F 002 DG9 H10 2018-08-21| Bosch Automotive Service Solutions GmbH
30 | RG8.0 / RG4.0 | Appendixen
9.1.6 Piston repair kit RGB800250
Fig. 19: Overview of valve assembly
i Piston Seal Kit (RGB800250) contains two piston seals, two O-rings and four wear bands.
i Adhere to the safety instructions in chapter 2 before proceeding with repair.
! To prevent equipment damage, do not kink, twist, bend, or grab the copper tubing inside the RG8.0 / RG4.0.
1. Unplug unit from power source. Remove enclosure halves, and tip the unit on end with fan facing up.
2. Remove copper tubing from compressor only by disconnecting four flare fittings at compressor heads.
3. Carefully move front panel (with copper tubing still attached) over fan, and set panel aside.
4. Remove four head bolts from one side of compressor. Lift cylinder head off compressor and set aside, keeping
valve plate intact.
5. Pull cylinder straight up and away from piston.
6. Remove and discard two wear bands from piston.
7. Remove and discard piston seal and O-ring, being careful to not scratch sealing surface of piston.
8. Use vacuum pump oil to lubricate new wear bands, seals, and O-rings.
9. Clean debris from piston; inspect sealing surfaces.
10. Assemble new O-ring, piston seal and wear bands to piston.
i Assemble O-ring under the piston seal.
11. Inspect and clean cylinder bore; use vacuum pump oil to lube bore.
12. Assemble cylinder over piston, with radius edge of cylinder sliding over piston first.
13. Verify correct placement of springs, valves, and O-rings in valve plate and cylinder head. Assemble valve plate
to cylinder head, aligning tab on valve plate with notch in cylinder head.
14. Assemble cylinder head to compressor and manually tighten head bolts.
15. Repeat this procedure on the other side of the compressor and then proceed to assembly.
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