Gardner Denver Thomas 2660AT32-492W Quick start guide

Field Service Manual
FOR MODEL NUMBER
2660AT32-492W
©2006 Gardner Denver Thomas, Inc. FSM 0182 04/06

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A Field Service Manual
Prepared by:
Table of Contents
Page
Introduction ..................... 4
Safety First ...................... 5
Exploded View and Parts List ......................................................................................................................... 6
Wiring Diagram ................ 8
Preventive Maintenance and Troubleshooting Guide ....................................................................................... 9
Required Tools and Materials ....................................................................................................................... 11
Component Repair ....... 12
Servicing the Valve Assembly ................................................................................................................. 13
Rebuilding the Connecting Rod Assembly .......................................................................................... 17
Replacing the Connecting Rod and Eccentric Assembly ........................................................................ 18
Assembly of the Compressor ................................................................................................................ 20
Field Service Manual
for model number
2660AT32-492W
©2006 Gardner Denver Thomas, Inc.
Field Service Manual
FSM 0182 04/06

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Introduction
This Field Service Manual is intended for use ONLY by properly trained and experienced repair personnel employed
by an authorized service center. THIS SERVICE MANUAL SHOULD NOT BE USED BY OR DISTRIBUTED TO
THE PUBLIC. THE INSTRUCTIONS AND WARNINGS HEREIN PRESUME EXISTING FAMILIARITY WITH THE
DESIGN AND FUNCTION OF THESE AND SIMILAR PRODUCTS, AND THEIR COMPONENTS.
Please Note:
The model(s) represented in this manual may have additions and/or modifications made at any time. Pictures
represent a standard unit series and an actual unit may vary slightly. This manual is based on the latest technical
information available at the time of creation or last revision. It is believed to be generally accurate and reliable.
Consult the factory if additional detailed information is desired, or whenever there is a question about a given unit’s
configuration or performance specifications.

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Safety First
It is recommended that you thoroughly read and understand this manual before you attempt to
service the Thomas series of compressors to which this applies. PLEASE NOTE THE FOLLOW-
ING CAUTIONS AND WARNINGS FOR YOUR OWN SAFETY.
CAUTION
To avoid personal injury and/or property damage, only authorized service personnel should
service this unit.
WARNING
To avoid the risk of electrical shock, personal injury, or death, disconnect power before
servicing this unit.
CAUTION
To avoid personal injury, do not remove fan guards while unit is connected to power.
CAUTION
To avoid personal injury, especially to eyes and face, use eye and face protection when
servicing this unit.
CAUTION
To avoid personal injury, especially to eyes and face, never point the exhaust air flow at
yourself or other people in the area. Unit is capable of pressures of very high pressures.
CAUTION
To avoid damage, never lubricate any component in your compressor. All moving parts
are permanently lubricated.
CAUTION
To avoid property damage or personal 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 finger 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.

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Exploded View and Parts List
Exploded View of the Thomas 2660AT32/492W

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Field Service Parts List for Thomas 2660AT32/492W
Item
No.
Part No. Qty. Per
Assembly
Qty. Per
Unit
Description
1 640109 -- 2 Connecting Rod, Eccentric & Bearing Ass'y
2 624680W 1 2 Piston Cup
3 625776 1 2 Screw - Piston Cup Retainer
4 626392 1 2 Piston Cup Retainer
5 618114 1 2 Cylinder Sleeve
6 610534 -- 1 Head
7 623143 -- 2 O-Ring - Head Gasket
8 625175 -- 8 Screw - Head
9 621591 -- 2 Valve Plate Assembly
10 617177 1 2 Valve Restraint
11 617562 2 4 Valve Keeper Strip
12 621485 2 4 Valve Flapper - Intake & Exhaust
13 621641 1 2 Valve Plate
14 625094 2 4 Screw - Valve Flapper
15 623137 -- 2 O-Ring Valve Plate
16 638281 -- 1 Fan - Gray
17 638282 -- 1 Fan - Black

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Use this wiring diagram to connect your
compressor to the power source.
Wiring Diagram
2660AT32-492W
LINE
LINE
CAPACITOR
BLUE
RED
BROWN
RED

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Thomas Products Group recommends that you perform the following service to minimize
unexpected downtime for your compressor:
• Replace the connecting rods or piston cups and sleeves
• Replace the flapper valves
• Replace the head gasket O-rings
• Replace the valve plate O-rings
Preventive Maintenance and Troubleshooting Guide

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Troubleshooting Guide
If you are having a problem with your compressor, use this table to help determine the cause(s):
Problem Possible Cause Corrective Action
Low
Flow
Low
Pressure
Unit Will
Not Start
Motor
Overheats
Loud
Unit
xHigh voltage at
compressor Reduce voltage
x x x x Low voltage at
compressor Increase voltage
x x x Damaged valves Replace flapper valves
x x x Debris in valves Remove debris and
check for valve damage
x x x Damaged gaskets Replace gaskets
x x x Worn Cup Replace connecting rod
assembly or cup
x x x Loose head screws Tighten head screws
x Broken fan Replace fan
x x x Bent motor shaft Replace entire unit
x x Damaged capacitor Replace capacitor
x Loose fittings Tighten fittings
x x Insufficient ventilation
in enclosure
Increase air circulation
to enclosure
x x Worn bearings Replace eccentric and
bearing assembley
1 Thermal protector in motor will interrupt current when motor overheats.