Thomas SK100772 Manuale utente
MODEL SK100772
COMPRESSOR SERVICE KIT
For use on 1007 Compressor Series
with .72 Stroke Connecting Rod
CAUTION: Improper assembly or use of damaged parts may lead
to premature failure. To avoid frequent repairs follow the recom-
mended assembly procedures.
Part No.634473G 0305
NOTE: Before you begin, read these instructions thoroughly and
assemble the necessary tools. You will need:
●Phillips head screwdriver attachment for torque wrench
●Flat blade screwdriver attachment for torque wrench
●Torx T-20 attachment for torque wrench
●Torx T-25 attachment for torque wrench (for head screws).
●5/32” allen wrench for eccentric set screw
●Clean Cloths
WARNING: Unplug the compressor before beginning disassembly.
This kit includes the following parts:
617124 Valve Restraint (2)
617135 Valve Keeper Strip (1)
638415 Dust Shield
625446 Screw (6)
666888 Connecting
Rod Assembly
625646 Head Screw (6)
638760 Head Gasket
656708 Valve Flapper (4)
Exhaust
623638 O-Ring
641010 Filter
656887 Valve Flapper (1)
Intake
DISASSEMBLY
STEP 1. Clean loose dirt from the outside of
the compressor. Loosen the 6 head screws
(#1) and remove the head (#2). Lift off the
valve plate (#3).
STEP 2. (Fig. #2) Remove the 4 screws (#4)
securing the plastic front cover assembly (#5),
and lift off the cover. Place cover and capaci-
tor assembly off to side leaving it connected
to the lead wires.
STEP 3. Remove the head gasket O-ring and
discard. Turn the valve plate over. Remove the
valve plate O-ring and discard.
STEP 4. Remove the fan (#7) by taking out the
screw (#6) holding it to the eccentric nib.
1
Figure #1
3
2
1
Figure #2
5
7
Set Screw
Access Hole
6
4
2
STEP 5. Insert the hex key into the hole in the right
side of the compressor housing (See Fig. #2). Loosen
clamping screw at the base of the connecting rod.
Slide the connecting rod off the bearing, lift it out
through the top of the compressor housing.
NOTE: It may be necessary to insert a flat tip
screwdriver into the slot in the base of the connecting
rod, and spread the base slightly, in order to break
the Loctite®bond and free it from the bearing (See
Fig. #3).
Insert Screwdriver
Figure #3
REBUILD VALVE PLATE
ASSEMBLY
STEP 1. Remove the valve keeper and
intake valve apper from the bottom of
the valve plate. Clean the bottom of the
plate with a clean soft cloth. Install the
new intake apper valve. The valve keeper
should be placed on top of the apper so
that the word “UP” is visible (See Fig. #4).
Tighten the screws to 12 in-lbs.
STEP 2. Remove the two restraints and
four exhaust apper valves (two over
each port) from the top of the valve plate.
Clean the top of the plate with a clean
soft cloth. Install the new apper valves
and screws as shown in Fig. #5. Tighten
the screws to 12 in-lbs. Set Valve Plate
Assembly aside.
UP
Figure #4
Valve Flapper
Valve Keeper
Figure 5
Valve Flappers
Valve Restraint
3
REBUILD AND ASSEMBLY
NOTE Look down through the top of the housing, and spin the eccentric by hand. The
eccentric should run parallel to the housing ribs. If the gap between the eccentric and
housing ribs varies by more than 1/16 inch during rotation, the eccentric is misaligned.
Contact the nearest Service Center. If the eccentric is misaligned do not continue installing
the rebuild kit, as premature rod or sleeve failure may result.
STEP 2. Align the front face of the
connecting rod with the front face of the
bearing. This will result in a clearance
of about .032 inch between the rod and
the eccentric (See Fig. #7). Tighten the
clamping screw to 15 in. - lbs. torque.
DO NOT OVERTIGHTEN, or bearing
damage/connecting rod breakage may
result.
STEP 3. Slide the sleeve down until it
contacts the housing. The 4 locator ribs
should bear against the inside surface
of the sleeve and the sleeve should hold
the dust shield in place.
STEP 1. Clean the old adhesive
from connecting rod bearing
(mounted on the eccentric).
Apply Loctite® #680 (supplied)
or equivalent to the bearing bore
of the new connecting rod. (See
Fig. #2). Apply Loctite®#242
(supplied) or equivalent to the
threads of the connecting rod
screw, and turn the screw a few
turns into the new rod. Do not
tighten. Slide the dust shield onto
the rod. Drop the new rod and
sleeve assembly through the top
of the compressor housing with
the head of the rod clamping
screw to the right (as viewed
through the open end of the
compressor housing). Slip the
rod onto the bearing. Locate
the dust shield by lining up the
locator slots of the shield on the
locator ribs of the housing. (See
Fig. #6)
Figure #6
Dust Shield
Cylinder
Sleeve
Locator
Ribs
Connecting
rod
Nib
Eccentric
Bearing
Assembly
.032
Figure #7
4
Figure #8
NOTE: The purpose of the following procedure is to correctly position the connecting
rod assembly on the the motor shaft before the Loctite® bond has dried.
STEP 4. Hold the sleeve down against the housing with one hand, and slowly rotate
the eccentric with the other hand. As the piston travels up and down it will also rock
from side to side. This is a feature of the WOB-L Piston. If it rocks from front to rear, the
connecting rod is misaligned on the eccentric. If front to rear rocking is detected, loosen
the connecting rod clamping screw and repeat Steps 1, 2, and 3. If the connecting
rod cannot be properly aligned, contact the nearest service center.
STEP 5. Install the new O-ring into the
bottom of the valve plate assembly,
seating it rmly into the groove with
your nger or blunt object.
STEP 6. With the sleeve located and
rmly seated on the housing, replace
the valve plate as shown in Fig. #8.
Make sure the top edge of the cylinder
sleeve locates in the O-ring groove in
the bottom of the valve plate.
Figure #9
STEP 7. Clean the inside of the head with
a soft clean cloth. Install the new gasket,
seating it rmly in the groove with your
nger or blunt object.
STEP 8. Place the head on the top of the
valve plate. The exhaust tting should be
facing the rear of the compressor, and
the smaller cavity inside the head will be
over the curved valve restraints on the
top of the valve plate. Install the 6 head
screws and tighten to 45 in-lbs. NOTE:
The handle, if present, should extend
over the exhaust tting to provide proper
balance.
5
STEP 9. Install the fan onto the eccentric nib. Align the slot marked ‘1007’ with the
notch on the eccentric nib. Insert the screw and washer into the threaded hole in
the nib. Tighten to 30 in-lbs. DO NOT OVERTIGHTEN. When properly assembled
the fan will remain centered in the housing when rotated by hand. NOTE: it may be
helpful to insert the hex key through the hole in the housing, and into the set screw
hole in the eccentric. This will prevent the eccentric from rotating while tightening
the fan screw.
Caution
To avoid property damage or personal injury, always try rotating the fan by
HAND prior to connecting the unit to the power source. Check for suction
at the air inlet port by placing your nger over the port as you turn the fan.
You should feel a slight suction with each rotation of the fan. If you don’t feel
suction, or if you feel or hear a thump as you turn the fan, DO NOT CONNECT
THE UNIT TO A POWER SOURCE; review the assembly procedure for
possible error.
Place Allan
Wrench in
Access Hole
Figure #10
6
Capacitor
Blue
Yellow
Black
STEP 10. Make sure the lead wires are attached as shown in Fig. #11. Assemble
the front cover to the housing so that the capacitor is vertical with the leads on top.
Make sure that the wires are clear of the fan. Tighten the front cover screws to 18
in-lbs.
Figure #11
STEP 11. Remove the lter cap from the lter assemlby. Remove and discard old
lter. Replace new lter in the lter holder and snap lter cap back into place.
Figure #12
Filter Holder
Filter
Filter Cap
3524 Washington Avenue
Sheboygan, Wisconsin 53081 USA
(920) 457-4831 www.gd-thomas.com
1419 Illinois Avenue
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