Compressor Overhaul

1. Remove the magnetic clutch assembly.
2. Remove the oil filler plug and drain plug and draw out the oil.
3. Remove the shaft seal assembly.

Compressor Disassembly:

4. Remove the felt and the six through bolts.
5. Pass two through bolts through the bolt hole near the spring pin holes and screw them into the rear cylinder head.

Rear Head Removal:

6. Tap the head of the through bolt evenly with a plastic mallet and remove the rear cylinder head, intermediate plate, rear valve plate and rear suction valve.
7. Remove all gasket material from the rear cylinder head, intermediate plate and rear valve plate.
8. Remove the O-ring.

Front Head Removal:

9. Alternately tap the four projections on the circumference of the front head with straight blocked screwdriver and a plastic mallet and remove the front cylinder head, front valve plate and front suction valve.
10. Remove all gasket material from the front cylinder head and front valve plate.

Inspection
Check the front and rear valve plates for scratched, bent or otherwise damaged parts. Inspect both cylinder heads and both valve plate assemblies for nicks or burrs on the sealing surfaces. Clean or replace if badly damaged. Make sure that all passages in the valve plate are unobstructed. If either the cylinder head or valve plate is cracked, it must be replaced.

Rear Cylinder Head Side

Rear Head Disassembly:

1. Place the cylinder shaft assembly with the rear side upward.
2. Coat the new O-rings with clean compressor oil and install on the rear cylinder head.
3. Install the rear suction valve so that it matches the spring pin.

NOTICE: Make sure that the valve aligns with the valve escape groove of each cylinder.

4. Install the rear valve plate on the rear suction valve.

NOTICE: Be careful not to mistake the valve plate for that on the front side.

5. Lubricate gasket with clean compressor oil and install it on the rear valve plate.
6. Install the intermediate plate.
7. Install the rear cylinder head.
If difficulty is encountered in fitting, tap the cylinder head lightly with a plastic mallet.

Front Cylinder Head Side

Front Head Disassembly:

1. Place the cylinder shaft assembly with the front side upward.
2. Coat the new O-rings with clean compressor oil and install it on the front cylinder head.
3. Install the front suction valve so that it matches the spring pin.

NOTICE: Make sure the valve aligns with the valve escape groove of each cylinder.

4. Install the front valve plate on the front suction valve.
5. Coat the new gasket with clean compressor oil and install it on the front valve plate.
6. Install the front cylinder head.
In case difficulty is encountered in fitting, tap the cylinder head lightly with a plastic mallet.
7. Mount the new gasket on the through bolts.

Tightening Sequence:

8. Insert six through bolts from the front side and tighten them to 15.0 N m (11.0 ft. lbs.). Each bolt should be tightened alternately and in three passes. Install the felt to front cylinder head.
9. Turn the drive shaft 2 or 3 times by hand and make sure that the shaft rotates smoothly.
10. Install the shaft seal assembly.
11. Install the oil drain plug with the new O-ring, and tighten it to 15.0 N.m (11.0 ft. lbs.).
12. Fill a specified amount of clean compressor oil from the oil filler.
13. Install the oil filler plug with the new O-ring and tighten it to 15.0 N.m (11.0 ft. lbs.).
14. Install the magnetic clutch assembly.
15. Carry out leak test.