Grp27: Appendix I

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Appendix I


Compressor Difficulties

  • The following difficulties are based on a scale from 1-6. That is, 1 being the easiest and 6 being the hardest. What this scale means by easy is that one can perform the task with extreme ease. For example: taking out a phillips head screw. When this scale indicates hard (6) it means a long, arduous, and time consuming task that often includes an analytical approach and solution.*

1. Removal of the Compressor Fluid:

a. (Difficulty Level: 1)

b. (Difficulty Level: 2) -> This step is pretty easy depending on what you pour the fluid into. If you have an oil pan then you should have no problem. Getting all the fluid out posed a little bit of a problem moving around the compressor might be necessary to get the last bit of fluid out.

2. Removal of the Front Plate:

a. (Difficulty Level: 3) -> The process its self is pretty easy but the bolts were tightened very tight. A use of a allen wrench socket can be used, or a hollow tube or the circle end of a crescent wrench can be used to give more torque and make it easier to loosen the bolt by sliding one or the other onto the end of the allen wrench.

b. (Difficulty Level: 1)

c. (Difficulty Level: 1)

d. (Difficulty Level: 1)

3. Removal of the Right Plate:

a. (Difficulty Level: 3) -> Once again the process is easy but the bolts were very tight. Use the processes described in Step 2.

b. (Difficulty Level: 1) -> This is a very easy task but make sure you do not damage or nick the gasket, use something more on the dull, and flat side (like your finger nail) and try to pull it off.

4. Removal of the Left Plate:

a. (Difficulty Level: 3) -> Once again the process is easy but the bolts were very tight. Use the processes described in Step 2.

b. (Difficulty Level: 1) -> This is a very easy task but make sure you do not damage or nick the gasket, use something more on the dull, and flat side (like your finger nail) and try to pull it off. If that does not work use a dull flat head screw driver.

c. (Difficulty Level: 4) -> Sometimes it seems like that c- clip will never come off. One way to take care of this problem is as follows. In the space where the clips ends are located, place the point of the closed pliers. Open the pliers and spread the c-clip out. Have someone else try to get a flat head screw driver under one side of the c-clip to try and knock it off the grooved guide it is on. Also this clip has the tendency to shoot off. Make sure you have some one watching the clip, and maybe have some one with another set of pliers holding another part of the clip.


5. Removal of the Pneumatic System on back side of Compressor:

a. (Difficulty Level: 1) -> Hint: It’s a different color than the compressor, and it is not the engine.

b. (Difficulty Level: 1) ->They are the only black bolts visable on the brass system.

c. (Difficulty Level: 4) -> A lot of these bolts are more difficult to get out than the ones previously removed in different steps. Utilize the ideas given in Step 2, and also make sure you have the tool completely in the bolt. A lot of times with these bolts our problem was we kept stripping them due to the fact we did not pay attention to how in was the tool to the bolt.

d. (Difficulty Level: 2) -> This process is pretty simple, but can be a little messy. At first you might not think the items are going to come apart, but don’t worry they will. Wiggle the brass system a little and that should help.

6. Removal of the Shaft:

a. (Difficulty Level: 5) -> Sometimes the plate you have in your kit wont line up with the entire bolt pattern like ours did. You can either make a new plate that aligns perfectly, or just align as many holes as possible and see if it works. manufacturing you have to do

i. (Difficulty Level: 1) -> These bolts just need to be hand tight to the plate.

ii. (Difficulty Level: 1) -> Hand tighten the rod in place to avoid stripping.

iii. (Difficulty Level: 3) -> You may need to use a little force in turning as the shaft is pushed out.

e. (Difficulty Level: 6) -> As the crank journals come dislodged, they still need to travel through the other pistons in order for the whole shaft to come out. This means aligning the connecting rods are essential. Sometimes this step calls for some rotation of the shaft in order to get everything aligned.

f. (Difficulty Level: 1)

7. Removal of the Pistons:

a. (Difficulty Level: 1)

b. (Difficulty Level: 2) -> Make sure the punch is small enough for the divot.

--Side Note: Due to the rigidness of the material, the polished coating, and the sound made upon being tapped on a table, we figured that the pistons were made of a ceramic material.

c. (Difficulty Level: 1)

8. Removal of the Bearing on the Left Side:

a. (Difficulty Level: 6) -> This step might require you to do some searching. We used an item from our press kit that went around the bearing and was slim on the other side that could be pushed on from the rod. Something like that is what to look for so the bearing does not get damaged.

b. (Difficulty Level: 3) -> The placement of this attachment is important.

c. (Difficulty Level: 1)

d. (Difficulty Level: 1)