Gardner Denver Thomas 2660AT32-492W Field Service Manual
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Gardner Denver Thomas 2660AT32-492W Field Service Manual

Gardner Denver Thomas 2660AT32-492W Field Service Manual

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Field Service Manual
FOR MODEL NUMBER
2660AT32-492W
©2006 Gardner Denver Thomas, Inc.
FSM 0182 04/06

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Summary of Contents for Gardner Denver Thomas 2660AT32-492W

  • Page 1 Field Service Manual FOR MODEL NUMBER 2660AT32-492W ©2006 Gardner Denver Thomas, Inc. FSM 0182 04/06...

  • Page 3: Table Of Contents

    A Field Service Manual Prepared by: Field Service Manual for model number 2660AT32-492W Field Service Manual ©2006 Gardner Denver Thomas, Inc. FSM 0182 04/06 Table of Contents Page Introduction ..... Safety First ...... Exploded View and Parts List ......................... 6 Wiring Diagram ....

  • Page 4: Introduction

    Introduction This Field Service Manual is intended for use ONLY by properly trained and experienced repair personnel employed by an authorized service center. THIS SERVICE MANUAL SHOULD NOT BE USED BY OR DISTRIBUTED TO THE PUBLIC. THE INSTRUCTIONS AND WARNINGS HEREIN PRESUME EXISTING FAMILIARITY WITH THE DESIGN AND FUNCTION OF THESE AND SIMILAR PRODUCTS, AND THEIR COMPONENTS.

  • Page 5: Safety First

    Safety First It is recommended that you thoroughly read and understand this manual before you attempt to service the Thomas series of compressors to which this applies. PLEASE NOTE THE FOLLOW- ING CAUTIONS AND WARNINGS FOR YOUR OWN SAFETY. CAUTION To avoid personal injury and/or property damage, only authorized service personnel should service this unit.

  • Page 6: Exploded View And Parts List

    Exploded View and Parts List Exploded View of the Thomas 2660AT32/492W...
  • Page 7 Field Service Parts List for Thomas 2660AT32/492W Item Part No. Qty. Per Qty. Per Description Assembly Unit 640109 Connecting Rod, Eccentric & Bearing Ass'y 624680W Piston Cup 625776 Screw - Piston Cup Retainer 626392 Piston Cup Retainer 618114 Cylinder Sleeve 610534 Head 623143...

  • Page 8: Wiring Diagram

    Wiring Diagram Use this wiring diagram to connect your compressor to the power source. 2660AT32-492W CAPACITOR LINE BLUE LINE BROWN...

  • Page 9: Preventive Maintenance And Troubleshooting Guide

    Preventive Maintenance and Troubleshooting Guide Thomas Products Group recommends that you perform the following service to minimize unexpected downtime for your compressor: • Replace the connecting rods or piston cups and sleeves • Replace the flapper valves • Replace the head gasket O-rings Replace the valve plate O-rings •...
  • Page 10 Troubleshooting Guide If you are having a problem with your compressor, use this table to help determine the cause(s): Problem Possible Cause Corrective Action Unit Will Motor Loud Flow Pressure Not Start Overheats Unit High voltage at Reduce voltage compressor Low voltage at Increase voltage compressor...

  • Page 11: Required Tools And Materials

    Required Tools and Materials To disassemble and reassemble your compressor, you need the following tools and materials:  Torque wrench that has an inch-pound scale (for head screws, set screws, flapper valve screw, and pipe plugs).  Torx T-25 driver (for head screws). ®...

  • Page 12: Component Repair

    Component Repair Servicing the Head, Valve Plate Assembly and Connecting Rod and Bearing Assembly The head would only need to be replaced if it is visibly damaged. Component Parts Required You will need:  Head (if damaged)  Head gasket O-ring ...

  • Page 13: Servicing The Valve Assembly

    Removing the Flapper Valves Opposite Lead Side Note:We recommend you remove and replace one flapper valve at a time. This will help to simplify the repair process and orient the flapper valve correctly on the valve plate. 1. If you are replacing a flapper valve on the t o p side of the valve plate (side facing the head), remove the flapper valve screw (1) with a 1/4"...
  • Page 14 5. Place a valve restraint (3) over the flapper valve. 6. Place a valve keeper strip (4) over the valve restraint observing that the word “UP” is facing you and oriented as shown in the illustration. 7. Line up the screw holes in all of the valve components and insert the flapper valve screw (5) into the valve plate.
  • Page 15 1. If you are replacing a flapper valve on the Tab indicates bottom side of the valve plate (side facing the exhaust side Port 1 compressor housing), remove the flapper valve screw (1) with a 1/4" hex socket, lift off the valve keeper strip (2), and lift off the flapper valve (3).
  • Page 16 4. Place a valve keeper strip (3) over the flapper valve, observing that the word “UP” is facing you, not the valve plate, and oriented as shown in the illustration. 5. Line up the screw holes in all of the valve components and insert the flapper valve screw (4) into the valve plate.

  • Page 17: Rebuilding The Connecting Rod Assembly

    Servicing the Connecting Rod Assembly and Eccentric Assembly Refer to the Preventive Maintenance and Troubleshooting Guide in this manual to determine whether a complete connecting rod assembly, or its component parts, or an eccentric needs to be serviced. Component Parts Required You will need: ...

  • Page 18: Replacing The Connecting Rod And Eccentric Assembly

    3. Make sure the connecting rod is at "Top Dead Center". Slide the connecting rod assembly straight off the shaft through the opening in the housing. Opening in Housing Caution Do not crimp the piston cup (4) when you remove the connecting rod assembly from the compressor housing.
  • Page 19 Assembly of the Connecting Rod to the Compressor 1. Line up eccentric set screw with flat on shaft. Slide connecting rod assembly over shaft through front of housing with eccentric toward end of shaft. Push connecting rod assembly tight against housing bearing. Note: Both connecting rod assemblies shown for orientation.

  • Page 20: Assembly Of The Compressor

    O-ring Gasket Top of Valve Plate Reassembling the Compressor After the connecting rod assembly and eccentric are correctly assembled, you can assemble the valve plates and head to the compressor. Caution To prevent damage to the compressor, never apply any sealant or lubrication to the O-rings.
  • Page 21 3. Position the compressor housing as shown in the illustration. Notice the orientation of the power leads. Note: Make sure that the connecting rod sleeves are seated against the compressor housing. 4. Observe the orientation of the valve plate assemblies. The tabs on the valve plate indicate exhaust side.
  • Page 22 Opposite Lead Side 5. Place the head on the valve plate assemblies Tabs Exhaust observing the position of the air intake and exhaust ports. Note: Make sure the head gasket O-rings are not pinched. 6. Insert the head screws and finger tighten each screw until it is snug.Use a Torx®...
  • Page 23 NOTES...

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