MODEL SK2755/2775
COMPRESSOR SERVICE KIT
For use on 2755/2775 Series Compressors
WARNING: Unplug the compressor before beginning disassembly.
CAUTION: Improper assembly or use of damaged parts may lead to
premature failure. To avoid frequent repairs follow the recommended assembly
procedures.
This kit includes the following parts:
O-Ring (Sleeve) (2)
Head Screw (8)
Head Gasket (2) Cylinder Sleeve (2)
Screw (2)
Flapper Screw (4)
Valve Flapper (4)
Piston Cup (2)
NOTE: Before you begin, read these instructions thoroughly and assemble the
necessary tools. You will need:
• 1/4” Hex Socket attachment for torque wrench.
• Flat blade screwdriver attachment for torque wrench.
• Torx T-27 attachment for torque wrench.
• Torx T-25 attachment for torque wrench (for head screws).
• 5/32” hex wrench for eccentric set screw.
• Clean Cloth
Part No.642936B
DISASSEMBLY / REASSEMBLY
NOTE: To avoid confusion, service one side of the compressor at a time.
1st Stage Repair (lead end of compressor)
WARNING: Unplug the compressor before beginning disassembly.
STEP 1. Clean loose dirt from the outside of the compressor.
STEP 2. Loosen the 8 head screws (1) and remove the compressor head.
Carefully remove the valve plates (3) from the bottom of the head.
Caution: Place capacitor off to side leaving it connected to lead wires.
STEP 3. Remove the head gasket O-rings (4) and discard them.
STEP 4. Turn the valve plates over. Remove the valve plate O-rings (5) and
discard. Use a blunt object to aid this removal. Any scratch or dent in this area
can cause an air leak.
Figure 1 1
1
STEP 5. Remove the exhaust valve
flapper and valve restraint from the
bottom of the valve plate (discard valve
flapper and screw). Clean the bottom of
the plate with a clean, soft cloth. Install
the new exhaust valve flapper and
restraint.
NOTE: Torque flapper screw to 12 in-
lbs.
STEP 6. Install the new O-ring, seating
it firmly into the groove with your finger
or blunt object. See figure 2. Figure 2
STEP 7. Remove the intake valve
flapper and valve restraint from the top
of the valve plate (discard valve flapper
and screw). Clean the top of the plate
with a clean, soft cloth. Install the new
intake valve flapper and restraint.
NOTE: Torque flapper screw to 12 in-
lbs.
STEP 8. Install the new head gasket,
seating it firmly into the groove with
your finger or blunt object. See figure 3.
Set aside.
Figure 3
STEP 9. Remove the fan guard by
unscrewing the 2 screws holding it to
the housing. See figure 4.
STEP 10. Remove the fan by releasing
the pressure from the clip holding it
to the shaft. Note position of fan for
reassembly. (Hub facing in? Hub facing
out?)
Figure 4
2
STEP 11. Insert the 5/32” hex wrench into the access hole on the side of the
compressor housing. Loosen the set screw 1/4 turn. Rotate connecting rod
to top dead center (180°) and slide the connecting rod/eccentric assembly off
the shaft and through the opening in the housing.
Note: Before cup removal, check direction of pistion cup edge for proper
reassembling (Does it curve up or down?), See Figures 6A & 6B on Page 4.
STEP 12. Secure the rod assembly in a fixture. Remove the sleeve (1 -
discard) from the connecting rod. Remove the screw (2 - discard) from the
cup retainer (3-retain for reassembly). Remove the piston cup (4 - discard)
and wipe debris from the top of the connecting rod and retainer with a clean
damp cloth.
Figure 5
Eccentric Set
Access Hole Screw Access Hole
Eccentric Set Screw
3
STEP 13A. (Pressure rod assmbly) Carefully place new sleeve (1) over the
connecting rod top. Place new cup (4) in center of connecting rod top with
the curve of the cup facing up. Do not damage the cup. Place retainer (3)
on top of cup (counterbore up), making sure that the cup inside diameter is
seated properly over retaining boss.
Note: The retainer (3) should be flat, fully contacting the rod top.
Drive new retainer screw to 100 inch-pounds. Carfully push the sleeve
up forming the cup. Stop pushing the sleeve up when the piston cup is
positioned midway inside the sleeve.
STEP 13B. (Vacuum rod assembly) Place new cup (4) in center of
connecting rod top with the curve of the cup facing down. Do not damage the
cup. Place retainer (3) on top of cup (counterbore up), making sure that the
cup inside diameter is seated properly over retaining boss.
Note: The retainer (3) should be flat, fully contacting the rod top.
Drive new retainer screw to 100 inch-pounds. Carefully push sleeve (1) over
the top of the rod assembly forming the cup. Stop pushing the cylinder sleeve
down when the piston cup is positioned midway inside the sleeve.
1 1
2
2
3 3
4
4
Edge of
Edge of piston cup
piston cup curves
curves up down
Figure 6A- Pressure Rod Figure 6B - Vacuum Rod
4
STEP 14. Rotate the rotor shaft so that flat faces up (12:00) Position piston
cup at bottom dead center of cylinder sleeve.
STEP 15. Follow this step if eccentric does not have
the built on Spacer. See figure 7.
Insert the 0.04” spacer tool though the slot in the side
of the housing. Slide connecting rod assembly onto the
shaft until it meets spacer. Skip Step 16. Figure 7 Spacer
STEP 16. Follow this step if eccentric has the built on Spacer. See figure 6A.
Slide connecting rod assembly onto the shaft until the spacer meets the shaft
bearing.
STEP 17. Align the eccentric setscrew with the flat of the shaft. Rotate the
eccentric and shaft 90 degrees so the setscrew is visible through the access
hole in the housing. Seat the Hex wrench into the setscrew. See Figure 5.
STEP 18. Temporarily place the valve plate assembly on the compressor
housing so the lip of the cylinder sleeve fits into the O-ring on the bottom
of the valve plate assembly. Position the valve plate so the mounting holes
line up with the threaded holes in the housing. Temporarily insert two head
screws into the mounting holes to secure the valve plate assembly. See
figure 8.
NOTE: The purpose of this procedure is to correctly position the connecting
rod assembly on the motor shaft before tightening the set screw.
STEP 19. Use a torque wrench to tighten the eccentric setscrew to 125 in-
lbs. Remove the valve assembly and head screws.
STEP 20. Align the flat on the fan with the flat on
the motor shaft and slide the fan back onto the
motor shaft, making sure you position the fan
clip in the same orientation as it was before you
removed it. Incorrect orientation of the fan will not
provide adequate cooling of the compressor.
REPEAT FOR SIDE TWO
Figure 8
5
STEP 21. With the sleeves firmly seated on
the housing, replace the valve plates in same
manner as they were removed. See figure 8.
Make sure the top edge of the sleeve locates
in the O-ring groove in the bottom of the valve
plate. See figure 9.
Caution: Make sure gasket is not twisted
when seated in groove.
Figure 9 O-Ring Groove
CHECK OPERATION
Hold the sleeve down against the housing with one hand, and slowly rotate
the fan with the other hand to ensure all components are lined up properly.
As the piston travels up and down it will also rock from side to side. This is a
feature of the WOB-L Piston.
STEP 22. Place the head on the valve plates. Torque the head screws to 40
inch-lbs. in a criss-cross pattern.
Head assembly screw tightening sequence
4 6 2 8
5 3 7 1
Figure 10 Power Leads
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.
STEP 23. Reassemble the fan guards to the compressor. Tighten screws to
10 in-lbs.
6
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Sheboygan, Wisconsin 53081 USA
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