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W4
S
ERIES
B
REATHING AIR COMPRESSORS
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
HIGH PRESSURE BREATHING AIR COMPRESSORS
(W4 SERIES)
Instruction Manual & Parts List
2
I n s t r u c t i o n
Manual
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
A L K I N C O M P R E S S O R S
Breathing Air Compressors
©
This manual or any parts thereof cannot be copied by any means, or used for any other purposes other than servicing Alkin W4 series compressors, unless specific permission of Alkin ® in writing is received.
ALKIN KOMPRESOR San. ve Tic. Ltd. Sti
Cuneytbey Mh. Tabas Yolu Kume Evleri No.3, Menderes
35470 Izmir - TURKIYE
Tel: +90 232 78 222 90 • Fax: +90 232 78 222 89 www.alkin-compressors.com ii
W 4 S E R I E S
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CONTENTS
2.0 General information on W4 series 4 Stage compressors ....................... 10
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Foreword
Your new ALKIN air 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 in the maintenance section of this manual. This way the proper manner, as well as maintain it using the simple instructions your air compressor will always be in top operating condition, giving you years long trouble free service.
A
LKIN 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: ALKIN KOMPRESOR San. ve Tic. Ltd. Sti
Cuneytbey Mh. Tabas Yolu Kume Evleri No.3 , Menderes
35470 Izmir - TURKIYE
Tel: +90 232 78 222 90 • Fax: +90 232 78 222 89 • e-mail: [email protected]
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Section 1
1.0 SAFETY
1.1 General
1.1.1 General safety information
All ALKIN air and gas compressors are designed and manufactured with equipment & components that allow 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 these compressors. 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.
1.1.2 Pressure release
Have the safety valves tested periodically by certified service personell and in conformity with the specific manufacturer’s 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.
1.1.3 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, and draining or adding oil. Do not permit liquids such as airline 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.
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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 pressure vessels or any other parts or to the piping. Any such works or repairs can only be made by certified technicians and with prior written approval of the manufacturer.
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.
1.1.4 Moving parts
Keep Hands, arms and other parts of the body and clothing away from the 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.
1.1.5 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 ki t handy. Seek medical assistance promptly in case of injury. Don’t ignore small cuts and burns as they may lead to infections.
1.1.6 Toxic and Irritating Substances
Do not use air from this compressor for breathing unless it is equipped with proper purification equipment and 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. Lubricants used in this compressor are typical industrial oils designed for use in high-pressure compressors. Accidental ingestion and skin contact should be avoided. Wash with soap and water after skin contact. If swallowed, seek medical treatment promptly.
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1.1.7 Electrical Shock
Keep the compressor, hoses, tools and personnel at least 3 meters (10ft) from power lines, panels and underground cables.
Keep all 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.
1.1.8 Lifting
The vertical configured compressors are provided with slots in the base to accept the forks of standard pallet jacks. Use this method to move the compressor around.
If you must lift the compressor, 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. Keeps lift operator in constant attendance whenever the compressor suspended. Set the compressor down on level surfaces, capable of carrying its full weight.
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Section 2
2.0 General information on W4 series 4 Stage compressors
2.1 General
The W4 Series compressors are four stage , reciprocating type, aircooled, splash lubricated compressors.
The pressure range these compressor operate vary depending on the cooling system and valve heads installed and it ranges from 100 Bars (1500 psi) to 415 Bars (6000 psi). Do not attempt to modify a compressor to operate at a higherpressure range without written approval of Alkin. Failure to do so may result in heavy damage to equipment, injury or death.
The compressor is built with oversize intercoolers and an aftercooler to allow superior performance, longer life and lower operating & discharge temperatures.
The first and second stage cylinders are built in a common cylinder assembly (see Figure 1 in this section). The first stage compression occurs in the up-stroke of the piston, and the second stage compression in the down-stroke.
Figure 1
The third and fourth stage compression takes place in the up-stroke of 3rd and 4th stg steeple piston working in its crosshead guide and cylinder.
The W4 series compressors are equipped with oversize copper intercoolers between the 1st & 2nd and 2nd & 3rd stage cylinders and stainless steel intercooler between the 3rd and 4th stage cylinders and stainless steel aftercooler downstream
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H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R the 4th stage cylinder. A moisture trap (or condensate separator) is installed Downstream the 2nd & 3rd stage aftercoolers and downstream the aftercooler. Each of these moisture traps is connected to automatic drain valves that periodically open and drain the condensate in these traps. The opening intervals and duration is set by a time control relay found in the electrical control panel of the compressor (see the controls section). This time relay can be adjusted for both functions. Normal – factory set- values of the drain valve timer are 15 minutes closed, and 6 seconds open operation.
A safety valve is installed between each stage and after the final stage to protect the system against an unexpected pressure rises due to a malfunctioning valve or component. These safety valves must be inspected periodically to insure proper operation and set pressure verification (see the maintenance schedule for inspection periods).
The W4 series compressors incorporate stainless steel valves on all 4 stages. They are designed to have an onobstructed passage of air with no pressure loss; they are easy to maintain and replace. Particular attention must be paid to valve maintenance, as these valves are the basis for proper operation of the compressor package. Do not use oils other than the recommended oils in this manual for keeping the valves clean and free of carbon collection. Unsuitable oils will cause carbonization which will collect on the valve discs and springs, resulting in improper sealing of valves, This will increase the operating temperatures, generating a chain reaction for further deterioration of the oil and valve operation.
Lubrication is created by dipstick found in the bottom of the 4 th stage connecting rod. While the crankshaft rotating, the connecting rod reciprocates and the dipstick enters the oil bath in the bottom of the crankcase; while coming out of this oil bath, the dipstick splashes oil to the moving parts of the compressor. Efficient oil wiper rings control the economical lubrication of the system.
See the process and instrument diagram to study the general system layout and operation sequence
Figure 2
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2.2 P&I (Process & Instrument) Diagram
The following process and instrument diagrams are prepared with the drawing of the physical components rather than pneumatic symbols, in order to facilitate the understanding of the system by users who are not specifically trained to understand pneumatic symbols.
Some compressors are designed to operate at a “single pressure”
(see P & I diagram Figure 3). This is, when the
compressed air is used to fill all the cylinders to that single pressure. On some other systems there might be different cylinders that need to be filled to two different pressures. For instance some cylinders are filled to 3200 psi, and others to 4500 psi. In such applications “dual pressure” controls are used to operate the compressors to the
selected pressure between the two available set pressures see P & I diagram Figure 4).
Figure 3
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Figure 4
2.3 Principles of Operation
The P & I diagram have to be reviewed carefully to understand the principle of operation. The air is drawn at atmospheric pressure, through the inlet filter (see Figure 2 ) into the 1 st stage cylinder on the down-stroke of the piston (see Figure 1 in section I-4). The up-stroke motion of the piston will cause compression and the air will be forced out of the cylinder through 1 st stage discharge valve and than the manifold ( Figure 2 ). Air will than pass through the intercooler tubes between the 1 the 2 nd st and 2 nd stages and into the 2 nd stage compression chamber. Note that
stage compression chamber, unlike the other 3 cylinders, is the volumetric difference between the 2 nd stage cylinder walls and the lower section of the piston (see Figure 1 in section I-4). On the down-stroke of the same piston, the air contained in the 2 forced through the 2 nd manner to the 4 th nd stage compression chamber is compressed to the second stage pressure and
stage valves + 2 nd stage intercooler + 2 the 3rd stage cylinder. Here, the air is compressed to the 3 rd nd stage moisture separator + 3 rd stage inlet valve into
stage compression level. The air than is forced in similar
stage cylinder where it is compressed to the final pressure level and forced out to the aftercooler, moisture separator, to a pre-filter unit where it is cleaned of any particles and oil content, than passing through a check valve enters the purifier chamber, where it is purifier and prepared to be used for breathing purposes. A priority (or minimum pressure valve) is installed downstream the purifier; this valve prevents the air to exit the purifier until the pressure builts to approximately 180 bars (2610 psi), a pressure level where the purification process is more efficient than at lower pressures. The air is than ready to be directed to a filling panel and with proper connections to the cylinders to be filled.
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The intercoolers and the aftercooler are designed to dissipate the heat generated from the previous compression cycle, reducing the air temperatures, allowing the water vapors to condensate and settle in the bottom sections of the moisture separators. The 3 moisture separators and the pre-filter unit are equipped with an automatic drain valve. The drain valve is a 3 way pneumatic valve controlled by a 3 way solenoid valve installe on the piping adjacent to the centrifugal unloader. This solenoid valve sends or removes the control air from the drain valves, thus letting them to open or close. The solenoid itself is controlled by a sequential timer relay in the electric panel.
The dual time adjustmens on this relay allows to adjust the duration (t1~ 15 min) during which the solenoid will remain energised (=the drain valve will remain closed), and the length of time (t2~ 6 seconds) during which the solenoid will become de-energised (=the drain valve will open and perform the drain function).
The compressor starts and stops with automatic regulation by a pressure switch (see section 2.5.1
for adjustments and functional details).
The oil level of can be monitored on a sight gage provided in the right bottom side of the crankcase (next to the
Low oil level switch) – see Figure 2. The oil level can also be checked through the dipstick found in the filling plug.
In principle the level of oil has to be up to the filling plug thread. A low oil level switch is provided to protect the compressor from lack of oil in its sump. When the oil level drops, the switch cuts off (opens its contacts), thus cutting the control circuit of the motor starter, and stops the electric motor. A signal lamp is provided to indicate that the motor stopped as a result of low oil level.
2.4 Description of Major Components
2.4.1 Major Components - Compressor Unit
Crankcase:
This is the frame that holds everything on it. It contains the oil that lubricates the system. The cylinders are mounted on it. The crankshaft is inserted into the bearing housings which is an integral part of the crankcase.
There is no maintenance or repair works that need to be done on this part; it needs to be cleaned inside when the oil is changed. Due to its unique overhung design, the cleaning inside the crankcase is made possible as the cover does not carry the bearing housings as in most other type compressors.
Crankshaft:
It is overhung type; that means the bearings are on one side, and the crank pin (where connecting rods are mounted) are on the other side. This unique feature allows usage of single piece connecting rods which are far more accurate and safe than split con rods. Large bearings in conjunction with low speeds, allow very long crankshaft life.
Connecting Rods:
There are three connecting rods which are similar in the 1st/2nd stg and the 3rd stage, and is different on fourth stage. The 4th stage con.rod has a stick extending in the bottom that enters the oil sump at every rotation, thus creating splash of oil that lubricates the system. It is equipped with high quality copper- bronze alloy plated inserts that serve as journal bearings. These journals wear in time and therefore the con rods will require replacement or renewal of its bushings in when wears.
Cylinders:
They are cast separately and are made of high grade casting materials, machined & honed to fined tolerances for long service life. When worn, they will need replacement. The compression cylinders on the 3rd and 4th stages are mounted on guide cylinder to guide the crosshead piston ass’y.
Head Assembly:
The head assemblies are the cover plates and the valve assemblies housed inside; these assemblies are mounted on top of the cylinders. The valve assemblies inside the covers need to be maintained periodically; they need to be opened and cleaned; if valve disks or springs are worn, they need to be replaced. See valve maintenance section of this manual for futher details.
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Beather:
All piston type machines have some compression leak through the rings into the crankcase; to prevent pressure build up in the crankcase, a breather system is pr ovided to allow the crankcase to “breath”. In the air compressor the crankcase is connected via a copper tube to the inlet from where the breathing is made possible, or a breather device is installed on the crankcase to vent the pressure from within the crankcase. In the gas compressors the crankcase is piped to the inlet
.
2.4.2 Major Components – System
The Canopy:
The semi open canopy is designed to carry the various components, the electrical panel, and permits lifting the system through the pallet jack slots. It is painted electrostatically for extended life. It has four easily removable door panels to easily and quickly access all parts of the package.
The Sub Base:
This is the base carrying the motor & compressor units; it is supported on four vibration mounts; this base plate is separate from the canopy and with this unique design no vibration is transmitted to the canopy. The vertically mounted compressor / motor assembly, is a belt driven system; the belts are automatically tightened by the weight of the motor on which it is mounted. This unique device saves to pay extra attention to the belt tightening on W4 series machines.
The Electrical Panel :
It is mounted inside the fan duct on the top section and can be accessed by removing the top door. It accommodates all the electrical gear to start the motors and control the system.
Pressure Switch:
This unique Alkin device is installed on the right door, this switch both indicates the purifier pressure, and the set pressures on its dial, while serving as a double circuit pressure switch. It controls the start-stop operation of the compressor. The pressure-sensing end of the pressure switch is connected to a port on the purifier; when the pressure inside the purifier reaches the set pressure, it cuts off the contnrol circuit, and stops the electric motor.
Automatic Drain Valves:
The automatic drain incorporates a small piston with high pressure in the bottom, and low pressure on top; the surface where low pressure acts on is larger than the surface where the high pressure effectively acts on the piston.
Therefore the force on the top is larger and causes the piston to sit and seal the high-pressure vent port. The drain valves are controlled by a solenoid mounted on the pilot valve fitting. It receives compressed air from the 2 nd stage moisture separator and sends it over the 4 drain valves forcing them to close. When the solenoid is de-energised, it removes the control air over the top of the drain valve pistons, allowing the high pressure acting from the botto of the pistons, to open and perform drain operation.
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Note
Do not run the compressor on wooden pallet where the unit is mounted for transportation purposes.
2.5 Description of Controls
2.5.1 Compressor Controls
The W4 Series compressor may operate with the following two controls:
Automatic Start – Stop Control (Single Pressure Only):
This is the standard control type for all single pressure compressor systems. With this type of control, once the compressor is manually started, it will run till it reaches the high set pressure where is will automatically stop (the pressure where the motor will cut-out); after the pressure drops to the low set-pressure (the pressure where the motor will cut in), it will automatically re-start. This control system is standard on all single pressure compressors.
Manual Start – Automatic Stop Control (Dual Pressure Only):
This control is used on compressors with dual pressure controls. The dual pressure systems have two cut out pressures (at which level the motor will be stopped): One is the low cut-out pressure (for example at this mode, the compressor will stop at 3200 psi), the other is the high cut-out pressure (for example 4500 psi).
With this type of control, the compressor will always have to be started manually; there is a valve on the filling panel which allows the operator to select between low and high pressure cylinder filling depending on the type of cylinders be ing filled. If the lever is at the “high pressure” mode, the pressure switch wil sense the high pressure and will cut out at that pressure (for example at 4500 psi). When the lever is set to the low pressure mode, an electropneumatic valve will be activated, enabling the low cut-out pressure circuit of the pressure switch to control the system; when the low cut out pressure (inthis example 3200 psi) is reached, the pressure switch will cut out the motor.
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Pressure Swtich:
The W4 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 incor-porated 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 compressed air. See specific instructions for diesel driven units
Examples:
W4-15-225/310 FRAM 4 Stage 15 kW compressor, dual pressure [225/310] 225 and 310 bars (3260 /
4500 psi), with a combined oil/particle removal filter [F], a regenerative desiccant dryer [R], an active carbon filter [A], and a removable filling panel [M].
W31x2-4-310-P2N 3 stage duplex compressor [x2], 4 kW, 310 bars {4500 psi} operating pressure, P2 size purifier, integrated filling panel [N].
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2.6 Owner 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
Model
Serial Number
Medium
Application
Rated Free Air (gas) delivery
Operating Pressure
General Arrangement Drwg.
Process & Instrument Drwg.
Production File Number
Relevant Drawing Numbers
Parts List
4 stage breathing air compressor
W4 - - - -
Air
Breathing Air Cylinder filling
Compressor Unit
Model W4-
Year
Application Air
Stroke 4”
Electric Motor
Type Recip.
Max. Operating Pressure
Oil Type
LP Bore x nr.of LP cyl. 4,5”
Type Sq.cage ind.motor
Power (kW)
Voltage
Insulation F
Current
Rating
Drive
Type
Belt Section
Pressure Control
Make
Power (HP)
Frequency
Frame
Full Load
Current
Compressor Flywheel
Belt Size
Type Pressure switch
Differential P.
Other Data
Model
Cut out pressure
Electrical Control Panel & Motor Starter Drawing Number
Parts List Number
Additional Electric Motors (Fan Motors)
Fan Motor #1
Serial Nr.
Inlet Pressure Atmospheric
Other
HP Bore 2.3/8&1”&9/16”
Serial Number
RPM
Phase
Type
Off Load Current
2950
3
IP55
Motor Sheave
Number of belts
Make Alkin
Cut In press.
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Description
Type
Power (kW)
Voltage
Insulation
Current Rating
ODP
0,175
Fan Motor #2
Type
Power (kW)
Voltage
Insulation
Current Rating
ODP
0,175
Electrical Panel
Panel type
Drawing Number
Starter Type
List of Components
Make
Power (HP)
Frequency
Frame
Full Load Current
0,25 HP
Make
Power (HP)
Frequency
Frame
Full Load Current
0,25 HP
Starter and control panel
Make
Serial Number
RPM
Phase
Type
Off Load Current
3
Serial Number
RPM
Phase
Type
Off Load Current
3
Designation Model Rating
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Section 3
3.0 Installation
3.1 Inspection
The compressor should be inspected and checked for the following:
1.
2.
Damage during shipping, handling etc.
Check the compressor nameplate to verify the equipment conforms the working parameters.
3.
4.
Check the electrical motor nameplate to match the available power and electrical supply.
Check if the machine is filled with oil or supplied dry.
3.2 Location
The location where the compressor is installed determines to a considerable extent the overall performance and service life of the unit. 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, vapor, 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 (preferably a 6” [150 mm] concrete floor). There is no need to bolt the vibration mounts down, except if there is more than a slight vibration. Use shims to level and than tighten the bolts. Do not exert force bolting the subbase down, as this will created unwanted stresses in the structure of the subbase ass’y. Use shims to take the gaps between the feet and the concrete foundation. The canopy doesn’t need t o be bolted down
3.3 Piping
Inlet Piping: If it is necessary to carry the inlet air filter to a clean location, due to excessive dirt, heat, dampness, or toxic fumes in the near vicinity of the compressor, use 1¼” diameter good quality flexible hose; the distance from the compressor should not exceed 3 meters (10 ft). If the inlet filter will be outdoors, protect it with a proper hood against moisture.
Discharge Piping: If piping is required between the compressor package and the filling station, properly selected stainless stell pipes must be used. The piping should be installed in full compliance with all Federal,
State and local codes, standards and regulations. If required, consult the manufacturer for details.
Drain Line Piping: The drain valves inside the compressor assembly are piped to a manifold, which has a port in the bottom – rear- section of the canopy (on the side of the belts). This port must be piped with a next larger size pipe to an area where the condensate can be collected and disposed off according to local codes and regulations. Make sure this pipe is as short and as striaght possible as it is. Make sure the end of this pipe is firmly secured to avoid whipping during the venting cycle.
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3.4 Electrical check
Important!
Al though 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 .
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 will be trouble free. Make the following checks before attempting any start up
1.
2.
3.
4.
Check the line voltage. Verify that the compressor motor corresponds to mains specifications.
Check the starter and overload for conformity with the motor power and current data.
Check all electrical connections for tightness, including those in the electrical panel of the compressor.
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.
3.5 Wiring
It is important to select the right size wire and fuses. Install an isolation switch on the wall where the mains line is carried to, with magnetic protection and a capacity three times greater than the motor full load current. Use the same size wire between this unit and the compressor electrical panel. Here are the proper wire sizes to be used on compressors from 10 to 20 HP:
Motor Power – kW (HP)
7 ½ kW (10 HP)
11 kW (15 HP)
15 kW (20 HP)
In USA and Canada
AWG
230 V
8
6
4
SWG
10
8
6
AWG
12
10
8
440 V
SWG
14
12
10
In Europe and other countries with 50 Hz supply
380 – 400 V
3.6 Sheaves and V-belt alignment check
The W4 Series compressors are supplied with a self tightening rotary slide; therefore these are no adjustments need to be made. However it is a good practice to check at the initial start up the driver sheave and the compressor flywheel 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 pnds) weight applied at the center of each belt. Check the condition of the belts periodically (see the maintenance table for details.
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Section 4
4.0 Operation
4.1 Initial start-up Procedure
Follow up the following procedure when making initial start-up of the compressor:
1.
Make sure you have read this manual carefully, and you understand it. If any questions, call the nearest ALKIN distributor, service or factory.
2.
3.
4.
5.
Be sure all the preparations described in the installation section of this manual have been made.
Check the oil level in the crankcase.
Check the pressure switch and make sure that the dials are set to the proper pressure settings.
Rotate the compressor flywheel several times by hand to see that the compressor is free and in
6.
7.
working order.
Remove all objects such as tools, rugs, etc. from the vicinity of the compressor.
Jog the compressor to check the direction of rotation. Rotation must be in the direction of the arrow on the compressor crankcase and flywheel.
8.
9.
Press the start button to start the machine.
Check for possible leaks in the piping.
10.
Close the filling valves on the filling panel and allows the pressure to rise to the set point.
11.
Make sure that the compressor stops at the set pressure.
12.
Allow the compressor warm up
13.
Open the filling valves and allows the air into the cylinders to be filled.
14.
Observe the stage pressures and make sure it is within the limits shown in stage pressures table. Any deviation from these limits will indicate a mulfunction.
15.
After the first 200 hours of operation, shut the compressor off, drain the oil from its crankcase while oil is hot. Fill the crankcase with recommended oil.
16.
FILL IN THE comissioning report and return a copy to the manufacturer for track record.
4.2 Oil recommendation
The oil level should be checked daily. Top up to the overfill point when required.
On all W4 Series Compressors use the following oils only:
Anderol 750-Anderol 755-Chemlube 751
• Do not use another type of oil without prior written approval of the manufacturer.
• Do not mix oils.
• If you will have to change the type of oil to another approved oil, remove the crankcase cover and clean thoroughly the inner surfaces of the compressor crankcase. Make sure there will be no lint left inside after the cleaning.
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• We strongly recommend to replace it every 500 hours for safety. When replacing the oil, remove the crankcase cover and clean inside the crankcase with a clean cloth. Do not use kerosene or gasoline to flush the crankcase.
While doing that, pay attention not to damage the oil level switch extending into the crankcase.
Extreme Cold Operating Conditions:
Operating conditions at below freezing temperatures must be reported to the manufacturer for taking necessary measures to avoid damage. Generally a crankcase heater is fitted to prevent the effect of cold ambient temperatures.
Motor Lubrication :
Most TEFC motors are supplied with greased and sealed breaings which do not need maintenance. Motors with greasing nipples indicate that it needs to periodically be greased. In that case you will find a specific instruction booklet inside this manual which will refer to all maintenance works regarding the electric motor. Follow the instructions in this manual.
4.3 Adjustment
4.3.1 Pressure Swtich Adjustment
You can adjust PH1 pressure switch to the required upper pressure (working pressure) by turning the screw on the pressure switch clockwise or anti-clockwise. Turn the screw clockwise to increase the upper pressure. In this case you may also need to change the safety valve as it is set to open when it reaches the upper pressure. Turn the screw anticlockwise to decrease the upper pressure. Compressor is already set in the factory upon the customers working pressure needs. You can adjust the working pressure if you need a higher or lower working pressure than the factory settings. Compressor will stop when it reaches the adjusted upper pressure.
Standard Pressure Switches used on Alkin Automatic Start/Stop controlled W4 units have standard differential of
20 Bar. In other words lower pressure is set automatically at 20 Bar below the upper pressure limit which is set.
Compressor will restart when the final pressure decreases to a pressure 20 Bar below the upper pressure.
CAUTION
You also have to change the safety valves on the compressor in case you change the working pressure of the.
4.3.2 Sequential Drain Timer Adjustment
These are the drain timers on which the draining times and duration adjustments are made for automatic drain function. On this timers you will find two dials to make the time adjustments.
Upwards dial controls the duration of the automatic drain which the drain valve remains open
(drains the condensate) It is adjustable between 0 to 10 seconds. The dial does not have figures
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H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R showing the times on it; it needs to be proportionally adjusted. The full scale shows 10 seconds while half of the scale indicates 5 seconds. The downwards dial is used to adjust the time period of the automatic drain during which the drain valve will remain closed. Draining time periods and duration are adjusted as 6 seconds for every 7 minutes.
Factory settings should not be changed for trouble free operation.
4.3.3 Safety Valve Adjustment
Safety valves are set slightly above the normal working pressure of the stage they protect. The normal stage pressures are shown in the following table:
Stage Pressures
Discharge Pressure
275 Bars (4000 psi )
345 Bars (5000 Psi)
Warning!
1 st Stage Pressure 2 nd stage pressure 3 rd Stage pressure
Bars Psi Bars Psi Bars Psi
5 - 5,5 72 - 79 16 - 17,4 232 – 252 55 - 65 865 – 955
5,3 - 6 76 – 87 16,5-17,9 240 – 260 64 - 71 940 – 1040
• Do not adjust the safety valves and do not alter their original settings. Only authorized service technicians are certified to make such adjustments. If required, replace and return the old one for reconditioning to the factory or to a dealer nearest you.
• Do not remove the leaking safety valves and do not replace it with a plug. This may be extremely dangerous. If safety valve leaking, replace it.
Fill in the following forms (total 2 pages) at the initial start up. Send a copy to the manufacturer for record keeping, and retain the original report n the file of your compressor.
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COMISSIONING REPORT – INITIAL START UP
CUSTOMER DETAILS
Name of the Company
Address
Contact Name Position
Name of Plant Where Equipment Installed
(If different than the above)
Address
Contact Name
Distributor
Position
Phone
Phone
Persons Attending the Commissioning
Full Name Position
Equipment Details
Model
Application
Medium
Air
PRELIMINARY CHECKS
Serial Nr.
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.
Other Remarks
In charge of
Date of purchase
Gas (specify) :
Remarks
Fax
Fax
Signature
……………………………………………………………………
V Hz
Date of comissioning
Signature
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START UP CHECKS Remarks Signature
Direction of rotation
Start up current and voltage
Fill in the pressure reading table
Pressure switch cut out pressure
Main Motor Current and voltage at full load
Max current and voltage ratings & supply frequency conform the nameplate values.
Fan Motor Current
Centrifugal unloader venting when compressor stops
Amps. Volts
Bars
Amps. Volts
Amps. Volts
Centrifugal unloader stops venting when compressor runs
Vibration
Noise
No back flow in the Check valve when the compressor stops.
Interstage and final safety valves not leaking
Ambient Temperature
Crankcase oil temperature after 30 minutes of operation
Discharge air/gas temperature after 30 minutes of operation
Duty Cycle (…min operating;
Other Remarks
V Hz
C
C
C
Min. runnig; min.stops
Pressure Readings
1 st stage 2 nd stage 3 rd stage 4 th stage
50 Bars
100 Bars
150 Bars
Engineer in charge of the plant
1 st stage 2 nd stage 3 rd stage 4 th stage
200 Bars
250 Bars
Full Name
Remarks
Singature Date
Distributor / Manufacturer’s Representative Attending the Commissioning
Full Name
Remarks
Signature Date
Other Attendants
Full Name
Remarks
Singature Date
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Section 5
5.0 Maintenance
5.1 General
As you proceed through this section, it will be easy to see how simple is the compressor to maintain. By following these recommendations, you will get long and trouble free operation from your air compressor.
The following are general guidelines for periodical maintanence; specific details will be mentioned in the following chapters. Use the Maintenance Table for maintenance and record keeping.
Warning!
Before attempting any maintenance work, isolate the compressor by switching off the power and blowing down the pressure inside all devices, including the filters, purifier, piping etc. If a bank system exists, isolate by closing the appropriate valves.
5.2 Daily
1.
2.
3.
4.
Check the oil level and fill the crankcase if needed.
On gas compressors, check the seal chamber oil level.
Drain the condensate from pressure vessels – if any- and the piping network (not applicable to individual filling stations)
Observe the compressor for any irregularities, such as loose bolts, unusual noise, loose belts, leaking pipes etc.
5.3 Weekly
1.
2.
3.
Inspect the intake air filters to make sure they are not clogged or punctured.
Clean dust and dirt from the compressor flywheel, intercooler, aftercooler and cylinders to insure proper cooling.
Check the V-belt tension. The proper tension should allow 13 mm ( ½ ”) deflection with a 1 kg (2 pounds) weight applied on the center of each belt.
5.4 Every 120 hours
Change or re-fill the purifier cartridge. Depending on the ambient conditions, this period can be shortened or extended.
5.5 300 hours maintenance
1.
2.
Check the pressure relief valve(s) against leaks.
Change the pre-filter cartridge.
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3.
4.
Clean the surfaces of the intercoolers, aftercooler, fan blades, flywheel blades.
If any deviation in the stage pressures is noticed, clean all stage valves.
5.6 500 hours maintenance
1.
Change the oil in the compressor crankcase.
2.
3.
4.
Change the intake air filter catridge.
Clean valves; replace worn discs and springs.
Tighten all bolts and nuts (do not overtighten; if not sure, use a torquemeter). See the torue values in this manual
5.
Inspect the valves; make sure there is no dirt or carbon collection on any parts of the valve assemblies.
5.7 1000 hours maintenance
1.
2.
3.
Replace the o-rings and gaskets in the valve assemblies.
Clean compressor valves. Replace any worn parts. Take care to replace the cylinder covers and valve plates in original position. All gaskets should be replaced with new gaskets.
Replace sintered filter elements.
5.8 2000 hours maintenance
1.
2.
Check and replace worn piston rings.
Replace the valves.
3.
Replace the “V” belts.
5.9 As required
1.
2.
3.
Check the motor or engine manual for recommended service intervals.
Check and replace worn piston rings.
See the specific instruction sections for additional maintenance rules for the specific compressor and ancillary equipment delivered to your plant.
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5.10 MAINTENANCE TABLE
Maintenance Period
I:Inspect/M:Maintain/R:Replace I
DAILY
M R
WEEKLY
I M R I
500 Hours
M R
1000 Hours
I M R
2000 Hours
I M R
LUBRICATION
1. Oil
2. Crankcase Cleaning
INTAKE FILTER
V - BELT
Pressure Vessels w/o auto.drain vlv.
1 . C O N D E N S A T E D R A I N
2. Pressure vessel test
PIPING & CONNECTIONS
1. Leaks
2. Tightening of bolts & fittings
CLEANING
1. Intercoolers
2. Aftercooler
3. Flywheel
4. Cylinders
5. General
6 . S I N T E R E D M E T A L F I L T E R
E L E M E N T
SWITCHES & GAGES
1. Pressure Switch Settings
2. Pressure Gages
SAFETY VALVES
Drain collector filter element
COMPRESSOR VALVES
Piston rings
1
4 st th
& 2 nd & 3
stages rd stages
ELECTRICAL
1. Contactor connections
2. Contacts
3. Current (loaded and unloaded)
3. Terminals (tighten the screws)
Filling Valves
Whips & Yokes
Vibration Mounts, motor mounts
Filter Cartridges
Every 300 Hours
Purifier Cartirdge Every 120 Hours
Surroundings of the compressor
General Overhaul
Check daily for a clean and well ventilated surrounding in the compressor room .
As it may be necessary. Consult your dealer or the factory for details.
Other equipment, filling stations cylinders, pipe network etc.
As may be required. Consult in case of specific applications
See the specific instructions section to check if additional service / maintenance requirements apply to the specific equipment delivered to you.
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5.11 Maintenance procedures
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.
5.11.1 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.
5.11.2 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.
Bol tor Screw
Bolt&screw
Bolt&screw
Bolt&screw
Bolt&screw
Bolt&screw
Bolt&screw
Size
M6
M8
M10
M12
M14
M16
TORQUE VALUE TABLES
Maximum Torque
10 Nm (7 ft.lbs)
25 Nm (18 ft.lbs)
45 Nm (32 ft.lbs)
75 Nm (53 ft.lbs)
75 Nm (53 ft.lbs)
200 Nm (141 ft.lbs)
5.11.3 Servicing 1 st stage valve
The valves must be in good and clean condition at all times for proper operation of the system. The valves must be checked periodically and maintained (see Maintenance Table).
5.11.4 Servicing 2 nd stage valve
2nd stage valves are concentric ring type and are similar in construction. See the figure. To inspect and clean the 2nd stage valve, observe the following step-by-step procedure:
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6.
1.
Loosen the valve acorn nut as shown in Figure; then take out the air head cap screws and remove the air head assembly from the cylinder.
2.
Remove the valve assembly from the covers. To disassemble the valve assembly, use a plate with two pins that will fit the holes in the valve seat
(position #3); clamp this plate firmly in a vice and remove the nut (#10) and beleville washer (#9). Note the manner in which the valve parts are assembled in order to replace them in the same order and position after cleaning or installing new parts.
3.
The valve parts can be cleaned by light scraping or stiff brushing (do not use a wire brush!). If necessary, use a non-flammable safety solvent to loosen dirt, oil or carbon deposits.
4.
Discard the worn, scrateched or broken valve discs and springs. Reassemble the cleaned (or replaced) valve parts in their place in the reverse sequence of dismantling and in proper position as shown in the above illustration and in the parts manual. Make absolutely sure that the stop plate is centred properly on its guide; otherwise, the valve will be damaged when it is pulled up tight in the airhead. Replace the beleville washer on the valve bolt and tighten the nuts to the torque values recommended.
5.
Before replacing the valve in the air head (the two halves of the top cover), scrape the old shellac off the valve bolt steel washer and coat it with new shellac to prevent air from leaking under the washer. Replace the acorn nut and tighten it to the lower limit of the torque value, recommended. Do not over tighten this nut, since this will distort the springs and plates, causing the valve to leak. After the valve has been replaced in the airhead. Make certain that the valve operates freely by lifting at its edges with a knife blade.
Replace the cover gasket between the two cover valves, and between the head and the cylinders; then replace the air head asembly. Tighten the air head cap screws to the torque values recommended.
IMPORTANT!
Handle the valve parts with care. Do not nick, scratch or bend them.
32
5.11.5 Servicing 3 rd &4 th stage valve
The 3 rd and 4 th stage valves are plate type valves, made of stainless steel for longer service life and relaible operation. These stages are under particular stress caused by temperatures and high-pressure rates. They should be periodically checked and maintained as inst ructed in the Maintenance Table. Refer to illustration on figüre.
To disassemble the remove the 3 rd or 4 th stage valves, observe the following step by step procedures:
1.
Remove the airhead from the cylinder and pull the valve out of the head. If the valve assembly is covered with hard carbon, soak the valve in a suitable carbon solvent overnight to permit easier disassembly.
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H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
2.
Remove the snap ring (#22 & 32) from the valve by prying under its tapered edge with a penknife.
Withdraw the internal parts of the valve and place them on a clean surface in the correct relationship so that the valve can be properly reassembled.
3.
After disassembly, inspect the condition of all the parts. If theres are no signs of wear, clean the parts or replace them with new original.
4.
To clean the valve parts use a light brush to brush and scrape. When cleaning valve parts use extreme care to prevent damaging the parts.
Use new o-rings and gaskets. When reassembling the valve, make sure all parts are replaced exactly as removed and t hat new gaskets and “O” rings are used. Figure 14 illustrates the relationship of these parts. It is important to install original Alkin “O” rings as these are made of special high temperature resistant material and ordinary o-rings will be promptly damaged causing failures
5.11.6 Piston ring replacement
The high-pressure stage rings (4th and 3rd) wear faster than the other stages. You may need to replace the 4th stage piston rings earlier than the other stages. If this will be the case, it is recommended that all piston rings on a specific piston be replaced at the same time. To remove and replace rings observe the following procedure:
1.
To replace piston rings on the 1st or 2nd stage double-ended piston, both the cylinder and piston are to be removed from the compressor.
2.
3.
To replace piston rings on the 3 rd stage steeple piston and the 4th stage split type piston, only the compression cylinder need be removed. Remove the cylinders in the manner outlined in “ Cylinder replacement ” section.
Remove the old piston rings off the 1st and 2nd stage double-ended piston.
4.
5.
6.
7.
8.
Remove the rings from the 3rd stage piston in the same manner as on the 2st and 2nd stages.
Remove the rings on the 4th stage steeple piston by driving out the dowel pin and unscrewing the piston top. The rings and spacers may then be pulled off the center bolt.
With the rings removed, thoroughly clean the pistons by brushing or scraping lightly. Pay particular attention to cleaning the piston ring grooves, oil return holes and gasket seating surfaces on the cylinderI
Inspect the cylinder bore for scoring or scuffing. If the cylinder bore shows signs of being scored or worn (as indicated by a visible ridging at the end of ring travel.) it must be replaced to establish effective oil control.
Inspect the piston for signs of excessive scoring or cracking. Particularly check the condition of the ring grooves for wear on the sides of the ring lands. If any of these conditions are observed, the piston(s) should be replaced.
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2nd STAGE RING SET
1st STAGE RING SET
1
6
7
4
5
2nd STAGE RING
3
2
3
4
1st STAGE RING
7
6
5
4
3
2
1
Nr
302.884.500
302.883.850
370.045.380
Part Nr.
6781-4
6781-3
6781-2
6781-1
0018
6477
Drwg. Nr.
Oil Ring(2+1)
Compression Ring
Oil Ring(2+1)
Compression Ring
Lockring
Piston Pin
Piston Ass'y
Description
1
5
2
1
3
1
1
Qty
# 6770
3
1
4
5
2
3
3
2
1
5
4
Nr.
6781-10
6781-09
7103-01
0018
6477
Part Nr.
Scraper Ring
Compression Ring
Lockring
Piston Pin
Piston
Description
1" x 3/32"
1" x 3/32"
1"
Dimensions
4
4
4
5
5
2
1
1
2
3
Qty
11
8
10
9
8
10
3
7
6
5
4
1
2
3
5
4
3
2
1
Nr
7
6
9
8
11
10
6476-06
6476-05
6476-04
6476-07
6476-03
BOLT
BUSH
COMPRESSION RING
SPACER
SOCKET HEAD SCREW
PISTON RETAINER
6476-02
0018
SPRING WASHER
FLOATING PISTON
LOCKRING
PISTON PIN
6476-01 PISTON
Part Nr.
Description
2
1
2
1
1
Qty
2
1
5
6
1
5
9
10
9
8
9
8
8
10
10
9
8
Ø13.85xØ6.3x1.58
9/16" x 1.97
Ø10.60xØ6.3x2.03
Dimensions
8
10
9
To replace the rings of the 1 st and 2 nd stage double-ended piston, or 3 rd stage steeple piston, lubricate the ring grooves and replace the rings with a piston ring expander to avoid breakage and distortion. Pay particular attention to install the rings with the marks facing the appropriate direction into the proper groves, as indicated in the following drawing.
9.
34
Work from bottom compression ring up on the top end of the piston and from the compression ring down on the lower end. Observe this drawing to see the manner, which the tapers are to be positioned.
The word “top”, a white dot or similar marking must face the compression chamber. Caution then must
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R be exercised in placement of the rings labeled on the second stage piston. The three bottoms rings on the leftmost figure shows the 2nd stage compression rings, which will have its “top” mark facing the crankcase. On the second figure from left, the ring marking will face away from the crankcase.
The oil rings on the first and second stages are four piece oil wiper rings with an expanderseparator and two steel rails. See second figure from left (above). Place the expander and make certain that these ends do not overlap accidently when installing the other ring segments. Next, install one of the steel rails in the bottom of the groove; this will hold the expander in place.
Now install the separator on top of the steel rails and over the expander. Make certain the butt ends of the expander and the end gap of the separ ator are 180º apart. The second steel rail may now be installed in the top of the ring groove over the separator. With all rings installed, stagger the end gaps
1st Stage Compression Ring
Total 2 pcs.on 1st stg & 3 pcs on 2nd stg.
Part Number : 6781-05
The mark should face up 2nd Stage Compression Ring
Total 3 pcs.
Part Number : 6781-07
Ø4½"
The mark should face up
3rd Stage Compression Ring
Total 3 pcs.
Part Number : 6781-09
9/16"
Ø1"
Ø4½"
Ø3 13/16" or
This side
Down
This side
Down
1st Stage Oil Ring
Total 1 pcs.
Part # : 6781-06
Ø4½"
The mark should face down
Part # : 6781-05
1st STAGE
RING SET 6781-01
2nd STAGE
RING SET
4th Stage Compression Ring
Total 5 pcs.
Part Number : 6781-11
Ø3 13/16"
Ø1" or
3rd Stage Scraper Ring
Total 2 pcs.
Part Number : 6781-10
2nd Stage Oil Ring
Total 1 pcs.
Part # : 6781-08
6781-02
3rd STAGE
RING SET 6781-03
4th STAGE
RING SET 6781-04
10.
To replace the rings of the 4th stage piston, first examine the spacers and make certain they are not worn or damaged. Next, insert the spacers and rings on the center bolt in the sequence shown in Figure on page 30. The small diameter groove spacers are inserted on the center bolt inside the piston rings. With all rings and spacers in place, return the center bolt to the piston; tighten it and replace the dowel pin.
After the center bolt has been tightened, check to make certain that each ring has a slight freedom of movement (as opposed to extreme rigidity, which may occur if the rings are pinched by the spacers).
11.
When new piston rings are to be installed in the original cylinder of the 1 st or 2 nd stage, the cylinder bore must be “deglazed” to provide a proper seating surface for the rings. Use a #80 grit abrasive cloth and go over the cylinder bore using a rotating, reciprocating motion. Do not overdo “deglazing”; dulling the glaze is usually sufficient and can be accomplished with light pressure.
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Caution!
Do not attempt to deglaze the cylinder bore with a harsh abrasive agent. The use of such abrasive agents usually results in oil carryover and faulty compressor.
After deglazing, the cylinder walls should be thoroughly cleaned by scrubbing the bore with a stiff bristle (do not use wire brushes); brush using ordinary soap or a detergent and hot water. Rinse thoroughly with hot water and then check the cleanliness of the cylinder bore by wiping it with a soft white cloth.
12.
The cylinders may now be replaced. Replace the cylinders in the manner outlined under “ cylinder removal & replacement ”.
13.
After the new piston rings have been installed, the compressor should be operated for at least 10 hours at full load before checking for proper air delivery or oil consumption.
5.11.7 Crankshaft bearing replacement
Do not replace the crankshaft bearings unless you are equipped and trained to do so. In case of bearing failure, we recommend to install a new crankshaft assembly (complete with bearings).
INSTALLING THE CRANKSHAFT ASSEMBLY:
A new crankshaft assembly includes the crankshaft itself, the two ball bearings, spacers, and a woodroof key, all installed as a complete assembly. To remove the old crankshaft and install the new one proceed as outlined in the following:
First, drain the oil from the frame. Then remove the beltwheel key and shaft end cover.
1.
2.
Disconnect the tubing to the pilot valve and remove the crankcase cover together with the pilot valve as a unit. Next, take the centrifugal unloader assembly off the end of the crankshaft.
Remove the cylinders as explained in section cylinder removal & replacement.
3.
4.
5.
6.
7.
8.
9.
Remove the connecting rods from the crankshaft pin section.
Pry off the snap ring from the outer bearing (on the flywheel side).
The crankshaft assembly is a moderate press fit in the crankcase and may be forced out by tapping the flywheel end of the shaft with a lead hammer.
Prepare the new crankshaft assembly for installation by removing the snap ring from the outer bearing.
The new crankshaft may be inserted into the crankcase from the cover side. Since the assembly is a moderate press fit it may be forced into position by tapping it with a lead hammer; pay attention to strike the center of the shaft, since an off center blow may cause damage.
The crankshaft assembly must be pushed in until the outer bearing clears the end of the frame by about
1/16”(1.56 m). Replace the snap ring by putting one end in the groove and springing it into place.
Tap the crankshaft back until the snap ring is tight against the frame.
10.
Before replacing the shaft end cover make certain that there are no burrs on the beltwheel end of the crankshaft and that the edges of the keyway are smooth and slightly rounded to prevent damage to the oil seal. When satisfied that the crankshaft is smooth, replace the shaft end cover. As an added precaution against damaging the oil seal, use a piece of.003” (.076 mm) brass shim of necessary size and form it into a cone. Lubricate the surface of the cone; position it on the shaft as shown in Figure 3-7 and slide the cover and seal over the cone and into position against the frame.
11.
Replace the pistons and cylinders as outlined “ cylinder removal & replacement ”.
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12.
Replace the centrifugal unloader assembly and crankcase cover. Reconnect all tubing.
13.
Replace the flywheel. Replace the belts.
14.
Fill the crankcase with recommended oil to the overflow point of the filler hole.
5.11.8 Oil seal replacement
To replace the oil seal, proceed as follows:
1.
Remove the belts, flywheel and the woodroof key and seal cover.
2.
3.
The oil seal may be removed from the cover by prying under the inside lip with a pinch bar or driving it out with a metal rod.
Insert the new seal with the sealing lip facing in the same direction as the one removed and coat the
4.
outside diameter of the seal with shellac or pipe compound. Press the seal into the shaft end cover with a padded vise.
After the seal has been installed in the shaft end cover, the cover should be returned to its original location on the frame by sliding it over the end of the crankshaft. To avoid damaging the seal lip, make sure that the surface of the crankshaft is free of burrs and sharp edges. As a precaution to prevent cutting the seal, use a piece of .00
3” (.76 mm) brass shim stock of adequate size and form it into a cone.
Lubricate the surface of the cone; position it on the shaft as shown and slide the cover and seal over the cone and into position against the frame.
5.
Replace the key and flywheel and the belts.
5.11.9
Piston&piston pin removal and replacement
1.
2.
To remove a piston from the connecting rod, first remove the piston and rod from the compressor as outlined under “ cylinder removal & replacement ” on thi s page.
With the piston and connecting rod removed from the compressor, remove the lock rings at the ends of the piston pin. With a dowel of appropriate size and a soft hammer drive out the pin. To prevent distorting the piston during this operation, inserting fork-type shims of the necessary thickness between the rod and the boss must eliminate the play between the piston pin boss and the connecting rod.
3.
4.
To install the new pin, align the connecting rod between the bosses inside the piston, and insert the same number of shims between the boss and rod that were used when the pin was driven out.
Lubricate the pin and drive it into the piston and through the connecting rod with an appropriate dowel and a soft hammer. When the pin is in place, snap the lock ring back in their grooves.
5.
To replace the assembled piston and rod in the compressor, follow the instructions given under Cylinder
& piston removal & replacement in the following section.
5.11.10 Cylinder&piston removal and replacement
To Remove Cylinders and Pistons Proceed as follows:
1.
Disconnect all tubing connected to the cylinders and drain the oil from the crankcase.
2.
Disconnect tubing to the pilot valve and remove the crankcase cover and the pilot valve as one unit.
3.
4.
5.
Remove the centrifugal unloader assembly from the end of the crankshaft.
Remove the bolts attaching the 3 rd and 4 th stage cylinders to the crosshead cylinders, and pull the compression cylinder off the piston. Next, take out the attaching screws connecting the crosshead cylinder to the crankcase and pull the crosshead cylinder off the piston. Pull the end of the connecting rod off the end of the crankshaft and withdraw the rod and piston. If the piston is to be removed from the connecting rod, follow the procedure outlined under piston removal & replacement on this page.
To remove the 1 st and 2 nd stage double-acting piston, first take out the attaching screws between the
1st and 2 nd stage cylinders, and pull the 1 st stage cylinder off the top of the piston. Next, take out the attaching screws between the 2 nd stage cylinder and the crankcase. Pull the end of the connecting rod off the end of the crankshaft and lift the cylinder -with the piston inside- off the crankcase. The piston
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H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R can now be pushed out of the cylinder. To remove the piston from the connecting rod, follow the procedure outlined under “ Piston Pin Removal and Replacement ” on this page.
To Replace Piston and Cylinders – Proceed as follows:
6.
To replace the 1st and 2nd stage double-acting piston, lubricate the 2nd stage cylinder bore and insert the connecting rod and small diameter end of the piston into it. Use an appropriate piston ring compressor
7.
method to prevent damage to the rings when inserting, and push the piston into the cylinder as far as possible. Next, replace the crankcase-to-cylinder gasket, after which, the cylinder, piston and connecting rod may be replaced as a unit by inserting the connecting rod (with its oil dipper pointing down) into the crankcase. Slip the end of the connecting rod over the crankshaft pin and bolt the cylinder to the frame.
Next, replace the gasket between the 1st and 2nd stage cylinders. Lubricate the piston rings and slide the
1st stage cylinder over the piston using an appropriate piston ring compressor method to prevent damage to the rings. With the 1st stage cylinder replaced, bolt it to the 2nd stage cylinder. If the airheads have been removed from the cylinders they must be replaced according to the procedure outlined under “ air head replacement ”
To replace the 3 rd &4 th stage pistons lubricate the bore of the crosshead cylinder and insert the connecting rod and piston into it. Next replace the cylinder to frame gasket, after which the cylinder, piston and connecting rod may be replaced as a unit by inserting the connecting rod (with its oil dipper pointing
8.
9.
down) into the crankcase and slipping the end of it over the crank pin. With this done bolt the cylinder to the crankcase. Next, replace the gasket between the crosshead and compression cylinder. Lubricate the piston rings and slide the compression cylinder over the piston using an appropriate piston ring compressor method to prevent damage to the rings. With the compression cylinder replaced, bolt it to the crosshead cylinder. If the airhead was removed, it is essential that it be replaced in the manner described under “ air head replacement ”
Replace the centrifugal unloader assembly to the end of the crankshaft.
Replace the crankcase cover and all tubing and fittings that were removed.
10.
Fill the crankcase to the overflow point with UL751 oil
5.11.11 Air head replacement
The attaching screws for all airheads are to be tightened evenly and in rotation to the torque value given in the torque values table. To avoid faulty valve operation, the 3 rd and 4 th stage air head attaching screws must be tightened as closely as possible to the torque values given, and a feeler gauge is to be used between the air head and cylinder to make certain the air head is drawn down evenly.
5.11.12 Precautions for storing
Whenever the compressor is taken out of service the following precautions must be taken to prevent general deterioration.
1.
2.
3.
Drain the oil from the frame. To prevent rusting, all interior surfaces of the unit must be treated with a rust inhibiting oil. To treat all interior surfaces properly, remove the air heads from all cylinders, and fog or pour a small amount of rust inhibiting oil directly into the cylinder. Remove and clean the valves as outlined in section “ servicing valves ” and treat the valves and heads wit h rust inhibiting oil. Reassemble the valves in the air head and replace the heads on the cylinders according to the instructions given under
“ airhead replacement and torque values. Fill the frame with a suitable rust inhibiting oil, and operate the machine for about 10 minutes. Leave the rust inhibiting oil in the frame until the compressor is put back in service.
Relieve tension from the V-belts by lifting the electric motor underneath the compressor unit, and placing under a proper size wood block.
Remove the intake air filter assembly.
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4.
5.
Plug all openings to prevent moisture from entering the unit.
Store the unit in a dry, sheltered location.
6.
Drain all condensate from the air storage bot tles. Follow the manufacturer’s instructions for storing the electric motor, gasoline engine or any system that may be used in conjunction with the compressor.
5.11.13 Intercoolers and aftercooler
A set of tubes acting as heat exchangers are installed between each stage (intercoolers) and after the last stage
(aftercooler ). A moisture trap is installed after the 2nd and 3rd stage intercoolers and downstream the aftercooler. As the compressed air is cooled in these tubes, the water vapors condensate; the moisture traps cause the water in liquid state to collect in the bottom section of the trap, from where it is preiodically removed through externally mounted automatic drain valves.
Servicing the Cooler Tubes:
Clean the surface of the tubes periodically; see “ Maintenance Table ” for recommended cleaning intervals.
5.11.14 Automatic drain valves
The automatic drain valves are simple, yet reliable draining devices, controlled with low-pressure air taken from the second stage moisture trap. A Normally Closed 3 way low pressure solenoid valve sends the control air to close the drain valves, and removes the control air to open them. A sequential timer in the control cabinet controls the opening intervals and the time opened. See also the section under “Drain Timer”.
5.11.15
Filtration equipment
Prefilter:
The prefilter housing is made of stainless steel and it contains a disposable filter cartridge. Replace this cartridge every 250 hours. At the first replacement, inspect its condition and if excessive dirt is observed, reduce the replacement interval to 200 hours. If necessary, clean the housing as well. Use a clean lint free cloth to clean. Make sure not to leave any parts or rugs inside the housing, which may block the air passages in the caps.
Purifier:
The purifier housing as well is made of stainless steel and it contains in it a refillable cartridge. Follow the refilling instruction that is supplied with the refilling kits for this procedure. The procedure to remove and replace a purifier cartridge is as follows:
1.
Loosen the nuts (4) that is located in the center of the top cover.
4
5
2
3
6
5
6
8
2.
Install the adapter tool (3) which is supplied with the compressor, onto the cover (5), using the two bolts (2), that come with the adapter.
3.
Use a ratchet tool (1) to loosen the cover (5).
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4.
cover.
2
1
3
5
6
8
Turn the cover four turns and then remove the two bolts (2) and the adapter tool (3) from the
Put the two bolts (2) in place to turn the cover
(5) by hand. Turn the cover (5) and remove the whole assembly from the purifier chamber.
9.
Insert the cartridge back into the purifier chamber. Do not drop. Make sure the cartridge sits in place properly.
10.
Inspect – and replace if necessary- the o ring and
/ or the backing ring on the seal housing.
11.
Insert the whole cover in to the purifier chamber.
Install the mountny adapter (3) in place, using the same bolts (2). Tighten the cover until it is flat with the purifier chamber top surface.
2
1
3
5
6
5
8
8
5.
Pull the cartridge (7) out of the purifier chamber(8).
8
7
6.
7.
8.
Open the flat end of the cartridge; remove its contents. Clean the inside of the cartridge by rinsing, adn throughly drying. by rinsing, adn throughly drying.
Use the instrcutions supplied with the cartridge refilling kit to refill the cartridge. Always replace the chemicals, felt pads and the o-rings with new materials and parts.
Inspect and clean – if necessary- the inside of the purifier chamber.
40
The tool (1) is designed not to let go to tighten beyond this point but we have seen custumers who lost the tool, used a makeshift tool that allaws further tightening, wich may result in over pressing and crushing cartridge.
12.
Remove the tool (1) and the adapter (3); the installation of the cartridge is completed.
4
5
6
7
For filters, use similar procedures, except for the cartridge which is not refillable and it needs to be replaced periodically. See the instruction manual for detail
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Section 6
6.0 Trouble shooting
6.1 COMPRESSOR WILL NOT OPERATE
•
•
•
•
•
No electrical power
Motor starter overload tripped
Fan motor overload tripped
Low Oil level in the crankcase
Pressure switch not making contact
Switch the power on
Re-start and check if trips again. If it does check if the centrifugal unloader venting air at shutdown, resulting in staring under load.
Reset the overload; re-start and check the cause.
Check; add oil if necessary; reset through the reset button and retart.
Check all the terminals, and wires. If pressure switch defective replace it
6.2 EXCESSIVE NOISE DURING OPERATION
• Loose sheave, flywheel, belt, belt-guard, intercooler, bolts or accessories
• Faulty vibration mounts
Detect and tighten.
Check if the mounts in good condition; if damaged, replace.
(damaged vib.mounts can cause the baseplate to hit the base of canopy)
6.3 COMPRESSOR KNOCKS
• Crankshaft bearing failure Replace bearings or crankshaft assembly
• Connecting rod journal bearings worn. Replace the connecting rods; if worn,replace the crank pin bush as well
• Wrist pins and journals are worn Replace complete pin and rod assembly.
• Loose motor fan Tigten; if damaged, replace.
• Lack of oil in the crankcase
• Piston hitting the valve plate a. Check for possible damage to bearings b. Fill oil and check if the noise persists.
Remove the compressor cylinder head; add a new gasket and reassemble.
Tighten • Compressor mounting loose
• Deflected crankshaft or crankshaft Replace crankshaft bearing failure
• Excessive dirt or carbon on piston (s) Remove the compressor cylinder head; clean pistons and valve(s)
(Or replace if worn); reassemble.
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6.4 MILKY OIL IN RECERVOIR
• High moisture content in the ambient air
6.5 EXCESSIVE OIL CONSUMPTION
• Restricted air intake
• Oil leaks
• Worn piston rings
Pipe air intake from less humid source.
Change oil more frequently.
Replace air filter element
Tighten bolts and fittings; replace gaskets.
Replace piston rings
• Low oil viscosity
• Piston rings misassembled
• Compressor tilted too much
• Scored or worn cylinder(s)
6.6 OIL IN DISCHARGE AIR
• Restricted air intake
Drain oil; refill with oil of proper viscosity (see section 4.3.)
If piston rings are upside down, install in proper position.
Level compressor
Replace cylinders.
• Worn piston rings
• Excessive oil in the crankcase
•
•
Low oil viscosity
Piston rings misassembled
Replace air filter element; check for other restrictions at the inlet.
Replace piston rings
Drain to the overflow level
Drain oil; refill with oil of proper viscosity (see recommended oils )
If piston rings are upside down, install in proper position; check ring gap
6.7 COMPRESSOR VIBRATES
• Mounting bolts are loose
• Compressor not properly mounted
Tighten the mounting bolts
Level the compressor so that all feet touch the floor.
• Motor sheave & the flywheel misaligned Align.
• Bent crankshaft Replace the crankshaft
6.8 AIR BLOWING OUT OF INLET
•
Broken first stage inlet valve Replace valve strip or disc
6.9 INSUFFICIENT AIR AT THE POINT OF USE
• Leaks or restrictions
• Restricted air intake
• Slipping belts
Check for leaks and restrictions in the piping and hoses.
Replace the intake air filter element.
Tighten the belts
• Air piping too small
• Excessive air consumption
Redesign and re-pipe the system. a. Limit the air consumption to the capacity of the compressor. b. Increase your air capacity with an additional compressor unit.
6.10 PRESSURE VESSELS DO NOT HOLD THE PRESSURE WHEN THE COMPRESSOR IS
UNLOADED
• Faulty check valve.
• Excessive leaks in the plant piping
Relieve the vessel pressure and replace the check valve.
Relieve the tank and piping air pressure; repair leaks.
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Warning!
Do not service tank, valves, piping etc. With air/gas in the system. Relieve alla ir before attemting any repairs.
6.11 EXCESSIVE BELT WEAR
• Sheaves misaligned
•
•
•
Belts too tight
Belts too loose
Sheave or crankshaft wobble
Realign the driver sheave and the flywheel.
Adjust tension – the compressor has automatic tightening slides; consult factory.
Adjust tension – the compressor has automatic tightening slides; consult factory.
Check for worn or bent crankshaft, keyway or sheave bore.
Repair to smooth the surface or replace. • Damaged sheave /flywheel belt groove
6.12 EXCESSIVE DISCHARGE AIR TEMPERATURE
• Dirty valves / carbon on valves Remove valves; clean or replace.
• Dirty cooling surfaces and intercooler Clean cooling surfaces of the cylinders, intercooler & the discharge pipe
• Poor ventilation and air circulation Improve ventilation or relocate the compressor
• Blown head gasket
• Restricted air intake
• Worn valves
Replace head gasket
Replace air intake filter element.
Repair or replace the valves.
• Comp. rotating in the wrong direction Correct the direction of rotation.
6.13 AIR LEAKING FROM THE INTERSTAGE SAFETY VALVE
• Safety valve faulty Replace the safety valve.
• Inlet valve of the next stage leaks
• Inlet valve of the next stage broken
Remove valves; clean or replace.
Remove valves; clean or replace.
6.14 CYLINDER PRESSURE BUILDS UP SLOWLY
• Dirty air filter Replace air intake filter element
• Blown cylinder gasket Install a new gasket
Replace valves • Worn or broken valves
• Air leaks in the system
• Loose belts
• Speed too slow
Search for leaks; correct the situation.
Adjust tension – the compressor has automatic tightening slides; consult factory.
Check the compressor speed.
6.15 RECEIVER PRESSURE BUILDS UP TOO FAST
• Water in the storage cylinders/filters Drain the receiver frequently or install an automatic drain.
• Speed too fast. Check the speed.
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6.16 RESET MECHANISM CUTS-OUT REPEATEDLY
• Motor overload Shut down and check for cause
• Faulty pressure switch or pilot valve Adjust or replace
• High ambient temperature Improve ventilation.
6.17 FUSES BLOWN REPEATEDLY
• Wrong fuse rating
• Loose wiring, terminals or connections
Replace with fuses of proper rating.
Tighten all electrical connections.
6.18 COMPRESSOR DOESN’T UNLOAD WHEN STOPPED
• Leaking pilot valve / seat leaking
• Automatic drain valves blocked
Check pilot valve; replace if necessary
Check, disassemble, clean; install new o-ring and seat if
• Centrifugal unloader is not necessary.
Check; replair or replace. functioning
• Pilot valve Pin is broken or bent Replace pin.
6.19 AUTOMATIC DRAIN VALVES DO NOT DRAIN
• Pilot Solenoid valve faulty Replace solenoid valve.
• Automatic Drain blocked Disassemble the drain valve; clean and replace o-rings and spring.
6.20 AUTOMATIC DRAIN VALVE(S) REMAINS OPEN ALL THE TIME
• Low 2 nd stage control air pressure
• Faulty pilot solenoid
• Blocked drain valve
• Worn pilot valve seat
Check the nterstage pressures
Replace the pilot solenoid
Clean
Replace drain valve (or if trained to repair, use a repait kit to correct)
6.21 COMPRESSOR WILL NOT COME UP TO NOMINAL OPERATING SPEED
• Low voltage Check line voltage
• Loose motor / control gear terminals Check motor and starter terminals for good contact; tighten if needed
• Poor power regulation (unbalanced phases)
Notify the power company.
6.22 UNUSUAL PISTON, RING OR CYLINDER WEAR
• Imporper oil
• Low oil level
Replace with proper oil.
Check level; check why low oil level switch did not cut out; correct fault, top up oil.
• Extremely dirty ambient conditions. Pipe the intake filter to a cleaner location if possible; alternatively use a heavy duty two stage filter (consult the factory)
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7.0 Part List
Part
List
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7.1 Crankcase Assy
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
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No Part no. Description
1.01 AYD-358 OIL SEAL - Ø60xØ110x13
1.02 AYD-360 CIRCLIP - Ø60 DIN471
1.03 AYD-411 BEARING - 6212
1.04 AYD-361 CIRCLIP - Ø110 DIN472
1.05 7185-06 REDUCTION - 1/2” x 1/4”
1.06
1.07
7672-23 FITTING - 1/4” x Ø10
6884-40 NUT - M10 x 13,80
1.08 7091-12 WASHER - M10
1.09 AYD-367 CRANK BEARING
1.10
1.11
6882-40 BOLT - M10x55
7375-05 O-RING - 210x3 NBR
1.12 AYD-418 CRANK SPACER
1.13 AYD-419 CRANK SPACER
1.14 6937-87 BEARING - 2212 NUP
1.15 AYD-420 CRANK COUNTER-WHEIGHT
1.16 AYD-220 CRANK SHAFT
1.17 7867-79 SCREW - M10x50
1.18
1.19
1.20
1.21
7102-01 WOODRUFF KEY
7083-03 HEX HEAD PLUG - 3/8"
6821-07 BONDED SEAL - 3/8”
3007-19 STUD
1.22 AYD-218 CRANKCASE
1.23
1.24 80088-03 UNION
1.25
3006-85 STUD
7867-46 SETSCREW - M6x10
1.26
1.27
6434-00 GUARD- OIL LEVEL SWITCH
6182-00 OIL LEVEL SWITCH
1.28 7776-01 GASKET
1.29 AYD-63 OIL LEVEL SIGHT GLASS - 1"
1.30 AYD-61 OIL DRAIN PIPE
1.31 6821-02 BONDED SEAL - 1/2"
1.32 AYD-62 HEX. CAP
1.33 AYD-359 O-RING - Ø247x 3
1.34
1.35
3004-21 CRANKCASE COVER
6882-09 SCREW - M8x20
1.36 AYD-86 HEX HEAD PLUG - 3/4"
1.37 6821-05 BONDEDSEAL - 3/4"
48
Qty.
1
8
1
2
1
1
1
1
1
1
1
3
1
1
1
4
1
1
1
1
1
6
1
1
1
1
1
1
1
1
6
6
1
6
1
1
1
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7.2 Connecting Rods
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No Part no. Description
2.01 3007-47 HEX. BOLT - M10x30
2.02 7091-12 WASHER - M10
2.03 AYD-415 WASHER
2.04
2.05
6937-86
7868-50
BEARING - NA 6910
HEX. BOLT - M8x15
2.06 AYD-171 PIN RETAINER
2.07 AYD-168 LUBRICATING STICK
2.08 7096-18 HEX. BOLT - M6x10
2.09 AYD-221 PIN - Ø20x40
2.10 AYD-135 SHIM - Ø34
2.11 AYD-274 BUSH - Ø 23,35x23,40
2.12 0023-17 MASTER ROD
2.13 AYD-357 BEARING - NK30_30
2.14
2.15
3000-84 SHIM - 84x50,1
0023-18 ARTICULATED ROD
Qty.
1
1
1
1
2
2
1
6
2
4
2
1
3
1
2
50
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7.3 1st&2nd Stage Assy
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No Part no. Description
3.01 80055-21 BOLT - M10x80
3.02 7091-12 WASHER - M10
3.03 AYD-256 CYLINDER COVER – 1st STAGE
3.04 AYD-447 INTAKE FILTER ELEMENT
3.05 3001-47 FILTER CLAMP
3.06
3.07
3.08
3.09
3001-49 FILTER COVER
7672-22 ELBOW - 1/4"xØ10
- HOSE - Ø10x8
3001-30 GASKET
3.10 AYD-255 VALVE ASSY – 1st STG.
01 3008-96 • BODY
02 3008-93 • WASHER
03
04
05
06
3.11
3.12
3.13
3008-97
3008-95
3008-98
3008-94
• SPRING - INTAKE
• INSERT
• CIRCLIP
• SPRING – DISCHARGE
3001-29 GASKET
7450-00 GASKET
6604-00 VALVE ASSY – 2nd STG.
01
02
03
04
05
06
07
08
6487-06
6487-01
6201-04
6201-03
6201-01
6201-02
• BOLT - 5/8”
• SEAT
• WAVE WASHER – INTAKE
• WASHER – INTAKE
• WASHER – DISCHARGE
• WAVE WASHER – DISCHARGE
6487-02
7104-02
• RETAINER – DISCHARGE
• CONICAL SPRING WASHER - 5/8"
0094-00 • NUT - 5/8” UNF
7119-00 VALVE BOTTOM COVER – 2nd STG.
7120-01 VALVE TOP COVER – 2nd STG.
09
3.14
3.15
3.16
3.17
3.18
3.19
3014-61 BOLT - M10x70
7104-02 CONICAL SPRING WASHER - 5/8"
0043-00 NUT - 5/8" UNF
6479-04 CYLINDER - 1st STG.
3.20
3.21
6588-00 GASKET
6884-41 NUT - M12
3.22 7091-07 WASHER - M12
3.23 80055-22 BOLT - M12x35
3.24
3.25
3.26
6480-00 CYLINDER – 2nd STG.
7729-37 O-RING - Ø154x3 NBR
6478-04 PISTON ASSY – 1st&2nd STG.
52
Qty.
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
4
8
4
1
1
1
4
4
1
1
2
1
1
1
1
1
1
4
2
4
4
2
1
1
1
1
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.4 3rd Stage Assy
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
53
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
4.01
4.02
4.03
4.04
4.05
05
06
07
08
09
4.13
4.14
4.15
4.16
7867-46 SETSCREW - M6x10
6771-01 PISTON ASSY – 3rd STG.
7729-37 O-RING - Ø154x3 NBR
7091-07 WASHER - M12
6884-41 NUT - M12
4.06 80536-06 PLUG - 1 1/4"
4.07
4.08
4.09
0027-00 GUIDE CYLINDER - 3/5"
0054-00 GASKET
6481-01 CYLINDER
4.10 80055-22 BOLT - M12x35
4.11
4.12
01
02
03
04
3008-20 O-RING - Ø24xØ2
6605-00 VALVE ASSY – 3rd STG.
6486-01
6800-01
• VALVE CAGE
• COPPER WASHER
6645-01
6203-01
• SPRING – DISCHARGE
• WASHER – DISCHARGE
6486-02 • SEAT
6202-01
6202-02
6486-03
6800-05
• WASHER – INTAKE
• WAVE WASHER – INTAKE
• RETAINER
• RETAINING RING
6486-04 O-RING - Ø40x5
6800-03 COPPER WASHER
7065-03 VALVE COVER – 3rd STG.
3010-36 SCREW - M12x60
Qty.
1
1
1
1
1
1
1
1
4
2
1
1
10
4
1
1
1
1
6
1
1
1
1
1
1
54
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.5 4th Stage Assy
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
55
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
5.01
5.02
5.03
5.04
5.05
7867-46 SETSCREW - M6x10
6772-02 PISTON ASSY – 4th STG.
7729-37 O-RING - Ø154 x Ø3 NBR
0027-00 GUIDE CYLINDER - 3/5"
7091-07 WASHER - M12
5.06
5.07
6884-41 NUT - M12
0054-00 GASKET
5.08 6482-01 CYLINDER – 4th STG.
5.09 80055-22 BOLT - M12x35
5.10
5.11
01
02
03
3008-21 O-RING - Ø24xØ2
6606-00 VALVE ASSY – 4th STG.
6485-01
6645-02
6800-02
• VALVE CAGE
• SPRING – DISCHARGE
• COPPER WASHER
04
05
06
07
08
09
5.12
5.13
5.14
5.15
6203-03
6485-02
6202-03
6202-04
6485-03
6800-06
• DISK – DISCHARGE
• SEAT
• WASHER – INTAKE
• WAVE WASHER
• RETAINER
• RETAINING RING
6485-04 O-RING - Ø34,52xØ3,53
6800-04 COPPER WASHER
7066-03 VALVE CAP
3010-36 SECREW - M12x60
Qty.
1
1
1
1
1
1
1
1
1
4
2
1
1
1
10
4
1
1
6
1
1
1
1
1
56
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.6 Pistons
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
57
No
7.04
7.05
7.06
7.07
7.08
7.09
7.10
8.00
8.01
8.02
6.00
6.01
6.02
6.03
6.04
6.05
6.06
6.07
6.08
7.00
7.01
7.02
7.03
8.03
8.04
8.05
8.06
8.07
8.08
8.09
8.10
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
Part no. Description
6478-04 PISTON ASSY – 1st&2nd STG.
6882-13
6781-01
6478-06
7729-59
6478-05
6781-02
• SCREW - M6x45
• RING SET
• PISTON UPPER PART – 1st STG.
• O-RING - Ø91,7 x Ø1,78
• PISTON LOWER PART – 1st&2nd stg
• RING SET
7103-01
0018-02
• CIRCLIP - M30 DIN472
• PISTON PIN
6771-01 PISTON ASSY – 3rd STG.
6781-12
7867-09
7091-14
6477-02
6477-04
6203-04
• RING SET
• SCREW - M6x20
• SPRING WASHER - M6
• PISTON
• PISTON RETAINER
• SPRING
7103-01
0018-02
6477-03
7867-46
7867-09
7091-28
• CIRCLIP - M30 DIN472
• PISTON PIN
• GUIDE PISTON
• SETSCREW - M6x10
6772-02 PISTON ASSY – 4th STG.
6781-04 • RING SET
• SCREW - M6x20
• SPRING WASHER - M6
6476-03
6203-02
6476-09
6476-08
0018-02
7103-01
7867-46
• PISTON RETAINER
• SPRING
• PISTON
• GUIDE PISTON
• PISTON PIN
• CIRCLIP - M30 DIN472
• SETSCREW - M6x10
Qty.
1
1
2
2
1
1
2
1
1
2
1
6
1
1
1
1
1
2
1
1
1
2
2
2
1
2
1
1
1
2
2
58
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.7 Pipe Lines
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
59
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
9.01 AYD-86 HEX HEAD PLUG - 3/4"
9.02 AYD-202 FINNED TUBE
9.03
9.04
6882-06 BOLT - M8x25
7091-09 WASHER - M8
9.05 AYD-228 GASKET
9.18
9.19
9.20
9.21
9.22
9.23
9.24
9.25
9.26
9.06 AYD-548 ELBOW - 3/4"
9.07
9.08
9.09
3004-48 ELBOW - 1” Ø 20
2514-65 INTERCOOLER ASSY – 1st STG.
7068-07 DISCHARGE PIPE – 1st STG.
9.10
9.11
9.12
9.13
9.14
9.15
9.16
9.17
-
7078-48
7672-24
2514-66
7930-00
3012-66
7084-02
7425-01
DISCHARGE PIPE
NIPPLE
ELBOW -
NIPPLE -
ELBOW
NIPPLE -
–
1/2" x 3/4”
RETAINING PLATE
1/4” x Ø10
2nd STG.
3/4" x Ø20 BSP
INTERCOOLER ASSY – 2nd STG.
7672-14 ELBOW - 3/8"x1/4"
7068-08 TUBE
7055-35 2nd STG. WATER SEPARATOR
7933-03 SAFETY VALVE - 20 BAR
7672-07 TEE - 1/4”
3005-25 INTAKE HOSE – 2nd STG.
7078-06 NIPPLE - 3/8”x3/4”
3015-16 ELBOW - 1/8"NPT
7933-90 SAFETY VALVE - 9 BAR "CE" 1/4"
Qty.
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
2
2
1
1
1
1
1
1
1
2
1
60
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
61
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No
9.38
9.39
9.40
9.41
9.42
9.43
9.44
9.45
9.46
9.47
9.16
9.17
9.27
9.28
9.29
9.30
9.31
9.32
9.33
9.34
9.35
9.36
9.37
Part no. Description
7084-02 ELBOW
7425-01 NIPPLE - 1/4" x Ø10
7118-00 ELBOW - 1/4"
7696-03 PLUG – 1 1/4"
7309-18 INTERCOOLER ASSY – 3rd STG.
7309-20 AFTERCOOLER ASSY – 4th STG.
7867-54 BOLT - M12x30
7091-59 SPRING WASHER - M12
7091-07 WASHER - M12
7068-09 INLET PIPE – 4th STG
7078-42 NIPPLE
7933-06 SAFETY VALVE - 80 BAR
7084-27 TEE
- SAFETY VALVE
7055-38 WATER SEPARATOR ASSY – 3rd&4th STG.
7672-12 ELBOW - 1/4" x 1/4" Ø7
7813-02 CLAMP
7868-87 BOLT - M14x30
7091-61 SPRING WASHER - M14
7091-62 WASHER - M14
7070-05 CLAMP RETAINER
7091-17 WASHER - M6
6884-21 FIBERED NUT - M6
Qty.
1
2
2
2
1
1
1
1
4
4
1
5
1
3
1
1
2
2
2
1
1
1
2
62
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.8 Intercoolers (1st&2nd Stage)
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
63
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
10.00 2514-65 INTERCOOLER ASSY – 1st STG.
10.01
10.02
10.03
10.04
10.05
10.06
3003-98
AYD-64
3004-24
3004-15
7291-54
7091-23
• FINNED TUBE
• HEX. PLUG - 1"
• HEX. PLUG
• NIPPLE
• FIXING PLATE
• WASHER - M8
10.07
10.08
7091-11
6882-14
• SPRING WASHER - M8
• BOLT - M8x25
10.09 7868-50 • BOLT - M8x15
11.00 2514-66 INTERCOOLER ASSY – 2nd STG.
11.01
11.02
11.03
11.04
3003-98
AYD-64
3004-24
3004-15
• FINNED TUBE
• HEX. PLUG - 1"
• HEX. PLUG
• NIPPLE
11.05
11.06
11.07
11.08
11.09
7291-54
7091-23
7091-11
6882-14
7868-50
• FIXING PLATE
• WASHER - M8
• SPRING WASHER - M8
• BOLT - M8x25
• BOLT - M8x15
Qty.
1
3
1
5
2
1
5
2
2
3
1
3
1
5
2
1
5
2
2
3
64
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.9 3rd Stage Intercooler & 4th Stage Aftercooler
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
65
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
12.00 7309-18 INTERCOOLER ASSY – 3rd STG.
12.01
12.02
12.03
12.04
12.05
12.06
7309-19
7867-90
7091-17
3007-10
3007-12
6884-21
• TUBE
• SCREW - M6x40
• WASHER - M6
• CLAMP
• BRACKET
• NUT - M6
12.07 7867-37 • SCREW - M6x35
13.00 7309-20 AFTERCOOLER ASSY – 4th STG.
13.01 7309-21 • TUBE
13.02
13.03
13.04
13.05
13.06
13.07
13.08
3007-11
7867-90
7091-17
3007-13
6884-21
7867-37
3007-10
• CLAMP
• SCREW - M6x40
• WASHER - M6
• BRACKET
• NUT - M6
• SCREW - M6x35
• CLAMP
Qty.
1
1
10
40
4
1
20
10
1
1
2
11
42
1
21
10
2
66
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.10 Water Separators
2nd Stage Water Separator
3rd&4th Stage Water Separator
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
67
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
14.00 7055-35 2nd STG. WATER SEPARATOR
14.01
14.02
7055-36
7055-01
• HOUSING
• O-RING - Ø 50x2.5
14.03 7055-37 • TOP CAP
15.00 7055-38 WATER SEPARATOR ASSY – 3rd&4th STG.
15.01
15.02
15.03
15.04
7055-41
3005-28
7983-01
7055-39
• TOP CAP
• O-RING - Ø42x 3
• MUFFLER - 1/4"
• HOUSING
15.05 7055-40 • BOTTOM CAP
Qty.
1
1
1
1
2
1
2
1
1
1
68
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.11 Discharge Line
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
69
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
16.01 6882-20 BOLT - M8x120
16.02 7091-32 SPRING WASHER - M8
16.03 7091-31 WASHER - M8
16.04 7894-01 CARBON FILTER
16.05 7894-09 GASKET
16.06 - TUBE
16.07 7423-01 NIPPLE - 1/8” x Ø6
16.08 6436-03 PNEUMATIC VALVE - LP
* 6436-17 • PNEUMATIC VALVE REPAIR KIT
16.09 7423-04 NIPPLE - 1/8” x Ø6
16.10 - PNOMATIC VALVE – HP
01 6436-01 • PNEUMATIC VALVE - 330 BAR
02 6436-14 • PNEUMATIC VALVE - 415 BAR
16.11 7079-14 TEE - 1/8" NPT
16.12 7078-07 NIPPLE - 1/8” x 1/8” NPT
16.13 7187-06 NIPPLE - 1/8” x Ø6
16.14 7083-05 PLUG - 1/8” BSP
16.15 - TUBE
16.16 - TUBE
16.17 7078-02 NIPPLE - 1/8” x 1/8”
16.18 6398-23 SOLENOID VALVE - 1/8"
16.19 7192-01 COUPLING - 1/8"
16.20 - HOSE
16.21 7752-08 BODY
Qty.
1
1
1
1
1
1
9
2
-
2
2
-
-
3
4
2
1
1
1
1
1
1
1
1
70
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
71
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
16.22 7890-01 NIPPLE - 1/4" x 1/4"
16.23 7672-01 ELBOW - 1/4" x Ø6
16.24
16.25
-
-
TUBE
TUBE
16.26 7868-09 BOLT - M4x16
16.27 6884-17 NUT - M4
16.28 7291-02 TUBE HOLDER PLATE
16.29 7291-01 TUBE HOLDER PLATE
16.30 7192-27 NUT - 1/2"
16.31 7187-33 NIPPLE - 1/2” Ø16
16.32 - HOSE
16.33 7187-32 ELBOW - 1/2" Ø16
16.34 7813-01 CLAMP
16.35
16.36
-
-
TUBE
TUBE
16.37 7422-01 NIPPLE - 1/4” x Ø6
16.38 - TUBE
16.39 - TUBE
16.40 6884-21 NUT - M6
16.41 7091-17 WASHER - M6
Qty.
2
2
1
1
6
2
2
2
1
1
1
1
2
1
1
5
1
1
4
4
72
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.12 Filter Panel
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
73
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
17.01 7912-12 HOSE
17.02 7912-13 HOSE
17.03 7084-02 ELBOW
17.04 7145-02 NUT - 5/8” (8 mm)
17.05 7051-00 NIPPLE
17.06 7672-12 ELBOW - 1/4" x 1/4" Ø7
17.07 7890-01 NIPLLE - 1/4" x 1/4"
Qty.
2
1
1
1
1
1
1
74
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
75
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
17.04 7145-02 NUT - 5/8” (8 mm)
17.06 7672-12 ELBOW - 1/4" x 1/4" Ø7
17.07 7890-01 NIPLLE - 1/4" x 1/4"
17.08 7235-07 PRESSURE GAUGE - 400BAR
17.09 7053-02 THUMBSCREW
17.10
17.11
01
02
-
-
7813-04
7813-07
PURIFIER (PAGE 79)
CLAMP
• CLAMP - 225 BAR
• CLAMP - 330/415 BAR
17.12 - TUBE
17.13 7422-01 NIPPLE - 1/4" x Ø6
17.14 - FILTER (PAGE 77)
17.15 7084-09 ELBOW - 1/4"
17.16 7742-01 ELBOW
17.17 7084-05 MANIFOLD - 1/4"
17.18 7078-15 NIPPLE - 1/4" NPT x 1/4" NPT
17.19 7140-00 CHECK VALVE - 400BAR
* 7140-09 • CHECK VALVE REPAIR KIT
17.20 - TUBE
17.21 6883-03 CAP NUT - M6
17.22 7091-42 WASHER - M6
17.23 6460-00 PRIORITY VALVE
*
17.24
6460-15
-
• PRIORITY VALVE REPAIR KIT
TUBE
17.25 7053-05 MANIFOLD
17.26 7423-01 NIPLLE - 1/8” x Ø6
17.27 - TUBE
17.28 7820-00 UNION
17.29 7078-41 NIPLLE - 1/4" BSP x 1/4" NPT
17.30 80071-01 PRESSURE SWITCH
Qty.
-
1
5
1
4
1
1
2
1
-
1
8
8
1
-
1
1
1
1
1
1
1
2
2
3
1
1
1
4
-
76
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.13 Coelescer Filter Assy
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
77
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
18.00
01
02
18.01
-
7168-39
7168-45
-
FILTER COMPLETE
• FILTER COMPLETE - 225 BAR
• FILTER COMPLETE - 330/415 BAR
BOTTOM CAP
01
02
7168-31
7168-38
• BOTTOM CAP - 225 BAR
• BOTTOM CAP - 330/415 BAR
18.02 7168-24 BACKING RING
18.03 7168-25 O-RING - 72,4x5,33 NBR
18.04 7168-28 RING
18.05 7091-17 WASHER - M6
18.06 7867-67 BOLT - M6x10
18.07 - HOUSING
01 7168-30 • HOUSING - 225 BAR
02 7168-37 • HOUSING - 330/415 BAR
18.08 6554-05 COALESCER FILTER ELEMENT
18.09 7168-32 TOP CAP
18.10 7168-23 END PLATE
18.11 7867-03 BOLT - M6x10
Qty.
1
-
-
1
-
-
2
2
1
2
2
1
-
-
1
1
1
2
78
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.14 Purifier Assy
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
79
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
19.00 - PURIFIER COMPLETE
01
02
7168-29
7168-46
• PURIFIER COMPLETE - 225 BAR
• PURIFIER COMPLETE - 330/415 BAR
19.01 7867-91 BOLT - M10x25
19.02 7369-00 REMOVAL BOLT
19.03 7168-32 TOP CAP
19.04 7168-24 BACKING RING
19.05 7168-25 O-RING - 72,4x5,33 NBR
19.06 7168-23 END PLATE
19.07 7867-03 BOLT - M6x10
19.08
01
-
7168-19
HOUSING
• HOUSING - 225 BAR
02 7168-35 • HOUSING - 330/415 BAR
19.09 7673-00 CARTRIDGE
* 7913-02 • PURIFIER REFILL KIT
19.10 7047-13 O-RING - 12,37x2,62 NBR
19.11 7047-14 O-RING - 9,92x2,62 NBR
19.12 7867-67 BOLT - M6x10
19.13 7091-17 WASHER - M6
19.14
01
-
7168-20
BOTTOM CAP
• BOTTOM CAP - 225 BAR
02 7168-36 • BOTTOM CAP - 330/415 BAR
19.15 7168-28 RING
Qty.
1
-
-
2
1
1
2
2
1
2
1
-
-
1
-
1
1
2
2
1
-
-
1
80
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.15 Pressure Gauge Lines
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
81
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
20.01 - TUBE
20.02 7422-01 NIPPLE - 1/4" x Ø6
20.03 7423-01 NIPPLE - 1/8” x Ø6
20.04 - TUBE
20.05 7672-12 ELBOW - 1/4" x 1/4" Ø7
20.06
20.07
-
-
TUBE
TUBE
20.08 7742-01 ELBOW
20.09 7235-03 PRESSURE GAUGE - 25 BAR
20.10 7235-05 PRESSURE GAUGE - 60 BAR
20.11 7235-07 PRESSURE GAUGE - 400BAR
20.12 7235-01 PRESSURE GAUGE - 10 BAR
20.13 7820-00 UNION
20.14 - TUBE
20.15 7145-02 NUT - 5/8” (8 mm)
Qty.
1
7
1
1
1
1
1
4
1
1
1
1
4
4
4
82
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.16 Drive Assy
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
83
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Parça No Açıklama
21.01 7867-71 BOLT - M12x50
21.02 7091-59 SPRING WASHER - M12
21.03 7091-18 WASHER - 1/2" 3mm
21.04 7349-00 CLAMP – COMPLETE
21.05 6884-23 NUT - M12
21.06 6810-82 MOTOR SLIDE BASE
21.07 80055-22 BOLT - M12x35
21.08 7091-07 WASHER - M12
21.09 3016-99 STUD
21.10 6414-00 SHOCK MOUNT
21.11 7335-30 BASE FRAME
21.12 7822-02 BELT TIGHTENER
21.13 AYD-317 PULLEY HUB
21.14
01
-
3008-88
02
03
21.15
01
02
03
3008-24
3008-25
-
80050-00
80060-02
80064-00
PULLEY
• PULLEY – 11 KW
• PULLEY – 15 KW
• PULLEY – 18,5 KW
MOTOR
• MOTOR - 11 KW / 15 HP
• MOTOR - 15 KW / 20 HP
• MOTOR - 18,5 KW / 25 HP
Adet
4
12
4
2
12
1
4
12
2
4
1
1
1
1
-
-
-
1
-
-
-
84
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.17 General Connectors
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
85
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
22.01 80099-38 FAN
22.02 6884-29 NUT - M8
22.03 7091-23 WASHER - M8
22.04 3005-70 SOCKET
22.05 7091-11 SPRING WASHER - M8
22.06 7867-41 BOLT - M8x20
22.07 7291-51 CLAMP
Qty.
2
8
16
8
8
8
8
86
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
87
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Part no. Description
22.08 7096-24 BOLT - 5/8 ” x 2 1/2"
22.09 7091-27 SPRING WASHER - 5/8”
22.10 7091-26 WASHER - 5/8 ”
22.11 6884-16 NUT - 5/8"
22.12 3007-46 PULLEY
22.13 AYD-416 PULLEY WASHER
22.14 7091-62 WASHER - M14
22.15 7091-61 SPRING WASHER - M14
22.16 3003-18 BOLT - M14x45
22.17
01
- V-BELT
7953-06 V-BELT – 11 KW
02 7953-33 V-BELT – 15 KW, 18,5 KW
22.18 6882-11 BOLT - M6x30
22.19 7091-08 WASHER - M6
22.20 3007-91 CLAMP
22.21 6884-04 NUT - M6
Qty.
4
4
8
4
1
1
1
1
1
2
-
-
1
1
2
1
88
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.18 Filling Panel – Dual Pressure
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
89
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No
26
27
28
29
22
23
24
25
18
19
20
21
14
15
16
17
34
35
36
37
30
31
32
33
38
10
11
12
13
6
7
8
9
1
2
3
4
5
Part no. Description
7038-05 BUSHING
7880-06 O-RING - Ø 10,8x2,62
7880-15 DIN CONNECTOR – 330 BAR
7829-04 O-RING - Ø 6,07x1,78
7880-19 HANDLE – 300 BAR
7670-03 NUT - DIN CONNECTOR
7891-04 FITTING
7670-13 O-RING - Ø 7x1.5
7912-12 HOSE - R2 1/4"x100 CM
7038-04 HOLDER
7429-00 YOKE VALVE - COMPLETE
7880-04 DIN CONNECTOR – 225 BAR
7880-03 HANDLE – 225 BAR
7866-22 NIPPLE
7866-00 FILLING VALVE
6460-10 O-RING - Ø 7.66x1.78
7866-11 NUT - 5/8 ” (5 mm)
7866-21 NIPPLE
7882-06 TUBE
7866-26 NIPPLE
7145-02 NUT - 5/8” (8 mm)
7866-20 MANIFOLD
7933-88 SAFETY VALVE - 275 BAR "CE"
80071-00 PRESSURE SWITCH
7078-41 NIPPLE - 1/4"BSPx1/4” NPT
7084-02 ELBOW
7882-02 TUBE
7867-55 BOLT - M6x25
- TUBE
7422-01 FITTING - 1/4"x Ø 6
7191-00 HYDRAULIC VALVE - 1/4"
7078-15 NIPPLE - 1/4"NPTx1/4” NPT
7672-12 ELBOW - 1/4"x1/4” Ø 7
- TUBE
7084-21 NIPPLE - 1/4" NPT 1/4" BSP
- TUBE
7820-00 UNION
7235-07 PRESSURE GAUGE - 400BAR
90
Qty.
4
1
1
1
1
2
4
1
4
4
4
8
4
4
5
5
8
1
1
1
1
2
1
1
1
2
4
2
4
2
4
4
8
4
2
2
2
2
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.19 Filling Panel – 330 Bar
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
91
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No
22
23
24
25
26
18
19
20
21
14
15
16
17
10
11
12
13
6
7
8
9
1
2
3
4
5
Part no. Description
7866-22 NIPPLE
7866-00 FILLING VALVE
6460-10 O-RING - Ø 7.66x1.78
7866-11 NUT - 5/8 ” (5 mm)
7867-55 BOLT - M6x25
7038-05 BUSHING
7880-06 O-RING - Ø 10,8x2,62
7880-15 DIN CONNECTOR – 330 BAR
7829-04 O-RING - Ø 6,07x1,78
7880-19 HANDLE – 300 BAR
7670-03 NUT - DIN CONNECTOR
7891-04 FITTING
7670-13 O-RING - Ø 7x1.5
7912-12 HOSE - R2 1/4*100 CM
7866-21 NIPPLE
7882-06 TUBE
7866-26 NIPPLE
7145-02 NUT - 5/8” (8 mm)
7866-20 MANIFOLD
7422-01 FITTING - 1/4"x Ø 6
7882-07 TUBE
7882-02 TUBE
7882-01 TUBE
7882-08 TUBE
7820-00 UNION
7235-07 PRESSURE GAUGE - 400BAR
Qty.
4
4
4
5
5
4
8
1
2
1
1
1
1
4
4
4
8
4
4
4
4
4
4
4
4
8
92
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
7.20 Filling Panel – 225 Bar
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
93
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
No Parça No Açıklama
21
22
23
24
17
18
19
20
25
26
13
14
15
16
9
10
11
12
5
6
7
8
1
2
3
4
7866-22 NIPPLE
7866-00 FILLING VALVE
6460-10 O-RING - Ø 7.66x1.78
7866-11 NUT - 5/8 ” (5 mm)
7867-55 BOLT - M6x25
7038-04 HOLDER
7429-00 YOKE VALVE - COMPLETE
7880-06 O-RING - Ø 10,8x2,62
7880-04 DIN CONNECTOR – 225 BAR
7829-04 O-RING - Ø 6,07x1,78
7880-03 HANDLE – 225 BAR
7670-03 NUT - DIN CONNECTOR
7891-04 FITTING
7670-13 O-RING - Ø 7x1.5
7912-12 HOSE - R2 1/4"x100 cm
7866-26 NIPPLE
7882-06 TUBE
7866-21 NIPPLE
7866-20 MANIFOLD
7422-01 FITTING - 1/4"x Ø 6
7882-02 TUBE
7882-07 TUBE
7882-01 TUBE
7882-08 TUBE
7820-00 UNION
7235-07 PRESSURE GAUGE - 400BAR
Adet
4
4
4
8
2
1
1
1
1
1
4
4
4
4
4
8
4
5
4
4
4
13
4
4
4
4
94
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ
95
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