SOP – REACH STACKER
STANDRAD OPERATING PROCEUDRE FOR MAINTENANCE OF REACH STACKER
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SOP – REACH STACKER
INDEX
1.0
DAILY CHECK UP
2.0
MAINTENANCE PROCEDURES
2.1
Drive chain adjustment
1 DAILY CHECK UP 1) Check oil level before starting 2) Check the hydraulic oil level 3) Check the coolant level in the radiator 4) Check the coolant level in the coolant reservoir 5) ubricate the designated locations !) Drain the "ater se#arator $) check the o#eration of all s"itches %) Check o#eration of all controls &) Check level of "indo" "asher li'uid
2
MAINTENANCE PROCEDURES
2
SOP – REACH STACKER
2.1
Removal of AC om!"e##o" l$%& '
Responsibilit! In"C#$%&e' S#i(t En&inee%' )o%* Le$+e% P,%pose!
Des-%iption o( p%o-e+,%e (o% %eo/$l o( AC -op%esso% -l,t-#
S-ope!
To be +one $t %e-oen+e+ inte%/$l.
Ope%$tin& P%o-e+,%es
TOOLS AND MATERIAL REUIRED! (ool bo* +rmature nut removal 1) ,emove bolts holding dust cover in #lace and remove cover. -f auiliary sheet metal #ulley is #resent* remove the scre"s holding is it #lace. (hen remove #ulley. 2) -nsert #ins of armature #late s#anner into threaded holes of armature assembly. 3) old armature assembly stationary "hile removing retaining nut "ith "rench. /ey shaft armature removal ,emove armature #late assembly using #uller. (hread 3 #uller bolts into the threaded holes in the bolts into the threaded holes in the armature assembly. (urn center scre" clock"ise until armature assembly comes loose. 0#line shaft armature removal 1) (he s#line shaft armature "ill not have threaded holes to acce#t the armature #uller. 2) ift off armature #late "ith fingers. -f armature does not come off easily* s#ray an antiseie oil into shaft to loosen. +rmature #late can also be loosened by gently #rying bet"een rotor and armature #late "ith t"o flat scre"drivers. ,emove clutch accessories ,emove bearing dust cover* shaft key and shims ,otor #ulley assembly removal 1) ,emove rotor sna# ring. 2) -nsert the li# of the ja"s into the sna# ring groove. 3) lace rotor #ulley shaft #rotector over the e#osed shaft. 4) +lign thumb scre"s to #uller ja"s and finger tighten. 5) (urn #uller center bolt clock"ise using a socket "rench until rotor #ulley is free. ield coil assembly removal 1) oosen lead "ire clam# scre" "ith hili#s scre" driver until "ires can be sli##ed out from under clam#. 2) 6ndo any "ire connection on the com#ressor "hich "ould #revent removal of the field coil assembly. 3) ,emove field coil sna# ring.
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SOP – REACH STACKER
4) ,emove the field coil assembly.
2.2
Re!laeme(% of l$%& '
Responsibilit! In"C#$%&e' S#i(t En&inee%' )o%* Le$+e% P,%pose!
Des-%iption o( p%o-e+,%e (o% %epl$-eent o( -l,t-#
S-ope!
To be +one $t %e-oen+e+ inte%/$l.
Ope%$tin& P%o-e+,%es
TOOLS AND MATERIAL REUIRED! (ool bo* ield coil assembly installation ,everse the ste#s of 7-8D C9- +008:;< ,8:9=+>. rotrusion on underside of coil ring must match hole in front housing to #revent movement and correctly locate lead "ires. ,otor assembly installation 1) lace com#ressor on su##ort stand* su##orted at rear end of com#ressor. -f the com#ressor must be clam#ed in a vise* clam# only on the mounting ears* never on the body of the com#ressor. 2) 0et rotor s'uarely over the front housing boss. 3) lace the rotor installer ring into the bearing bore. 8nsure that the edge rests only on the inner race of the bearing* not on the seal* #ulley or outer race of the bearing. 4) lace the driver into the ring and drive the rotor do"n onto the front housing "ith a hammer or arbor #ress. Drive the rotor against the front housing ste#. + distinct change of sound can be heard "hen using the hammer to install the rotor. 5) ,einstall rotor retaining sna# ring "ith eternal sna# ring #liers. -f a bevel is #resent on the sna# sing* it should face u# ?a"ay from the body of the com#ressor). !) ,einstall rotor bearing dust cover by gently ta##ing it into #lace. +rmature assembly installation 1) -nstall clutch shims. @9(8 clutch air ga# is determined by shim thickness. Ahen installing a clutch on a used com#ressor* try the original shims first. Ahen installing a clutch on a com#ressor that has not had a clutch install before* first try B.B4* B.B2 and B.BB4 shims. 2) -nstall shaft key "ith #liers. 3) +lign key"ay in armature assembly to shaft key. 6sing driver and a hammer or arbor #ress* drive the armature assembly do"n over the shaft until it bottoms on the shims. + distinct sound change "ill be noted if driving "ith a hammer. 4) +lign slit in armature "ith locator tooth on shaft. ress armature to"ards rotor "ith hand until armature rests against the shims.
4
SOP – REACH STACKER
2.)
Re!laeme(% of *l+(,e" &ea, '
Responsibilit! In"C#$%&e' S#i(t En&inee%' )o%* Le$+e% P,%pose!
Des-%iption o( p%o-e+,%e (o% %epl$-eent o( -lin+e% #e$+
S-ope!
To be +one $t %e-oen+e+ inte%/$l.
Ope%$tin& P%o-e+,%es
TOOLS AND MATERIAL REUIRED! (ool bo* Cylinder head removal 1) ;e sure all internal com#ressor #ressure has been relieved. 2) -ns#ect cylinder head for fitting or thread damage. 3) ,emove cylinder head bolts. 4) 6se a small hammer and gasket scra#er to se#arate the cylinder head from the valve #late. ;e careful not to scratch the gasket surface of the cylinder head. 5) Carefully lift the cylinder head from the valve #late. !) -t is recommended that both the head gasket ?bet"een the cylinder head and the valve #late) and the block gasket ?bet"een the valve #late and the cylinder block) be re#laced any time the cylinder head is removed. o"ever* if no service is re'uired to the valve #late* it may be left in #lace. -f the valve #late comes loose from the cylinder block* the block gasket must be re#laced. $) Carefully remove old head gasket from to# of valve #late "ith gasket scra#er. ;e careful not to disturb the valve #late to cylinder block joint if valve #late has been left in #lace. -f valve #late comes loose from cylinder block* #roceed to valve #late removed* and re#lace block gasket. Cylinder head removal 1) 6sing a small hammer and gasket scra#er* carefully se#arate valve #late from cylinder block. ;e careful not to damage sealing surface of cylinder block. 2) -ns#ect reed valves and retainer. ,e#lace valve #late assembly if any #art is damaged. 3) Carefully remove any gasket material remaining on valve #late* cylinder block or cylinder head. Do not damage sealing surface on com#onents. =alve #late and cylinder head installation 1) Coat ne" block gasket "ith clean 50 refrigerant oil. 2) -nstall block gasket. +lign ne" gasket to location #in holes and orifices. @otch should face same direction as oil #lug or ada#tor. 3) lace valve #late on cylinder block "ith discharge valve* retainer and nit facing u# and location #ins #ro#erly located in holes. 4) 6se vacuum #um# and small tube to remove residual oil from each bolt hole. -f this ste# is not #erformed* hydraulic #ressure can be created "hen the cylinder head bolts are tightened. (his #ressure can beak the cylinder block. 5) Coat head gasket "ith clean 50 refrigerant oil. !) -nstall head gasket cover location #ins* checking for correct orientation. $) -nstall cylinder head. %) -nstall cylinder head bolts and tighten in a star #attern.
5
SOP – REACH STACKER
2.
A##em-l* of ,"+ve !+(+o( -ea"+( '
Responsibilit! In"C#$%&e' S#i(t En&inee%' )o%* Le$+e% P,%pose!
Des-%iption o( p%o-e+,%e (o% $ssebl +i/e pinion be$%in&.
S-ope!
To be +one $t %e-oen+e+ inte%/$l.
Ope%$tin& P%o-e+,%es
TOOLS AND MATERIAL REUIRED! (ool bo*
1) -nsert the t"o outer rings of the ta#er roller bearings into the differential carrier. 2) Calculate the thickness of s#ace ring. 3) eat the drive #inion side ta#er roller bearing to about 1BB
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SOP – REACH STACKER
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