Stratus Series Repair Kit Instructions for Stratus SRC25, SRC252, SRC50, and SRC502 Compressors

Before beginning, you will need:

1. Clean work space
2. T20 and T25 Torx driver
3. Torque driver
4. Water-based solvent
5. Thread locking compound (Loctite® 222)

Repair Kit Contents

1. Piston Cups
2. Cylinders
3. Cylinder O-Rings
4. Head O-Rings
5. Cup Retainer Screws

Repair kit contents may vary depending on your compressor. The SRC50K contents are shown, SRC25K will have half the components shown for single-cylinder repair.

Repair Steps

1. Mark the orientation of head plate(s) and remove. Mark the orientation of valve plate(s), and remove valve plate(s). Clean valve plates with a water-based solvent. Take care not to scratch valve seats.
2. Remove the cylinder o-ring(s) from the bottom of valve plate(s) and install new o-rings.
3. Remove screws from the head of the compressor using a T25 Torx driver. Remove the head.
4. Remove old cylinders and discard.
5. Remove screws from the cup retainer plate with a T20 Torx driver. Discard old cups and retainer screws.
6. Remove new piston cup(s) from protective cardboard packaging. Set new piston cups onto the retainer plate; these parts will sit flat against each other.
7. Set new cylinder(s) on piston(s).
8. Press the retainer plate with piston cup into the cylinder all the way to the piston. The cylinder can be rotated to align the screw holes. Apply thread locking compound (Loctite® 222) to retainer screws, torque screws to 10-13 inch-pounds.
9. Check that the orientation of the valve plate(s) with ports is correct and place over cylinders.
10. Remove old and install new head o-rings in the o-ring grooves on top of the valve plate.
11. Inspect the leaf valves for damage or wear.
    NOTE: There is one intentionally “bent” leaf valve per set. If leaf valves need to be replaced, a complete leaf valve plate can be ordered. The screws holding the leaf valves are susceptible to breaking, which makes individual leaf valve replacement very difficult.
12. Reinstall the head over the valve plate(s), checking that the orientation with ports is correct. Torque screws to 50 inch-pounds.
13. Before putting the unit back into service:

• Install the air intake filter into the inlet port and leave the outlet port open. It is not necessary to connect outlet plumbing connections at this point.
• Plug in the unit and run for five minutes, listening for any odd noises or clicking sounds. If any of these noises are heard, unplug the unit immediately.
• After running for five minutes, remove the head and valve plate and check the cylinder head screws. Tighten the screws to 10-13 inch-pounds and reassemble the valve plate and head to put the unit back into service.

Safety Warnings

⚠️ WARNING: Electrical shock hazard. Disconnect electrical supply before performing maintenance. Vent all air lines to release vacuum or pressure. Failure to follow these instructions may result in death, fire, or electrical shock.

⚠️ WARNING: Injury hazard. Product surfaces become very hot during operation; allow surfaces to cool before handling.

⚠️ WARNING: Do not use oil to lubricate parts. SRC compressors use an oil-less design. Using oil may result in unit failure.

Final Check

✔ Check that all external accessories, such as relief valves and gauges, are not damaged before re-operating the product.
✔ Before putting the unit back into service, it should be run for five minutes, and the cylinder head screws should be checked for tightness. If these screws come loose during operation, the unit will experience extensive damage, which voids the warranty of the unit.