QT

Series

Tear
down & Rebuild
eardown

Instruction Manual

Information contained in this manual is presented as typical to all

QT Series compressors. Photos, graphics and verbiage may or may
not be model specific. This manual contains important safety
information and should be carefully read and understood by all
personnel who service this product.

Manual No. 50365-100

September 2008 Edition

Contents
SECTION 1

SAFETY

Safety First ................................................................................................................................................... 2

SECTION 2

TEARDOWN

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

SECTION 3

CLEANING AND INSPECTION

Cleaning and Inspection ............................................................................................................................... 7

SECTION 4

REBUILD

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

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Quincy Compressor
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3501 Wismann Lane, Quincy IL - 62305-3116

SECTION 1

SAFETY

Safety First
At Quincy Compressor safety is not only a primary concern, but a faithfully
performed practice. Beginning with the design stage, safety is built into The
Worlds Finest Compressor. It is the intention of this manual to pass along
the safety first concept to you by providing safety precautions throughout its
pages.
DANGER !, WARNING !, and CAUTION ! are displayed in large
bold capital letters in the left hand column to call attention to areas of vital
concern. They represent different degrees of hazard seriousness, as stated
below. The safety precaution is spelled out in bold upper and lower case letters
in the right hand column.

DANGER !

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

WARNING !

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

CAUTION !

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

Each section of this instruction manual, as well as any instructions

supplied by manufacturers of supporting equipment, should be read and
understood prior to performing teardown and rebuild procedures. If there are
any questions regarding any part of the instructions, please call your local
Quincy Compressor distributor, or the Quincy Compressor factory before
creating a potentially hazardous situation. Life, limb, or equipment could be
saved with a simple phone call.
Compressors are precision high speed mechanical equipment requiring
caution in operation to minimize hazard to property and personnel. There are
many 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 power
disconnect 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 service
procedures. Some surface temperatures exceed 350F when the compressor is
operating.
Per OSHA regulation 1910.147, relieve the system of all pressure before
attempting to service any part of the unit.
Do not operate the unit with any of its safety guards, shields, or screens
removed.
Do not remove or paint over any DANGER!, WARNING!, CAUTION!, or
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instructional materials attached to the compressor. Lack of information

regarding hazardous conditions can cause property damage or personal
injury.
Alterations must not be made to this compressor without Quincy Compressors
approval.

WARNING !

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

Reckless behaviour of any kind involving compressed air is dangerous and

can cause very serious injury to the participants.
Provisions should be made to have the instruction manual readily available
to the operator and maintenance personnel. If for any reason any part of the
manual 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 or
FDA 21 CFR 178.3570 regulations. Failure to do so may cause severe injury or
death.

WARNING !

The owner, lessor or operator of any compressor unit manufactured by

Quincy Compressor is hereby warned that failure to observe the safety
precautions and procedures outlined in this manual may result in serious
personal injury, damage to property, and may void your warranty. Quincy
Compressor must authorize all warranty service. Before contacting your
distributor or the factory, check the maintenance requirements and the
troubleshooting guide for your compressor. Most warranty issues can be
resolved by following proper maintenance procedures.
Quincy Compressor neither states as fact, nor in any way implies that the
above list of safety precautions is an all inclusive list, the observance of which
will prevent all damage to property or injury to personnel.
Every effort has been taken to ensure that complete and correct instructions have been included in this manual. However, possible product updates
and changes may have occurred since this printing. Quincy Compressor
reserves the right to change specifications without incurring any obligation
for equipment previously or subsequently sold.

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SECTION 2

TEARDOWN

Preparation
A clean, well lighted area with ample space to move about the compressor
must be available for the teardown and rebuild of a Quincy QT series
compressor. Working in a confined area can lead to dangerous situations, so
allow yourself plenty of room. Mount the basic compressor on a rigid, sturdy
workbench 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 good
workshop habits and techniques when performing teardown and rebuild
procedures.

Removal of Basic Compressor

Perform Steps 1 through 9 prior to removing the basic compressor from the
unit.
Step 1. Turn off and lockout/tagout (per OSHA regulation 1910.147) the
main power disconnect switch.
Step 2. Allow ample time for the compressor to cool before attempting to
remove the basic compressor from the unit.
Step 3. Relieve all system air pressure from air tank(s). Also relieve air
pressure from interstage cooler (intercooler, if so equipped) by
pulling the ring on the pressure relief valve located on the head of
the compressor.

WARNING !

Never attempt to relieve system pressure by disconnecting fittings, pipes, tubing

or any other system components.

WARNING !

Do not rely upon a check valve to isolate a compressor from a pressurized tank
or 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 and
remove the air filter.
Step 6. Loosen and remove the flywheel nut or bolt (NOTE: Left Hand
Threads). Use a wheel puller and lifting strap to remove the
flywheel 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 and
fasten the lifting strap to a suitable lifting device. Remove the
mounting bolts and lift the basic compressor off of the base or tank.
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Step 9. Secure the basic compressor in an upright position on a sturdy

workbench. 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 then
remove the head capscrews.
Step 2. Remove the intercooler.
Step 3. Carefully separate the head from the cylinder and lift the head off
of 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 connecting rods will fall away from the cylinder as it is lifted from the
crankcase.

Removal of Pistons, Rods and Rod Bearings

Step 1. Use a ring spreader to remove all piston rings. Throw away all used
rings.
Step 2. Push the piston pin through the piston to disconnect it from the
connecting rod.
Step 3. Note the differences between the low pressure and high pressure
connecting rods (high pressure connecting rods have needle bearings). Mate each connecting rod and cap by striking them lightly on
an outer surface with a metal punch and hammer. Connecting
rods and caps must be correctly
matched during re-assembly. Do not
allow these components to be reversed or interchanged at any time.

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3501 Wismann Lane, Quincy IL - 62305-3116

Removal of Bearing Carrier and Crankshaft

Step 1. Provide support for the crankshaft inside the crankcase. Loosen the
capscrews and remove the bearing carrier.
Step 2. Carefully remove the crankshaft assembly (with bearings) from the
crankcase.
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 orings must be removed and replaced. Adhere to strict workshop practices
when removing these components. A hydraulic press should be used to remove
crankshaft bearings and cups, and a ring expander should be used to remove
piston rings.

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3501 Wismann Lane, Quincy IL - 62305-3116

SECTION 3

CLEANING AND INSPECTION

All salvageable components must be thoroughly cleaned with a non-flammable solvent. Damaged and / or worn components must be replaced. Surfaces
that sandwich gaskets must be completely void of gasket residue. Piston ring
and o-ring grooves must be inspected for nicks or burrs and free of dirt and
grime. Threaded components must also be cleaned and inspected; all thread
sealant must be removed. Components with damaged threads
must be replaced. Refer to the
appropriate parts book for genuine Quincy Compressor parts
available from an authorized
Quincy distributor.

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3501 Wismann Lane, Quincy IL - 62305-3116

SECTION 4

REBUILD

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 work
area 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 reassembly
process. Honing is a critical operation and should be performed by trained
personnel with proper equipment. An improperly honed cylinder can result in
excessive oil consumption or loss of air delivery. Consult the factory for proper
honing 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 located
at 6 oclock.
Step 3. Match connecting rods to their respective rod caps and install them
on the crankshaft.
Step 4. Position support blocks on the rim of the crankcase and insert guide
pins to ease installation of the cylinder and piston assembly.

QT Teardown & Rebuild

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3501 Wismann Lane, Quincy IL - 62305-3116

Reassembly of Pistons and Cylinder

Step 1. Follow piston ring installation instructions provided with the ring
set. Use a ring expander to properly install the rings.
Step 2. Place the cylinder and piston assembly over the crankcase. Slowly
guide the assembly down over the guide pins to rest on the support
blocks.
Step 3. Lightly oil the piston pins. Insert the piston pins through each
piston and rod.
Step 3. Carefully remove the blocks and let the cylinder rest on the rim of
the 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 the
cylinder.
Step 2. Place the head on top of the valve plate assembly, insert capscrews
and torque to specifications. Head capscrews must be torqued in a
specific cross pattern; refer to model specific parts book). Note:
Head capscrews must be re-torqued after first 30 minutes of
operation.

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3501 Wismann Lane, Quincy IL - 62305-3116

The Finishing Touches

Step 1. Re-install the intercooler and
the interstage pressure relief valve.
Step 2. Recheck all capscrews and fittings for tightness.
Step 3. Re-install the flywheel and
torque capscrews to specifications.
Step 4. Install a new air filter element
in 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 basic
compressor 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 to
drive belt installation and tension setting instructions in the
associated instruction manual) and belt guard.
Step 8. Add clean lubricant to the crankcase per specifications (refer to QT
Series Instruction Manual).
Step 9. Check for proper rotation of the flywheel by jogging the starter after
the basic compressor is completely installed.
Step 10. Check all control line fittings and discharge fittings for leaks by
applying a soapy solution to the fitting joints during operation.

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

WARNING !

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

Flywheel Run-out
Radial flywheel run-out can be measured with a dial indicator positioned
adjacent to the belt groove of the flywheel (see illustration). The maximum
allowable run-out is .018.

CAUTION !

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

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Specifications

Cylinder Bore
Diam eter

HP
LP

QT-5
PLT-5
2.250 / 2.251
4.000 / 4.001

Piston Skirt
Diam eter

HP
LP

2.247 / 2.246
3.995 / 3.994

2.497 / 2.496
4.499 / 4.498

Piston to Cylinder
Clearance at Skirt

HP
LP

.003 / .005
.005 / .007

.003 / .005
.003 / .005

Crankshaft Throw
Diam eter
Main Bearing

QT-7.5
PLT-7.5
2.500 / 2.501
4.502 / 4.503

QT-10
PLT-10
2.753 / 2.752
5.003 / 5.002

QT-15
PLT-15
2.500 / 2.501
4.502 / 4.503

QT-30

QT-54

3.250 / 3.251
6.000 / 6.001

2.000 / 2.001
2.750 / 2.751

2.7505 / 2.7495 2.4985 / 2.4980 3.2480 / 3.2475 1.9955 / 1.9945

4.997 / 4.995
4.499 / 4.498
5.993 / 5.992
2.7455 / 2.7445
.0015 / .0035
.005 / .008

.0015 / .0030
.003 / .005

.002 / .0035
.007 / .009

.0045 / .0065
.0045 / .0065

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
Opp. Pulley End

Crankshaft End
Play
RPM Range

Electric
Gas

1.1819 / 1.1812 1.3788 / 1.3781 1.5756 / 1.5749 1.5753 / 1.5749 2.1275 / 2.1265 1.1816 / 1.1812
1.1819 / 1.1812 1.1819 / 1.1812 1.3788 / 1.3781 1.3785 / 1.3781 2.0025 / 2.0015 1.1816 / 1.1812
N/A

N/A

N/A

N/A

.002 / .0035

N/A

400-1000
1060

500-1060
1060

550-1000

400-1150

600-940

550-1420

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

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Recipr
ocating / Systems:
Reciprocating

217.222.7700

Air Master

217.277.0270

E-mail:
Website:

info@quincycompressor.com
quincycompressor.com
quincyairmaster.com

2006 Quincy Compressor, an EnPro Industries company

All Rights Reserved. Litho in U.S.A.