DISASSEMBLY & REPAIR PROCEDURES OIL LUBE GAS PORTABLE Tools needed: Adjustable Crescent Wrench ½ Crescent Wrench Impact Wrench, Socket Wrench with at least a 9 Bar Extension and ½, 3/8 and 7/8 Sockets 3/16, 5/16 and ¼ Nut Driver Small Flathead and a Medium size Phillips Head Screwdriver Needle Nose Pliers Bearing Puller 2lb Brass Hammer WARNING! Before making any repairs to this unit, be sure the tank is drained of all air. Drain all gas and oil if any repairs are being made to the engine. Always follow state regulations for proper oil disposal. 1. To replace the belt: Remove the belt guard- Use a 5/16 nut driver to remove the bracket bolt located on the upper right hand side of the belt guard. 2. Remove the other 3 bolts located at the bottom of the belt guard. 3. Lift the belt guard straight up and set to the side. 4. Using a ½ socket with an extension bar, loosen the 3 engine/frame bolts that are facing toward the pump. Use a ½ crescent wrench to loosen the 3 engine/frame bolts located on the opposite side. Oil lube Port/Gas Repair Manual 1 TAB: Disassembly and Repair
5. With the ½ socket, loosen the stiffener bar nut. Slide the engine toward the pump and the belt will slip off. 6. These same steps will apply if the engine pulley needs replacing. To remove the pulley from the engine crankshaft, loosen the pulley bolt with an adjustable crescent wrench and slide from shaft. If the pulley will not slide off easily a bearing puller may be necessary. 7. To put the new belt on: a. Fit the belt to the proper grooves. b. Place a medium sized screwdriver in between the middle inner engine bolt and the groove in the frame. c. Force the engine away from the direction of the pump, while holding the screwdriver in place use ½ socket with an extension bar and tighten snug. d. Place the screwdriver in between the inner bolt closest to the pulley side of the unit and the frame groove and force the engine back. When the belt is substantially tight use the ½ socket with extension to tighten the inner/pulley side bolt. 8. Tighten all engine/frame bolts and torque to 17-23 ft. lbs. Oil lube Port/Gas Repair Manual 2 TAB: Disassembly and Repair
9. To replace the check valve, use an adjustable crescent wrench to remove the outlet tube, at the nut sleeve assembly. From there, use the air impact wrench with a long extension bar and a 7/8 socket to remove the check valve from the tank. 10. To place the check valve back into the tank, use the air impact wrench. 11. When the new check valve is secure into the tank, reconnect the check valve and the pressure switch. Then reconnect the outlet tube to the check valve and compressor head.with a new check valve the break-in procedure must be ran for 30 minutes. Oil lube Port/Gas Repair Manual 3 TAB: Disassembly and Repair
12. Before the unloader or the manifold can be replaced, the belt and pump has to be removed and the engine must be loosened from the frame in order to be slid towards the handle. 13. Use ½ and 3/8 sockets to remove the stiffener bar from the engine and pump. 14. Loosen the engine bolts, slide engine forward, remove belt and slide the engine towards the handle. 15. To remove the pump, first remove the nut holding on the stiffener bar with a 3/8 socket. 16. Unscrew the nut sleeves, located on each end of the outlet tube with an adjustable crescent wrench. Do the same with the nut sleeves on the pressure relief tube. Oil lube Port/Gas Repair Manual 4 TAB: Disassembly and Repair
17. Use a ½ socket to remove the pump base bolts. Set to the side. 18. To remove the unloader from the manifold you must first have the pressure relief tube and the throttle control tube removed. Both of these tubes are held on with nut sleeve assemblies and can be removed with an adjustable crescent wrench. With these tubes removed, unscrew the unloader relief valve from the unloader body with an adjustable crescent wrench. Oil lube Port/Gas Repair Manual 5 TAB: Disassembly and Repair
19. Use an adjustable crescent wrench on the upper portion of the unloader body to unscrew from the manifold. 20. For removing the manifold and nipple assembly from the tank, first remove the globe valve from the manifold with your adjustable wrench. The adjustable crescent wrench will need to be set on the lower half of the manifold where it meets the nipple in order to be loosened from the tank. 21. Reassembly will involve repeating these steps in reverse. Oil lube Port/Gas Repair Manual 6 TAB: Disassembly and Repair
DISASSEMBLY & REPAIR PROCEDURES SINGLE STAGE OIL LUBE PORTABLE Tools needed: 3/16, 5/16, & ¼ Nut Driver Small Flathead and a Medium size Phillips Head Screwdriver Needle Nose Pliers Bearing Puller 2lb Brass Hammer 7/16 and Adjustable Crescent Wrench Impact Wrench With a Bar Extension and a 7/8 Socket Socket Wrench With 9/16, 3/8 and ½ Sockets. WARNING! Before making any repairs to this unit, the power going to the motor must be turned off and the tank needs to be drained of all air. Always follow state regulations for proper oil disposal. 1. To remove the line and load cords from the pressure switch: a. Remove the pressure switch. Use your Phillips head screwdriver to loosen the screw located either on the top or on the side of the cover. b. Unhook all of the black and white wires from the pressure switch using the needle nose pliers. Oil lube Port/Gas Repair Manual 7 TAB: Disassembly and Repair
c. Take a 5/16 nut driver and remove the ground screws, holding down the ground wires. d. To take out the cord assemblies, loosen the bracket bar with a 5/16 nut driver. Slide out the cords from the bottom. Oil lube Port/Gas Repair Manual 8 TAB: Disassembly and Repair
2. To change out pressure switch, first remove the pressure relief tube using an adjustable crescent wrench. With the same wrench, remove the pressure switch from the manifold. To reassemble, repeat these steps in a reverse order. 3. If the gauges are faulty, use the 7/16 crescent wrench to remove them from the regulator. When screwing the new ones on, be sure to put the tank gauge on the right and the regulator gauge on the left. Oil lube Port/Gas Repair Manual 9 TAB: Disassembly and Repair
4. For regulator replacement, first remove the gauges with the 7/16 crescent wrench. Next, slowly remove the plastic knob assembly from the main body. Be sure not to lose the internal components of the regulator. Then, unscrew the regulator body from the ¼ x 2 nipple using the adjustable crescent wrench. 5. For putting the new regulator on, unscrew the plastic cap assembly and screw the main body on to the adapter. Have the arrow, which is stamped on the side of the regulator body facing out toward the air hose line. When reattaching the cap assembly, the parts go as followed: piston/ gasket assembly plastic washer regulator spring cap nut (threaded side down) regulator knob. Oil lube Port/Gas Repair Manual 10 TAB: Disassembly and Repair
6. The check valve will need to be replaced if: a. The compressor will only build up to 20 PSI and continues to run. b. Motor hums or throws a breaker at cut-in pressure. c. Pressure relief valve goes off periodically. 7. To replace the check valve, use an adjustable crescent wrench to remove the outlet tube at the nut sleeve assembly, and the pressure relief tube at the connector. From there, use the air impact wrench with a bar extension and a 7/8 socket to remove the check valve from the bushing or tank. Oil lube Port/Gas Repair Manual 11 TAB: Disassembly and Repair
8. If your having to replace the check valve bushing, cote the outer threads with white, pipe dope and screw it on to the check valve first and then use the air impact wrench to screw it into the tank. 9. When the new check valve is secure into the tank, reconnect the pressure relief tube to the check valve and the pressure switch. Reconnect the outlet tube to the check valve and the head.with a new check valve the break-in procedure must be ran for 30 minutes. 10. Before making any repairs to the pump, or if the belt needs changing, the belt guard will need to be removed. To remove the belt guard: a. Using a flat head screwdriver to pry off the front section. b. Then use a 9/16 socket to remove the bracket located on the pump head. c. Then unscrew the two bolts located at the bottom of the guard with a 5/16 nut driver. Oil lube Port/Gas Repair Manual 12 TAB: Disassembly and Repair
11. Carefully lift the motor and slide the belt off the motor pulley and flywheel. Loosen the bolt on the motor pulley with an adjustable crescent wrench and slide the pulley from the motor crank. If the pulley does not slide off easily a bearing puller might be needed. 12. With the motor pulley removed, the belt guard can now be removed as well. Oil lube Port/Gas Repair Manual 13 TAB: Disassembly and Repair
DISASSEMBLY & REPAIR PROCEDURES OIL LUBE GAS WHEEL BARROW Tools needed: Adjustable Crescent Wrench ½ Crescent Wrench Impact Wrench, Socket Wrench with at least a 9 Bar Extension and ½, 3/8 and 7/8 Sockets 3/16, 5/16 and ¼ Nut Driver Small Flathead and a Medium size Phillips Head Screwdriver Needle Nose Pliers Bearing Puller 2lb Brass Hammer WARNING! Before making any repairs to this unit, be sure the tank is drained of all air. Drain all gas and oil if any repairs are being made to the engine. Always follow state regulations for proper oil disposal. BELT GUARD REMOVAL 1. Disconnect the spark plug wire on the engine and release all air tank pressure. 2. (Refer to Figure 8) Remove the six screws (A) from the belt guard. The front of the belt guard can now be removed. B A BELT REPLACEMENT 1. Disconnect the spark plug wire on the engine and release all air tank pressure. 2. Remove the front of the belt guard as previously described. 3. Mark engine position on saddle. 4. Loosen stiffener bracket screw on engine. 5. (Refer to Figure 9) Being careful not to remove the stiffener plate under the saddle, loosen the four engine mounting bolts (C). 6. Slide engine toward pump to remove tension from the belt, and then remove the old belt. 7. Install the new belt over the pulleys. NOTE The belt must be centered over the grooves on the engine pulley and flywheel. 8. Slide the engine back into its regular position. Line the engine up with the mark made earlier on saddle. Fig. 8 Oil lube Port/Gas Repair Manual 14 TAB: Disassembly and Repair C Fig. 9
BELT TENSION - ADJUSTMENT 1. Slide the engine back into its regular position. Line the engine up with the mark made earlier on saddle. 2. Hold belt tension and securely tighten two engine mounting bolts. 3. Measure correct belt tension. Proper tension is achieved when a three (3) pound weight or equivalent finger pressure applied midway between the motor pulley and compressor flywheel causes a 1/4" deflection of the belt. Refer to Figure 10. 4. When proper belt tension is achieved, tighten the remaining engine mounting bolts. 5. Tighten stiffener bracket screw. NOTE Once the engine pulley has been moved from its factory set location, the grooves of the flywheel and pulley must be aligned to within 1/16" to prevent excessive belt wear. Verify the alignment by performing the following Pulley and Flywheel - Alignment. Fig. 10 3 Pound Force At Midpoint 1/4 Inch Deflection PULLEY AND FLYWHEEL - ALIGNMENT The air compressor flywheel and engine pulley must be in-line (in the same plane) within 1/16" to assure belt retention within flywheel belt grooves. To check alignment, perform the following steps: 1. Disconnect the spark plug wire on the engine and release all air tank pressure. 2. Remove belt guard. 3. Place a straightedge against the outside of the flywheel and the engine drive pulley. Refer to Figure 11 as required. 4. Measure the distance between the edge of the belt and the straightedge at points A1 and A2 in Figure 11. The difference between measurements should be no more than 1/16". 5. If the difference is greater or less than 1/16", loosen the setscrew holding the engine drive pulley to the shaft and adjust the pulley's position on the shaft until the A1 and A2 measurements are within 1/16" of each other. 6. Tighten the engine drive pulley setscrew to 70-80 in.-lbs. 7. Visually inspect the engine drive pulley to verify that it is perpendicular to the drive motor shaft. Points B1 and B2 of Figure 10 should appear to be equal. If they are not, loosen the setscrew of the engine drive pulley and equalize B1 and B2, using care not to disturb the belt alignment performed in step 2. 8. Retighten the engine drive pulley setscrew to 70-80 in.-lbs. 9. Reinstall belt guard. 10. Reconnect spark plug wire to spark plug on engine. Fig. 11 ENGINE PULLEY Oil lube Port/Gas Repair Manual 15 TAB: Disassembly and Repair B1 B2
UNLOADER, GAUGE, REGULATOR OR MANIFOLD REPLACEMENT 1. If the unloader needs replacing you must use an adjustable crescent wrench to remove the outlet tube and the throttle control tube. 2. Unlike the other compressors, there is no pressure relief tube. The pressure relief valve is located in the top of the unloader and looks similar to a safety valve. If there is a problem with the pressure relief valve, the entire unloader will need to be replaced. 3. With the outlet and throttle control tubes removed from the unloader, the next step is to remove the belt guard, belt guard closure and the flywheel shield. The belt guard will take a 5/16 nut driver to remove. The belt guard closure and the flywheel shield are held on together by 3 bolts and will require a 3/8 nut driver to be removed. 4. To unscrew the unloader from the tank, use your adjustable crescent wrench on the lower half of the body, where it connects to the tank. 5. Before unscrewing the manifold, the throttle control tube must be removed. To remove the tube unscrew the nut sleeve assemblies at the throttle and the unloader ends and then use a 3/8 nut driver to remove the 3 tube brackets that are located along the frame. Oil lube Port/Gas Repair Manual 16 TAB: Disassembly and Repair
6. With the tube removed, unscrew the regulator and gauge assembly from the manifold with an adjustable crescent wrench. 7. The manifold can now be removed by placing the adjustable crescent wrench on the lower half of the manifold, where it joins to the tank, and unscrewing. Reassembly will involve repeating these steps in reverse. 8. For repairs in the pump, it is not necessary to have the pump removed from the unit if the repairs are in the head. Oil lube Port/Gas Repair Manual 17 TAB: Disassembly and Repair
PUMP REPAIR DISASSEMBLY & REPAIR PROCEDURES Tools needed: Adjustable Crescent Wrench ½ Crescent Wrench Impact Wrench, Socket Wrench with at least a 9 Bar Extension and ½, 3/8 and 7/8 Sockets 3/16, 5/16 and ¼ Nut Driver Small Flathead and a Medium size Phillips Head Screwdriver Needle Nose Pliers Bearing Puller 2lb Brass Hammer WARNING! Before making any repairs to this unit, be sure the tank is drained of all air. Drain all gas and oil if any repairs are being made to the engine. Always follow state regulations for proper oil disposal. 1. When making repairs to the pump, first remove the outlet tube from the unit with an adjustable crescent wrench. Then use a ¼ nut driver to remove the filter cover screws. Set the filter and cover to the side. Oil lube Port/Gas Repair Manual 18 TAB: Disassembly and Repair
2. Use a 9/16 socket to remove the 6 head bolts. Carefully lift the head from the pump and you will notice the intake flapper valves installed into the base of the head. Inspect these valves for any warping or damage due to excessive heat. If the valves need replacing, use a 3/16 nut driver to remove both screws from each flapper valve. 3. Check the flapper valves on the valve plate for the same symptoms and replace if needed. Oil lube Port/Gas Repair Manual 19 TAB: Disassembly and Repair
4. When making any repairs in the head or valve plate, it is suggested to replace all gaskets. 5. Before going into the pump, check the oil filters to make sure that there nothing clogged in the ports or the filters. 6. For any other repairs in the pump, the pump will have to be removed from the unit. To remove the pump, unscrew the 4 base bolts using a ½ socket. Oil lube Port/Gas Repair Manual 20 TAB: Disassembly and Repair
7. To work on the internal components of the pump you must first unscrew the drain plug and drain out all the oil from the crankcase. 8. From this point, remove the 8-crankcase bolts from the pump base using a 3/8 socket. 9. Before removing the connecting rod it is best to use a marker and draw a line going from the connecting rod to the rod bearing so when reassembling, the parts will match up as they did before being touched. 10. To remove the rod and bearing assembly, remove both bolts from each connecting rod using a 3/8 socket. Slide out of cylinder housing. Oil lube Port/Gas Repair Manual 21 TAB: Disassembly and Repair
11. Check the inside of the rod and bearing and the crankshaft for excessive heat damage, scoring, and any abnormal wear. If any of these signs are evident, replacements will be needed. 12. Look for the same symptoms listed in step 11 on the piston rings and cylinders. When replacing the rings, always clean out the ring grooves on the piston. Also, let the rings fit loosely. Gently slide back into the piston housing. 13. If the crankshaft needs changing, first remove the flywheel bolt using a ½ socket. The flywheel is tapered fit and may require a bearing puller to remove. If this tool is not available, use a brass hammer and tap around the outer area of the flywheel. Oil lube Port/Gas Repair Manual 22 TAB: Disassembly and Repair
14. Use a small, flat head screwdriver or a dental pick to pry out both of the shaft oil seals. Be careful not to damage the seals. 15. To remove the bearing use a punch and a 2lb brass hammer and push the crank towards the flywheel side. When the crank is through the rear bearing, remove the bearing and repeat this step for the flywheel bearing. 16. Lift the crank out through the bottom of the crankcase. 17. If the crank needs replacing, it is recommended to replace all bearings and seals. 18. Reassembly involves following these steps in reverse. The torque specifications are as follows: connecting rod bolts 7 to 10 ft. lbs., base plate bolts 9 to 12 ft. lbs., flapper valve screws 13 to 17 in. lbs., head bolts 25 to 30 ft. lbs., flywheel bolt 15 to 20 ft. lbs., pump mounting screws 15 to 20 ft. lbs., engine pulley bolt 70 to 80 in. lbs., and the belt guard lock nut 60 to 70 in. lbs. 19. When reinstalling the valves and head assembly, the intake valves, located on the bottom portion of the head, are to face away from the engine. Your exhaust valves, located on the valve plate, are to face towards the engine. 20. With the pump bolted back to the frame, reattach all tubes and the stiffener bar at that point follow steps 7 and 8 for resetting the belt tension. Oil lube Port/Gas Repair Manual 23 TAB: Disassembly and Repair