Quincy Compressor QT Series Repair Manual 50365-100SEP08

Manual No. 50365-100

September 2008 Edition

QTQTQTQTQT

Series Series Series Series Series

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Instruction Manual

Information contained in this manual is presented as typical to allQT Series compressors. Photos, graphics and verbiage may or maynot be model specific. This manual contains important safetyinformation and should be carefully read and understood by allpersonnel who service this product.

QT Teardown & Rebuild Quincy Compressor

50365-100, September 2008 1 3501 Wismann Lane, Quincy IL - 62305-3116

Contents

SECTION 1SECTION 1SECTION 1SECTION 1SECTION 1 SAFETYSAFETYSAFETYSAFETYSAFETYSafety First ................................................................................................................................................... 2

SECTION 2SECTION 2SECTION 2SECTION 2SECTION 2 TEARDOWNTEARDOWNTEARDOWNTEARDOWNTEARDOWNPreparation ................................................................................................................................................... 4Removal of Head, Valve Plate and Cylinder ............................................................................................... 5Removal of Pistons, Rods and Rod Bearings ............................................................................................... 5Removal of Bearing Carrier and Crankshaft .............................................................................................. 6Removal of Rings, Bearings, Gaskets and O-rings ..................................................................................... 6

SECTION 3SECTION 3SECTION 3SECTION 3SECTION 3 CLEANING AND INSPECTIONCLEANING AND INSPECTIONCLEANING AND INSPECTIONCLEANING AND INSPECTIONCLEANING AND INSPECTIONCleaning and Inspection............................................................................................................................... 7

SECTION 4SECTION 4SECTION 4SECTION 4SECTION 4 REBUILDREBUILDREBUILDREBUILDREBUILDPreparation ................................................................................................................................................... 8Reassembly of Pistons and Cylinder ............................................................................................................ 9Reassembly of Valve Plate and Head .......................................................................................................... 9The Finishing Touches ............................................................................................................................... 10Retorque Capscrews ................................................................................................................................... 10Flywheel Run-out ....................................................................................................................................... 10Specifications .............................................................................................................................................. 11Paint ............................................................................................................................................................ 11



SECTION 1SECTION 1SECTION 1SECTION 1SECTION 1 SAFETYSAFETYSAFETYSAFETYSAFETY

Safety First

At Quincy Compressor safety is not only a primary concern, but a faithfullyperformed practice. Beginning with the design stage, safety is built into TheWorlds Finest Compressor. It is the intention of this manual to pass alongthe safety first concept to you by providing safety precautions throughout itspages.

DANGER !, WARNING !, and CAUTION ! are displayed in largebold capital letters in the left hand column to call attention to areas of vitalconcern. They represent different degrees of hazard seriousness, as statedbelow. The safety precaution is spelled out in bold upper and lower case lettersin the right hand column.

Immediate hazards which will result in severe personal injury or death.

Hazards or unsafe practices that could result in personal injury or death.

Hazards or unsafe practices which could result in minor personal injury, productor property damage.

Each section of this instruction manual, as well as any instructionssupplied by manufacturers of supporting equipment, should be read andunderstood prior to performing teardown and rebuild procedures. If there areany questions regarding any part of the instructions, please call your localQuincy Compressor distributor, or the Quincy Compressor factory beforecreating a potentially hazardous situation. Life, limb, or equipment could besaved with a simple phone call.

Compressors are precision high speed mechanical equipment requiringcaution in operation to minimize hazard to property and personnel. There aremany obvious safety rules that must be observed during these procedures.Listed below are some additional safety precautions that must be followed.

Turn off and lockout/tagout (per OSHA regulation 1910.147) the main powerdisconnect switch before attempting to work on or perform any maintenance.

Do not attempt to service any part of the unit while it is operating.

Allow ample time for the compressor to cool before performing serviceprocedures. Some surface temperatures exceed 350F when the compressor isoperating.

Per OSHA regulation 1910.147, relieve the system of all pressure beforeattempting to service any part of the unit.

Do not operate the unit with any of its safety guards, shields, or screensremoved.

Do not remove or paint over any DANGER!, WARNING!, CAUTION!, or

WARNING !

CAUTION !

DANGER !



instructional materials attached to the compressor. Lack of informationregarding hazardous conditions can cause property damage or personalinjury.

Alterations must not be made to this compressor without Quincy Compressorsapproval.

Do not operate a Quincy QT Series compressor in excess of 250 PSIG.

Reckless behaviour of any kind involving compressed air is dangerous andcan cause very serious injury to the participants.

Provisions should be made to have the instruction manual readily availableto the operator and maintenance personnel. If for any reason any part of themanual becomes illegible or the manual is lost, have it replaced immediately.The instruction manual should be read periodically to refresh ones memory.It may prevent a serious or fatal accident.

Never use a flammable or toxic solvent for cleaning the air filter or any parts.

Air used for breathing or food processing must meet OSHA 29 CFR 1910.134 orFDA 21 CFR 178.3570 regulations. Failure to do so may cause severe injury ordeath.

The owner, lessor or operator of any compressor unit manufactured byQuincy Compressor is hereby warned that failure to observe the safetyprecautions and procedures outlined in this manual may result in seriouspersonal injury, damage to property, and may void your warranty. QuincyCompressor must authorize all warranty service. Before contacting yourdistributor or the factory, check the maintenance requirements and thetroubleshooting guide for your compressor. Most warranty issues can beresolved by following proper maintenance procedures.

Quincy Compressor neither states as fact, nor in any way implies that theabove list of safety precautions is an all inclusive list, the observance of whichwill prevent all damage to property or injury to personnel.

Every effort has been taken to ensure that complete and correct instruc-tions have been included in this manual. However, possible product updatesand changes may have occurred since this printing. Quincy Compressorreserves the right to change specifications without incurring any obligationfor equipment previously or subsequently sold.

WARNING !

WARNING !



SECTION 2SECTION 2SECTION 2SECTION 2SECTION 2 TEARDOWNTEARDOWNTEARDOWNTEARDOWNTEARDOWN

Preparation

A clean, well lighted area with ample space to move about the compressormust be available for the teardown and rebuild of a Quincy QT seriescompressor. Working in a confined area can lead to dangerous situations, soallow yourself plenty of room. Mount the basic compressor on a rigid, sturdyworkbench before beginning the teardown and rebuild procedures.

Proper tools in good condition are also required and must be readily available.Inspect all lifting hoists and straps prior to use. Always practice goodworkshop habits and techniques when performing teardown and rebuildprocedures.

Removal of Basic Compressor

Perform Steps 1 through 9 prior to removing the basic compressor from theunit.

Step 1. Turn off and lockout/tagout (per OSHA regulation 1910.147) themain power disconnect switch.

Step 2. Allow ample time for the compressor to cool before attempting toremove the basic compressor from the unit.

Step 3. Relieve all system air pressure from air tank(s). Also relieve airpressure from interstage cooler (intercooler, if so equipped) bypulling the ring on the pressure relief valve located on the head ofthe compressor.

Never attempt to relieve system pressure by disconnecting fittings, pipes, tubingor any other system components.

Do not rely upon a check valve to isolate a compressor from a pressurized tankor compressed air delivery system during maintenance procedures.

Step 4. Remove the belt guard and belt(s) from the unit / basic compressor.

Step 5. Disconnect the discharge tube from the basic compressor andremove the air filter.

Step 6. Loosen and remove the flywheel nut or bolt (NOTE: Left HandThreads). Use a wheel puller and lifting strap to remove theflywheel from the crankshaft.

Step 7. Remove all control tubing.

Step 8. Loosen compressor mounting bolts at the feet of the crankcase.Carefully wrap a lifting strap around the basic compressor andfasten the lifting strap to a suitable lifting device. Remove themounting bolts and lift the basic compressor off of the base or tank.

WARNING !

WARNING !



Step 9. Secure the basic compressor in an upright position on a sturdyworkbench. Drain all oil from the crankcase.

Removal of Head, Valve Plate and Cylinder

Step 1. Remove the pressure relief valve located on top of the head and thenremove the head capscrews.

Step 2. Remove the intercooler.

Step 3. Carefully separate the head from the cylinder and lift the head offof the valve plate.

Step 4. Lift the valve plate up and away from the cylinder and set aside.

Step 5. Slowly remove the cylinder from the crankcase. Pistons and con-necting rods will fall away from the cylinder as it is lifted from thecrankcase.

Removal of Pistons, Rods and Rod Bearings

Step 1. Use a ring spreader to remove all piston rings. Throw away all usedrings.

Step 2. Push the piston pin through the piston to disconnect it from theconnecting rod.

Step 3. Note the differences between the low pressure and high pressureconnecting rods (high pressure connecting rods have needle bear-ings). Mate each connecting rod and cap by striking them lightly onan outer surface with a metal punch and hammer. Connecting

rods and caps must be correctlymatched during re-assembly. Do notallow these components to be re-versed or interchanged at any time.



Removal of Bearing Carrier and Crankshaft

Step 1. Provide support for the crankshaft inside the crankcase. Loosen thecapscrews and remove the bearing carrier.

Step 2. Carefully remove the crankshaft assembly (with bearings) from thecrankcase.

Step 3. Pry out the shaft seal from the back side of the crankcase.

Step 4. Inspect the crankcase breather. Clean or replace if necessary.

Step 5. Remove the oil sight glass to clean it or replace it.

Removal of Rings, Bearings, Gaskets and O-Rings

All piston rings, rod bearings, crankshaft bearings and cups, gaskets and o-rings must be removed and replaced. Adhere to strict workshop practiceswhen removing these components. A hydraulic press should be used to removecrankshaft bearings and cups, and a ring expander should be used to removepiston rings.



SECTION 3SECTION 3SECTION 3SECTION 3SECTION 3 CLEANING AND INSPECTIONCLEANING AND INSPECTIONCLEANING AND INSPECTIONCLEANING AND INSPECTIONCLEANING AND INSPECTION

All salvageable components must be thoroughly cleaned with a non-flam-mable solvent. Damaged and / or worn components must be replaced. Surfacesthat sandwich gaskets must be completely void of gasket residue. Piston ringand o-ring grooves must be inspected for nicks or burrs and free of dirt andgrime. Threaded components must also be cleaned and inspected; all thread

sealant must be removed. Com-ponents with damaged threadsmust be replaced. Refer to theappropriate parts book for genu-ine Quincy Compressor partsavailable from an authorizedQuincy distributor.



SECTION 4SECTION 4SECTION 4SECTION 4SECTION 4 REBUILDREBUILDREBUILDREBUILDREBUILD

Preparation

Prior to starting the reassembly procedures, thoroughly clean the work area.Clean all tools needed for the job and remove dirty rags. It is vital that the workarea be free from dirt, dust, grease and other foreign materials.

All compressor parts must be clean and within limits of specifications.Machining and honing should be done prior to starting the reassemblyprocess. Honing is a critical operation and should be performed by trainedpersonnel with proper equipment. An improperly honed cylinder can result inexcessive oil consumption or loss of air delivery. Consult the factory for properhoning specifications.

Reassembly of Crankcase

Step 1. Carefully install the crankshaft into the crankcase.

Step 2. Install the bearing carrier with a new gasket and the boss locatedat 6 oclock.

Step 3. Match connecting rods to their respective rod caps and install themon the crankshaft.

Step 4. Position support blocks on the rim of the crankcase and insert guidepins to ease installation of the cylinder and piston assembly.



Reassembly of Pistons and Cylinder

Step 1. Follow piston ring installation instructions provided with the ringset. Use a ring expander to properly install the rings.

Step 2. Place the cylinder and piston assembly over the crankcase. Slowlyguide the assembly down over the guide pins to rest on the supportblocks.

Step 3. Lightly oil the piston pins. Insert the piston pins through eachpiston and rod.

Step 3. Carefully remove the blocks and let the cylinder rest on the rim ofthe crankcase.

Step 4. Fasten and torque the cylinder to the crankcase per specifications(see model specific parts book for torque specifications).

Reassembly of Valve Plate and Head

Step 1. Install new gaskets and a new valve plate assembly on top of thecylinder.

Step 2. Place the head on top of the valve plate assembly, insert capscrewsand torque to specifications. Head capscrews must be torqued in aspecific cross pattern; refer to model specific parts book). Note:Head capscrews must be re-torqued after first 30 minutes ofoperation.



The Finishing Touches

Step 1. Re-install the intercooler andthe interstage pressure relief valve.

Step 2. Recheck all capscrews and fit-tings for tightness.

Step 3. Re-install the flywheel andtorque capscrews to specifications.

Step 4. Install a new air filter elementin the air filter and re-install the air

filter on the basic compressor.

Step 5. Use a sufficient lifting device to carefully place the rebuilt basiccompressor back onto the base or tank.

Step 6. Secure the basic compressor to the base or tank with capscrews.

Step 7. Re-install the discharge piping, control piping, drive belt (refer todrive belt installation and tension setting instructions in theassociated instruction manual) and belt guard.

Step 8. Add clean lubricant to the crankcase per specifications (refer to QTSeries Instruction Manual).

Step 9. Check for proper rotation of the flywheel by jogging the starter afterthe basic compressor is completely installed.

Step 10. Check all control line fittings and discharge fittings for leaks byapplying a soapy solution to the fitting joints during operation.

WARNING !

CAUTION !

Re-torque Capscrews

All capscrews and threaded fittings should be checked for tightness after 100hours of operation.

Turn off and lockout/tagout (per OSHA regulation 1910.147) the main powerdisconnect switch before performing maintenance procedures.

Flywheel Run-out

Radial flywheel run-out can be measured with a dial indicator positionedadjacent to the belt groove of the flywheel (see illustration). The maximumallowable run-out is .018.

Do not attempt to measure the run-out within the belt groove; measurementstaken from within the belt groove will be inaccurate.



Specifications

QT-5PLT-5

QT-7.5PLT-7.5

QT-10PLT-10

QT-15PLT-15

QT-30 QT-54

HP 2.250 / 2.251 2.500 / 2.501 2.753 / 2.752 2.500 / 2.501 3.250 / 3.251 2.000 / 2.001LP 4.000 / 4.001 4.502 / 4.503 5.003 / 5.002 4.502 / 4.503 6.000 / 6.001 2.750 / 2.751

HP 2.247 / 2.246 2.497 / 2.496 2.7505 / 2.7495 2.4985 / 2.4980 3.2480 / 3.2475 1.9955 / 1.9945LP 3.995 / 3.994 4.499 / 4.498 4.997 / 4.995 4.499 / 4.498 5.993 / 5.992 2.7455 / 2.7445

HP .003 / .005 .003 / .005 .0015 / .0035 .0015 / .0030 .002 / .0035 .0045 / .0065LP .005 / .007 .003 / .005 .005 / .008 .003 / .005 .007 / .009 .0045 / .0065

Crankshaft Throw Diameter

1.2500 / 1.2495 1.2500 / 1.2495 1.7500 / 1.7495 1.7500 / 1.7495 2.2485 / 2.2480 1.1250 / 1.1245

Pulley End 1.1819 / 1.1812 1.3788 / 1.3781 1.5756 / 1.5749 1.5753 / 1.5749 2.1275 / 2.1265 1.1816 / 1.1812Opp. Pulley End 1.1819 / 1.1812 1.1819 / 1.1812 1.3788 / 1.3781 1.3785 / 1.3781 2.0025 / 2.0015 1.1816 / 1.1812

Crankshaft End Play

N/A N/A N/A N/A .002 / .0035 N/A

Electric 400-1000 500-1060 550-1000 400-1150 600-940 550-1420Gas 1060 1060

RPM Range

Cylinder Bore Diameter

Main Bearing

Piston Skirt Diameter

Piston to Cylinder Clearance at Skirt

Paint

Quincy Compressor Blue II paint is available in individual 12 ounce spraycans. Order part number 125244-129.

ReciprReciprReciprReciprReciprocating / Systems:ocating / Systems:ocating / Systems:ocating / Systems:ocating / Systems: 217.222.7700

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Quincy Compressor QT Series Repair Manual 50365-100SEP08

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