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Alkin W4 Series - User Manual

Alkin W4 Series
100 pages
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W4
SERIES
BREATHING AIR COMPRESSORS

Table of Contents

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Summary

Safety Guidelines and Precautions

General Safety Information

General safety information covering operation, maintenance, and compliance with codes.

Pressure Release Procedures

Procedures for safely releasing pressure before dismantling components.

Fire and Explosion Hazards

Precautions to prevent fire and explosion hazards during operation.

Moving Parts Safety

Warnings about keeping body parts away from moving components.

Hot Surfaces and Sharp Edges

Advice on avoiding contact with hot surfaces and sharp edges.

Toxic and Irritating Substances

Guidelines on handling toxic substances and ensuring proper ventilation.

Electrical Shock Prevention

Safety measures to prevent electrical shock hazards.

Lifting and Moving Safety

Procedures for safely lifting and moving the compressor.

General Information on W4 Series Compressors

Compressor Overview

Overview of W4 series compressors, type, pressure range, and features.

Process and Instrument Diagram

Explains the P&I diagram for system understanding.

Operating Principles

Details the air intake, compression stages, and purification process.

Major Component Descriptions

Explains key components of the compressor unit and system.

Control System Description

Details the automatic start-stop and manual start-automatic stop controls.

Installation Procedures

Pre-Installation Inspection

Checks to perform upon receiving the compressor.

Optimal Location Selection

Guidelines for selecting an optimal installation site.

Piping Installation Guide

Instructions for inlet, discharge, and drain line piping.

Electrical System Checks

Pre-start electrical checks for safe operation.

Wiring and Fusing

Guidance on selecting wire sizes and installing wiring.

Sheave and Belt Alignment

Procedures for checking belt tension and alignment.

Operation and Adjustments

Initial Start-up Guide

Step-by-step guide for the first start-up of the compressor.

Recommended Lubricants

Specifies approved oils and handling instructions.

System Adjustments

Instructions for adjusting pressure switches and drain timers.

Maintenance Schedule and Procedures

General Maintenance Overview

General guidelines for periodical maintenance.

Daily Maintenance Checks

Daily checks for oil level, condensate, and general condition.

Weekly Maintenance Tasks

Weekly inspection of filters, cleaning, and belt tension.

120-Hour Maintenance

Maintenance for purifier cartridge.

300-Hour Maintenance

Checks for leaks and pre-filter cartridge change.

500-Hour Maintenance

Oil change, filter replacement, valve cleaning.

1000-Hour Maintenance

O-ring replacement and valve cleaning.

2000-Hour Maintenance

Piston ring and valve replacement, belt check.

As-Required Maintenance

Checks for motor/engine manual and specific instructions.

Maintenance Task Table

A comprehensive table detailing maintenance tasks and intervals.

Component Servicing Procedures

Detailed procedures for servicing components like valves.

Troubleshooting Guide

Compressor Not Operating

Solutions for common issues preventing compressor operation.

Excessive Noise Issues

Diagnosing and resolving excessive noise during operation.

Compressor Knocking

Troubleshooting causes of compressor knocking.

Oil Contamination

Addressing milky oil and oil in discharge air.

Vibration and Airflow Problems

Troubleshooting vibration and insufficient/excessive air issues.

Pressure and Belt Wear Issues

Resolving pressure vessel, belt wear, and temperature issues.

Valve and Cylinder Issues

Addressing air leaks and slow cylinder pressure build-up.

Control and Electrical Issues

Troubleshooting cut-outs, blown fuses, and speed problems.

Drain Valve Malfunctions

Fixing automatic drain valves not draining or staying open.

Piston;Ring;Cylinder Wear

Diagnosing unusual wear on pistons, rings, or cylinders.

Part Identification

Crankcase Assembly Parts

Exploded view and part numbers for the crankcase assembly.

Connecting Rod Components

Exploded view and part numbers for connecting rods.

1 st and 2 nd Stage Assembly Parts

Exploded view and part numbers for 1st and 2nd stage assemblies.

3 rd Stage Assembly Parts

Exploded view and part numbers for the 3rd stage assembly.

4 th Stage Assembly Parts

Exploded view and part numbers for the 4th stage assembly.

Piston and Ring Components

Exploded view and part numbers for pistons and related parts.

Pipe Lines and Fittings

Exploded view and part numbers for various pipe lines.

Intercoolers and Aftercooler

Exploded view and part numbers for intercoolers and aftercoolers.

Water Separator Components

Exploded view and part numbers for water separators.

Discharge Line Components

Exploded view and part numbers for the discharge line components.

Filter Panel Parts

Exploded view and part numbers for the filter panel.

Coalescer Filter Assembly Parts

Exploded view and part numbers for the coalescer filter assembly.

Purifier Assembly Components

Exploded view and part numbers for the purifier assembly.

Pressure Gauge Line Parts

Exploded view and part numbers for pressure gauge lines.

Drive Assembly Components

Exploded view and part numbers for the drive assembly.

General Connector Parts

Exploded view and part numbers for general connectors.

Dual Pressure Filling Panel

Exploded view and part numbers for the dual pressure filling panel.

330 Bar Filling Panel Parts

Exploded view and part numbers for the 330 Bar filling panel.

225 Bar Filling Panel Parts

Exploded view and part numbers for the 225 Bar filling panel.

Summary

Safety Guidelines and Precautions

General Safety Information

General safety information covering operation, maintenance, and compliance with codes.

Pressure Release Procedures

Procedures for safely releasing pressure before dismantling components.

Fire and Explosion Hazards

Precautions to prevent fire and explosion hazards during operation.

Moving Parts Safety

Warnings about keeping body parts away from moving components.

Hot Surfaces and Sharp Edges

Advice on avoiding contact with hot surfaces and sharp edges.

Toxic and Irritating Substances

Guidelines on handling toxic substances and ensuring proper ventilation.

Electrical Shock Prevention

Safety measures to prevent electrical shock hazards.

Lifting and Moving Safety

Procedures for safely lifting and moving the compressor.

General Information on W4 Series Compressors

Compressor Overview

Overview of W4 series compressors, type, pressure range, and features.

Process and Instrument Diagram

Explains the P&I diagram for system understanding.

Operating Principles

Details the air intake, compression stages, and purification process.

Major Component Descriptions

Explains key components of the compressor unit and system.

Control System Description

Details the automatic start-stop and manual start-automatic stop controls.

Installation Procedures

Pre-Installation Inspection

Checks to perform upon receiving the compressor.

Optimal Location Selection

Guidelines for selecting an optimal installation site.

Piping Installation Guide

Instructions for inlet, discharge, and drain line piping.

Electrical System Checks

Pre-start electrical checks for safe operation.

Wiring and Fusing

Guidance on selecting wire sizes and installing wiring.

Sheave and Belt Alignment

Procedures for checking belt tension and alignment.

Operation and Adjustments

Initial Start-up Guide

Step-by-step guide for the first start-up of the compressor.

Recommended Lubricants

Specifies approved oils and handling instructions.

System Adjustments

Instructions for adjusting pressure switches and drain timers.

Maintenance Schedule and Procedures

General Maintenance Overview

General guidelines for periodical maintenance.

Daily Maintenance Checks

Daily checks for oil level, condensate, and general condition.

Weekly Maintenance Tasks

Weekly inspection of filters, cleaning, and belt tension.

120-Hour Maintenance

Maintenance for purifier cartridge.

300-Hour Maintenance

Checks for leaks and pre-filter cartridge change.

500-Hour Maintenance

Oil change, filter replacement, valve cleaning.

1000-Hour Maintenance

O-ring replacement and valve cleaning.

2000-Hour Maintenance

Piston ring and valve replacement, belt check.

As-Required Maintenance

Checks for motor/engine manual and specific instructions.

Maintenance Task Table

A comprehensive table detailing maintenance tasks and intervals.

Component Servicing Procedures

Detailed procedures for servicing components like valves.

Troubleshooting Guide

Compressor Not Operating

Solutions for common issues preventing compressor operation.

Excessive Noise Issues

Diagnosing and resolving excessive noise during operation.

Compressor Knocking

Troubleshooting causes of compressor knocking.

Oil Contamination

Addressing milky oil and oil in discharge air.

Vibration and Airflow Problems

Troubleshooting vibration and insufficient/excessive air issues.

Pressure and Belt Wear Issues

Resolving pressure vessel, belt wear, and temperature issues.

Valve and Cylinder Issues

Addressing air leaks and slow cylinder pressure build-up.

Control and Electrical Issues

Troubleshooting cut-outs, blown fuses, and speed problems.

Drain Valve Malfunctions

Fixing automatic drain valves not draining or staying open.

Piston;Ring;Cylinder Wear

Diagnosing unusual wear on pistons, rings, or cylinders.

Part Identification

Crankcase Assembly Parts

Exploded view and part numbers for the crankcase assembly.

Connecting Rod Components

Exploded view and part numbers for connecting rods.

1 st and 2 nd Stage Assembly Parts

Exploded view and part numbers for 1st and 2nd stage assemblies.

3 rd Stage Assembly Parts

Exploded view and part numbers for the 3rd stage assembly.

4 th Stage Assembly Parts

Exploded view and part numbers for the 4th stage assembly.

Piston and Ring Components

Exploded view and part numbers for pistons and related parts.

Pipe Lines and Fittings

Exploded view and part numbers for various pipe lines.

Intercoolers and Aftercooler

Exploded view and part numbers for intercoolers and aftercoolers.

Water Separator Components

Exploded view and part numbers for water separators.

Discharge Line Components

Exploded view and part numbers for the discharge line components.

Filter Panel Parts

Exploded view and part numbers for the filter panel.

Coalescer Filter Assembly Parts

Exploded view and part numbers for the coalescer filter assembly.

Purifier Assembly Components

Exploded view and part numbers for the purifier assembly.

Pressure Gauge Line Parts

Exploded view and part numbers for pressure gauge lines.

Drive Assembly Components

Exploded view and part numbers for the drive assembly.

General Connector Parts

Exploded view and part numbers for general connectors.

Dual Pressure Filling Panel

Exploded view and part numbers for the dual pressure filling panel.

330 Bar Filling Panel Parts

Exploded view and part numbers for the 330 Bar filling panel.

225 Bar Filling Panel Parts

Exploded view and part numbers for the 225 Bar filling panel.

Alkin W4 Series Specifications

General IconGeneral
BrandAlkin
ModelW4 Series
CategoryAir Compressor
LanguageEnglish

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