alkin airtex manual

ALKIN® W31 (old designation #12T3)

Series 3 Stage High Pressure Compressors 100 – 330 Bars ½ to 4 kW

Instruction Manual

W31- Series Breathing Air Compressors .

Nr. SECTION Page I.1. Foreword

1 I.2. Introduction 1 I.3. Safety

1. General Rules 2. Pressure release 3. Fire & Explosion 4. Moving Parts 5. Hot Surfaces 6. Toxic and irritating Substances 7. Electrical Shock 8. Lifting

1 1 1 1 2 2 2 2 2

I.4. Installation 1. Inspection 2. Location 3. Service piping 4. Electrical Check 5. Sheaves and belt alignment

2 2 2 2 2 2

I.5. W31 Series Compressors Specific Instructions 1. General points to be observed 2. Gas Compressors

3 3 3

I.6. Technical Data 1. Model Designations 2. Performance Data 3. Stage Pressures 4. P & I Diagram – W31x2 Series 5. P & I Diagram – W31 Series

3 3 3 4 4 4

I.7. Operation Cylinder Filling Air Filter Purifier Purifier Cartridge Replacement Air Purifier Care

5 5 6 6 6 6

I.8. Long Term Storage Restarting After Long Term Storage

7 7

I.9. Maintenance LUBRICANT Maintenance Table

8 8 8

I.10 Maintenance Procedures 1. General 2. Torque Values 3. Torque Sequence 4. Valves

9 9 9 9

10&11&12 I.11. Trouble Shooting 13 I.12. Addendum for Gas Compressors 14 I-13. System layout W31x2 Series Compressors

System layout W31 Series Compressors 14 15

I.14. Wiring Diagram 17 II. Parts Manual

Instruction Manual


Your new ALKIN air or gas compressor will provide you with the solid and reliable performance that you should expect from a heavy duty industrial air compressor. Please read this manual carefully before you operate your compressor. This will enable you to start-up your compressor in the proper manner, as well as maintain it using the simple instructions in the maintenance section of this manual. This way your air compressor will always be in top operating condition, giving you years of trouble free service. ALKIN air compressors are well known with their faultless design and unique features combined with the best materials and

workmanship. Some of the most important features are centrifugal unloading regulators, overhung crankshaft design, solid end connecting rods, high efficiency valves, which all add to the superior and lasting performance of the ALKIN compressors. Your compressor is backed up with worldwide sales and service organization, ready to accommodate your everyday needs for parts & service. For any questions, please feel free to call our Menderes plant, in Izmir - Turkey. Here are the contact details:

Address: 3109 East Avenue E Arlington TX 76011

Phone : 817-633-5505 Fax : 817-633-5506 e mail : [email protected] Website: www.alkinusa.com

I – 2. Introduction This manual is consists of three main sections. Section I - General Information & Rules In this section general rule for location selection, installation, operation, maintainence and trouble shooting, warranty terms are taking place. These are general rules that need to be observed in all air and gas applications.

Section II- Specific Data & Instructions In this section, the specific data of the equipment supplied, description of components and the system, including the construction, Process and Instrumentation, controls, wiring diagrams, operation & special maintenance rules –if any- are indicated. Section III – Drawings & Spare parts In this Section, the specific parts lists of the equipment supplied takes place.

I – 3. Safety - GENERAL RULES 1. GENERAL

All ALKIN air and gas compressors are designed and manufactured with equipment, allowing safe operation of the compressors. It is the user’s responsibility however, to safely operate and maintain the compressor, observe the rules and instructions, as well as the local safety codes, to minimize the risk of accidents and injury. The following safety precautions are offered only as a guideline, and it is recommended to follow them along with the locale safety codes and regulations. Those who have been trained to do so, and who have read and understood the contents of this manual should only operate this compressor. Failure to do so will increase the risks of accidents and bodily injury. Never start this compressor unless it is safe to do so. Do not operate it with known unsafe condition. Tag the compressor and render it inoperative by disconnecting the power supply, so that others who may not know of the unsafe condition will not attempt to operate it until the unsafe condition is corrected. Install, use and operate this air compressor only in full compliance with all pertinent O.S.H.A. requirements (USA & Canada), and all relevant Federal, State and local codes and regulations. Do not modify this compressor and do not use beyond the specified limits and speeds except with prior written approval of ALKIN. 2. Pressure Release (air compressors only)

Pull the check ring under pressure on both safety valves weekly to make sure that they are not blocked, clogged or otherwise disabled. On gas compressors test the safety valves periodically as per the specific instructions and local regulations. Do not open the oil filling plug or any other connection, tube, hose, fitting, valve etc. when the compressor is running or when it is standing by (waiting for the pressure switch signal to re-start). Switch off the main electrical switch, shut off the discharge valve and vent all pressurized sections before attempting to dismantle such components. Keep all persons away from the discharge opening of hoses, tools accessories during venting. Do not use air pressure above 2 Bars (30

Psi) for blow cleaning purposes, and without use of proper protective equipment as per OSHA Standard Section 29 CFR 1910.242 (b). Do not engage in horseplay with hoses as serious injury or death may result. Drain daily the condensate from the air receiver, as it may accelerate the internal rusting and corrosion of the receiver. 3. Fire and Explosion

Clean up oil spills immediately, if and when it occurs. Shut off the air compressor and allow it to cool. Keep sparks, flame and other sources of ignition away and do not allow smoking in the vicinity when checking, draining or adding oil. Do not permit liquids such as air line anti-icer system anti-freeze compound, or oil film or any other combustible substance to accumulate on any external or internal surfaces of the compressor. Wipe down with aqueous industrial cleaner or steam to clean as required. Do not use flammable solvents for cleaning purposes. Disconnect the power supply prior to attempting any repair or cleaning. Tag the power supply to avoid unexpected start by someone else. Keep electrical wiring, including terminals, in good condition. Replace any wiring that has cracked, cut, abraded or otherwise degraded insulation or terminals that are worn, discolored and corroded. Keep all terminals clean and tight. Keep grounded conductive objects such as tools, away from exposed live electrical parts such as terminals, to avoid arcing which might serve as a source of ignition. Do not attempt to weld on the receiver or any part welded to the receiver or to the piping. Any such works or the receiver manufacturer can only make repairs; subsequently a hydrostatic pressure test will be required for re-certification for worthiness of the receiver for use as a pressure vessel. Keep a suitable BC or ABC fire extinguisher(s) nearby while servicing and operating the compressor. Keep oil rags, trash, leaves litter and other combustibles away from the compressor. Do not spray volatile materials into the compressor intake, as serious damage to the compressor and personal injury or death may result.

Instruction Manual


4. Moving Parts Keep Hands, arms and other parts of the body and clothing away from belts, pulleys and other moving parts. Do not attempt to operate the compressor with the belt guard removed. Wear snug fitting clothing and confine long hair when working around the compressor, especially when exposed to hot and /or moving parts. Make sure all persons are clear of the compressor prior to attempting to operate it. Make adjustments only when the compressor is shut off. When necessary, make adjustments, than start the compressor to check if the adjustment. If incorrect, shut the compressor, blow down the air, re-adjust, than re-start to check the adjustment. Keep hands, feet, floors, controls and walking surfaces clean and free from oil, water, anti freeze, or other liquids to minimize the possibility of slips, falls and shock hazard. 5. Hot Surfaces, Sharp Edges and Sharp Corners.

Avoid physical contact with hot oil, hot surfaces, sharp edges and corners. Keep all parts of the body away from all points of air discharge and away from hot cylinder heads, discharge pipes and intercooler surfaces. Wear personal protective equipment, including gloves and protective hat when working on or around the compressor. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. Don’t ignore small cuts and burns as they may lead to infections. 6. Toxic and Irritating Substances Do not use air from this compressor for breathing except in full compliance with OSHA standard 29 CFR 1910 and any other Federal, State and local codes and regulations. Operate the compressor only in well ventilated areas. Lubricant used in this compressor are specific oils to operate high pressure air and gas compressors, preventing carbon collection under heat and extreme operating conditions. Do not change the lubricant with another make. Accidental ingestion and skin contact should be avoided. Wash with soap and water after skin contact. If swallowed, seek medical treatment promptly. 7. Electrical Shock

Keep the compressor, hoses, tools and personnel at least 3 meters (10ft) from power lines, panels, and underground cables. Keep al parts of the body and any hand held tools or other conductive objects away from exposed live parts of the electrical system. Maintain dry footing, stand on insulating surfaces, and do not contact any other portion of the compressor when making adjustments or repairs to exposed parts of the electrical system. 8. Lifting

Lift in full compliance with codes and regulations. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition, and has a rated capacity of at least the wet weight of the compressor. If you are unsure of the weight, check before lifting. Make sure the lifting hook has a functional safety latch, and is fully engaged on the sling(s). Use guide ropes to prevent twisting or swinging of the machine once it has been lifted off the ground. Keep all persons clear from under and away from the compressor when it is suspended. Lift the compressor no higher than necessary. Keep lift operator in constant attendance whenever the compressor suspended. Set the compressor down on level surfaces, capable of carrying its full weight. 9. Carbon Monoxide Carbon Monoxide is VERY dangerous. We always recommend the electric when ever possible. Less noise, vibration, heat and no Carbon Monoxide. Now if your only choice is a gas power compressor and it is for breathing air let us know and we will include at no charge a 6 foot hose assembly to get the compressor intake farther away from the exhaust of the motor. Also good common sense helps here, put the fresh air intake up wind of the motor so the wind is blowing the exhaust AWAY from the intake. Change the filters regularly (Lawrence Factor has a filter that has Monoxycon and it is supposed to do a little better job of converting Carbon monoxide to a less dangerous Carbon Dioxide). Still bad air in will get you bad air out fairly quickly. The filter can get rid of small amounts of Carbon monoxide but how much? Be very careful and err on the side of safety. This is with any compressor brand you must be careful of Carbon Monoxide or any harmful contaminants. We sell several different types of Carbon monoxide Monitors. Call us for your needs.

I – 4. INSTALLATION - GENERAL RULES 1. INSPECTION The compressor should be inspected and checked for the following: 1. Damage during shipping, handling etc. 2. Check the compressor nameplate to verify the equipment

conforms the working parameters. 3. Check the electrical motor nameplate to match the available

power and electrical supply. 4. Check if the machine is filled with oil or supplied dry. 2. LOCATION The compressor should be located in an area that will be dry and sheltered, well ventilated, not exposed to high ambient temperatures, air borne contaminants such as dust, fumes, lint, vapour, steam, gases, engine exhaust and other contaminants. Install the compressor with a minimum of 600 mm (24”) clearance between adjacent surfaces, to insure adequate cooling and access for service.

Install the compressor on a level surface of sufficient strength to support the static weight of the equipment, as well as the dynamic forces resulting form its operation. Use 150 mm (6”) thick concrete foundation to bolt the compressor down. Use shims to level and tighten the compressor. Do not exert force bolting the receiver down, as this will created unwanted stresses in the structure of the vessel. Use shims to take the gaps between the feet and the concrete foundation. 3. SERVICE PIPING

Service air (or gas) piping should be installed in full compliance with all Federal, State and local codes, standards and regulations. A shut off valve should be installed to isolate the compressor receiver from the service line. Air outlets should be piped from top of the service line for drop legs. Drain legs should also be installed to remove condensating water vapor from the air piping.

Instruction Manual


4. ELECTRICAL CHECK Although all electrical instructions addressed to the reader directly, the actual inspection, wiring, installation, maintenance, repair etc. must be carried out by licensed and certified electricians only. Make electrical connections to the compressor in accordance with the wiring diagrams and in full compliance with all applicable Federal, State and Local standards, codes and regulations, including those dealing with the grounding requirements. A few electrical checks should be made to insure that the first start up would be trouble free. Make the following checks before attempting any start up: 1. Check the line voltage. Verify that the compressor motor

corresponds to mains specifications. 2. Check the starter and overload for conformity with the motor

power and current data.

3. Check all electrical connections for tightness. At start up, check the direction of rotation to insure flywheel rotating in the direction of the arrow on it. Although a few minutes of operation in the wrong direction of rotation will not damage the compressor, but running it this way in normal operation will create serious damage as the cooling air flow will be reversed, preventing the compressor cylinders to be cooled during operation. 5. Sheaves and V-belt alignment check Compressor and driver sheaves should be checked for parallel alignment of the V grooves. Check the V-belt tension. Proper tension should be adjusted to give about 13 mm (½ ”) deflection with a 1 kg (2 pounds) weight applied at the center of each belt. When operating, the V-belt should have a slight bow on the lower section of the belt.

I – 5. W31 Series Compressors - Specific Instructions

General Points to be observed 1. Make sure that the compressor operates in a well ventilated and

clean area and that no contaminants such as smoke, toxic gases, fumes, odor generating vapors will not enter the compressor through its inlet filter

2. The inlet filter should always be clean and in good condition; replace it on time or when needed.

3. Maintain the compressor in accordance with the specific instructions indicated in this manual.

4. The pressure vessels or bottles must be inspected, maintained, and used in strict accordance with the pressure vessel codes in force in the location of use.

5. Do not attempt to repair the compressor if you are not trained to do so.

6. Do not alter the safety valve settings. 7. Do not alter or modify the compressor, do not use it for any other

purpose than it is designed for, do not operate it with parameters other than those specified in the nameplate.

FOR GAS COMPRESSORS 1. Make sure all gas connections are tight and no leaks exist. 2. All the safety valve exhaust ports and the moisture drains are

connected to a single manifold. This manifold have to be piped to an open and remote area where -in case the safety valve blows- it will discharge the gas with no immediate danger to any persons, and will not create a fire hazard.

3. Inspect the fittings, connections, safety valves and drains, shaft seal area periodically to insure that there are no gas leaks.

I – 6. TECHNICAL DATA

The model designation for these series compressors have been changed as follows:

Old Model Designation New Model Designation 12T3 W31

12T3x2 W31x2 The W31x2 series are duplex configuration of the W31 series compressors, utilizing the same three-stage compressor unit on both series. The group consisting of both series are called Junior Series. Model Designations indicate the following details:

W31 – 2 – 225 – P2

Purifier (size 2 – Equivalent of Bauer P21) – refillable Operating Pressure in Bars (multipy by 14,5 to get this value in Psi) Basic two pressures are : 225 Bars (3260 Psi) 310 Bars (4500 Psi) If different pressure is required, specify in the model designation like : W31-2-240-P2 , which means the compressor you want should operate at 240 Bars (3480 Psi). Max. Pressure for this range compressors is 4500 Psi. Higher pressures are available with different cylinder heads. Specify your needs indicating the maximum operating pressure you need.

Motor Power in kilowatts; 2 indicated 2,2 kW (3HP), 4 indicates 4 kW (5½ HP)

W indicates the cylinder configuration to be of W type (three cylinders); 3 indicates 3 stages, and 1 indicates this compressor to have a free air delivery of 100 liters/minute (3,5 cfm). The models with W31x2 designation shows that, this model has two simlar compressor blocks of Model W31.

Instruction Manual


General specifications of the Junior Series Breathing Air Compressors (W31 and W31x2 series) are as follows: Performance Data

Operating Pressure FAD Motor Power

ALKIN Model Bars Psi Lt/min Cfm HP kW RPM Bore x Stroke Nr.of Stages

W31-2-225-P2 225 3260 3 2,2 W31-4P-225-P2 225 3260 5,5 HP petrol eng. 5 W31-2-310-P2 310 4500 3 2,2 W31-4P-310-P2 310 4500

100 3,6

5,5 HP petrol eng 4

1st Stage : 60 mm 2nd Stage : 36 mm 3rd Stage : 14 mm Stroke : 40 mm

W31X2-4-225-P2 225 3260 5,5 4 W31X2-6P-225-P2 225 3260 8 HP petrol eng 5,5 W31X2-4-310-P2 310 4500 5,5 4 JU

NIO

R S

ERIE

S

W31X2-6P-310-P2 310 4500

201 7,1

8 HP petrol eng 5,5

1200

60&36 &14 x40 [2x]

3

Instruction Manual


Stage Pressures

Stage Operating Pressure 200 Bars (2900 Psi) Operating Pressure 300 Bars (4350 Psi)

1st stage discharge 3,5 - 4,0 Bars 3,5 - 4,5 Bars

2nd stage discharge 25,0 - 30,0 Bars 25,0 - 35,0 Bars

3rd stage discharge 200 Bars 200 Bars

P & I Diagrams

W31x2 Duplex compressor series P & I Diagram

P & I Diagram for W31 series compressors

P&I Diagram- W31 Series (old model #12T3) 3 Stage Air Compressors D.Nr: 6993-2ALKINCOMPRESSORS®Menderes-IZMIR-TURKEYTEL: 0090 232 78 222 90FAX: 0090 232 78 222 89

2nd Stg.

PURIFIER

CONDENSATE SEP.

3rd Stg.

1st stg. AIR INLET

1st stg-2nd stg.

2nd stg.-3rd stg.

INTERCOOLER

INTERCOOLER

AFTERCOOLER

SAFETY VALVE

VALVESAFETY

SAFETY VALVE

Pressure Gage

FILLING YOKE

Drain

Drain

AIR FILTER

2nd Stg.

2nd Stg.

PURIFIER

DRAIN VALVE

CONDENSATE

CONDENSATE

SEP.

SEP.

3rd Stg.

3rd Stg.

1st stg.

1st stg.

AIR INLET

AIR INLET

1st stg-2nd stg.

1st stg-2nd stg.

2nd stg./3rd stg.

2nd stg./3rd stg.

INTERCOOLER

INTERCOOLER

INTERCOOLER

INTERCOOLER

AFTERCOOLER

AFTERCOOLER

SAFETY VALVE

SAFETY VALVE

VALVE

VALVE

SAFETY

SAFETY

SAFETY VALVE

0

0

400

400

bar

bar

PRESSURE GAGE

SWITCH GAGE

PRESSURE GAGE

PRIORITY VALVE

FILLING YOKE

FILLING VALVE

FILLING YOKEDrain

Drain

Drain

AIR FILTER

AIR FILTER

ALKINCOMPRESSORS®

P&I Diagram- W31x2 (old designation 2x12T3)Drw. Nr. :

Date :6993-3

26/11/2000

100 300

200

4000

Fig.1 P&I Diagram W31x2

Fig.2 P&I Diagram W31

Instruction Manual


I – 7. Operation

1. Read this manual carefully and make sure that

everything is clear. Do not let anyone to interfere or operate the compressor who has not learned and/or who is not qualified to do so.

2. Make sure that the persons in charge of filling are thoroughly familiar with the compressor, the operating principles, connecting the hose, gage readings and the filling procedure.

3. Check that the compressor is located in a well-ventilated are and is far from fumes, smoke and toxic gases. The compressor should sit on a horizontal floor, or should be levelled so that the maximum inclination does not exceed 5%.

4. Check the mains supply against the motor nameplate data to insure that the voltages and phases correspond.

5. Check the oil level. The correct level should be about the middle of the plastic sight gage. Do not overfill the compressor.

6. Jog the compressor (start it for a few seconds) to verify that the direction of rotation is correct. If it is not, reverse the phases on three phase motors, at the switch box (not on the motor terminal box). Qualified electricians must carry out all electrical works.

7. If the direction is correct you may start the compressor. Observe for the first time the pressure

and the general operating status of the compressor and make sure that the unit is sitting on the floor properly; there is no vibration, knocks or irregular sounds.

8. Prior to first operation and subsequent to each maintenance work, turn the compressor flywheel manually to verify that the compressor is turning freely.

9. Prior to first operation or subsequent to a maintenance / repair work, operate the compressor for at least 10 minutes with the condensate valves fully open, with no pressure built up; this will allow all the parts to be properly lubricated before the compressor is operated under load (before compressing air).

10. Open the filling valve when operating the compressor.

Cylinder Filling Operation 1. WARNING: Never open the filling valve unless a

bottle is connected and its valve is open. Otherwise hose whipping may cause serious injury.

2. Connect the yoke to the bottle. Open the valve of the bottle. Open the filling valve.

3. Run the compressor; on systems with automatic stop pressure switch, the compressor will stop at the pre set pressure. When stops, shut the valve of the bottle; remove the yoke.

1st STAGE

3rd STAGE

3rd STAGE2nd STAGE

90° ROTATED90° ROTATED

2nd STAGE

AIR INLETAIR DISCHARGE

AIR DISCHARGE

AIRDISCH.

AIR INLETAIR INLET

1st STAGE

2nd STAGE

2nd STAGE

2nd STAGE3rd STAGE

OIL FILL

OIL DRAIN

OILLEVELGAGE

CRANKSHAFT

CRANKCASE

Fig.3 W31 Compressor

Instruction Manual


4. On compressors with no automatic stop pressure switch, the safety valve will blow when it reaches the maximum working pressure. STOP the compressor at this point.

5. Shut the bottle valve and remove the yoke. Air Filter Check the intake filter element every 50 hours; clean blowing air from inside out. Replace the element every 3 months or earlier, depending on the environmental conditions. Purifier The compressor will safely operate between 5 C to 40 C; lower temperatures may cause blockage, while higher temperatures may affect the purification efficiency. The following table is provided as a guideline for replacing the purifier cartridge. It must be remembered however, that there might be additional factors that may affect the purifier cartridge life. Pressure Swtichgage The W31 series compressors are controlled by a pressure switch that cuts off the motor control line when the operating set pressure is reached; it cuts in when the pressure drops below the pre set low pressure limit, starting the motor again. When the main motor is stopped by the pressure switch, the two top fans keep working for an additional period of time (generally 4 to 10 minutes depending on the ambient temperatures); this is controlled by a timer (0-30 min setting range) . This feature is incorporated in the system to permit good cooling even after the compressor stops, thus allowing the next start in a cooler state. This improves the valve life and the performance, it protects the lubricant and prolongs the overall life of the compressor. On diesel engine driven

compressors, a constant speed control system is added to the package; this includes head and discharge unloaders for the compressor unit, and an unloading system which allows the compressor to run without compressint air. See specific instructions for diesel driven units. Pressure Switch Adjustment Remove the cap in the center of the dial of the pressure switch-gage unit. Insert the special key delivered with your compressor and turn clockwise to increase or anticlockwise decrease the setting of the first dial. Than push the key gently and perform the same operation for the second dial. When done, remove the key, return the cap in place and store the key in a safe place so that unauthorized persons cannot reach. Do not attach the key onto the switch or canopy it self. The key on a new compressor is attached in the back of the switch-gage; open the door and remove it for safe storage elsewhere

WARNING

The oil inside the pressure control switch-gage is special dielectric oil. DO NOT USE ANY OTHER OIL TO TOP UP OR FILL THE PRESSURE SWTICHGAGE

WARNING: The lifespan of a filter depends on many factors including proper maintenance, humidity levels, location of compressor, etc. Always air on the side of caution as operating your compressor without a properly functioning filter can be fatal, particularly if used for breathing air. Air Purifier CareWARNING: Before replacing the cartridge, clean the moisture separator and the purifier housing

thoroughly. Install the cartridge with care, making sure that the o-rings are in good condition and are in place.

100 300

200

4000

#7248

Fig.4 Pressure Switch Gage

Instruction Manual


I – 8. Long Term Storage Long Term Storage: Follow these instructions whenever the compressor will not be used for six months or more: 1. Store the compressor indoors, in a dry and clean

room. 2. Run the compressor under pressure for about 10

minutes 3. Check all the pipes, fittings, filters, drain points,

safety valves and make sure there are no leaks. 4. When the compressor is warm, shut it down. 5. Drain the condensate from the moisture trap and

the purifier. 6. Remove the intake filter; jog the compressor for a

few seconds, while spraying a small amount (5 - 6 cc) of compressor oil through its intake. Stop the compressor.

7. Close all the valves. 8. Remove the mains supply. 9. Place a dust cap at the intake port.

10. See specific motor / engine instructions for long term storage.

Restarting after long term storage: 1. Clean the dust from the compressor. 2. Remove the dust cap from the intake port. 3. Check the oil level; make sure there are no leaks

or sweating around the connections, gaskets etc. 4. Run the compressor until warm, for about 1o

minutes, with all the drain valves, filling valve (or outlet valve) opens. (the compressor will run against atmospheric pressure with no load)

5. Check for leaks at the connections, fittings, safety valves etc.

6. Stop the compressor; drain the oil while still hot; install a new purifier cartridge and an intake filter element.

7. Run the compressor again; verify that there are no leaks.

8. Put the compressor in normal service.

Instruction Manual


I – 9. Maintenance Lubricants: The compressor crankcase is designed to take 0,250 Lt. Oil. The lubricants have to be changed every 100 working hours. In any case, if these hours are not reached within 6 months, replace the oil no later than every 6 months. Use the proper lubricant at all times. Do not mix different lubricants. Here is a list of recommended oils:

Lubricant to be used an all W31 Series High Pressure compressors: UL 751

Maintenance Table

Maintenance Period DAILY WEEKLY 100 Hours 400 Hours 1000 Hours I:Inspect/M:Maintain/R:Replace I M R I M R I M R I M R I M R Oil Change INTAKE FILTER V - BELT Pressure Vessels w/o auto drain valve. 1. Condensate Drain 2. Pressure vessel test PIPING & CONNECTIONS 1. Leaks 2. Tightening of bolts & fittings CLEANING 1. Intercoolers & After cooler 2. Flywheel, cylinder fins 3. General SWITCHES & GAGES 1 Pressure Switch-gage Settings (W31x2) 2. Pressure Gages

SAFETY VALVES COMPRESSOR VALVES Piston Rings 1st & 2nd stages

3rd Stage

Check

Replace ELECTRICAL (for W31x2 Series) 1. Contactor/Soft Starter connections 2. Contacts 3. Current (loaded and unloaded) 3. Terminals (tighten the screws)

Filling Valves

Whips & Yokes Vibration Mounts, motor mounts Purifier Cartridge

I – 10. MAINTENANCE PROCEDURES

Instruction Manual


CAUTION Bring the main isolating switch to “Off” [or `0`] position before attempting doing any repair work on the unit to

prevent accidental (or automatic) starting. Blow down all pressure from the compressor, filter & purifier and isolate the unit from any outside sources of air pressure such as filling stations, cylinders etc. These simple precautions will

prevent fatal accidents

1. GENERAL This section covers the operations which the general users may not be too familiar. It is expected that the user would have the average technical training & knowledge and experience that will permit to perform the common maintenance functions without the need of detailed instructions.

2. TORQUE VALUES The following table indicates the torque values to which a torque wrench should be set for tightening the various size attaching bolts & nuts. Use these values to set a torque wrench to tighten these fastners at intervals indicated in the Maintenance table.

TORQUE VALUE TABLES

Bolt or screw Thread Max. torque

Hex and Allen head M 6 10 Nm (7 ft-lb)






Pipe connections (swivel nuts) Finger-tight+1/2turn

3. TORQUE SEQUENCE

1

2

3

4

1

2

3

4 5

6

Fig. 5 Torque sequene

Instruction Manual


4. VALVES

4.1. Initial operational check of valves After roughly half an hour’s operation, Valves should be checked. Note that intake line to valve heads should be hand warm and outlet-piping should be hot. Valves are then operating properly. Should the intake pipe to the valve head of second stage heat up excessively, and first stage safety valve blow off, this would be an indication that either intake or pressure valve of second stage is malfunctioning. It is, therefore, necessary to remove the valve head and to check and these valves, or to replace them. 4.2. General instructions for changing the valves

Always replace valves as a complete set. Carefully clean dirty valves. Never use a sharp

tool for this purpose. Soak the valves in diesel oil or petroleum and clean with soft brush.

Lubricate valves before installing with weicon AS 040, order no. N19753, or equivalent.

Check individual components for excessive wear. If the valve seat and valve disks are dented, replace the valves.

Valve head screws must be tightened with a torque wrench.(see page I-9)

Check the valve space in the valve heads for dirt and clean, if necessary.

Use only satisfactory gaskets and o-rings on reassembly.

Observe the correct sequence when fitting together again.

After finishing all maintenance work on the valves, turn the compressor manually using the flywheel and check whether all items have been correctly installed.

30 minutes after restarting the compressor unit stop unit, let is cool down to ambient temperature and retighten valve studs and cap nuts. Otherwise valves could work loose due to settings of the gaskets.

Remove and check the valves every 1000 operating hours.

Replace the valves every 2000 operating hours to avoid fatigue failure.

3.3. Changing the valves of the 1st stage

Removal of 1st stage pressure valve: Remove cap nut Loosen Allen set screw Remove the coupling

Assemble in reverse sequence

CAUTION In order to avoid damaging the special tool or the valve when using the tool, ensure that it is pushed properly and firmly into the valve bore

so that it will not tilt when it is turned

Intake and pressure valve of the 1st stage is combined in one plate valve under the valve head. Check that marks “TOP” is really at the top when installed.

3.4. Changing valves of the 2nd stage Unscrew intake and pressure lines from the

cylinder head (7, Fig.6). Remove internal hex. Screws fixing cylinder head

and completely remove the cylinder head from the cylinder.

Insert two metal pins – 8-mm diameter, any length – in the holes in the cylinder head and secure these in a vice with the cylinder head on top.

Unscrew intake valve body with the special tool.Fig.7)

CAUTION In order to avoid damaging the special tool or the

valve when using the tool, ensure that it is pushed properly and firmly into the valve bore so that it is

will not tilt when it is turned.

Turn the cylinder head and replace it on the metal

pins. Unscrew the cap nut (1, Fig. 6) refer to Fig.8. Unscrew stud (2) approx. 5 turns.

6

5

7

12

3

4

Fig. 6 Valves, 2nd stage

Instruction Manual


Unscrew screw - in pressure plug (3), take out the pressure valve parts.

Clean intake and pressure valves and check for damages. Valve seats and plate valves must not show any signs of wear damage. Replace damaged parts.

Check O-ring (4), replace if necessary. Clean cylinder head. Check that the intake

pressure valve bores are in perfect condition. Check with a precision straightedge that the

underside of the cylinder head is flat, if necessary use an emery cloth to smooth out the surface.

CAUTION Valve spring and valve plate must not be

jammed.

Check valve function. To do so, blow compressed air through the valve in the direction of flow.

Secure the intake valve as follows: Peen the cylinder head aluminium on the screw-in thread of the intake valve in two places opposite one another with a small drift pin, diameter approx. 5mm (fig. 10) Insert the pressure valve parts and the o-ring.

NOTE Check the pressure valve function and stroke

by lifting the valve plate.

Screw in the screw-in pressure plug with a

pressure pad and tighten.

NOTE

Fig. 7 Removing the intake valve

Fig. 8 Unscrewing the cap nut

Fig. 9 removing the screw-in pressure plug

Fig. 10 Securing the intake valve

Instruction Manual


Ensure that the stud is unscrewed.

Screw in the stud firmly, fit a new gasket and

secure with the cap nut. Put the cylinder head on the cylinder and secure it

with the internal hex. screws, for the correct torque value, see page I – 9.

Reconnect the intake and pressure lines. 4.5. Changing the valves of the 3rd stage For removal and installation of the 3rd stage intake valve proceed according to 4.4. Pressure valve (5) is merely inserted into valve head (7). It is sealed y O-ring (4) and fixed to the valve head by stud (3).

CAUTION Check intake and pressure valves together, only.

Removal and reinstallation of 3rd stage pressure valve (Fig. 11). Remove acorn nut (1), rewind stud (3) up to three

or four turns. Remove internal hex. Screw (9) fixing valve head

(7), take off valve head cover (8). Put two screwdrivers into the groove of outlet

valve body, see fig. 12. If necessary loosen valve first by using a 13-mm spanner on the flat surfaces.

Lift out pressure valve (5) together with o-ring (4).

Reinstall pressure valve (5) in reverse sequence: Put O-ring (4) into valve head (7). Check O-ring

for abrasions. Insert pressure valve (5). Put on valve head covers

(8). Fix valve head (7) with internal hex. screws. Screw in and fasten stud (3).

Put on gasket (2) Screw on acorn nut (1).

9

8

7

1

2

5

3

4

6

Fig. 11 Valve head 3rd stage

Fig. 12 Removal of 3rd stage pressure valve

Instruction Manual


I – 11. Trouble Shooting 1. COMPRESSOR WILL NOT OPERATE

Probable Cause Remedy 1. No electrical power Switch the power on 2. Motor starter overload tripped Re-start and check if trips again. Make sure that the compressor is not

starting against load, such as against pressurized purifier. 3. Pressure switch not making contact Check the pressure switch; replace if needed.

2. Slow filling 1. Intake filter blocked Replace the filter element 2. One or more valve sets are not closing due to dirt or carbon collection

Check the interstage pressure against the values indicated in this manual. Check the valves; clean or replace the valves.

3. Worn piston springs; compressed air blowing into the crankcase

Replace the piston rings.

4. Worn cylinders Replace the cylinders 5. Leaks in the system Check, correct fault.

3. Pressure is not building up 1. Moisture separator drain valve, filling valve or other fittings leaking

Check, re-seal, and tighten.

2. Safety valves are blowing at pressures below their settings

Replace the safety valve or have it re-set by authorized services.

3. Pressure gage reading faulty Check with another pressure gage; Replace the pressure gage if required.

4. Safety Valves Blowing 1. If 1st stage valve is blowing, the 2nd stage valve may not be properly closing.

Check, replace the 2nd stage valves if required.

1. If 2nd stage valve is blowing, the 3rd stage valve may not be properly closing.

Check, replace the 3rd stage valves if required.

3. The safety valve is faulty Check; replace. 4. The 3rd stage piston is stacked Replace the piston assembly

5. Compressor running hot 1. Hot ambient, insufficient ventilation Check and make sure that the ambient temperatures are below +40º C;

provide sufficient ventilation to the area. 2. Inlet and discharge valves are worn or dirty and not closing properly.

Check, clean valves; replace if required.

3. Wrong direction of rotation Check the arrow; the compressor flywheel must blow air onto the cylinders; if the direction of rotation is wrong, reverse the phases and make sure it is running in the right direction.

4. Low oil level Check; re fill.

6. Odors in the compressed air 1. Purifier cartridge saturated Replace the cartridge 2. Improper oil Drain the oil; flush and fill the compressor with proper oil (0,25 Lt) 3. Wrong direction of rotation Check the arrow; the compressor flywheel must blow air onto the

cylinders; if the direction of rotation is wrong, reverse the phases and make sure it is running in the right direction.

4. Carbonization of valves Clean; make sure that the ambient temperatures are within permissible

Instruction Manual


limits.

Warning 1. Do not alter safety valve settings 2. Do not alter pressure switch setting out with the

operational limits of the compressor. 3. Do not repair the hoses; if damaged replace. 4. Do not use work hoses; check the hose

periodically. 5. Check for leaks from time to time by using soaped

water.

6. Before any maintenance or repair works, isolate the mains supply blow down all the compressed air from within the purifier and other elements - if any-.

7. Do not carry any works if you are not familiar with the principles and basics of high-pressure compressors.

8. Call on the factory for any assistance.

I – 12. Addendum For Gas Compressors The gas compressors are supplied with safety valves the discharge ports of which have to be piped to remove the gas blown to a remote and safe area. For convenience the safety valves discharge ports are piped to a single manifold. Pipe this manifold to an area where -if the safety valve blows, the gas will not create a hazardous situation.

Also make sure that all electrical works are done according to local safety regulations. See the drawings that are attached when the compressor is built for gas applications, to identify the various system components.

I – 13. System Layout

W31x2 Series electric motor driven compressors

885 (34,8

")

470(18,5")

985(

38,8

")

Drwg.# 7365

Instruction Manual


W31 Series electric motor driven compressors

W31 Series mariner compressors

450

340 770

Safety Valve

Oil Discharge Plug

Condensate SeparatorDrain Valve Oil Level

Purifier

PurifierDrain Valve

Belt GuardWheel

Drw# 6991-01

450

340

Safety Valve

Oil Discharge Plug

Condensate SeparatorDrain Valve Oil Level

Purifier

Belt Guard

Wheel

850

Drw# 6991-02

Instruction Manual


Ownership Records If this section is not filled in, we strongly recommend that you make a record of all the data available to you upon receipt of the equipment. You will need to advise these details on any warranty matters and/or placing orders for spare parts.

Compressor System Type 3 stage breathing air compressor Model W31 – 2 - – P2 Serial Number Medium Air Application Breathing Air Cylinder filling Rated Free Air (gas) delivery 100 lt/min Operating Pressure BAR General Arrangement Drawing. Process & Instrument Drawing. Production File Number Relevant Drawing Numbers Parts List

Compressor Unit

Model Type Recip. Serial Number

Year Max. Operating Press. Inlet Pressure Atmospheric

Application Air Oil Type UL 751 Other

Stroke 40 LP Bore x nr.of LP cyl. 88 HP Bore

36&14

Electric Motor

Type Make Serial Number

Power (kW) Power (HP) RPM 2950 Voltage Frequency Phase 3

Insulation F Frame Type IP54

Current Rating Full Load Current Off Load Current

Drive

Type Belt dr. Compressor Flywheel Motor Sheave

Belt Section 13 mm Belt Size Number

Instruction Manual


of belts Pressure Control

Type Pressure switch gage Model Make Alkin

Differential P.

Cut out pressure Cut In pressure

Other Data Electrical Control Panel & Motor Starter Drawing Number Parts List Number

Instruction Manual


COMISSIONING REPORT – INITIAL START UP CUSTOMER DETAILS Name of the Company

Address

Contact Name

Position Phone Fax

Name of Plant Where Equipment Installed (If different than the above)

Address

Contact Name

Position Phone Fax

Distributor

Persons Attending the Commissioning Full Name Position In charge of Signature

Equipment Details Model

Serial Nr.

Date of purchase Date of comissioning

Application

Medium Air Gas (specify) : ………………………………………………………………… PRELIMINARY CHECKS Remarks Signature Compressor Received properly Location suitable/ventilated Bolitng down-canopy/sub-base Piping in the compressor intact Oil Type Oil Level in the crankcase External Conn.s & Pipework Suitable All electrical connections checked Mains Supply Voltage and Freq. V Hz

Instruction Manual


Other Remarks

Parts Book W31- Series Breathing Air Compressors

.

START UP CHECKS Remarks Signature Direction of rotation Start up current and voltage Amps.

Volts

Fill in the pressure reading table

Pressure switch cut out pressure

Bars

Main Motor Current and voltage at full load Amps. Volts Max current and voltage ratings & supply frequency conform the nameplate values.

Vibration Noise No back flow in the Check valve when the compressor stops. V Hz Interstage and final safety valves not leaking Ambient Temperature C Crankcase oil temperature after 30 minutes of operation C Discharge air/gas temperature after 30 minutes of operation C

Duty Cycle (…min operating; Min. runnig; min.stops

Other Remarks

Pressure Readings 1st stage 2nd

stage 3rd stage 1st stage 2nd stage 3rd stage

50 Bars 200 Bars 100 Bars 250 Bars 150 Bars

Engineer in charge of the plant Full Name Remarks Singature Date Distributor / Manufacturer’s Representative Attending the Commissioning Full Name Remarks Signature Date Other Attendants Full Name Remarks


.

Singature Date


.

6979-02-200503 C

123

4

16

17

20

21

2928

9

22

13

14

18

15

1923

252427

26

56

78

10

1187

12


.

FIGURE 1 - COMPRESSOR FRAME ASSEMBLY

Ref Nr. Part Nr. Description Qty

1.1 7867-38 ALLEN SCREW 1 M8x30 SST

1.2 7104-03 SPRING WASHER 1 M8

1.3 6885-01 WASHER 1 M8

1.4 6998 WHEEL-V-belt 1

1.5 6999 OIL SEAL 1

1.6 7003-03 LOCKRING 1

1.7 7030 BEARING 2

1.8 7003-04 LOCKRING 2

1.9 6884-01 NUT-hex 4 M8

1.10 6904-02 COVER-shaft end 1

1.11 6904-03 GASKET-shaft end cover 1

1.12 7000 CRANKSHAFT 1

1.13 6904-01 CRANKCASE 1

1.14 6882-09 SCREW 4 M8x1,25x20

1.15 8025-01 CONNECTING ROD SET 1

1.16 7001 ROD-connecting-2nd&3rd stg 2

1.17 7002 ROD-connecting-1st stg 1

1.18 6885-02 WASHER 1

1.19 7003-01 LOCKRING 1

1.20 6902-01 COVER-crankcase 1

1.21 6893-05 O RING-crankcase cover 1 136,2x3,53

1.22 6902-02 PLUG-oil filler 1

1.23 6893-11 O RING-oil filler plug 1 19,5x1,78

1.24 6902-04 OIL LEVEL GAGE 1

1.25 6893-04 O RING-oil disch plug 1 20x1,57

1.26 6882-04 PLUG-oil disch 1

1.27 6894-04 FIBER WASHER 1

1.28 6882-05 SCREW 1 M6x15(FLANSLI)

1.29 6893-12 O RING 1 5,8x1,9


.

126

104

5

6

2

11 12

68

6

9

15

3

1426

26

26

7

13

17

16

18

19

20

7

8

21

6979-03-210503 E

3rd

stg.

look

at

figur

e 3

2nd

stg.

look

at

figur

e 3

look

at

figur

e 3

look

at

figur

e 4

look

at

figur

e 4

look

at

figur

e 4

FIGURE 2 - MODELW31 BARE COMPRESSOR


.


2.1 6881 SOCKET 3 M6

2.2 6883-03 ACORN NUT 1 M6

2.3 6880-01 TIE ROD 4 M6x142

2.4 6872 GASKET 1

2.5 6871 CYLINDER-1st stg 1

2.6 6870 GASKET 3

2.7 7187-02 FITTING-1/8xØ6 for pl. tube 2

2.8 7187-06 ELBOW-1/8xØ6 for pl. tube 2

2.9 6997-02 TUBE-PL 1


2.11 7867-63 BOLT-Hex. 4 M6x20 SST

2.12 6834 CYLINDER-2nd stg 1


2.14 6884-21 NUT 4 M6 SST

2.15 6880-02 TIE ROD 4 M8x172

2.16 6841 SLEEVE-3rd stg 1

2.17 6893-02 O RING 1 23,53x1,78;NBR

2.18 6842 CYLINDER-3rd stg 1

2.19 6893-10 O RING 1 64x2;NBR

2.20 6892 CROSSHEAD CYLINDER-3rd stg. 1

2.25 6997-01 TUBE-PL 1

2.26 7091-17 WASHER 12 M6 SST


.

23

651

22

21

18

20

19

31

22

21

23

37

6979-01-210503 D

14

13 151617

11

32

33

34

35

36

25

24

29

10

2

3

4

11

9

8

7

12

30

28

27

26

2nd STAGE INLET&DISCHARGE VALVE ASSEMBLY

3rd STAGE INLET&DISCHARGE VALVE ASSEMBLY

1st STAGE VALVE ASSEMBLY

FIGURE 3 - VALVE ASSEMBLIES


.


3.1 6873-01 1st STAGE VALVE COMPLETTE 1

3.2 6875 •TOP COVER-1st stg 1

3.3 6874 •GASKET 1

3.4 6873 •VALVE ASS'Y-1st stg 1

3.5 6897-01 •2nd STAGE VALVE COMPLETTE 1

3.6 6887-05 •INLET VALVE ASS'Y-2nd stg 1

3.7 6887-01 •• BODY-2nd stg inlet valve 1

3.8 6887-02 •• SPRING-2nd stg inlet valve 1

3.9 6203-03 •• DISC-2nd stg inlet valve 1

3.10 6887-03 •• SEAT-2nd stg inlet valve 1

3.11 6894-01 •WASHER 2

3.12 6835-01 •VALVE HEAD-2nd stg 1

3.13 6888 •DISCHARGE VALVE ASS'Y-2nd stg 1

3.14 6888-02 •• BODY-2nd stg disch valve 1

3.15 6888-03 •• SPRING-2nd stg disch valve 1

3.16 6203-03 •• DISC-2nd stg disch valve 1

3.17 6888-04 •• SEAT-2nd stg disch valve 1

3.18 6888-01 •CAP-2nd stg disch valve 1

3.19 6894-02 •WASHER 1

3.20 6893-01 •O RING 21,82x3,53 1

3.21 7867-33 •BOLT M8x25 2

3.22 6883-04 •ACORN NUT M8 2

3.23 6894-03 •WASHER 2

3.24 6898-01 3rd STAGE VALVE COMPLETTE 1

3.25 6815 •INLET VALVE ASS'Y-3rd stg 1

3.26 6815-01 •• BODY-3rd stg inlet valve 1

3.27 6815-04 •• SPRING-3rd stg inlet valve 1

3.28 6815-02 •• DISC-3rd stg inlet valve 1

3.29 6815-03 •• SEAT-3rd stg inlet valve 1

3.30 6843-01 •VALVE HEAD-3rd stg 1

3.31 6814 •DISCHARGE VALVE ASS'Y-3rd stg 1

3.32 6814-01 •• BODY-3rd stg disch valve 1

3.33 6814-04 •• SPRING-3rd stg disch valve 1

3.34 6814-02 •• DISC-3rd stg disch valve 1

3.35 6814-03 •• SEAT-3rd stg disch valve 1

3.36 6893-09 •O RING 16x1,57 1

3.37 6844 •TOP COVER-3rd stg 1


.

5

4

212 3

4

10

9

78914

13

14

17

161 6

15

11

6979-4-290500 B

1st STAGE 2nd STAGE3rd STAGEPISTON&RING ASS'Y PISTON&RING ASS'YPISTON&RING ASS'Y

FIGURE 4 - PISTONS & RINGS ASSEMBLY


4.1 7004 PISTON COMPLETE-1st stg 1

4.2 6899-01 • PISTON-1st stg 1

4.3 6900 • PISTON PIN-1st stg 2

4.4 7003-02 • LOCK RING,PISTON PIN-1st stg 6

4.5 7008 • RING SET-1st stg 1

4.6 7005 PISTON COMPLETE-2nd stg 1

4.7 6836 • PISTON-2nd stg 1

4.8 6837 • PISTON PIN-2nd stg 1

4.9 7003-02 • LOCK RING,PISTON PIN-2nd stg 2

4.10 7009 • RING SET-2nd stg 1

4.11 7006 CROSSHEAD PISTON COMPLETE-3rd stg 1

4.12 6899-02 • PISTON-3rd stg crosshead 1

4.13 6900 • PISTON PIN-3rd stg 1

4.14 7003-02 • LOCK RING,PISTON PIN-3rd stg 2

4.15 7007 PISTON COMPLETE-3rd stg 1

4.16 6845 • PISTON-3rd stg 1


.

4.17 7010 • RING SET-3rd stg 1

6

51

42

3

9

7

8

1718

16

15

14

1312

11

10

6979-05-210503 B

FIGURE 5 - W31 CONDENSATE SEPARATOR&PURIFIER ASS'Y

Ref Nr. Part Nr. Description Qty 5.1 6876 INLET FILTER ASS'Y 1 5.2 6876-01 FILTER ELEMENT 1 5.3 7831 NIPPLE 1 5.4 6916 CONDENSATE SEPARATOR ASS'Y 1 5.5 6916-01 • BODY 1 5.6 6916-03 • DIFFUZER 1 5.7 6893-06 • O RING 1 28,17x3,53;NBR 5.8 6916-02 • COVER 1 5.9 7302 PURIFIER ASSEMBLY 1 5.10 7302-01 • BODY 1 5.11 6702 • PURIFIER ELEMENT 1 5.12 6702-11 • O RING 1 Ø9.19xØ2.62 5.13 6702-10 • O RING 1 Ø7,6xØ2,62;NBR 5.14 6893-07 • O RING 2 40,65x5,33;NBR 5.15 7302-02 • ADAPTER 1 5.16 7303-03 • COVER 1 5.17 7867-59 • ALLEN SCREW 1 M8x35 SST 5.18 7867-06 • ALLEN SCREW 2 M8x20 sst


.

4

3

19

18

9

8

16

14

2

3715

213

2

1

1326

9

38

27

3925

22

23

25

5 6

7

7

36

1210

11

12

17

12

21

24

20

6979-06-020603 D

28

29

41

4342

30

39

313233

3435

1

22

40

FIGURE 6 - W31 GENERAL PIPING


.

Ref Nr. Part Nr. Description Qty 6.1 7084-02 ELBOW 2 ¼x¼ Sst 6.2 7425-01 FITTIG 6 ¼xØ10 Sst 6.3 6907-01 INTERCOOLER ASS'Y-1st stg/2nd stg 1 6.4 6907-02 • INTERCOOLER TUBE ASS'Y 1 6.5 7961-05 • CLAMP 1 6.6 7961-06 • CLAMP 1 6.7 7867-57 • ALLEN SCREW 2 M4x20 SST 6.8 6908-01 INTERCOOLER ASS'Y-2nd stg/3rd stg 1 6.9 6908-02 • INTERCOOLER TUBE ASS'Y 1 6.10 7961-04 • CLAMP 1 6.11 7961-03 • CLAMP 1 6.12 7867-57 • ALLEN SCREW 2 M4x20 SST 6.13 7672-02 ELBOW CONNECTOR 2 ¼x¼ Sst 6.14 7020 DRAIN VALVE ASSEMBLY 2 6.15 7083-02 PLUG 1 ¼ Sst 6.16 7019-01 TUBE ASS'Y-Condensate Sep./3rd stg 1 6.17 7422-01 FITTIG 2 ¼xØ6 Sst 6.18 6909-01 AFTERCOOLER ASS'Y 1 6.19 6909-02 • AFTERCOOLER TUBE ASS'Y 1 6.20 7961-02 • CLAMP 1 6.21 7961-01 • CLAMP 1 6.22 7867-45 • ALLEN SCREW 1 M4x30 SST 6.23 7091-36 • WASHER 1 M4 SST 6.24 6884-17 • NUT 1 M4 SST 6.25 7867-57 • ALLEN SCREW 2 M4x20 SST 6.26 7890-01 NIPPLE-HOSE 1 6.27 7912-01 HOSE-1 m 1 6.28 7026 PRESSURE GAGE 1 6.29 7891-01 FILLING VALVE&BOTTLE CONNECTION ASS'Y 1 6.30 7891-06 • FILLING VALVE 1 6.31 7891-03 • HANDLE 1 6.32 7670-13 • O-RING 1 6.33 7880-05 • BOTTLE CONNECTION 1 6.34 7880-06 • O-RING 1 6.35 7429 • YOKE 1 6.36 7933-02 SAFETY VALVE 1 7 BAR 6.37 7933-04 SAFETY VALVE 1 35 BAR 6.38 - SAFETY VALVE 1 6.38.1 7933-08 SAFETY VALVE 240 BAR 6.38.2 7933-20 SAFETY VALVE 320 BAR 6.39 7829-04 O-RING 2 Ø6.07xØ1.78;90Sh 6.40 7672-12 ELBOW 1 1/4"Mx1/4"F (Ø7) 6.41 7038-02 SEAT-BOTTLE CONNECTION 1 6.42 7091-32 LOCK WASHER 1 M8 SST 6.43 7867-63 HEX.BOLT 1 M8X20 Sst;HEX.


.

1

2

3

6

7

7

8

1011

12

14

17

17

1820

18

9

15

4

58

8

2222

88

89

2119

1316

13

13

14

14

14

6979-07-310503 E

22

FIGURE 7 - SUBBASE & BELT GUARD ASSEMBLY


7.1 6913-01 SUBBASE 1 7.2 6913-02 CHANNEL-right 1 7.3 6913-03 CHANNEL-left 1 7.4 6913-14 BELT GUARD 1 7.5 6913-11 PLATE-BELT GUARD 1 7.6 7867-69 BOLT-SHEET IRON 11 7.7 7867-09 ALLEN SCREW 5 M6x20 SST 7.8 7091-17 WASHER 9 M6 SST 7.9 7823-03 NUT-INSERT 5 M6 7.10 6953-02 WHEEL 2 7.11 6953-03 PIN 2 7.12 7867-68 ALLEN SCREW 2 M8x55 SST 7.13 7091-34 WASHER 7 M8 SST 7.14 6884-19 NUT 6 M8 SST 7.15 7867-62 HEX.SCREW 4 M8x20 SST 7.16 7091-32 LOCK WASHER 4 M8 SST 7.17 6953-01 VIBRATION MOUNT 2 7.18 6953-04 SPACER 2 7.19 6913-15 BRACKET 1 7.20 6884-18 NUT 2 M10 SST


.

7.21 6884-21 NUT 1 M6 SST 7.22 7867-03 ALLEN SCREW 3 M6x10 SST

12

8

10

6

9

9

161616161717

132

3

5

76

11

14

14

15

6979-08-020603 D

12

18

19

6

67

3

3

3

4

4

21

FIGURE 8 -Support For Coolers, Water Separator and Purifier ; Screw


8.1 7867-61 HEX. SCREW 8 M8x30 SST 8.2 7091-32 LOCK WASHER 10 M8 SST 8.3 7091-34 WASHER 16 M8 SST 8.4 6884-19 NUT 8 M8 SST 8.5 7027-01 CLAMP-Condensate Sep. 1 M6x157 8.6 7091-17 WASHER 9 M6 SST 8.7 6883-03 ACORN NUT 4 M6 SST 8.8 7091-35 LOCK WASHER 2 M6 SST 8.9 6884-12 NUT 3 M6 SST 8.10 7867-60 ALLEN SCREW 2 M6x30 SST 8.11 7867-06 ALLEN SCREW 2 M8x20 SST 8.12 7027-02 CLAMP-Purifier 1 M6x287 8.13 6913-05 PLATE 1 8.14 7867-57 ALLEN SCREW 2 M4x20 SST 8.15 6913-08 SUPPORT 1 8.16 7091-36 WASHER 4 M4 SST 8.17 6884-17 NUT 2 M4 SST


.

8.18 7867-03 ALLEN SCREW 1 M6x10 8.19 6913-16 HANDLE 1

alkin airtex manual

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