Gardner Denver THOMAS SK61732 User manual

MODEL SK61732
COMPRESSOR SERVICE KIT
For use on 607 and 617 Model Compressors with .32 Stroke
CAUTION: Improper assembly or use of damaged parts may lead
to premature failure. To avoid frequent repairs follow the recom-
mended assembly procedures.
Part No.642672 0105
NOTE: Before you begin, read these instructions thoroughly and as-
semble the necessary tools. You will need:
1/8” Hex Socket attachment for torque wrench
Torx T-20 attachment for torque wrench (for retainer screws)
Torx T-25 attachment for torque wrench (for head screws).
5/32” allen wrench for for torque wrench (eccentric screw)
Flat Screwdriver 
Clean Cloths
WARNING: Unplug the compressor before beginning disassembly.
This kit includes the following parts:
625646 Head Screw (6)
666251 Connecting Rod
Assembly - .32 Stroke
625307 Flapper Screw (2)
625114 Conn. Rod
Screw
633629 Head Gasket
623539 O-Ring
634622 Loctite® #680
617045 Valve Keeper (2)
641034 Foam Filter
621102 Valve Flapper (2)
631623 Loctite® #242

DISASSEMBLY
STEP 1. Clean loose dirt from the outside of the compressor.
STEP 2. Unscrew the 6 head screws (1-discard screws) and remove
the compressor head (2).
STEP 3. Carefully remove the valve plate (4) from the bottom of the
head. Remove the head gasket O-ring (3) and discard it. Clean head
with a soft, clean cloth and set aside for re-assembly later in the repair
process.
STEP 4. Turn the valve plate over. Remove the valve plate O-ring and
discard it.
STEP 5. Remove the 4 screws (6) securing the plastic front cover (5),
and pull cover off. Retain screws and cover for reassembly.
1
Figure 1
1
5
3
4
6
2

STEP 6. Remove the valve ap-
per screw (1), keeper (2) and
valve apper from the top of the
valve plate and discard. Clean the
top of the plate with a clean, soft
cloth. Install the new valve ap-
per, keeper and screw centered
over the port as shown. The valve
keeper should be placed on top of
the apper so that the word “UP”
is visible.
NOTE: Torque new apper screw
to 18 inch-pounds.
STEP 7. Remove the valve apper
screw (6), restraint (5) and valve
apper (4) from the bottom of the
valve plate and discard them.
Clean the bottom of the plate with
a clean, soft cloth. Install the new
apper, restraint and screw cen-
tered over the port as shown. The
valve keeper should be placed on
top of the apper so that the word
“UP” is visible.
NOTE: Torque apper screw to
18 inch-pounds. Set Valve Plate
Assembly aside for re-assembly
later in repair process.
STEP 8. Remove the fan by pry-
ing the fan hub with a screwdriver.
(See Fig. #3).
Note position of fan for reassem-
bly. (Hub facing in? Hub facing
out?)
2
1
3
2
Figure 2
4
6
5
Figure 3
View of Fan with
Hub Facing In

STEP 6. Insert a 1/8” hex wrench into the hole in the left side of the
compressor housing (See Fig. #4). Loosen the set screw in the eccentric.
Insert a 5/32” hex wrench into the right side of the housing and loosen
the clamping screw at the base of the connecting rod .
3
Eccentric
Set Screw
Access
Hole Eccentric
Set Screw
Figure 4
NOTE: It may be necessary to in-
sert a at tip screwdriver into the
slot in the base of the connecting
rod, and spread the base slightly,
in order to free it from the bearing
(See Fig. #5).
STEP 7. Slide the bearing off of the
shaft, then pull the connecting rod
out of the top of the housing (See
Fig. #4).
Spread to release
loctite bond
Connecting
Rod
Set Screw
Access
Hole
Connecting Rod
Screw
Figure 5
Bearing
Bore

4
STEP 1. Clean the old adhesive from connecting rod bearing (mounted
on the eccentric). Apply Loctite® #680 (supplied) to the bearing bore of
the new connecting rod. (See Fig. #2). Apply Loctite®#242 (supplied) to
the threads of the clamping screw, and turn the screw a few turns into the
new rod. Do not tighten. Drop the new rod and sleeve assembly through
the top of the compressor housing with the head of the rod clamping screw
to the right (as viewed through the open end of the compressor housing).
Slide the eccentric and bearing assembly onto the shaft and into the bear-
ing bore of the connecting rod. (See Fig. #4)
CHECK OPERATION
STEP 5. Hold the sleeve down
against the housing with one hand,
and slowly rotate the eccentric with
the other hand. As the piston travels
up and down it will also rock from side
to side. This is a feature of the WOB-L
Piston. If it rocks from front to rear,
the connecting rod is misaligned
on the eccentric. If front to rear rock-
ing is detected, loosen the connecting
rod clamping screw and repeat Steps
6, 7, and 8. If the connecting rod can-
not be properly aligned, contact the
nearest service center.
Figure 7
Hold sleeve
down
STEP 2. Align the front face of the con-
necting rod with the front face of the bear-
ing. This will result in a clearance of about
.032 inch between the rod and the eccen-
tric (See Fig. #6). Tighten the connecting
rod screw to 15 in. - lbs. torque. DO NOT
OVERTIGHTEN, or bearing damage/con-
necting rod breakage may result.
STEP 3 Center rod and sleeve in pocket in the top of the unit.
STEP 4. Slide the sleeve down until it contacts the housing. The locator
ribs should bear against the inside surface of the sleeve.
.032
Connecting
Rod Ass’y
Eccentric
Bearing
Ass’y
Figure 6
REASSEMBLY

CAUTION: Make sure o-ring
is not twisted when seated in
groove.
STEP 7. Place the new head
gasket into the groove inside
the head, seating it rmly in the
groove with your nger or blunt
object.
STEP 8. Place the head on the
top of the valve plate in the same
orientation as it was when re-
moved. Install the 6 head screws
and tighten in a criss-cross pat-
tern to 45 in-lbs.
NOTE: Some of these models
are equipped with a carrying
handle. The handle, if present,
should extend over the motor to
provide proper balance when the
unit is carried.
STEP 9. Slide the fan onto the
shaft in the same orientation that
it was before it was removed.
STEP 6. With the sleeve located and rmly seated on the housing, re-
place the valve plate as shown in Fig. #8. Make sure the top edge of the
sleeve locates in the O-ring groove in the bottom of the valve plate.
Figure 8
5
Caution
To avoid property damage orpersonal injury, always try rotating
the fan by HAND prior to connecting the unit to the power
source. Check for suction at the air inlet port by placing your
nger over the port as you turn the fan. You should feel a slight
suction with each rotation of the fan. If you don’t feel suction,
or if you feel or hear a thump as you turn the fan, DO NOT
CONNECT THE UNIT TO A POWER SOURCE; review the
assembly procedure for possible error.

6
STEP 13. Assemble the front cover.
STEP 14. Run unit at free ow for ve minutes. Check that air exists
at exhaust port.
STEP 15. Remove the lter cap from the lter body by prying it with
a at screwdriver. Remove the old foam lter and discard. Replace
with the new lter and snap lter cap back into place.
Filter Body
Filter Cap
Foam Filter
Figure 9

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Sheboygan, Wisconsin 53081 USA
[phone] www.gd-thomas.com