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1.0 INTRODUCTION

P6A Petrol-Engine-Driven Blown Fibre Compressor The P6A Blown Fibre Compressor is designed to deliver clean, dry air for installation of optical fibre using the blown fibre technique. The set is mounted within a tubular steel frame which is equipped with two wheels and handles for one man on site operation. Model P6A Blown Fibre Compressor is a portable, petrol engine-driven rotary vane compressor unit. Producing 120 l/min of pulse-free treated compressed air at a working pressure of 10 bar, it provides the ideal source for field installation of fibre optic cable. The unit incorporates a 12V DC air-cooled after-cooler reducing the compressed air temperature to within 5°C of ambient. A 3-stage filtration system, complete with a pressure-maintaining valve, provides technically oil-free air, which reduces the moisture levels to prevent problems in the blowing operation. The unit is supplied with a 3-way control valve with purge position, 10m of 3/8” air hose with safety-type Instantair coupling and is complete with 24V DC outlet socket to supply the blowing head (other voltages available on request). The P6A compressor is fitted with a temperature mixing valve system to allow the temperature of the air entering the filters to be manually raised to increase the pressure dewpoint of the compressed air to prevent over drying in cold conditions.

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2.0 GENERAL INFORMATION 2.1 P6A On Site

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2.2 P6A Components

Fuel tank Pressure maintaining Dual filter Pre-filter Temperature gauge and 3.6 litres valve (9 bar) (see section (hidden by temperature mixing valve

5.3) the after-cooler) hidden by the after-cooler)

Recoil starter handle

Engine switch

Engine oil filler 0.6 litres

Hose storage

24V DC outlet socket

Air outlet and ON/OFF valve Condensate bottle

After-cooler

3-way outlet valve

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2.3 General Data

Engine The engine is a preset, mechanically-governed, single cylinder, four-stroke with air cooling and electronic ignition. The carburettor is fitted with a manual choke and a dry air cleaner. Starting is controlled by an on/off switch and is effected by a manual recoil starter mounted externally on the crankshaft. The engine is equipped with an oil alert system which, when activated by either high temperature compressor oil or low engine oil pressure, will automatically stop the engine. Type Honda GX160 K1 LX4 Horse power 5.2 HP 4.0 kW @ 4000 rpm Oil capacity 0.60 litre (0.53 Imperial quart) Oil grades SAE 10W-30 (recommended for general use) Fuel grade Petrol – automotive unleaded Fuel consumption 313g/kWh (230g/HP hr) Fuel capacity 3.6 litres (0.79 Imperial gallon) Starting Recoil

Compressor The compressor is an oil-flooded, rotary vane unit driven through a two-piece coupling by a petrol engine. Air enters the compressor via an air filter located at the end of the compressor unit and is cooled by a fan which draws air over the cooler. The compressor is automatically controlled.

Type Hydrovane VO1 Operating speed 1440 rpm Oil capacity 1 litre (1.76 pints) Oil grades 0°C - 40°C Hydrovane Fluid Force 2000) see -15°C - +45°C Hydrovane Fluid Force HPO) page 9 Free air delivered 4.0 cfm (1.88 litres/sec) Maximum operating pressure 150 psi (10 bar)

Dimensions

Length 905 mm Width 435 mm Height 650 mm Weight 68 kg

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3.0 SAFETY PRECAUTIONS GENERAL

WARNING Run the engine in a well-ventilated area. The machine should be as

level as possible in both planes whilst in operation. Operate the unit at least 1 metre away from buildings and flammable

objects. Do not smoke or allow flames in the refuelling area. Avoid inhaling the exhaust fumes. Do not run the unit except when

it is positioned down-wind from the work site. If any fuel is spilt make sure the area is dry before starting the

engine. Many parts, especially the exhaust muffler and spark arrestor, if

fitted, become very hot during operation and remain hot for a while after stopping the engine. To avoid burns or fire hazards, always let the unit cool before transporting, storing or servicing.

Do not attempt any work on the compressor until the engine has

been stopped and the system completely depressurised. Wait until the pressure gauge reads zero.

Do not insert any object through the fan guard rings. Serious

damage to the compressor and personal injury could result. If changing the oil when the compressor is still warm, take

necessary precautions to avoid contact of hot oil with the skin. Dispose of used oil with due regard to the environment.

Be aware of the location of the nearest fire extinguishers and their

method of operation. Great care should be taken not to spill fuel, especially near a hot exhaust.

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4.0 OPERATING INSTRUCTIONS 4.1 PREOPERATION CHECKS Engine – GX160 The engine and lubricator oil levels must be checked daily and

topped up if necessary. Ensure the unit is on a level surface with the engine stopped and the unit fully depressurised.

Remove the oil filler cap and wipe the dipstick clean. Insert dipstick into the oil filler neck – do not screw in. If the level is low, fill to the top of the oil filler neck with the

recommended oil – Grade SAE 10W-30.

Engine oil level alert An engine oil alert system, which automatically stops the engine, is

activated if the engine oil level is allowed to fall below acceptable levels or if the compressor oil overheats.

Fuel Before attempting to start the engine make sure the fuel tank is full.

Use automotive petrol (unleaded or low-leaded is preferred to minimise combustion chamber deposits). NEVER use oil/petrol mix or dirty fuel.

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4.1 continued Compressor – VO1 Check the oil level weekly when the compressor is cold, stopped

and depressurised, i.e. gauge reads zero. For oil grades see General Data – page 4.

Top up by slowly unscrewing the filler plug (A). If there is any

escape of oil or air, DO NOT CONTINUE REMOVING THE PLUG UNTIL ALL PRESSURE IS RELEASED.

Remove filler plug (A) and bonded seal (B). Top up with approved oil to the top of the plug hole. Replace seal to filler plug, then refit and tighten plug. Machine and its associated equipment Check for obvious damage to machine frame, carrying handles,

hoses, isolating cocks and associated equipment to be used with the machine.

THE MACHINE AND ITS ASSOCIATED EQUIPMENT MUST NOT

BE USED IF DAMAGE MAKES THEM UNSAFE.

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4.2 STARTING INSTRUCTIONS – RECOIL

Turn fuel valve to ON position

Turn ignition switch to the ON position

Close the carburettor choke by moving the lever in the direction

indicated. Note: A warm engine requires less choke level than a cold engine. Turn the outlet valve to the venting position. Take hold of the handle of the recoil start rope, pull lightly until

resistance is felt, return the handle to the initial position, pull the handle briskly with both hands.

Do not let the rope back into its housing quickly but keep some

tension on it and let it rewind slowly. Repeat the above until the engine starts. Decrease the choke level

when the engine starts and is running evenly. Turn the outlet valve to the open position, once maximum pressure

has been reached let the engine warm up for a few minutes.

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4.3 STOPPING INSTRUCTIONS

Disconnect all air hoses. Turn 3-way valve to the OFF position. Turn the ignition switch to the OFF position. Turn the fuel valve to the OFF position.

4.4 TEMPERATURE MIXING VALVE ADJUSTMENT

The P6A compressor is fitted with a temperature mixing system to allow the temperature of the air entering the filters to be manually raised to increase the pressure dewpoint of the compressed air to prevent over drying in cold conditions. To adjust, start the compressor and turn the 3-way outlet valve to the venting position. Progressively open the temperature mixing valve and monitor the compressed air temperature on the temperature gauge. (Note: when the compressor is started from cold the temperature will take approximately 15 minutes to stabilise.) When the desired temperature (dewpoint) is reached, close the 3-way outlet valve and use the compressor as normal.

VENT/START

OFF/STOP

ON

Temperature gauge IND066

Temperature mixing valve VAL0152

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5.0 MAINTENANCE 5.1 SERVICE SCHEDULE – COMPRESSOR (HYDROVANE V01)

PERIOD OPERATION Every

day First month or 20 hrs

Every 3 months or 50 hrs

Every 6 months or 100 hrs

Every year or 250 hrs

Every year or 2000 hrs

Check oil level • Check cable connection on over-temperature switch

•

Clean air filter • (1) Clean oil cooler • Change air filter • (1) Change oil • (2)

Note: 1 Service more frequently when used in dusty conditions. Note: 2 Interval reduced to 500 hours if not using HYDROVANE 2000 oil.

ALWAYS OBSERVE SAFETY PRECAUTIONS BEFORE WORKING ON THE COMPRESSOR

Approved Oils - Compressor

Hydrovane Fluid Force 2000 oil for 2000-hour oil change (ambient temperature range 0°C to +40°C).

Note: For applications where compressor is stored or used outside in winter then we recommend using HPO synthetic compressor oil. (Available from Factair.)

FOR 500-HOUR OIL CHANGE

AMBIENT TEMPERATURE RANGE °C

MAKE

Min Max 0 40

Min Max -6 30

Min Max -12 20

BP Vanellus

M40

M30

M20

Shell Rimula

X40

X30

-

Mobil Delvac

1240

1230

1220

Mobil Rarus

327

-

-

Castrol

CRI 40 CRB 40

CRI 30 CRB 30

CRI 20 CRB 20

Agricastrol

40

30

20

Essolube

HDX 40

HDX 30

HDX 20

Gulflube Motor Oil

XHD 40

XHD 30

XHD 20

Texaco Ursa Oil Extra Duty

SAE 40

SAE 30

SAE 20

Chevron EP Industrial Oil

68X

55X

55X

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5.1 continued

Servicing the Air Intake Filter

Every 50 hours

a) On PUTS models, first remove the outlet valve and pipework. b) Unscrew and remove two screws (A) from filter cover (B). c) Remove cover (B) on PUTS models, or slide it over the air

delivery pipe, if fitted, on PUAS and PURS models. d) Remove the filter support (C) and filter (D). e) Wash the filter (D) with soap and water, and allow to dry

before replacing.

DO NOT USE ANY OTHER METHOD OF CLEANING.

f) Renew the filter (D) if it cannot be cleaned satisfactorily. g) Clean inside of cover (B) and filter support (C). h) Refit filter (D) and support (C) ensuring they are correctly

located and secured in the filter clip (E). i) Refit cover (B) and secure with the two screws (A). j) Refit outlet valve and pipework on PUTS models.

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5.1 continued

Every 2000 hours

a) Carry out operations (a – d) as described above. b) Discard old filter and fit new one. c) Carry out operations (g – j) as described above.

Changing the Oil a) The oil change is best carried out as soon as possible after

stopping the compressor, as warm oil will drain more easily. Wear suitable protective clothing to avoid possibility of oil burns. (See SAFETY PRECAUTIONS).

b) Ensure that the compressor is depressurised. The pressure

gauge should read zero.

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5.1 continued c) Slowly unscrew the filler plug (A). If there is any escape of oil

or air, DO NOT CONTINUE REMOVING THE PLUG UNTIL ALL PRESSURE IS RELEASED.

d) Remove the filler plug (A) and discard its bonded seal (B). e) Position a suitable container under the compressor drain plug

(C). (Compressor oil capacity is 1.2 litres, 1.9 pints.) g) Drain oil into container. h) Fit a new bonded seal (d) to the drain plug (C). Refit and

tighten the drain plug (C).

i) Fill the compressor with APPROVED OIL to the top of the filler plug hole.

j) Fit a new bonded seal (B) to the filler plug. Refit and tighten

the filler plug. k) Run compressor for 10 seconds, then recheck the oil level.

Top up the oil as necessary. 5.2 SERVICE SCHEDULE – ENGINE (HONDA GX160)

Period Operation Each

Use First Month or 20 hrs

Every 3 months or 50 hrs

Every 6 months or 100 hrs

Every year or 250 hrs

Every year or 300 hrs

Engine oil Check Change Change Air cleaner Check Clean Sediment cup Clean Spark plug Clean

Adjust

Fuel tank and filter Clean Spark arrestor (optional) Clean Valve clearance check/adjust Adjust

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5.2 continued Approved Oils – Engine

Use a high detergent, premium quality motor oil. SAE 10W –30 or SAE 10W –40 are recommended for general all temperature use.

In temperature range of –15°C to +40°C use 15W– 40 or 15W-50

In temperature range of -10°C to +40°C use 20W-40 or 20W-50

Oil Change

Drain the oil while the engine is still warm to assure rapid and complete draining.

1 Remove the oil filler cap and drain plug to drain the oil.

2 Install the drain plug and tighten it securely.

3 Refill with the recommended oil and check the oil level.

4 Install the oil filler cap.

Engine oil capacity: 0.60 litre (0.53 Imp qt)

Air Cleaner Service

A dirty air cleaner will restrict air flow to the carburettor. To prevent carburettor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in extremely dusty conditions.

WARNING

Never use gasoline or low flash point solvents for cleaning the

air cleaner element. A fire or explosion could result. Caution: Never run the engine without the air cleaner. Rapid engine wear will result.

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5.2 continued

Dual element type 1 Remove the wing nut and the air

cleaner cover. Remove the elements and separate them. Carefully check both elements for holes or tears and replace if damaged.

2 Foam element: Wash the element in a solution of household detergent and warm water, then rinse thoroughly, or wash in non-flammable or high flash point solvent. Allow the element to dry thoroughly. Soak the element in clean engine oil and squeeze out the excess oil. The engine will smoke during initial start-up if too much oil is left in the foam.

3 Paper element: Tap the element lightly several times on a hard surface to remove excess dirt, or blow compressed air through the filter from the inside out. Never try to brush the dirt off; brushing will force dirt into the fibres. Replace the paper element if it is excessively dirty.

Spark Plug Service CAUTION: Never use a spark plug of the incorrect heat range.

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

1 Remove the spark plug cap and use the proper size spark

plug wrench to remove the spark plug. 2 Visually inspect the spark plug. Discard the spark plug if there

is apparent wear, or if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is to be reused.

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5.2 continued 3 Measure the plug gap with a feeler gauge. Correct as

necessary by bending the side electrode. The gap should be: 0.70 - 0.80mm (0.028 - 0.031") 4 Check that the spark plug washer is in good condition and

thread the spark plug in by hand to prevent cross-threading. 5 After the spark plug is seated, tighten with a spark plug

wrench to compress the washer.

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5.3 P6A HIGH EFFICIENCY FILTRATION

The pre-filter element which removes particulate, can be partially cleaned by washing in warm soapy water; it should be replaced annually, sooner if heavily contaminated. The dual function filter body incorporates an oil removal element (bottom) and an oil vapour activated carbon upper element. These elements are not washable and should be replaced if the unit is unable to produce 15 bar. If the top element becomes saturated with oil within a short period, the main element and/or ‘O’ ring may be faulty and should be replaced. Both the activated carbon and coalescing elements should be replaced every 6 months. The quality of air and condition of the elements may indicate an adjustment of maintenance interval, at which time the inside of the filter bowls should be washed in warm soapy water and cleaned. Before undertaking any servicing of the filter system, stop the compressor and wait until the compressor-mounted pressure gauge reads zero.

For filtration service procedures and service kits see spares page

Dual filter FIL0081

Pre-filter FIL0086

Temperature Gauge IND066

Temperature Mixing Valve VAL 0152

Pressure Maintaining Valve VAL0131

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5.4 TROUBLESHOOTING

Problem Solution Engine will not start 1 Is ignition switch turned to

ON? Set switch to ON.

2 Is there enough fuel?

Top up fuel tank.

3 Is there a spark at the

spark plug?

Remove the plug and install the plug in the cap, ground the side electrode, pull the recoil starter, check if spark jumps gap, clean or replace as necessary.

4 If unit has stopped

previously on compressor over temperature or low

engine oil

Allow engine to cool before attempting to restart and see (6) below.

Engine stops when running

5 Has it run out of petrol? Fill up fuel tank. 6 Did it shutdown through

over temperature of the compressor or because

engine oil was low?

Check compressor for over-temperature which could be low oil or debris blocking the oil cooler matrix. Over temperature switch will automatically reset when temperature has reduced. Check and top up engine oil if necessary.

7 Engine shutdown on low oil

The Honda GX160 petrol engine is fitted with an oil alert system which is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the oil alert system will automatically stop the engine, (the engine switch will remain in the ‘ON’ position).

8 Compressor shutdown on

over temperature

The compressor is fitted with a sensor and a switch mounted below the compressor which is activated by high temperature compressor oil causing the engine to stop.

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5.4 continued

Compressor – Hydrovane 501C10

INTRODUCTION The charts on the following pages detail the symptoms and remedial action required for faults which may occur on the Hydrovane compressor. HIGH PRESSURE Pressure rises until safety valve lifts HIGH TEMPERATURE Oil temperature higher than 100°C LOW AIR OUTPUT Lack of air at point of usage OIL DISCHARGE Oil discharged into air system IMPORTANT • All remedial action must be performed by suitable qualified persons and safe working practices must be employed • All seals and gaskets disturbed during this work must be renewed • Contact your distributor if you are unable to rectify a fault

HIGH PRESSURE HIGH TEMPERATURE INDICATIONS INDICATIONS • Pressure rises and safety valve blows • Compressor cuts out. • Air/oil vapour discharged from intake on stopping compressor

• Compressor seizing

• Rapid pressure loss on stopping compressor

• Low air output

• High temperature and power absorption • High power absorption CHECK CHECK • First ensure that the safety valve lifts at the correct pressure

• Check compressor oil temperature

ENVIRONMENTAL CHECK 1 Insufficient ventilation 2 Excessively dusty conditions 3 Air intake near heat source COMPRESSOR CHECK 1 Low oil level 2 Wrong type/grade of oil 3 Blocked oil cooler

LOW AIR OUTPUT OIL DISCHARGE INDICATIONS INDICATIONS • Malfunction in tools/equipment • Heavy oil consumption • Rapid pressure loss in air system • Low air output • Pressure gauge reading low • Possible high power absorption CHECK CHECK • Check compressor air output • Verify that oil discharge exceeds specification • Check for excessive air demand • Check pressure gauge for accuracy IF PRESSURE GAUGE READING NORMAL : -

GENERAL CHECK

1 Restriction in airline e.g. valves closed 1 Wrong type/grade of oil 2 Pipework too small 2 Excessive air demand IF PRESSURE GAUGE READING LESS THAN NORMAL:

3 Compressor not sited level

1 Air intake filter blockage

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6.0 TRANSPORTING/STORAGE

WARNING

When transporting the engine, turn the fuel valve OFF and keep the engine level to prevent fuel spillage. Fuel vapour or spilled fuel may ignite.

Before storing the unit for an extended period; 1 Be sure the storage area is free of excessive humidity and dust. 2 Drain the fuel.

WARNING

Petrol is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area.

a) Remove and empty the sediment cup. b)

Replace the sediment cup and tighten securely.

c)

Drain the carburettor by loosening the drain screw. Drain the petrol into a suitable container.

3 Change the engine oil. 4 Remove the spark plug and pour about a tablespoon of clean

engine oil into the cylinder.

Crank the engine several revolutions to distribute the oil, then reinstall the spark plug.

5 Pull the starter rope slowly until resistance is felt. Continue

pulling until the notch on the starter pulley aligns with the hole on the recoil starter (see illustration below). At this point, the intake and exhaust valves are closed, and this will help to protect the engine from internal corrosion.

6 Cover the engine to keep out dust.

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7.0 SPARES 7.1 STANDARD COMPONENTS

Description Part Nos Plastic bottle 0.5L BOT0001 Compressor COM0044 Oil Cooler 115mm COO0003 Auto-drain DRA0008 Heat sink ELE0200 Rectifier ELE0216 Fuse holder ELE0243 Capacitor ELE0244 DC converter ELE0529 Petrol engine ENG0036 Sub-frame FAB0206 Main frame FAB0208 Handle FAB0209 Filter FIL0081 Filter FIL0086 Rubber hose 3/8” HOS0018 Temperature gauge -30 +50 IND0066 Silencer SIL 0019 Ported relief valve VAL0131 Flow control valve ½” VAL0152 Three-way valve ¼” VAL0181 Wheel red plain bore WHE0012

7.2 SERVICE SPARES

High efficiency filtration Description Part No Element/Service Kit Pre-filter assembly FIL0086 Particulate removal – FIL0185

element 40 µm Change annually (washable)

Auto-drain Service kit – DRA0006 Dual function filter assembly FIL0081 Top element - oil vapour

removal – FIL0019 (activated carbon). Change every 6 months or sooner.

Dual function filter assembly FIL0081 Bottom element – oil removal – FIL0184 (coalescing). Change every 6 months or sooner.

Dual function filter assembly FIL0081 Service kit – KIT0026 Gaskets only

Auto-drain Service kit – DRA0006 Pressure regulator REG0025 Service kit – KIT0027