possible to the rear. It should seat
against the rear crankcase. Then place the square
key in the motor shaft keyway at the front of the motor
shaft with half of the square key in the keyway and the
other half protruding out from the keyway.
b. Slide the first piston and connecting rod assembly
onto the motor shaft, insuring that the offset of the pis-
ton and connecting rod faces outward with the piston
extending to the right of the motor shaft. The eccen-
tric keyway of the connecting rod assembly should be
aligned with the square key in the motor shaft keyway.
c. Place the compressor on a standard arbor press with
the blower end face down. Be sure to use a shaft pro-
tector (see "Tools to be made", section 12.3, page
118) on the blower end to protect the blower and
housing.
d. Use the shaft protector (see "Tools to be made", sec-
tion 12.3, page 118) for the cylinder head end. Press
the first piston and connecting rod assembly onto the
motor shaft just far enough to start the installation of
the second piston and connecting rod assembly.
e. Slide the second piston and connecting rod assembly
onto the motor shaft, insuring that the offset of the pis-
ton and connecting rod faces inward with the piston
extending to the left of the motor shaft. Installation of
the piston and connecting rod assemblies may be
made either way without affecting compressor perfor-
mance as long as each respective connecting rod off-
set faces the other.
f. The piston and connecting rod assemblies should
make positive contact with each other at the point
where the raised surfaces of each eccentric meet.
The square key must be secure in the keyway of the
motor shaft and both connecting rod assembly ec-
centrics.
g. Using the shaft protector for the cylinder head end,
press both of the piston and connecting rod assem-
blies firmly against the motor shaft spacer with the ar-
bor press. Make sure that the square key is pressed
on together with the piston and connecting rod as-
semblies.
h. After completing the press procedure, peen over the
leading edge of the eccentric keyway of the outside
connecting rod assembly to prevent movement of the
square key. DO NOT PEEN THE MOTOR SHAFT
KEYWAY AS DAMAGE TO THE SHAFT MAY RE-
SULT.
i. Install the four piston ring expanders, one in each of
the piston ring grooves (two per piston). Position the
expander gaps 180_ apart.
j. Install the four piston rings, installing the lower ring
first. Caution should be exercised when spreading
the ring since it can break if spread too far. Each ring
lap joint should be 180_ from the corresponding pis-
ton ring expander gap.
k. Install the four piston skirts, two per piston. Roll form
by hand to fit the piston skirt groove contour. Position
the piston skirt gaps 180_ apart. If desired, the piston
skirts may be held in place by rubber bands which
must be broken and removed during installation of the
cylinder sleeves.
l. To start the cylinder sleeve over the first piston ring,
gently compress the ring with one hand while working
the leading edge of the cylinder sleeve over the piston
ring. Repeat this process for the next piston ring. As
the cylinder sleeve is worked onto the piston, insure
that each piston skirt is in its proper groove and the
skirt joints are 180_ apart (Break and remove rubber
bands if so used). Complete the above process for
the second cylinder sleeve.
m.Insert two of the 5/16--18 x 1.00 inch long, 1/4 inch
socket head cap screws into the back half of the
sleeves and hand tighten. This will hold the sleeves in
place for the next step.
n. At this time the cylinder head and valve assemblies
may be installed. Properly align the cylinder head and
valve assemblies on the cylinder sleeves and secure
in place with four each 5/16-18 x 2-1/2 long, 1/4 inch
socket head cap screws. Do not tighten the cylinder
head and valve assemblies at this time so as to assist
in the ease of installation for the manifold assembly in
step o.
o. Install the discharge manifold assembly into the ap-
propriate compression fittings mounted to the bottom
of each cylinder head. Make sure not to distort the
manifold tubing, Apply "Locktite 569" and torque all
eight cylinder head and valve assembly socket head
cap screws to 25 ft-lbs. Tighten the compression fit-
tings on the manifold assembly, ensuring that you do
not over-tighten the fittings.
p. Apply "Locktite 569" as an adhesive to the front crank-
case. Install the front crankcase with four 1/4 inch
socket head screws and torque to 25 ft-lbs.
q. Connect and secure the crankcase vent tubing
(black) to both cylinder head compression fittings
mounted on the front of the heads. Do not over-tight-
en.
r. Connect the PVC tubing to the brass elbow on the cyl-
inder head and secure with a wire tie. Refer to section
12.2 , page 118 to install the compressor into the unit.
121
T-305
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