SchraderAir SA315240H346 Betriebsanleitung

Compressor Operating and

Maintenance Manual

TWO STAGE 15 HP PUMP

MODEL: _________________________

SERIAL #_________________________

9. Drain tank daily to prevent rust formation in the

tank.

10. Never reset pressure switch or safety valves.

11. Never store flammable liquids or gases in the

vicinity of the compressor or compressor

starting equipment.

12. SHUTOFF VALVES ARE NOT TO BE INSTALLED

IN THE DISCHARGE LINE BETWEEN THE

COMPRESSOR AND THE RECEIVER UNLESS A

SAFETY VALVE, WITH ADEQUATE FLOW

CAPACITY AND PRESSURE SETTING, IS

LOCATED BETWEEN SHUTOFF VALVE AND THE

COMPRESSOR.

13. When compressor is used for spraying:

Do not spray in vicinity of open flame or other

surfaces of ignition.

14. Do not smoke when spraying paint, insecticides,

or other toxic or flammable substances.

15. To avoid spontaneous combustion, discard waste

rags into approved metal waste cans.

16. Do not spray in confined spaces.

17. Use face mask when spraying.

18. Always direct paint or sprayed material away

from compressor and locate compressor to

minimize paint overspray accumulation on

compressor or sprayer parts.

19. When using cleaning solvent, follow the

instructions provided by the solvent manufacturer.

SAFETY INSTRUCTIONS

When using air compressors and compressed air

accessories, basic safety rules and precautions should

always be followed including the following:

1. Read all instructions fully.

2. Wiring, starters, breakers and other related

electrical equipment should conform to

electrical codes.

3. Shut off main power and release all pressure

from the unit and set pressure regulator to zero

pressure before removing or adding parts or

attachments and before cleaning compressor.

4. Do not operate any compressor with damaged

wiring. Do not operate after the compressor or

air handling parts have been dropped, damaged,

or shows signs of deterioration, weakness or

leakage. Do not use them if any deficiency is

found. Withdraw from service and repair or

discard such parts.

5. Regularly inspect hose and load handling

fittings for signs of damage, deterioration,

weakness or leakage. Do not use them if

deficiency is found. Withdraw from service and

repair or discard such parts.

6. Never use air pressurized accessories or parts

in the air system not suitable for the maximum

air pressure involved. This is dangerous. Be

sure maximum pressure specified by the manu-

facturer is well above the working pressure of

your compressor.

7. Keep clear of compressor. It will become

extremely hot. Moving parts should be avoided.

Do not operate without belt guard.

8. Keep pressure relief devices free from paint or

other accumulation.

DIRECTION OF ROTATION

As the compressor starts, check the rotation of the

units, Standard rotation is clockwise, viewing the

compressor from the side of the sight glass. A rota-

tion arrow, is placed on the flywheel at the factory.

Should the rotation be incorrect, disengage the power

and correct the motor wiring.

WARNING: AFTER THE COMPRESSOR IS STARTED,

IT WILL OPERATE AUTOMATICALLY.

START-STOP (PRESSURE SWITCH CONTROL)

When the air pressure in the receiver reaches the

preset high pressure level the pressure switch opens,

electrically stopping the compressor driver motor. As

the air is used from the receiver the pressure drops

allowing the pressure switch to close at the preset

low pressure level, restarting the driver motor.

UNPACKING INSTRUCTIONS

The two stage compressor was inspected at the fac-

tory and packaged to protect against shipping dam-

age. When you unpack your unit, inspect for damaged

or missing parts. If there is any damaged or missing

part, the transportation company’s agent should make

a notation to the effect on the Bill of Lading. Claims,

should be settled directly with

the transportation company.

INSTALLATION

The compressor must be placed in a clean and well-

ventilated room. Compressor should be located

at least 12 to 18 inches away from a wall or other

obstruction that will impede the flow of air through

the fan-bladed flywheel. Rotation of the fly-wheel

must be in the direction of the arrow cast into the

flywheel.

The compressor should be as near a possible to air

outlets to avoid long pipe lines. Do not place com-

pressor where heat is excessive. Provide adequate

fresh air and exhaust ventilation from area in which

the compressor is located.

Place compressor on a firm, level floor. Permanent

installations should be bolted to the floor. Bolting

holes are provided in the base feet. Shim compressor

level before bolting down to floor. Avoid putting stress

on a foot by pulling it down to floor. This may cause

abnormal vibration. Remove wood shipping skid

before installation.

INSTALLATION AND OPERATING INSTRUCTIONS

LUBRICATION OF COMPRESSOR

This compressor was shipped without oil. Before operating, fill crankcase with oil to level on oil sight gauge. Do

not over fill. Oil recommended: Premium Grade SchraderAir 826020 - 30WT Non-Detergent. Change oil every

three (3) months or 500 hours. After initial start up change oil after first two weeks of operation. If oil turns

milky replace oil and move unit to less humid conditions.

PRESSURE SWITCH ADJUSTMENT & UNLOADER

The pressure switch has a range adjustment and a differential adjustment. See instructions located under pres-

sure switch cover. The Cut-Out (Compressor Shutdown) is the pressure at which the contacts open, and the Cut-

In (Compressor Restart) is the pressure at which the switch contacts close.

Pressure switch controls the opening and closing of the contacts in the magnetic starter. Do not wire electric

motor directly to pressure switch.

The pressure switch has an unloader or bleeder valve which unloads compression from the compressor for a

loadless start-up. Each time the compressor cuts off air should be released to atmosphere from the bleeder

valve. Air will disperse from this valve for only a few seconds, then stop. (Check Daily)

AIR INLET FILTER/SILENCER

It is very important that the air inlet filter/silencer be kept clean at all times. A dirty inlet filter reduces the

capacity of the compressor.

WIRING DIAGRAM

Installation Should Be Made By a Competent Electrician

L2, L3 indicates supply line terminals. T1, T2, T3 indicates load.

Motor

Line

Phase

Motor

L1 L2 L3

C1 C3

Jumper

C1 - Blue & Orange

C2 -

C3 - Black & Red

MAINTENANCE

MONTHLY

• Check operation of high pressure safety valve

by pulling ring.

• Check flywheel and motor pulley for tightness.

QUARTERLY

• Every 90 days also check entire system for air

leakage around fittings, etc. using a soap solu-

tion. Tighten nuts and cap screws as required.

• Every 90 days or 1,000 operating hours,

whichever comes first, change crankcase oil.

Oil recommended: Premium Grade SchraderAir

826020 - 30WT Non-Detergent. Change oil more

frequently, if compressor is located in very dirty

environment.

DAILY

• Check compressor visually.

• Check oil level and add oil as required.

• Drain moisture from system piping.

• Drain moisture from tank daily to prevent rust.

WEEKLY

• Turn power off and drain moisture from tank

by opening drain cock in bottom of tank.

• Remove and clean intake air filters.

Disassemble and wash element in detergent

solution. Do not oil.

• Check V-belts for tightness. Belt tension should

be adjusted to allow approximately 1/4 - 1/2

inch deflection with normal thumb pressure.

• Turn power off and clean dust and foreign

material from cylinder head, motor, fan blade,

air lines, intercooler and tank.

MAINTENANCE SCHEDULE - CHECK CHART

PROCEDURE DAILY WEEKLY MONTHLY YEARLY

Check Oil Level. Caution! Do not overfill. X

Give Compressor overall visual check X

Drain moisture accumulation from X

the air receiver

Check the air distribution system for air leaks X

Clean cooling surfaces of compressor, X

intercooler and aftercooler

Operate safety valves (pressure relief valve) X

Replace or clean intake filter element X

Inspect oil for contamination and change if X

necessary

Check belts for correct tension and alignment X

Check pulley clamp bolts and set screws for X

tightness

Inspect valve assemblies XX

Inspect cushion chamber, if so equipped, X

and discharge line for excessive carbon

accumulations

Inspect pressure switch diaphragm and X

contact points

Service electric motor ‡ ‡ ‡ ‡

Drain Tank X

X= Check more often if extremely dirty condition exists. XX = Every 6 months

‡ = Per manufacturer’s recommendations 5

TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

1. Compressor will not operate. 1. No electrical power. 1. Turn on power.

2. Pressure switch not making contact 2. See pressure switch adjustment.

2. Excessive noise in operation 1. Loose pulley, flywheel, belt, beltguard, 1. Tighten.

cooler, clamps or accessories.

2. Lack of oil in crankcase. 2. Check for possible damage to

bearings, replenish oil.

3. Piston hitting the valve plate. 3. Remove the compressor cylinder

head and inspect for foreign

matter on top of the piston.

Add a new gasket and reassemble

the head.

4. Compressor floor mounting loose. 4. Tighten.

5. Defective crankcase. 5. Repair or replace.

6. Excessive crankshaft end play. 6. Adjust and shim properly.

3. Knock - same cycle as R.P.M. 1. Main bearings. 1. Replace bearings.

2. Connecting rod bearing. 2. TIghten.

4. Knock occurs while 1. Connecting rod bearings. 1. Replace rod.

compressor is loading. 2. Wrist pins, wrist pin bearings. 2. Replace complete piston

assembly.

5. Milky oil in oil reservoir. 1. Water entering oil reservoir due 1. Pipe air intake to less humid air\

to compressor operating in high source.

humidity environment.

6. Excessive oil consumption. 1. Restricted air intake. 1. Clean or replace air filter.

2. Oil leaks. 2. Tighten bolts or replace gasket.

3. Worn piston rings. 3. Replace piston rings.

4. Wrong oil viscosity. 4. Drain oil, refill with oil or proper

viscosity. See Lubrication Section.

5. Compressor titled too much. 5. Level compressor.

6. Scored cylinder. 6. Replace cylinder.

7. Oil in discharge air. 1. Compressor air intake restricted. 1. Clean air filter element and check

for other restrictions in the intake

system.

2. Worn piston rings. 2. Replace rings.

3. Excessive oil in compressor. 3. Drain down to full mark on sight

gauge.

4. Wrong oil viscosity. 4. Check viscosity. See Lubrication

Section.

5. Piston rings installed up-side down. 5. Install ring in proper position.

8. Compressor vibrates. 1. Mounting bolts loose. 1. Tighten.

2. Compressor not properly mounted. 2. Level compressor so that all feet

touch the floor before tightening

down.

3. Pulley and flywheel misaligned. 3. Realign.

4. Belts loose. 4. Tighten belts. See Maintenance

Section.

5. Bent crankshaft. 5. Replace crankshaft.

TROUBLESHOOTING (continued)

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

9. Air blowing our of inlet 1. Broken first stage inlet valve. 1. Replace valve assembly.

10. Insufficient pressure at point of use. 1. Leaks or restriction. 1. Check for leaks, restriction, or

piping. Repair problem.

2. Restricted air intake. 2. Clean or replace air filter

element.

3. Slipping belts. 3. Tighten belts. See Maintenance

Section.

4. Service hose too small. 4. Replace with larger hose.

5. Excessive air requirement. 5. Limit air requirement to

compressor capacity.

11. Receiver does not hold pressure 1. Faulty check valve. 1. Bleed Tank! Disassemble check

when compressor is unloaded. valve assembly, clean or

replace faulty parts. DANGER -

DO NOT DISASSEMBLE CHECK

VALVE WITH AIR IN TANK.

NOTE - CHECK VALVE IS

ALWAYS THE FIRST VALVE IN

THE LINE LEADING FROM THE

TANK TO THE COMPRESSOR.

12. Excessive belt wear. 1. Pulley out of alignment. 1. Realign motor pulley with

compressor flywheel.

2. Belts too tight. 2. Adjust tension. See Maintenance

Section.

3. Belts too loose. 3. Adjust tension. See Maintenance

Section.

4. Pulley or flywheel wobble. 4. Check for worn crankshaft,

keyway or pulley bore, resulting

from running with loose pulleys.

Check for bent crankshaft.

5. Nick in belt grove of pulley or 5. File smooth.

flywheel.

13. Excessive discharge air 1. Dirty cooling surfaces. 1. Clean cooling surfaces of cylinder,

temperature. intercooler and discharge tube.

2. Poor ventilation. 2. Improve ventilation or relocate

compressor. See Installation.

3. Blown head gasket. 3. Replace head gasket.

4. Restricted air intake 4. Clean or replace air filter element.

5. Worn valves. 5. Repair or replace valves.

14. Receiver pressure builds 1. Dirty air filter. 1. Clean or replace filter element.

up slowly. 2. Blown cylinder head gasket. 2. Install new gasket.

3. Worn or broken low pressure 3. Install new head gasket.

intake or discharge valves.

4. Air leaks. 4. Tighten joints.

5. Loose belts. 5. Tighten belts. See Maintenance

Section.

6. Speed too slow. 6. Check speed.

823015 Two-Stage

Compressor Pump

823015TX - PUMP PARTS

ITEM PART # DESCRIPTION QTY ITEM PART # DESCRIPTION QTY

1430001 Crankcase GS43 144 431030-1 HP Wrist Pin - Piston GS43 1

2430002 Cap-Rear GS43 145 431031 Snap Ring - Internal  30 4

3430003 Crankshaft GS43 145-1 431031-1 Snap Ring - Internal  28 2

4430004 Balance GS43 246 431032 Piston Ring Set GS43 2

5430005 Cap - Front GS43 147 431032-1 HP Piston Ring Set GS43 1

6430006 Flywheel GS43 148 431033 Gasket - Cylincer to Crankcase GS43 3 (*a)

7430007 Fan GS43 149 431034 Capscrew - Hex M12X335 24

8430008 Cylinder GS43 250 431035 Gasket - Cylinder Head GS43 2 (*a)

9430009 Head GS43 251 431035-1 Gasket - Cylinder Head GS33 1 (*a)

10 430008-1 HP Cylinder G43 152 431036 Valve Copper Gasket GS43 4

11 430009-1 Head GS43 153 431037 Disch Valve GS43 2

12 431001 Capscrew - HEX M10X30 26 54 431038 "O" Ring - Hold Down Cover GS43 4

13 431002 Lock Washer Φ10 35 55 431039 Hold Down Cover - Disch GS43 2

14 431003 Breather - Crankcase GS43 156 431040 Inlet Valve GS43 2

15 431005 Oil Baffle Plate GS43 157 431041 Unloader Piston GS43 2

16 431005 Gasket - Rear Cap GS43 1 (*a) 58 431042 "O" Ring - Unloader Piston GS43 2

17 431006 Oil Sight Glass GS43 159 431043 Hold Down Cover - Inlet GS43 2

18 431007 Oil Drain Plug GS22 160 431044 Capscrew - Hex M10X80 6

19 431008 Bearing - Front 32210 161 431036-1 Valve Copper Gasket GS33 2

20 431009 Capscrew - HEX M16X20 262 431037-1 HP Disch Valve G43 1

21 431010 Lock Washer Φ16 263 431038-1 "O" Ring - Hold Down cover GS33 2

22 431011 Bearing Rear 30310 164 431039-1 Hold-Down Cover-Disch GS33 1

23 431012 Gasket - Front Cap GS43 1 (*a) 65 431040-1 HP Inlet Valve G43 1

24 431013 Shim-Brg Adjustment GS43 166 431041-1 Unloader Piston G33 1

25 431014 Seal - Shaft GS43 167 431042-1 "O" Ring-Unloader Pisotn GS33 1

26 431015 Spacer - Flywheel GS43 168 431043-1 Hold Down Cover - Inlet GS331 1

27 431016 Key - Flywheel 169 431045 Capscrew - Hex M8X25 8

28 431017 Capscrew - Hex M12X40 170 431046 Copper Elbow GS43 1

29 431018 Lock Washer Φ12 25 71 431047 Copper Nut GS12 5

30 431019 Capscrew - Hex M8X30 672 431048 Copper Seal Ring GS43 5

31 431020 Lock Washer Φ 8 17 73 431049 Aluminum Tube Φ6 GS43 2

32 431021 Filter - Inlet Assembley GS43 274 431050 Tee-Male Tube GS12 2

33 431022 Filter - Replacement Element GS43 275 431051 Nut- Compression GS43 1

34 431023 Oil - Plug GS43 1 76 431052 Elbow GS43 3

35 431024-1 HP Connecting Rod GS43 1 77 431053 Tee GS43 1

36 431024 Connecting Rod GS43 2 78 431054 Intercooler Tube GS43 1

37 431025 Insert Half GS43 3 79 431055 Intercooler Tube GS43 1

38 431026 Nut M8 3 80 431056 Capscrew-Hex M10X20 1

39 431027 Straight Dipper - Oil GS43 1 81 431057 Cooler Line Strap G43 1

40 431028 Oblique Dipper - Oil GS43 2

41 431029 Piston GS43 2

42 431029-1 HP Piston GS43 1

43 431030 Wrist Pin - Piston GS43 2*a 430000-1 COMPLETE GASKET KIT GS43 1

#63 VITON HIGH TEMP O-RING = 55 X 3 PART# 93602-870055 need 2

#54 O-Ring - 93602-810065 - need - 4

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