Disassembly & Rebuild Instructions

for Quincy Compressor

QRD@Series Compressors

TI
ressors are complicated and can cause
injury or death if operated improperly.
efore installing or operating this compressor, read
understand this manual, and follow all safety precautions!!

April 1996
 Disassembly & Rebuild Instructions
for Quincy Compressor
QRD@ Series Compressors
These instructions explain in detail how to disassemble and rebuild a Quincy
Compressor Model QRD oil-less compressor. It is the responsibility of the
mechanic to read, understand and follow these instructions. Should questions
arise, consult with an authorized Quincy Distributor or call Quincy Compres-
sor.

Refer to the list of required tools and supplies, which can be purchased from
your local distributor. It is very important to use the special tools depicted in
these instructions to prevent any damage to components.

Special attention should be given to the fact that QRD basic compressors are
very unstable and awkward when removed from a stationary base or tank, with
the sheave still mounted on the crankshaft. Quincy Compressor recommends
that the basic compressor be removed from its base and mounted to a stable
fixture prior to performing any of the following procedures.

Tools and Supplies

General mechanics tools
“Lift strap
“Hoist
.Quincy Tool Kit #112029-104
-Hydraulic press & explosion blanket
-Oven
“Heat crayon or pyrometer
-Heat resistant gloves
.Loctite@ 609, 272& 242
Cleaning agent
Parts (bearings, seals, rings, grease kit, valve plates, gaskets - refer to the QRD
parts book)

Stopping for Maintenance

The following procedures should be followed when stopping the compressor for
maintenance or service:

Step 1. Per O. S.H.A. regulation 1910.147: The Control of Hazardous

Energy Source (Lockout/’l’agout), disconnect and lockout the main
power source. Display a sign in clear view at the main power switch
stating that the compressor is being serviced.

Never assume a compressor is safe to work on just because it is not

W=NING ! operating. Lockout & tagout per O. S.H.A. regulation 1910.147.

QRD Disassembly & Rebuild Quincy Compressor

50117-104, April 1996 1 3501 Wismann Lane, Quincy IL - 62305-3116

 Step 2. Isolate the compressor from the compressed air supply by closing
a manual shutoff valve upstream and downstream from the com-
pressor. Display a sign in clear view at the shutoff valve stating
that the compressor is being serviced.

Step 3. Lock open a pressure relief valve within the pressurized system to
allow the system to be completely depressurized. NEVER remove
a plug to relieve the pressure!

Step 4. Open all manual drain valves within the area to be serviced.

Step 5. Wait for the unit to cool before starting to service. (Temperatures
of 125°F can burn skin. Some surface temperatures exceed 350”F
when the compressor is operating. )

If you are servicing a QRD 10/15 compressor stamped Record of Change 100,
a piston from the compressor will have to be measured in order to determine
which ring set you will need. If you would like to order the ring set and other
replacement parts prior to total disassembly, one of the pistons can be
measured in the following manner:

Step 6. Disconnect the control line tubing (if so equipped) and the sheave
guard bracket from one of the cylinder heads.

Step 7. Remove the bolts that fasten the cylinder to the crankcase.

Step 8. Gently slide the cylinder and head assembly up and away from the
crankcase, exposing the bottom portion of the piston and the lower
rider ring. Do not completely remove the cylinder and head
assembly from the piston.

Step 9. Remove the lower rider ring and measure the diameter of the lower
rider ring seat with a caliper gauge. If the diameter of the lower
rider ring seat measures 4- U4”, order ring set 111638. If the
diameter of the lower rider ring seat measures 4-1/2”, order
111368-4.

Step 10. Re-installthe used lower rider ring so that the ring gap is staggered
with the ring gap of the upper rider ring (do not rotate the upper
rider ring).

Step 11. Gently slide the cylinder and head assembly back towards the
crankcase (do not rotate the cylinder and head assembly). Once
seated in its original position, fasten the cylinder and head assem-
bly with the original bolts and torque to 30 ft .-lbs.

Step 12. Re-connect the control lines, sheave guard bracket and guard.

-.
QRD Disassembly & Rebuild Quincy Compressor

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 Disassembly Procedures
Step 1. Wrap a sling or strap around the sheave to support it. Remove the
bolt and the washer from the end of the crankshaft that retains the
sheave on the crankshaft.

CAUTION! The compressor sheave bolt is left-hand

threaded.

Step 2. Fasten Quincy part number 112682 puller to the sheave and turn
the puller bolt to remove the sheave from the crankshaft.

CAUTION! The sheave weighs approximately 135 lbs.

Step 3. After removing the compressor sheave you will note that the
crankshaft has a roll pin located in it. If this pin indicates any wear,
replace it.

Step 4. Remove the discharge manifold and all control air lines, if so
equipped.

Step 5. Mark the heads and cylinders in their positions before being
disassembled to insure proper positioning when reassembling.

Step 6. Remove the heads from the cylinders. NOTE: If you are only
performing wrist pin lubrication maintenance, it is pos-
sible that the heads can remain attached to the cylinders.
However, it is good practice to inspect the valve assemblies during
this maintenance period for any damage or abnormal wear.

Quincv Cbmnressor

50117-104, April 1996 3 3501 Wismann Lane, Quincy IL - 62305-3116

 Step 7. Inspect the valve plates closely for any damage to the reed valves.
—
Replace the entire valve plate assembly if any reed valves are
broken, burnt or bent. Do not disassemble reed valves and rein-
stall.

Step 8. Remove the cylinders from the crankcase.

Step 9. Remove the piston rings and mark the top of the pistons with a
marker for location during reassembly.

~ Step 10. Visually inspect the piston rings and arrange them in the order in
which they were removed from the pistons.

Step 11. Use a blade micrometer or calipers to measure the compression

rings for wear. Measure each ring (while at room temperature) at
3 locations around its circumference (do not measure near butt gap
area). With newer one piece rings, measure the minimum radial
.—.. thickness of the sealing tabs at the overlapping
/~.— .\ joint (see PIX 1212 illustration). If the radial
/ \.
‘~, thickness of any ring is worn beyond accept-
4 MINIMUM i I able tolerances, replace them alJ with new
THICKNESS
I ‘ rings. Refer to the chart shown with Step 12
for the minimum radial thickness of each ring
i~
.&_ , that is considered allowable.
PIX 1212 —

Step 12. Also measure the rider (lower) rings for wear. Refer to the parts
book to determine replacement part numbers and quantities.

I Model Record of
Rider
Rmg Rider Rmg Mm Radial Plstan Rmg
Min.
Radial

I
I
hp Change Seat
Dm
Part # Thickness Part #
Thickness

I 5-15 100 425 111588 216 111524-1 .338

5-15 101-103 450 112372 .117 111745 218

10 & 1; 104 450 112372 .117 111745 .180

t= 20 100 113336-525 .114 113335-525 ,180

J
QRD Disassemble & Rebuild Quincv
-,––,Commessor
–
50117-104, April 1996 4 3501 Wismann Lane, Quincy IL - 62305-3116
 Step 13. Loosen the set screws that lock the piston pin in place,

Step 14. Use the piston pin removal tool, part number 112688, to remove
the piston pins. Always tap lightly on the removal tool and DO
NOT hit the piston. Side pressure to the piston and connecting rod
can cause damage to the main bearings on the crankshaft.

Step 15. Remove the bushings on each side of the piston pin to free the
piston from the connecting rod. Use a flat bladed screwdriver to pry
the seals from both sides of each connecting rod.

Iydre’
r boil

Step 16. Remove the needle bearings from each connecting rod by position-
ing the tools (of Tool Kit #112029- 104) as illustrated and turning
the bolt clockwise (tightening the nut and bolt).

‘iii==’;=::::’
worn 0, damaged

‘eed’ebear’ng
—slew.
—c1 ..sh.r
~— ““,

Step 17. Remove the bearing carrier bolts and the rear cover plate.

Quincv Comrxessor

50117-104, April 1996 5 3501 Wismann Lane, Quincy IL - 62305-3116

 Step 18. Attach the push block, part number 112682, to the rear of the
crankcase where the cover plate was and turn the push bolt
clockwise.

Step 19. When the bolt in the push plate has been screwed in far enough, the
crankshaft assembly will drop down into the crankcase.

CAUTION ! Crankshaft is very heavy - keep hands clear.

Step 20. Remove the push block, and turn the crankcase so that the
crankshaft is in a vertical position. Use a soft hammer to tap upon
the bearing carrier assembly, while turning the carrier until it is
free from the main bearing.

Step 21. Attach a sling as shown and carefully remove the crankshaft
.— assembly from the crankcase.

Step 22. Position the crankshaft assembly in a press as shown and carefully
remove the front main bearing.

DANGER! Wrap the assembly with an explosion blanket

(not shown) whenever using a press.

Step 23. Remove the snap ring located between the front bearing position
and the first connecting rod.

QRD Disassemhlv -. Reh(tild

& Quincy Compressor

50117-104, April 1996 6 3501 Wismann Lane, Quincy IL - 62305-3116

 Step 24. Remove the first connecting rod by placing a fitted plate under the
connecting rod and pressing downward with a hydraulic press. It
is important that the plates be positioned under the inside race of
the connecting rod bearing.

DANGER! Wrap the assembly with an explosion blanket

(not shown) whenever using a press.

Step 25. After all the rods have been removed, reverse ends of the crank-
shaft and slide the plate under the rear main bearing to push it off
with a hydraulic press.

RE-ASSEMBLY OF QRD
Before you start to rebuild, properly clean all reusable parts and have all the necessary new components on
hand. Refer to the parts book for replacement parts.

Step 1. Pre-heat an oven to 250”F and bake the connecting rods for 45
minutes. The connecting rods may be checked for proper tempera-
ture by using a heat wax pencil rated for 250”F or a pyrometer.
Follow all instructions provided with these helpful tool ~ Lay room
temperature bearing on flat surface and slip connecting rod over
bearing.

WARNING! Wear heat protective gloves to install bearings

into the heated connecting rods.

Step 2. Heat the crankshaft rear main bearing to 250”F and slide the rear
bearing journal of the crankshaft into it. Use a flat surface to assure
proper positioning of the main bearing.

Step 3. As indicated, the inner face of the bearing must be against the
shoulder of the crankshaft.

“ew nede
bean”,
r
E?-’-
Ml

---uim,,,,,
Step 4. Use a cleaning agent to remove all traces of packing grease
from each new connecting rod bearing before installing
them into the connecting rods. Install new (thoroughly dry)
bearings into each connecting rod by positioning the tools (of Tool
Kit # 112029-104) as illustrated and turning the bolt clockwise

6==’=’
~ sleeve
until the collar of the mandrel bottoms on the inside face of the
connecting rod.

)RD Disassembly & Rebuild Quincv Comrxessor

50117-104, April 1996 7 3501 Wismann Lane, Quincy IL - 62305-3116

 Step 5. Slide the seal installation ring over the end of the mandrel. The

I
eon face of the seal should be against the seal installation ring. Insert
the loaded mandrel into the installed needle bearing. Then slip the
the bolt through the mandrel and secure with the washer and nut
(note that the washer is inverted). Install the seal by turning the
w“=”’”’ aga!ns(
>eal IMlF3!allatmn ring bolt clockwise until the collar of the mandrel touches the face of the
new
needle be.r,ng
—3 new seal (Oute(
,,W,MIO”
ma
,,ng)
connecting rod.
.,0$, S. CI,O” 0,
connwl$ng rod

~washer The seal installation ring keeps the seal from “bottoming out”
-nut
against the needle bearing. Install the second seal in the same
manner. Repeat the above procedures for the remaining connect-
ing rock.

Step 6. Heat the first connecting rod to 250”F and carefully slide it over
the crankshaft into the first position on the crankshaft.

WARNING! Wear heat protective gloves to install heated

connecting rods.

Step 7. Before installing the second rod, install a spacer ring,

Step 8. If the compressor that you are rebuilding is a two cylinder machine,
a bob weight must be installed on the crankshaft for proper weight
distribution. Apply Loctite@ 242 to the threads of the bob weight set
screw and torque it to 45 ft. -lbs.

Step 9. If you are rebuilding a three cylinder machine, proceed with the
installation of the remaining rods and spacers. After the rod
assemblies have been installed, install the snap ring using snap
ring pliers.

Step 10. Align the connecting rods in the positions indicated. Remove all
traces of grease, oil, rust or residual Loctite@ from the o.d. of the
rear crankshaft sealed bearing and the housing bore in the crank-
case with a cleaning solvent. Allow the solvent to dissipate. Apply
a very thin layer of fresh Loctite@ 609 to the o.d. of the sealed
bearing and the housing bore just before installing the crankshaft
connecting rod assembly into the crankcase.

QRD Disassemble & Rebuild Quincy Compressor

50117-104, April 1996 8 3501 Wismann Lane, Quincy IL - 62305-3116
 Step 11. With the aid of a sling load the crankshaft assembly into the
crankcase from a vertical position. Carefully lower the assembly
into the crankcase and position the connecting rods into their
proper cylinder hole.

Step 12. After the connecting rod/crankshaft assembly is properly posi-

tioned, apply Loctite@ 609 to the o.d. of the front main bearing and
the id. of the front bearing seat in the bearing carrier housing.
Reinstall the front cover bearing carrier. Lightly tap around the
circumference of the carrier with a soft hammer to start it over the
front main bearing. Be sure that when you tap, you do so only on
the raised boss next to the crankshaft to prevent cracking the
bearing carrier.

Step 13, Install, tighten and torque all the bearing carrier bolts to 30 ft.-lbs.

Step 14. Install the rear cover plate with bolts and torque them to 30 ft.-lbs.

Step 15. Shown are the three syringe tubes necessary for the lubrication of
the needle bearing in each connecting rod. Each tube contains 4 cc
of specially formulated grease to be evenly distributed to each
connecting rod. IMPORTANT NOTE: DO NOT attempt to
substitute another grease for the grease supplied by Quincy
Compressor. This grease is specifically blended for use in
the QRD compressor. A substitution will lead to premature
.“.

failure of the needle bearings.

Step 16. Stretch the latex glove (supplied with grease kit) over your fingers
and hand. Inject 4 cc of grease into each bearing and smear the
grease around the inside of each bearing with a gloved finger. It is
very important that you use the glove supplied to limit the
possibility of contaminating the grease. Dispose of the glove
properly.

QRD Disassembly & Rebuild Quincy Compressor

50117-104, April 1996 9 3501 Wismann Lane, Quincy IL - 62305-3116

 Step 17. Inspect the piston pin bushing for any burrs and remove them with
fine sandpaper. Carefully apply alight film of the grease to the o.d.
of the bushing. Gently press the bushing into the seal far enough
.
to clear the inside pin boss of the piston. Refer to the photo for
proper orientation of the chamfer, clearance hole and notch.

Step 18. Install the piston over the rod assembly and push the piston pin
through the rod (as shown).

Step 19. Line up the slots shown on the end of the pin with the bushing so
that the set screw on the bottom side of the piston can be screwed
through the bushing. Torque the set screw to 100 in.-lbs. against
the flat spot on the pin.

Step 20. Install the bottom compression ring assembly onto the piston.

Step 21. Install the top compression ring assembly onto the piston, Make
sure the gap on this assembly is installed 180° apart from the gap
of the bottom compression ring assembly.

PISTtX TOP

m
install notched rings with notches up
and gaps slaggered
newer rings do not have notches

Step 22. Install the cylinder (chamfered opening towards crankcase) over
the first compression ring by compressing the ring and slowly
sliding the cylinder over it. Use this same procedure on the second
compression ring.

QRD Disassembly & Rebuild Quincy Compressor

50117-104, April 1996 10 3501 Wismann Lane, Quincy IL - 62305-3116

 Step 23. Install the larger rider rings onto the pistons and push the cylinder
over each one as shown making sure the rider ring gaps are
staggered 180°.

Step 24. Install the bolts holding the cylinders to the crankcase and torque
to 30 ft.-lbs.

Step 25. If the head assemblies are equipped with unloaders, remove the
unloaders and bench test each unloader with air pressure to be
sure there are no leaks, and the movement of the unloader fork has
not been impaired.

Step 26. If new valve plate assemblies are required, install a new valve
plate gaskets between the valve plate assembly and the head
assembly, and fasten the valve plate assemblies to the heads with
the center studs and bolts. Position the fork of the unloader directly
above the reed valves so that the fork moves freely, Improper
positioning of the fork will result in damage to the valve plate
assembly and improper loading and unloading.

Step 27. Torque the center stud nuts to 30 ft.-lbs. Note: If installing
center stud to head, use Loctite@ 272 on threads and allow
to cure before torquing nut on stud.

Step 28. Re-install each head/valve assembly to their correct positions on

the corresponding cylinders with new gaskets. Torque the head
bolts to 30 ft.-lbs.

Quincv Comtxessor

50117-104, April 1996 11 3501 Wismann Lane, Quincy IL - 62305-3116

 Step 29. Re-connect the control tubing to the head unloaders. Re-install the
discharge manifold with new gaskets. Then torque each manifold
bolt to 30 ft.-lbs.

Step 30. With the help of a lift strap, align the slot of the sheave with the
crankshaft roll pin and slide the sheave onto the crankshaft..
Fasten the sheave with the flatwasher and bolt, and torque to 75
ft,-lbs,

CAUTION! This bolt has a left-hand thread.

If so equipped, be sure that the flyweight on the backside of the

sheave has not been tampered with or removed.

Step 31. Re-install the cooling shroud.

&l bolts should be re-torqued to specifications after the QRD has

been run at operating temperature for 20 minutes and allowed to
completely cool (approximately 30 minutes). NOTE: Lockout &
tagout the power source per O. S.HA. regulation 1910.147
prior to re-torquing bolts.

This completes the reassembly of the QRD model compressor. If you have any questions, contact the Quincy
Compressor Service Department at (217)222-7700.

QRD Disassembly & Rebuild Quincy Compressor

50117-104, April 1996 12 3501 Wismann Lane, Quincy IL - 62305-3116

 Quincy Service is always near. For recitxocatina
There are Authorized Quincy Distributors located and natural gas engine driven
throughout the United States & Canada that stock helical screw products:
genuine Quincy parts & accessories for a wide range of ca// 1-217-222-7700
Quincy products. or fax requests to 1-800-219-9124

Quincy Service specialists are factory trained and will For all other helical screw products:
help keep you in business. Call for Authorized Quincy call 1-334-937-5900 ACC@ N<, Subsr,t.!s

Service. or fax requests to 1-800-219-9131

—— QC!’W?Y
.—
.—

UIVDENIABL Y THE WORLD’S FINEST COMPRESSORS

@1991 Qumq Compressor Dm,lon Coltec Industries