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Improper placement will cause premature wear of the ring and piston. NOTE: When removing HP piston on two-stage pumps, remove piston and then insert retention sleeve having the same diameter of piston pin or piston to small end of connecting rod. If not, you may drop or lose needles from the bearing, as HP needle bearing does not have support. Fit piston by referring to . marking on the top of the piston surface and list on above chart. NOTE: Gradually insert piston pin while turning it. Inserting with force can * FOR LOW PRESSURE PISTON ONLY 8 Oilless Reciprocating Air Compressor Pumps WRIST PIN BEARING SEAL REPLACEMENT (REPLACE EVERY 10,000 HOURS) Replacing Oil Seal Figure 16 Figure 18Figure 17 1. Insert the plastic retention sleeve 2. Remove the two oil seals by using a 3. Clean both surfaces where oil seals which protects the needle bearing screwdriver. are removed. from dropping out. Pushing Board Figure 20Figure 19 4. Push the oil seal into the small bear-5. Press the oil seal with a C-clamp into 6. Repeat on opposite side. ing end horizontally. the small bearing end. Figure 21 Figure 22 7. Apply a small volume of adhesive at 8. Remove the retention sleeve inserted several points. at the first step. NOTE: You may use a “C” clamp or two large washers and bolt with nut through the bearing. Then apply pressure to install the seals. This makes it easy to replace the seals without removing the crankshaft. 9 Oilless Reciprocating Air Compressor Pumps Inspect Connecting Rod, Wrist Pin and Crankshaft REPLACE CONNECTING ROD SET AND CRANKSHAFT AS A SET Pressing bearing into connecting rod and connecting rod set into crankshaft requires special fixtures. Without such fixtures, the squareness and parallelism of each part will be affected. DISASSEMBLE AND REMOVE CYLINDER COVER, CYLINDER AND PISTON IN THIS ORDER 1. Bearing at large end of connecting rod: Replace if it does not move or feels stuck holding and moving small end of connecting rod. 2. Bearing of crankshaft: Replace if you feel some resistance when slowly turning shaft. 3. Bearing at wrist pin: Check for breakage of needle bearing and damage of cage. DISASSEMBLING: CRANKSHAFT SET 1. Disassemble cylinder head, cylinder and piston. 2. Remove bolts from bearing cap and remove bearing cap. 3. Lightly tap shaft fan side with non-shock hammer (avoid metal hammer) and remove crankshaft. After bearing leaves the crankcase bore, pull connecting rod out as illustrated and remove it from crankcase (See Figure 23). REASSEMBLY 1. Heat bearing housing of crankcase with industrial dryer or simple burner just the same as disassembling. 2. Insert crankshaft set into crankcase in reverse order of disassembling and insert bearing into housing. 3. Tap shaft from pulley side with non-shock hammer and insert it inwards. 4. Fit bearing case. Grease bearing housing of bearing case. Shaft fan side Figure 23 10 Oilless Reciprocating Air Compressor Pumps Notes Oilless Reciprocating Air Compressor Pumps Figure 24 - Replacement Parts Illustration for OPS010 12 Oilless Reciprocating Air Compressor Pumps Ref. Part Number for model No. Description OPS010 Qty 1 Cylinder 91000560 1 6 Cylinder head 91002630 1 16 Elbow (Unloader) 06800261 1 18 Unloader cap 01052041 1 24 Spring guide set 91932560 1 27 Bolt (cylinder head) 06137835 4 33 Bolt (cylinder) 06137825 8 34 Bolt (bearing cap) 06137620 8 35 Crankcase 91100630 1 36 Bearing cap 91101630 1 47 O-ring 01146550 1 50 Crank shaft 1 51 Flywheel pulley 91201551 1 52 Parallel pin 01271550 1 57 Ball bearing (bearing cap) 2 62 Hex blot (fan, flywheel) 06992857 1 65 Connecting rod w/bearings 1 67 Piston set 91903640 1 67-1 Piston ring 91237640 1 72 Intake filter set 91906630 1 72-1 Intake filter 91348550 1 84 Screw (dust cover) 06131508 2 99 Seat (intake valve) 01301560 1 121 Dust cover 91383630 1 197 Lip seals wrist pin 97191000 2 200 Unloader set 91931560 1 500 Gasket set 91936640 1 600 Valve set with gasket 91933640 1 Crank shaft set (Includes 50, 57 and 65) 91918630 1 13 Oilless Reciprocating Air Compressor Pumps Figure 25 - Replacement Parts Illustration for OPS030 14 Oilless Reciprocating Air Compressor Pumps Ref. Part Number for model No. Description OPS030 Qty 1 Cylinder 91000560 2 6 Cylinder head 91002640 2 16 Elbow (unloader) 06800261 1 17 Tee union assembly 06803261 1 20 Intake joint (1) 91345561 1 21 Intake joint (2) 91346571 1 24 Spring guide set 91932560 2 27 Bolt (cylinder head) 06137835 8 30 Flange (breather) 91176660 1 31 Bolt 06995831 20 33 Bolt (cylinder) 06137825 8 34 Bolt (bearing cap) 06137620 8 35 Crank case 91100640 1 36 Bearing cap 91101560 1 38 Filter (crank case) 91348690 1 47 O-ring 01146560 1 50 Crank shaft 1 51 Flywheel pulley 91202560 1 52 Woodruff key 06600013 1 53 Hex nut 06994016 2 57 Ball bearing (bearing cap) 1 58 Ball bearing (crank case) 1 59 Fan 91220560 1 60 Cover (fan) 91134560 1 61 Hex bolt (fan, flywheel) 06992857 2 64 Liner (connecting rod) 01480640 1 65 Connecting rod w/bearing 2 67 Piston set 9...

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