3
CONTENTS
Warranty ............................................................................................................................................................................4
General Information ...........................................................................................................................................................5
Compressor Nameplates ...................................................................................................................................................5
Safety ................................................................................................................................................................................6
Introduction to Oil Free Ambient Air Compressors ............................................................................................................7
Introduction to Air Boosters and Gas Compressors ..........................................................................................................8
Section 1 - Compressor Installation...................................................................................................................................9
Using This Manual ......................................................................................................................................................9
Receipt of Compressor...............................................................................................................................................9
Location ......................................................................................................................................................................9
Foundation .................................................................................................................................................................9
Inlet Piping and Inlet Filtration ....................................................................................................................................10
Discharge Piping ........................................................................................................................................................11
Receivers - Ambient Air Compressors........................................................................................................................12
Receivers - Air Boosters and Gas Compressors ........................................................................................................12
Compressor Cooling - Air Cooling ..............................................................................................................................12
Compressor Cooling - Water Cooling .........................................................................................................................12
Compressor Control Panel .........................................................................................................................................13
Unloader Controls ......................................................................................................................................................13
Safety Devices ...........................................................................................................................................................17
Plumbing of Air Booster and Gas Compressor Packings ...........................................................................................18
Section 2 - Compressor Startup ........................................................................................................................................25
Installation Checklist...................................................................................................................................................25
Using this Manual .......................................................................................................................................................26
Inspection After Extended Storage .............................................................................................................................26
Compressor Speed ....................................................................................................................................................26
Crankcase Lubrication................................................................................................................................................26
Oil Pressure Regulation .............................................................................................................................................27
Oil Pump Direction of Rotation ...................................................................................................................................27
‘V’ Belt Tension Settings .............................................................................................................................................28
Adjustment of Manual Unloader Controls...................................................................................................................30
Adjustment of Automatic Unloader Controls...............................................................................................................32
Additional Controls Adjustment ..................................................................................................................................34
Pre-Startup Check List ...............................................................................................................................................36
Initial Startup and Operation (Ambient Air Compressors) ..........................................................................................36
Initial Startup and Operation (Air Boosters and Gas Compressors)...........................................................................37
Daily Startup Checklist ...............................................................................................................................................38
Section 3 - Maintenance and Troubleshooting ..................................................................................................................39
Maintenance Schedule (Ambient Air Compressors)...................................................................................................39
Maintenance Schedule (Air Boosters and Gas Compressors) ...................................................................................39
Troubleshooting ..........................................................................................................................................................42
Section 4 - Compressor Servicing .....................................................................................................................................44
Torque Settings ..........................................................................................................................................................46
Clearances and Tolerances .......................................................................................................................................47
Compressor Disassembly ..........................................................................................................................................49
Oil Pump Replacement ..............................................................................................................................................50
Bearing Replacement .................................................................................................................................................51
Compressor Assembly ...............................................................................................................................................52
Valve Replacement ....................................................................................................................................................54
Appendix 1 - Tool List ........................................................................................................................................................56
Appendix 2 - Compressor Storage ....................................................................................................................................
57
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