With my various other projects, installing an On-Board Air system in my Jeep had been one of the most satisfying yet most frustrating projects I'd ever taken on. There were many unscheduled trips to the hardware store to purchase a needed part or to return/exchange a part for the correct one. My wife was instrumental in this area, willing to make the run on a moments notice. Hopefully, this write-up will alleviate most of the frustrations I encountered. Now would also be a good time to download the York Compressor Service Manual from this link: http://www.ccicompressor.com/. It is in PDF Acrobat Reader Format so you will also need to download and install this no cost software from http://www.adobe.com.
After weeks of searching for a salvage yard York compressor (I live in a very small town), one was finally located on the "For Sale" forum of JeepsUnlimited and was purchased from one Mr. Trappet who had decided not to install an On-Board Air system on his Jeep. I was very fortunate (Thanks Dave) because not only was there one York compressor included in the package, but 2 compressors (a 210 and a 206 for parts) and a Kilby KE-1000 bracket kit (bracket, pulley, belt and hardware).
With the deal finalized and the package in the mail, it was time to organize and start getting things together. First stop, I called Kilby Enterprises and ordered an air manifold (can also be purchased from Harbor Freight Tools), Flange/Roto Lock (depending on the York head type) fittings, oil removal filter (optional if you want to filter the oil and return it to the York compressor), 0-160 PSI pressure gauge, adjustable relief valve, pressure switch, intake filter, assorted hose barb connectors and Insta-Grip Goodyear high temp/300 PSI air hose.
Parts I scrounged from other sources include a one-way check valve and a pressure regulator from Ebay (Kilby Enterprises also sells this check valve and pressure regulator). The regulator was purchased for when ARB Lockers are installed and has not been installed as of yet. A rubber Quick Connect cover and 1/4" NPT tap were located at the local John Deere tractor implementation parts store and all other parts (i.e. tape, nuts, bolts, 1/4" NPT fittings...) were all locally purchased from Home Depot/Lowe's and auto part stores. The lighted on/off switch was obtained off the internet from Overtons.com.
Time to start preparing all the parts for installation after they arrive and all required parts were purchased. (WOW...what a jigsaw puzzle.)
1. With the double V belt clutch
pulley installed on the York compressor, attach a negative
ground jumper cable from a 12 volt battery (negative side) to the body
case of your compressor. Then attach a positive jumper cable from
your battery positive pole to the wire lead of the clutch pulley. You
should hear the clutch engage with an audible "click". Hear the
click? If so, the clutch is good. Great! If not, then one needs
to be purchased. Now spin the clutch pulley and listen/feel the two top
ports. One port (discharge) should be pumping air out and the other
port (suction) should be sucking air in. Does it work? Great!
Compressor and clutch pulley work. We are on a roll. If possible, do
this check at the salvage yard prior to paying for it.
2. I removed the clutch pulley and magnet from the compressor and, using masking tape, covered the two ports and shaft/shaft bearing seal and took the compressor to my nearest bead blaster for a thorough cleaning. I then painted the compressor with some Wal-Mart Rust-Oleum semi-gloss black rattle can spray paint and allowed it to dry over night.
3. Once the painted compressor was totally dry, all the masking tape was removed. The flange fittings that came on the compressor are also removed at this time and the new Flange fittings with gaskets or the Tube-O Roto Lock fittings with "O" rings are installed using 10W-30 oil to coat the gaskets or the "O" rings. The Flange fittings can be tightened down to spec (17 - 25 ft-lb), while the Roto Locks are just finger tight at this time.
4. Remove both oil fill plugs (one on each side) and completely drain all of the old oil and refill with 12 fl-oz of new 10W-30 oil. Replace the oil plugs. Also at this time, I made my own dip stick for checking the oil level from the instructions provided by Kilby Enterprises web sight. See Figure 1.
5. Apply some Teflon pipe tape to the threads of the discharge flange fitting
and install the 1/2" NPT - 3/8" NPT reducer. Now apply Teflon pipe tape to the
threads of the 3/8" NPT male connector and install the male connector into the
1/2"NPT - 3/8" NPT reducer. See Figure 2.
6. Apply some Teflon pipe tape to the suction flange and install the
female/female 1/2" NPT fitting to the suction flange. Apply Teflon pipe tape to
the compressor air filter and install it into the 1/2" NPT fitting.
See Figure 3.
7. This step is optional if you did or did not purchase the Oil
Removal Filter Kit. If the Filter kit was purchased, then now would be the time
to install the 90 degree elbow provided in the kit with Teflon pipe tape applied
to the threads into the compressor oil filler hole. See Figure 4.
8. Re-install the clutch magnet and clutch pulley with a
spreader wrench, socket and ratchet. See Figure 5.
Take note of the key location and apply a red or yellow mark on the clutch pulley to show the key location. This mark can be utilized to check the oil level per the York Compressor Manual. The Key must be oriented a certain way to properly check oil level.
Finish tightening the flange fittings and the compressor is
now finished. See Figure 6.
Set the compressor aside, admire your handy work and let's begin creating the other two modules. You will need assorted standard combination wrenches, Teflon tape and brass fittings.
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