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Steps for inspecting and reporting any damage incurred during shipment.
Essential safety rules to prevent injury and property damage during operation and maintenance.
Guidance on inspecting, selecting a location, and installing the compressor correctly.
Steps to follow before initial startup, including checking oil and rotation direction.
Regular checks for air leaks, fastener tightness, and overall cleanliness.
Instructions for checking, topping up, and changing compressor oil, including break-in periods.
Procedures for cleaning and replacing the air filter element.
A table outlining maintenance tasks and their recommended intervals based on usage.
Steps for inspecting and reporting any damage incurred during shipment.
Essential safety rules to prevent injury and property damage during operation and maintenance.
Guidance on inspecting, selecting a location, and installing the compressor correctly.
Steps to follow before initial startup, including checking oil and rotation direction.
Regular checks for air leaks, fastener tightness, and overall cleanliness.
Instructions for checking, topping up, and changing compressor oil, including break-in periods.
Procedures for cleaning and replacing the air filter element.
A table outlining maintenance tasks and their recommended intervals based on usage.
This document serves as an instruction manual for an Industrial Series Piston Air Compressor manufactured by Kellogg-American, a company with a history dating back to 1906. The manual provides essential information for the safe and effective operation and maintenance of the compressor.
The Kellogg-American Industrial Series Piston Air Compressor is designed to generate and store compressed air for various industrial applications. It operates by drawing in ambient air, compressing it using a piston mechanism, and then storing the compressed air in an integrated air tank. This compressed air can then be used to power pneumatic tools, machinery, or other systems requiring a reliable source of pressurized air. The compressor is built for industrial environments, emphasizing durability and consistent performance.
The manual outlines several key aspects related to the usage of the compressor, ensuring both safety and optimal performance. Before initial operation, users are instructed to carefully unpack and handle the unit, noting that the pump or drive should not be used as a lift point. A thorough inspection for any shipping damage is crucial, and any issues must be documented with the trucking company and reported to the Kellogg Distributor. It is recommended to keep the unit on its shipping skid until it reaches its final installation site to prevent damage during movement.
Regarding installation, the manual stresses the importance of selecting a clean, dry, and well-lit location. In colder climates, the compressor should be installed in a heated building to prevent issues like condensate dripping onto the motor. It explicitly warns against installing the compressor in environments with high levels of contaminants such as boiler rooms, paint spray rooms, or areas with sandblasting operations. If the ambient air is acid-laden or dust-laden, the compressor intake should be piped to the outside, with specific guidance on increasing pipe size for longer runs to maintain airflow efficiency. The motor's exposure to water, oil, dirt, acid, or alkaline fumes should be minimized, or a specially constructed motor should be used in such conditions. The unit must be securely bolted to a level base, and sufficient space around the compressor is required for maintenance access, with a minimum of six inches from the wall on the pulley side.
Before starting the compressor, if it was shipped without oil, the crankcase must be filled to the high level mark on the sight glass with Kellogg-American oil that meets specific viscosity, flash point, pour point, carbon residue, and base requirements based on ambient temperature. For damp or humid conditions, the addition of a rust inhibitor is recommended. Users are advised to manually turn the compressor over a few revolutions to ensure all parts move freely and to check the tension of the belts. Crucially, all tools, rags, and loose objects must be removed from the vicinity of the compressor, and hands or tools should never be placed on the belts of idle units unless the main power is disconnected and locked. The direction of rotation, indicated by an arrow on the flywheel, must be verified to be counter-clockwise when facing the flywheel, ensuring air is drawn through the intercooler onto the cylinders for maximum cooling.
The manual also emphasizes the importance of understanding and adhering to all safety precautions. Users must read all instructions completely before operation, disengage power before any maintenance, and relieve all pressure from the tank and lines before attempting to remove any pressurized systems. The compressor should never be serviced while in operation, nor should it be operated at pressures or speeds exceeding its nameplate ratings. Guards, shields, or screens must remain in place during operation and be replaced after any maintenance. Daily observation of the delivery pressure gauge is necessary to ensure the automatic control system functions within proper limits. Periodic checks of all safety and relief devices are mandatory. The manual strictly warns against playing with compressed air due to the risk of serious injury or death. It also advises against using flammable solvents for cleaning parts and stresses the importance of cleanliness during repairs. Pressure relief valves should be installed in any isolated piping in the plant system. Finally, users must check pipes for wear or deterioration and ensure all connections are secure before each use.
The manual places significant emphasis on a consistent preventative maintenance program to ensure reliable and satisfactory service from the compressor. Maintenance schedule pages are provided to help users keep proper records.
General maintenance tasks include regular checks of the compressor, the entire system for air leakage around fittings, connections, and gaskets using a soap and water solution, removal of rust and oil soiling, and checking fastener tightness with a torque wrench according to the full operations manual.
For compressor oil, the oil level must be checked weekly and topped off if necessary, filling the tank until the sight glass is ¾ full. A critical instruction is to always use the same brand of oil and never mix different types, weights, or brands. The compressor is initially filled with Kellogg break-in lubricant, an ISO non-detergent industrial lubricant with rust and oxidation inhibitors. A normal break-in period of 25 hours is required, after which the oil must be drained and replaced with Kellogg Synthetic Lubricant. After this first synthetic oil change, the compressor should run for 200 hours, followed by another thorough drain and replacement with synthetic lubricant. For the first 500 hours of operation, a careful and regular check of the oil level is essential, maintaining a full oil level at all times. After 500 hours, the compressor is ready for extended periods between lubricant changes, with oil changes recommended every 3000 operating hours. For constant run applications or units subjected to extremely heavy use, monthly oil changes are advised. The manual also specifies strict adherence to local effluent disposal laws when disposing of condensate.
Air filter maintenance involves checking and cleaning the filter monthly to ensure it is free from debris and functioning properly. The filter element should be replaced every 1500 hours or annually, whichever comes first.
A detailed maintenance intervals table is provided, outlining tasks and their frequencies:
Users are strongly encouraged to download, read, and review the full Operations Manual for their compressor from the Kellogg-American website for comprehensive information.
General| Model | V8073-335 |
|---|---|
| Type | Reciprocating |
| Horsepower | 5 HP |
| Maximum Pressure | 175 PSI |
| Voltage | 230V |
| Cooling Method | Air Cooled |
| Tank Size | 80 gallons |
| Drive Type | Belt |
