Rietschle Thomas 2660CE37-807 Quick start guide

2660CE37-807&2660CGHI42-807
Compressor
Field Service Manual
©2003 Thomas Industries Sheboygan, Inc.
FSM 0159 Rev. A 07/04
A Thomas Industries Company

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3
A Field Service Manual
Prepared by
Thomas Compressor
2660CE37-807 & 2660CGHI42-807
Field Service Manual
©2003 Thomas Industries, Sheboygan Inc. Field Service Manual FSM 0159
Rev. A 0704
Table of Contents
Page
Introduction ..................................................................................................................................................................... 4
Safety First ....................................................................................................................................................................... 5
Exploded View and Parts List..................................................................................................................................... 6 - 7
Preventive Maintenance and Troubleshooting Guide.................................................................................................9 - 10
Required Tools and Materials ........................................................................................................................................ 11
ComponentRepair ......................................................................................................................................................... 11
Servicing the Head or Valve Assembly.................................................................................................................... 11
Servicing the Connecting Rod Assembly and Eccentric Assembly ....................................................................... 16
Reassembling the Compressor ................................................................................................................................ 20
A Thomas Industries Company

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Introduction
This Field Service Manual is intended for use ONLY by properly trained and experienced repair personnel employed by an
authorizedservice center. THISSERVICE MANUALSHOULD NOTBE 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:
Themodel(s)representedinthismanualmayhaveadditionsand/ormodificationsmadeatanytime. Picturesrepresentastandard
unit series and an actual unit may vary slightly. This manual is based on the latest technical information available at the time of
creationorlastrevision. Itisbelievedtobegenerallyaccurateandreliable. Consultthefactoryifadditionaldetailedinformation
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. PLEASENOTETHEFOLLOWINGCAUTIONS
AND WARNINGS FOR YOUR OWN SAFETY.
Caution
Toavoidpersonalinjuryand/or property damage, only authorized servicepersonnelshould
service this unit.
Warning
Toavoidtheriskofelectricalshock,personalinjury,ordeath,disconnectpowerbeforeservicingthis
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 100 psig.
Caution
Toavoiddamage,neverlubricateany component in your compressor. All moving parts are
permanently lubricated.
Caution
Toavoidpropertydamage or personal injury,alwaystryrotatingthe fan by HAND priorto
connectingtheunittothepowersource. Checkforsuctionattheairinletportbyplacingyour
finger over the port as you turn the fan. You should feel a slight suction with each rotation
ofthefan. Ifyoudontfeelsuction,orifyoufeelorhearathumpasyouturnthefan,DONOT
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 2660CE37-807 & 2660CGHI42-807 Series Compressor

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Field Service Parts List for Thomas 2660CE37-807 & 2660CGHI42-807 Compressor
Item Part Qty. Qty.
No. No. Per Ass'y Per Unit Description
1 SeeChart -- 2
ConnectingRod,Eccentric&BearingAssembly
2 624677 1 2 PistonCup
3 625776 1 2 Screw-Piston CupRetainer
4 626392 1 2 PistonCupRetainer
5 618114 1 2 CylinderSleeve
6 610880 -- 1 Head
7 623143 -- 2 O-Ring-HeadGasket
8 625175 -- 8 Screw-Head
9 621591 -- 2 ValvePlate Assembly
10 617177 1 2 ValveRestraint
11 617562 2 4 ValveKeeperStrip
12 621485 2 4 ValveFlapper -Intake &Exhaust
13 621461 1 2 ValvePlate
14 625094 2 4 Screw-ValveFlapper
15 623137 -- 2 O-RingValvePlate
16 638282 -- 1 Fan - Black
17 638281 -- 1 Fan - Gray
18 638702 -- 1 PressureReliefValve
Connecting Rod, Eccentric & Bearing Assembly Chart
1 666660 -- 2 For2660CE37-807
1 666702 -- 2 For2660CGHI42-807

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Thomas Industries 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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If you are having a problem with your compressor, use this table to help determine the cause(s):
Problem Possible Cause Corrective Action
Low Low Unit Will Motor Loud
Flow Pressure Not Start Overheats Unit
x High voltage at Reduce voltage
compressor
x x x x Low voltage at Increase voltage
compressor
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 Increase air
ventilation circulation
in enclosure to enclosure
x x Worn bearings Replace Conn Rod
Eccentric and
Bearing assembly
1
1Thermal protector in motor will interrupt current when motor overheats.
Troubleshooting Guide

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Required Tools and Materials
To disassemble and reassemble your compressor, you need the following tools and materials:


Torque wrench that has an inch-pound scale (for head screws, set screws, flapper valve screw, and pipe plugs).


Torx®T-25 driver (for head screws).


1/8" Allen wrench attachment for torque wrench (for eccentric set screw).


1/2" Hex Socket attachment for torque wrench (for flapper valve screw).


Torx®T-27 driver (for retainer screws).


Soft, clean cloths
Compressor
Housing
CapacitorLEADEND
Reference Drawing: Terminology to assist with the following instructions.
CapacitorLEADSIDE
ofCompressor

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Component Repair
Servicing the Head, Valve Plate
Assembly and Connecting Rod and
Bearing Assembly
Theheadwouldonlyneedtobereplacedifitisvisibly
damaged.
Component Parts Required
Youwillneed:
Head (if damaged)
Head gasket O-ring
Valve plate O-ring


Completevalveplateassemblyorindividual
flapper valves.


Flappervalvescrew(s)ifreplacingindividual
flapper valve(s).
Removing the Head
1. Disconnect the power.
2. Disconnect all air lines and remove
compressor from the enclosure.
3. Remove all screws (1) that fasten the head (2)
to the compressor housing.
4. Carefully separate the head from the
compressor body.
5. Carefully separate the valve plate assemblies
(4) from the heads.
6. Remove the head gasket O-rings (3) and
replace.
7. Turn the valve plates over and replace the
valve plate gasket O-rings (5).
Attention
If you are replacing the head and gaskets
only, see the assembly instructions on page
20. To replace the valve flappers and
connectingrodassembly,continuetopage
12.
1
2
3
4
5

12
Removing the Flapper Valves
Note: We recommend you remove and replace one
flapper valve at a time. This will help to
simplify the repair process and orient the
flapper valve correctly on the valve plate.
1. If you are replacing a flapper valve on the
top side of the valve plate (side facing the
head), remove the flapper valve screw (1)
with a 1/4" hex socket, lift off the valve keeper
strip (2), lift off the valve restraint (3), and lift
off the flapper valve (4).
2. Remove any debris from the valve plate with
a damp, lint free cloth. (Soaps and
detergeants should not be used due to the
potential for corrosion from soap residue.)
3. Place the valve plate on the compressor
housing and orient it as illustrated. Note the
orientation of the valve ports.
4. Orient a new flapper valve (1) over Port 1.
Observe the location of the notches (2) at the
end of the flapper valve.
2669-6
OppositeLeadSide
2
2
1
Port2
Port1
1
2
34
OppositeLeadSide

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5. Place a valve restraint (3) over the flapper
valve.
6. Place a valve keeper strip (4) over the valve
restraint observing that the word “UP” is
facing you and oriented as shown in the
illustration.
7. Line up the screw holes in all of the valve
components and insert the flapper valve screw
(5) into the valve plate.
8. Make sure the flapper valve is centered over
the port and that all of the other components
line up with the flapper valve.
Caution
Do not overtighten the flapper valve
screw or it will shear off in the valve plate.
9. Tighten the flapper valve screw to 18 inch-
pounds, using a torque wrench with a 1/4" hex
socket attachment.
5
3
4

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LeadSide
1. If you are replacing a flapper valve on the
bottom side of the valve plate (side facing
the compressor housing), remove the flapper
valve screw (1) with a 1/4" hex socket, lift off
the valve keeper strip (2), 1
2
3
Port1
Port2
2. Clean any debris with a soft, damp cloth. Turn
the compressor head upside down and place the
valve plate on the compressor head and orient it
as illustrated. Note the position of the valve
ports and the location of the power leads on the
compressorhousing.
3. Orient a flapper valve (1) over Port 2. Observe
the location of the notches (2) at the end of the
flapper valve.
LeadSide
2
1

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3. Place a valve keeper strip (3) over the flapper
valve, observing that the word “UP” is facing
you, not the valve plate, and oriented as shown
intheillustration.
4. Line up the screw holes in all of the valve
components and insert the flapper valve screw
(4) into the valve plate.
5. Make sure the flapper valve is centered over
the Port and that the valve keeper strip lines up
with the flapper valve.
Caution
Do not overtighten the flapper valve
screw or it will shear off in the valve
plate.
6. Tighten the flapper valve screw to 18 inch-
pounds, using a torque wrench with a 1/4" hex
socket attachment.
3
4
Attention
Ifyouareonly replacing the valve
flappers, see the assembly
instructionsonpage20.
Ifyouarereplacingthecupand
sleeveturnto theRebuilding
ConnectingRodAssembliesSection
foundonpage17.

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Servicing the Connecting Rod Assembly
and Eccentric Assembly
Refer to the Preventive Maintenance and
TroubleshootingGuideinthismanualtodetermine
whether a complete connecting rod assembly, or its
component parts, or an eccentric needs to be
serviced.
Component Parts Required
Youwillneed:


Connecting rod assembly(ies) or piston cups and
sleeves


Valve plate gasket O-ring(s)


Head gasket O-ring(s) (if defective)
Removing the Connecting Rod Assembly
and Eccentric
NOTE:ONLY REMOVE ONE CONNECTING
ROD ASSEMBLY AT A TIME.
1. Carefully remove the fan by pulling it straight off
the motor shaft. Do not pull the fan blades.

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2. Turn the motor shaft to align the eccentric set
screw with its access hole and use an Allen
wrench to loosen the eccentric set screw (see
illustration for location of access hole).
3. Make sure the connecting rod is at "Top Dead
Center". Slide the connecting rod assembly
straight off the shaft through the opening in the
housing.
Eccentric
Eccentric Set Screw
AccessHole
Openingin
Housing

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Caution
Do not crimp the piston cup (4) when you
remove the connecting rod assembly from
the compressor housing. If the cup is
crimped, you must replace it.
Rebuilding Connecting Rod Assemblies
If you are rebuilding the connecting rod
assemblyusingcomponentparts,followthis
procedure:
When replacing the piston cup (4), be sure
to replace the sleeve (1) at the same time.
Place the con rod shaft in a fixture before
attempting to remove the retainer screw.
Heat will help to dissolve the loctite bond.
1. Remove the retainer screw (2) from the
cup retainer.
2. Remove the retainer (3) from the
connectingrod.
3. Remove the cup (4) and discard.
4. Place the new piston cup (4) on the
connectingrod.
5. Place a piston cup retainer (3) on the
cup/connecting rod making sure the boss of
the retainer is seated in the pilot of the rod.
6. Insert the retainer screw (2) into the
connecting rod (5) and tighten to 95-105
inch-pounds.
Attention
Toreplacetheconnectingrodand
bearingassemblycontinue
to page 19.
Note:
BothConnectingRods
shownfor
orientation,
DO NOT remove
both at once.
1
2
3
4
5
1
2
3
4
5

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Note: Bothconnecting rod assembliesshown
for orientation.
DO NOT remove both at once.
Assembly of the Connecting Rod to the
Compressor
1. Line up eccentric set screw with flat on shaft.
Slide connecting rod assembly over shaft
through front of housing with eccentric toward
end of shaft. Push connecting rod assembly
tightagainsthousingbearing.
2. Rotate eccentric to line up set screw with
access hole in bottom of housing. Tighten
screw to 125 in. lbs. Make sure the eccentric
set screw is seated perpindicular on the shaft
flat.
Set Screw
AccessHole

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Reassembling the Compressor
After the connecting rod assembly and eccentric
are correctly assembled, you can assemble the
valve plates and head to the compressor.
Caution
To prevent damage to the compressor,
neverapply any sealantor lubrication to
the O-rings.
1. Insert a new head gasket O-ring into the
groove located on the top of the valve plate.
2. Insert the valve plate gasket O-ring into the O-
ring groove located on the bottom of the valve
plate.
O-ringGasket
Groove
O-ringGroove
O-Ring BottomofValvePlate
TopofValvePlate