instruction and operation manual - Jordair Compressors Inc.

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Lubrication System (Year 2,000 and prior) The compressor is provided with forced-feed lubrication for the 3 rd , 4 th , or 5 th stage. A Bosch injection pump is driven either by a cam lobe on the end of the crankshaft, or a camshaft driven via a V-belt or cog belt, depending on the model of compressor. It pumps oil into the pressure regulating valve at the 3 rd, 4 th or 5 th stage cylinder. The oil pressure regulator doses the oil quantity and is adjusted to the respective oil pressure. The oil pressure on these machines is adjusted to between 850 P.S.I. and 950 P.S.I. On the IK 14.11 and the IK 18.1 compressors, the oil pressure is regulated by the 3 rd stage pressure and the oil pressure gauge will match the 3 rd stage pressure gauge. These compressors use an oil controller and the pressure is non adjustable. The drive gear atomizes the oil and the mist lubricates the piston rings and rod bearing. The crank and main bearings are splash lubricated when the crankshaft counter weight enters the oil. The first stage cylinder receives additional lubrication from the crankcase breather pipe, which is connected to the intake port of the cylinder head. Compressor Oil Pump Drive Bauer Blocks 2000 and newer production series IK100II to IK18.1II – The compressor oil pressure of 5 bar (72 PSIG) is developed by a low revving gear type oil pump. The oil is pumped up through a final oil filter element. The filter element is to be changed every time the oil is changed to ensure correct service procedures. Oil Pump Drive Service On the 2000 and newer series compressors the oil pressure is not adjustable, if the oil pressure drops below the minimum of 30 psig, replace the minimum pressure valve as an assembly, part number 81050. If the oil pressure is still not correct then the pump must be replaced. An oil pump assembly is replaced under part number N24585. The oil filter element number for replacement is N25326. Review the specific model parts list and Bauer manual for service procedures. Initial Trial Run of the Compressor On start-up, a clicking or knocking sound will be heard from the final stage of the compressor. This is a normal condition produced by the free-floating piston tapping the guide piston in the final stage. This noise will only last until a counter pressure is built up, usually within 15 to 20 seconds. If the knocking sound continues check for inter-stage leaks, open drain cocks, or a defective automatic drain system seat or solenoid valve. Follow the repair procedures as outlined for the specific component in this manual. 101-7950 Huston Rd. Delta, BC V4G 1C2 Canada Website: www.jordair.ca JORDAIR – “RELIABILITY & SAFETY” - BAUER Phone: 1-604-940-8101 Fax: 1-604-940-8131 Email: info@jordair.ca Doc. Jordair COMPRESSOR-MANUAL-2013 7
Pressure Relief Valves As required by ASME and Boiler & Pressure Vessel, each stage of compression is provided with a spring-loaded type pressure relief valve factory set and sealed to operate at a suitable pressure to protect the individual stages of the compressor. The pressure relief valves are set high enough to allow for the momentary pressure surges, which occur as a cylinder discharges. The final discharge pressure relief valve is located on top of the final oil and water separator. The final separator is usually mounted on the same part of the compressor frame as the purification chambers. Safety valves between stages protect the prior cylinder and also indicate a compressor inlet or exhaust valve malfunction when the safety valve is venting. For example: a final stage inlet or exhaust valve leak will cause excessive pressure rise between it and the preceding stage, opening the third stage relief valve. The over pressure that is built up by the final stage and not pumped onward in the system is vented safely to atmosphere by the relief valve. Warning! Never adjust inter-stage relief valves; this can cause failure of a cylinder or intercooler resulting in a possible injury or death. Only a certified company can reset relief valves. Worn or defective valves must be replaced as a complete assembly. On some compressor models, the unitized valves can be returned to the factory for repair. Contact Jordair to determine if a compressor valve is suitable for repair or must be replaced. Always replace both the inlet and exhaust valves in a compressor cylinder head as a set to avoid premature failure of the valves. Valve Heads Each cylinder has its own individual valve head complete with intake and exhaust valve. Valve heads of individual stages form the top part of the cylinder. The valves are spring loaded and operated by airflow. On the suction stroke the intake valves open and air flows into the cylinders. At the start of the compression stroke, the intake valve closes and the air opens the outlet valve allowing it to flow out of the cylinder. All suction and discharge valves are spring-loaded, disc type valves consisting of a valve insert, valve spring, valve disc, and valve seat. On most models the suction valves are mounted at the bottom side of the valve head. The first stage cylinder has either a reed valve assembly between the head and cylinder or the valves installed from the topside of the valve head. 101-7950 Huston Rd. Delta, BC V4G 1C2 Canada Website: www.jordair.ca JORDAIR – “RELIABILITY & SAFETY” - BAUER Phone: 1-604-940-8101 Fax: 1-604-940-8131 Email: info@jordair.ca Doc. Jordair COMPRESSOR-MANUAL-2013 8
Page 1 and 2: INSTRUCTION AND OPERATION MANUAL FO
Page 3 and 4: WARNING! HIGH PRESSURE UNITS Never
Page 5 and 6: Automatic Drain Operation .........
Page 7 and 8: If there is a change in the wind di
Page 9 and 10: stage. In five stage compressors th
Page 11: To Prepare the Compressor for Prolo
Page 15 and 16: Piston Final Stage First and second
Page 17 and 18: Service steps for the auto drain: 1
Page 19 and 20: HAT Fault Indicator Light and Audib
Page 21 and 22: Compressor Air Pressure Switch The
Page 23 and 24: Changing of the element: 1. Be sure
Page 25 and 26: April 15, 2006 To: All Operators of
Page 27 and 28: RECOMMENDED PROCEDURE FOR TESTING P
Page 29 and 30: GENERAL RECOMMENDATIONS: CSA has re
Page 31 and 32: J O R D A I R COMPRESSORS INC. 6300
Page 33 and 34: TROUBLE SHOOTING Trouble Probable C
Page 35 and 36: Date Operator Hours Oil level, Pres
Page 37: SERVICE LOG PAGE 2 Date Intake Filt

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