CB9A-020 page 15
MAINTENANCE
10. PISTONS
a. If necessary, replace the piston rings and piston ring expanders (see "Piston Ring Replacement").
b. Rotate the flywheel by hand to bring one piston rod to top dead center of the cylinder assembly.
c. Set one (1) thrust washer and one (1) shim down against the shoulder of the piston rod.
d. Squeeze the piston rings inward, with light pressure, while threading the piston clockwise onto the rod.
Tighten with the 3" adjustable spanner wrench.
e. Follow this same procedure for the second piston.
f. Rotate the compressor by hand a number of times to verify that the pistons are centered in the cylinder
bores. The pistons must not touch the cylinder walls. If necessary, adjust the cylinder.
g. Tighten the cylinder capscrews per the Bolt Torque Table in an alternating pattern.
h. It is important that the proper number of shims be installed under the piston. To check, rotate the
flywheel by hand to bring one piston to the top.
1. Measure the distance from the top of the piston to the top of the cylinder.
HD161 .010" to .025"
(.254 to .635 mm
HD361 .020" to .035"
(.508 to .889 mm)
HD601
HDL601
.020" to .035"
(.508 to .889 mm)
HD162 .015" to .030"
(.381 to .762 mm)
HD362 .025" to .040"
(.635 to 1.016 mm)
HD602
HDL602
.030" to .045"
(.762 to 1.143 mm)
HD163 .025" to .040"
(.635 to 1.016 mm)
HD363 .050" to .065"
(1.270 to 1.651 mm)
HD603
HDL603
.060" to .075"
(1.524 to 1.905 mm)
2. If necessary, remove the piston and add or subtract shims accordingly.
3. Follow this same procedure for the second piston.
i. Replace the nylon locking inserts in the piston retainer nuts.
j. Thread the piston nuts onto the piston rods and tighten with the spanner wrench.
11. CYLINDER HEAD ASSEMBLY
If the valve assemblies have been removed from the cylinder head, it is easiest to reinstall them before
attaching the cylinder head to the cylinder assembly. Refer to "Valve Replacement" for instructions.
a. Place the cylinder head O-rings in the grooves located on top of the cylinder.
b. Place the cylinder head assembly on top of the cylinder.
c. Hand tighten the outer capscrews and center capscrews into the cylinder head.
Note: Gaskets are used on the HD160 series center capscrews.
d. Uniformly torque the cylinder head capscrews according to the Bolt Torque Table.
12. Rotate the compressor by hand to verify that it turns freely. Make sure the pistons are not hitting against
the bottom of the cylinder head assembly.
13. Refer to the "Pre-Startup Check List", and "Startup Procedure".
14. After the compressor has been run for a sufficient enough time to reach operating temperature, allow to
cool and retighten the valve hold down screws.
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