PRECISION IN HIGH QUALITY

Assembly Instruction

Installation

Instructions

 

IMPORTANT! PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOIDPERSONAL INJURY OR DEATH

 

GENERAL CONDITIONS

When working on or around a vehicle, the following general precautions should be observed at all times.

1.     Park the vehicle on a level surface, apply the parking brakes, and always block the wheels.
2.     Stop the engine when working around the vehicle.
3.     If the vehicle is equipped with air brakes, make certain to drain the air pressure from all reservoirs before beginning any work on the vehicle.
4.     Follow the vehicle manufacturer’s recommended procedures; deactivate the electrical system in manner that removes all electrical power from the vehicle.
5.     When working in the engine compartment the engine should be shut off. Where circumstances require that the engine be in operation, extreme caution should be used to prevent personal injury resulting from contact with moving, rotating, leaking, heated, or electrically charged components.
6.     Never connect or disconnect a hose or line containing pressure; it may whip. Never remove a component or plug unless you are certain all system pressure has been depleted.
7.     Never exceed recommended pressures and always wear safety glasses.
8.     Do not attempt to install, remove, disassemble or assemble a component until you have read and thoroughly understand the recommended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools.
9.     Replacement hardware,tubing, hose, fittings, etc. should be of equivalent size, type, and strength as original equipment and be designed specifically for such applications and systems.
10.  Components with stripped threads or damaged parts should be replaced rather than repaired. Repairs requiring machining or welding should not be attempted unless specifically approved and stated by the vehicle or component manufacturer.
11.  Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition.

 

SERVICE INSTRUCTIONS

 

1.General

For cleaning, a non-aggressive acid-free solvent with corrosion inhibitor must be used.

For lubrication of components, use clean motor oil unless otherwise stated.

These instructions are written for a single cylinder compressor. For twin cylindercompressors, references to components should be read as plural and actions should be duplicated as appropriate.

 

Note!

If components are damaged during the dismantling and/or assembly phases, ATAKUL Makine shall accept no liability and shall reject any claim for warranty costs concerning the Compressor.

Any dismantling operation invalidates the compressor warranty.

 

2. Replacing a Cylinder Head or Head Gasket

 

Service Parts/Kits required:

Cylinder Head complete, Gasket Kit.

 

When replacing a Cylinder Head, both the Cylinder Head-Valve Plate and Valve Plate-Crankcase Gaskets must always be replaced.

Replacing a Cylinder Head (as a single part or as a pre-assembled part in the case of an energy saving compressor) requires careful dismantling to overcome the adhesive force between the Cylinder Head Gasket and the mating surfaces.”

If the Cylinder Head or Valve Plate is not being replaced, clean the gasket contact area without causing scratches that might cause leakage problems later.

Fit the new Cylinder Head Gasket and then the Cylinder Head.

Lubricate the Cylinder Head Bolts.

Insert the Cylinder Head Bolts and tighten them in two stages following the sequence shown on the diagrams below. Firstly, tighten them to a torque of 15 to 20 Nm. Repeat the sequence, tightening to a final torque of 30 to 33 Nm.

 

3. Replacing a Valve Plate

 

Service Parts/Kits required:

Valve Plate complete, Gasket Kit.

Replacing a Valve Plate requires the prior removal of the Cylinder Head assembly (with the Cooling Plate, if fitted), the Valve Plate-Cylinder Head Gasket and, depending on the version, the Valve Plate-Crankcase Gasket or the combined Inlet Reed Valve/Gasket.

Take care when overcoming the adhesive force between the Valve Plate Gasket and its mating surfaces Carefully clean the top face of the Crankcase in order to remove any contamination or metallic burrs without causing scratches that might cause leakage problems later.

Clean the Piston Crown if the Piston is not being replaced.

Irrespective of their condition, the gaskets should be replaced.

Some models are equipped with a screw fixing the Valve Plate to the Crankcase and some with a screw fixing the Valve Plate to the Cylinder Head. In these cases, clean the screw carefully, lubricate the threaded area and tighten to a torque of 11.4 to 12.6 Nm.

Fit the new Valve Plate-Crankcase Gasket onto the Crankcase, then fit the Inlet Reed and any Spacer, taking care that it is correctly located and that the Inlet Reed is not trapped. Then fit the new Valve Plate and the Valve Plate-Cylinder Head Gasket.

Finally, re-fit the Cylinder Head

 

4. Replacing a Piston

Service Parts/Kits required:

Piston Assembly, Gasket Kit.

Replacing a Piston requires the disassembly of the Connecting Rod Cap in order to remove the Piston/Connecting Rod assembly. The Connecting Rod Cap is accessed through the Sump Plate opening and before removing the cap it should be noted which way round it is fitted with respect to the Connecting Rod.

Remove the Cylinder Head and Valve Plate The Piston/Connecting Rod assembly can now be withdrawn through the top of the Crankcase.

Remove the Circlips holding the Gudgeon Pin in the Piston, then withdraw the Gudgeon Pin to separate the Piston from the Connecting Rod.

Lubricate the Gudgeon Pin, fit the Connecting Rod into the new Piston and insert the Gudgeon Pin.

Fit the Circlips retaining the Gudgeon Pin and make sure that they are correctly fitted into the grooves of the Piston. Fit the Piston Rings to the Piston, if not already fitted.

Clean the Crankcase bore taking care to remove any contamination or metallic burrs.

Lightly lubricate the Piston Skirt as well as the Piston Rings.

Position each Piston Ring so that its gap is approximately 120° from the gap in theadjacent ring. This is to ensure that the three gaps are not in alignment duringre-assembly.

Locate the Piston carefully in the Crankcase bore without scoring the aluminium skirt.

When the Piston Skirt is located, compress the Piston Rings in their respective grooves using a Ring Compression Tool. Depending on the tool used, the Piston Rings may be compressed successively, in which case the Piston is fitted into the Crankcase bore in three successive steps, or the rings may be compressed all together in which case the complete Piston is fitted in one operation.

The fitting of the Piston into the bore requires some force to be applied and so there is a need to proceed cautiously as any impact on the lips of the Piston Rings could cause irreparable damage and seriously harm the compressor performance.

Lubricate the Crankshaft and Connecting Rod bearing surfaces and threads.

Finally re-assemble the Connecting Rod Cap over the Crankshaft taking care to assemble the cap the right way round. The tightening torque of the Connecting Rod Bolts is 13 to16 Nm.

Rotate the Crankshaft with the Connecting Rod/Piston assembly fitted to make sure that there are no tight spots.

Fit a new Sump Plate Gasket and assemble the Sump Plate.

Fit the Valve Plate-Crankcase Gasket and the Valve Plate. Fit new Valve Plate-Cylinder Head Gasket and Cylinder Head

Note: Any scratch in the Crankcase bore or on one of the Piston Rings will lead to a noticeable increase in the oil carry-over of the compressor.

 

5. Replacing the Rear Bearing Cover Seal

Service Parts/Kits required:

Gasket Kit.

After removal and cleaning of the Bearing Cover, make sure that there are no burrs or sharp edges, which might cut the Seal during assembly.

Lubricate the seal groove in the Bearing Cover and fit the new Seal.

Lightly lubricate the spigot (Bearing Cover to Crankcase) and fit the Bearing Cover in position.

Lubricate the 4 screws and tighten crosswise in one single step to a torque of 22 to 24 Nm.

Make sure that the Crankshaft rotates freely and has finite but minimal clearance in the axial direction.

 

6. Replacing the Sump Plate Gasket:

Service Parts/Kits required:

Gasket Kit

After removal of the Sump Plate and Gasket, carefully clean the mating faces of both the Crankcase and Sump Plate.

Place the new Gasket on the cleaned surface of the Sump Plate (for a metallic gasket, place the raised pre-formed side on the Sump Plate). Fit the Sump Plate and fasten crosswise the 4 screws in one step to a torque of 11 to 13 Nm.

 

7.Servicing the Energy Saving Systems (ESS):

Service Parts/Kits required:

Complete Kit.

 

7.1. ESS in crankcase:

 

Remove the Cylinder Head, the Valve Plate and the Inlet Reed plus the associated ESS components on the top face of the Crankcase.

Remove the Dowel Pin from the ESS Piston.

Clean the top face of the Crankcase and check that there are no burrs.

Check that the machined slot in the top face of the Crankcase is not damaged.

Remove the Plug/Cap holding the ESS Piston in the Crankcase and remove the Piston and Spring.

After lubricating the parts, reassemble the new Spring and new ESS Piston with Anti-extrusion Ring and O-ring in the Crankcase.

Fit the Dowel Pin through the top face of the Crankcase into its hole in the ESS Piston.

Manually operate the Piston to make sure that it returns fully under the load of the Spring to the off-position (on-load condition).

Fit the ESS Bell Crank pressing it over the Dowel Pins and fit the Sliding Pin in themachined slot in the Crankcase.

Position the Inlet Reed. It must be fitted within the profile of the new steel gasket. Make sure that the Inlet Reed is not jammed under the steel gasket.

After reassembly of these parts, manually operate the ESS Piston again to make sure that the Inlet Reed moves correctly without sticking and that the assembly returns fully to the off-position (on-load condition).

Depending on the version, fit the Plug/Cap in the ESS Piston bore in the Crankcase:

- Bored hole: refit the Cap with its O-ring into the bored hole and secure in place with the circular ring.

- Threaded hole: assemble the Plug with its flat gasket into the unused port and tighten to a torque of 50 to 55 Nm.

- Assemble the new Valve Plate-Crankcase Gasket, Valve Plate, new Valve Plate-Cylinder Head Gasket and Cylinder Head.

 

7.2. ESS in Cylinder Head

 

This work can be carried out without removing the Cylinder Head.

Remove the Cover and ESS Piston, clean the bore machined in the Cylinder Head. Check the surface condition of the bore.

Grease all of the components and the bore in the Cylinder Head.

Fit new O-Ring on the ESS Piston and reassemble the Piston in the Cylinder Head.

Position the new Cover Gasket and fit the Cover (the breather hole must not be blocked or covered). Finally, secure the Cover with both screws, tightening them to a torque of 5,5 to 8,5 Nm.