LPV5145 - Class Leading Air Compressors and Air Compressor
Contents
1. In addition to the obvious safety rules that should be followed with machinery we recommend the following additional safety precautions I Read and understand all instructions completely before operating this compressor 2 Disengage power mains and disconnect power lines to the machine if used prior to attempting to work or perform maintenance on this unit 3 Open tank discharge valve and relieve all pressure from tank and compressor lines Do not attempt to remove any pressurized system parts without first relieving the pressure within the unit 4 Do not attempt to service any part while the machine is in operation 5 Do not operate the compressor at pressures in excess of its indicated rating on the compressor nameplate 6 Do not operate the compressor at speeds in excess of its indicated rating on the compressor nameplate 7 Do not remove guards shields or screens while the compressor is operating If removed for maintenance replace before resuming operation 8 Observe the delivery pressure gauge daily to be sure the automatic control system is operating within proper limits 9 Periodically check all safety and relief devices for proper operation 10 Do not play with compressed air Pressurized air can cause serious injury or death to personnel 11 Be sure that no tools rags or loose parts are left on the compressor or drive parts Section Pump Operation Manual 12 13 Do not use flammable solvents f2. The low pressure oil ring provided is of the latest design and is the same as furnished on the new automobile engines It is of three piece construction with two chrome plated rails and an expander ring Some new units may pump a slight amount of oil for a period of time but as the chrome plated rails seat to the cylinder walls this will gradually diminish Should excessive oil consumption continue the cylinders should be checked for scoring and the oil ring checked for proper assembly The two ends of the expander rings are colored with paint for identification and when properly assembled should be butted not overlapped The high pressure oil ring is of the one piece construction A coating of clean oil should be placed on the rings and the inside of the cylinders for ease of assembly and to minimize possibility of scoring cylinder See Paragraph 16 for reassembly procedure 3 Noisy Operation Can Be Caused By A Loose parts external Tighten loose bolts particularly the flywheel pulley to the crankshaft B Foreign matter such as carbon metal chips etc on pistons striking head at top of stroke Remove head and clean C Piston extending above cylinder at top of stroke and hitting head Remove cylinder and add base gasket not upper cylinder gasket D End play in crankshaft Remove end cover take out one end cover gasket or shim and replace Do not remove too many shims or binding may result see Paragraph under fitting and
3. BO Ja 9 D a O Date 16 Pump Operation Manual Section III fin cooler jas oO Tj O 2 Q oO K O change Check safety Oil Check replace air filter element Check top Clean check Replace air filter up oil level BO Ja 9 D a O Date 17
4. Manual 10 Oil out of from the breather Compressor piston jammed Replace pistons and cylinders Maintenance To obtain reliable and satisfactory service this unit requires a consistent preventive maintenance program Maintenance schedule pages are included in the back of this manual to aid in keeping the proper records General 1 Check your compressor regularly 2 Check entire system for air leakage around fittings connections and gaskets using soap solution 3 Remove dust or oil soiling 4 Check fastener tightness by using torque wrench to the corresponding values within this guide Safety information DANGER Please observe the following instructions when performing any maintenance cleaning repair work when relocating the compressor plant prior to installing and dismounting component parts receivers fittings and screw connections e Always isolate the compressor at the main switch prior to per forming any maintenance work Secure the main switch against accidental switching on Remove the electrical fuses in order to avoid accidents e Depressurize the compressor Disconnect from the compressed air network by closing the ball valve on the compressed air outlet Perform maintenance or servicing work Only allow skilled and qualified welders to perform welding work on compressed air receivers After welding work on compressed air receivers new constructional and hydrostatic pressure tests are to be carr
5. lubricant Compressor now ready to run for extended period before next lubricant change made Maintain oil level at the full line Lubricant Frequency Of Oil Change Change oil every 3000 operating hours whichever comes first For constant run applications in daily use or units subjected to extremely heavy use change oil monthly Oil Recommendation Any Approved Oil Which Is Equal To Those Specified May Be Used Ambient Or Room Temperature 55 F To 120 F AMOCO SHELL MOBIL TEXACO CHEVRON GULF EXXON Tellus Oil 41 Rotella Del vac 1230 o ER amp O EP68X Paramount 58 Teresstic NN DTE Heavy 10 Section III Pump Operation Manual Ambient Or Room Temperature 32 F TO 55 F AMOCO SHELL MOBIL TEXACO CHEVRON GULF EXXON Tellus Oil 33 Rotella Delvac 1220 __ E CR amp O EP55X Paramount 49 Teresstic a Oil 20 20W DTE Heavy Med Ambient Or Room Temperature 0 F TO 32 F AMOCO SHELL MOBIL TEXACO CHEVRON GULF EXXON Tellus Oil 25 Rotella Delvac 1210 Cetus a EP45X Paramount 65 Teresstic DTE Medium Suction Filter Regularly and carefully maintain the suction filter approx every 500 operating hours depending on the degree of soiling of the air taken in Soiled suction filters can cause high oil consumption and reduced delivery quantity If the installation site is heavily contaminated with dust provide a dry air filter with paper cartridge If the ambient air is heavily contaminated we recommend u
6. motor by hand to prevent flat spots on the bearings that will lead to premature failure At the end of the storage period follow the uncrating and start up procedures If the unit has been stored for more than eighteen months you should contact LP COMPRESSOR before restarting the compressor Section Pump Operation Manual Appropriate use As standard LP COMPRESSOR piston compressors are intended for the compression of ambient air The air may not contain any aggressive or combustible mixtures The pressure chambers of the compressor are oil lubricated Therefore the compressed air produced may only be used as breathing air or come into contact with food if it has been treated beforehand WARNING As standard this LP COMPRESSOR piston compressor is not of an explosion protected design and it may not be operated in areas subject to explosion hazards Section Symbols used Pump Operation Manual We have used the following symbols in this text to mark particularly important points DANGER WARNING The general warning sign indicates information concerning possible danger to operator and machine The lightning symbol indicates work which must exclusively be performed by skilled electricians The pointing hand indicates particularly important statements The spanner indicates maintenance work Danger is used to indicate the presence of a hazard which will cause severe personal injury death or su
7. reassembling E Loose valves Hex head cap screws are not tight enough Tighten screws Screws should be tightened snugly but not too tight as hold down cover corners could be broken Screws should be tightened evenly keeping covers parallel with cylinder head Screws have nylon insert in threads and are of self locking construction They will not loosen from vibration and can be removed and retightened several times without losing their holding ability Section III Pump Operation Manual F Loose or worn parts Internal e g pistons connecting rods wrist pins valves Pump should be overhauled preferably in distributors service department or factory Loose rod bolts can be tightened after removing crankshaft but if bearings are worn or scored new insert bearings must be installed 4 Oil Leak At base or end cover gasket Disassemble at point of leak shellac or perma gasket on both sides and reassemble Maintain correct oil level 5 Vibration Characteristic of all reciprocating machines can be held to a minimum by keeping the compressor securely fastened to a solid level foundation maintaining proper belt alignment and keeping nuts and bolts tight 6 Overheating Compression of air generates heat much of which is dissipated as air passes over the cylinder Overheating can be caused by A Pump running backwards Reverse direction Proper rotation is counterclockwise facing flywheel B One or
8. representative for assistance To move your compressor to its installation site we recommend that you leave the unit on its shipping skid as long as possible The forks should be extended the width of the compressor and padding should be placed between the compressor and the fork truck boom If it is necessary to lift the compressor with a crane we recommend the use of spreader bar and chains The spreader bar should be greater than the width of the compressor and padding placed on the edges to prevent chain damage DO NOT UTILIZE THE PUMP OR DRIVE AS A LIFT POINT Procedure for Handling Damaged Shipments 1 The customer at the receiving point MUST inspect each shipment for damage 2 If the shipment is damaged the customer should so note it on the freight bill 3 The customer should request an inspector from the freight company to inspect the equipment immediately It is best to send a confirming letter with the following information a Freight bill number b Date delivered shipper s name amp address c Description of item s damaged d Description of damage a Polaroid picture if possible e A copy of your invoice for the equipment 4 After inspection before the inspector leaves a Get a copy of the inspection report b Request the unit be shipped back free astray c Request a credit for the original freight bill 5 Call the factory and a Get a Return Material Authorization RMA number b Give a pu
9. the valve does not blow off although you have pull the ring up to the end of the stud it is defective Please have a new safety valve fitted by LP COMPRESSOR Service Test the valve as described in section Testing safety valve on compressor Compressor Oil General Compressors are factory filled with LP COMPRESSOR hydrocarbon based recip lubricant This is an ISO non detergent industrial lubricant with rust and oxidation inhibitors specially formulated for reciprocating compressors It is recommended this compressor be maintained using this oil for ambient temperature above 32 F degreed LP COMPRESSOR synthetic is a premium grade diester based synthetic lubricant providing excellent performance in high temperature applications Section III Pump Operation Manual Do not mix oil types weights or brands Normal break in period of LP COMPRESSOR air compressors is 25 hours for the first 500 hours of compressor operation a careful and regular check of the oil level should be made Maintain oil level at the full time Change To Synthetic Lubricant If changing to synthetic lubricant the following steps must be completed Compressor must run for a 25 hour break in period using LP COMPRESSOR ISO 100 oil Thoroughly drain existing oil from crankcase Fill crankcase with a full charge of synthetic lubricant Run compressor for 200 hours Stop compressor and thoroughly drain the synthetic lubricant Add a full charge of synthetic
10. unit is properly shimmed vibration will be nominal Allow sufficient space around compressor so that it is accessible from all sides for maintenance Mount unit with pulley side toward the wall but at least six 6 inches from it 3 Starting A If compressors are shipped without oil in the crankcase Before starting fill crankcase to the high level mark on the sight glass with LP Compressor compressor oil meeting the following specifications AMBIENT OR VISCOSITY FLASH CARBON PREFERRED ROOM TEMP AT 100 F RESIDUE BASE S S U 55 to 120 490 to 600 Naphthenic e Above 120 or CONSULT FACTORY below 0 Naphthenic Section II Pump Operation manual For operation in damp or humid locations addition of rust inhibitor is recommended B Turn compressor over a few revolutions by hand to make sure that everything is free and in running condition C Check tension of the belts See Paragraph 6 D Remove tools rags and any other objects from the vicinity of the compressor E Never put hands on the belts of idle units unless main power is secured F Note direction of arrow on flywheel and be sure direction of rotation is correct when machine is started Correct direction is counter clockwise when standing facing the flywheel Air should be drawn through inter cooler onto the cylinders for maximum cooling Section II Pump Operation manual Operation Every compressor undergoes a trial run in the factory and is carefull
11. 0117 HexHeadCapscrewM8x 0___________ 4 6 180082 Lockwasher 6 CSS woo joist O O wma W 1 WaW 070394 Qaei Front Cover i g 1 IMAP p 050163 Bal Bearing 204 FS 9 m et gt M 200106 SnapRingExtemal E O a 2 ON NA 4 880155 Ball Bearing205 SE 1 K R Sal 200107 RingReting gt oa o S a SEP 7092257 Crankshat My a u o o 1 NM MS ogam Crankcase wae 950 gt o 1 FF 16 731022 OilLevelSightGlass 2 NPT TC te 070217 Gasket Cylinder Vale Deck CT 2 19 070216 Gasket Valve Deck CylinderHead 2 2077 0702707 GasketCylinder Y T Ci BEM MA 21 Say cyi 4h 4 F Fo 2 MM SMA A NN og p 23H 120062 Hex Nut Ms a S AA A ER CO EEN Fm 1 FT 28 noa ar Flow AA 26 AI Elbow Male Tube MM 1 7 28 719061 PistonRingSet 2 29 110148 Hex Head Capscrew M6X35 LL 8 20 720018 Piston5imm WN 31 200105 SnapRingi2 7 LL L 2 72900 WristPin eT 2 A 33 705216 ComectingRod ______________ 2 O 34 130072 Breather Washer 4 35 703007 Breather 36 2198 Filter o 2 O Filter Element 38 727268 Vale Deck Complete CT 2 39 1102332 O 4 4 727141 ValelockPlate CSC 2 am 727140 inletValePlate _ _____________ 2 O 42 727139 lVawePlae 2 0 43 727138 Outlet Valve Plate 2 O 0 4 727137 Vale StopPlate ________________ 2 45 130061 LockwasherM3_________
12. LAWS IOLATIONS MAY RESULT IN O e Specification 4 Can ep ELA UN sPower Range 0 25 1HP 0 2 0 75Kw RA so Maximum Pressure 145Psi 10Bar 7 a 8 A mCylinders 2 2 r a mBore 2 51mm a oo mStroke 1 77 45mm 374 M 16UNF mRPM 5001500 i mFlywheel Dia Groove 10 5 266mm 1A a Features 5 eee mCast Iron Crankcase 138315457 T 7 a Cast Iron Cylinder eon ee a Cast Iron Cylinder Head 7 E hi i aDuctile Iron Crankshaft mAluminun Conn Rod Bronze Bushings Wrist Pin LPV5145 Performance Delivery LPV5145 Performance Power mBabbitt Bearings Crankshaft a Ball Main Bearings a Steel Breather and Brass Sight Glass 10 Em mPower Coated Steel Filter Silencer mFilled with DAB150 Lubricant a s mSynthetic Lubricant as Optional s Standard Package 3 y mSingle 1 Pcs Weight 41LB 19kg 2 mCrate 36 Pcs Weight 1520LB 705kg s 20 Container 864 Pcs 0 8 0 5 0 6 c 0 3 5 600 700 800 900 1000 1100 1200 1300 1400 1500 500 600 700 800 900 1000 1100 1200 1300 1400 1500 RPM T RPM Address 1830 W 15th Street Houston TX 77008 Displ
13. Operating instructions Industrial piston air compressors Model LPV5145 Address 1830 W 15th Street Houston TX 77008 Telephone 713 635 6291 Email Sales LPCompressor com Website www lpcompressor com COMPRESSOR Issue 06 2010 Contents Pump service manual Contents Page BEE i J I OG OO AO A A gl WTE ODBC ada R A OC AO AAAA RE 1 URP REIN ANDAN DORIN a ARON aran E RAN cu WIE E 2 APPROPRIATE USP kob a A GA da E 4 SYMBOLS USED A A e A a e JARE A 5 SYMBOLS USED AAA O A RR RY NN AW 5 SYMBOLS ON THE COMPRESSOR a AO WENN NE EEN M 6 SAFETY GUIDE ARRNNRR SDE BOA aaa aaa AAA 8 ANI oe 4 AMM AA PA ee A JERN al INSIDE AMM ee OTN ree 1 Mr i U oo SM PEN RE MO IMM W R l I W SMEREK 4 A AM AMA WNE MK I 2 AE E AW AERTS MERINO eee WENN THE NN 1 A 3 JJ ON HA A E SMN Se AAA MM AN AAA ee 4 E 8 A ANS AMA A A NAW A ee AA 6 _ RA i CRA ee eee E AA A A AAA 1 RT i ARMA AN A i SOREN 1 OVER eee AA NE WU See l nc ye ONW EUR Jr R JE MUN M W O 1 A a RB se MAME AU O ee eee 1 in SIKRET Se AS eee eee eee ee AA 1 By OTE AN i NOE el KAN AAA W 2 2 IRAN UI ne co E A E eee R AB 3 ASSEMBLE PUMP III rm oro or aeaaaee o ooa CO eeaeee aeaaeae aeaaaee eee eea ee a O E 5 TROUBLESHOOTING 22242444022004000000440000 le ie aan aa IM 1002 20 o OM essences a MAINTENANCE cccccccsssessesssscscssssssssesecsessnseeessensses
14. _______ 2 as ti0240 a ALC O U Section II Pump Operation Manual Installation Instruction l Inspection Check for possible damage in transit and see that the pulley turns freely by hand Report any damage to delivering carrier at once 2 Location Select a clean dry and light location In cold climates the compressor should be installed in a heated building Insulate cold water or other low temperature pipes that pass overhead to avoid the possible collection and dripping of condensate onto the compressor and motor which could cause rusting and or motor shorting Do not install the compressor in a boiler room paint spray room or area where sandblasting is carried on If air in the area where the compressor is to be installed is acid laden or dust laden the compressor intake should be piped to the outside This intake pipe should be increased one pipe size for every twenty 20 feet of run and the intake filters should be installed at the end of the pipes with a hood to protect them from the elements If the compressor has to be located where the motor will be exposed to appreciable quantities of water oil dirt acid or alkaline fumes the motor must be of special construction to avoid rapid deterioration Bolt the unit securely and evenly to a level base Unless base is exactly level shims will probably be required Any space between base and foot should be shimmed rather than drawing foot down thus placing strain on unit When the
15. acement DeliveryG90psi 6 bar Delivery0125psi 8 5 bar Delivery 145psi 10 bar Power 90psi 6 bar Power I25psi 8 5 bar ___ Power 145psi 10 bar Telephone 713 635 6291 Email Sales LPCompressor com Website www lpcompressor com SEN COMPRESSO LPV5145 Specifications Section II Pump Operation Manual Explode drawing SHEET 1 HF 1 REVISIONS DATE amp SYMBOL IESCRIPTION Al AS GE s Y l y IN 15 SA PARE LAPLANTE COMPRESSOR KN DN lt gt GA TRADE CENTER 22 XY AIR COMPRESSOR APPROVED BY o eit AA T IRON HOUSII LINDER sate IR LTD STRICT EXPLODED VIEW DRAWING SCALE CAD REV Section II Pump Operation Manual Bill of material list LPV5145 Parts List LAP 010037 010038 010039 010040 110147 130058 130070 713129 Description QTY Overhaul Kit Includes 1 each of items B C amp D Ring Set Includes 1 each of item 28 Valve Set Includes 1 each of item 38 Gasket Set Includes 1 each of items 9 20 18 19 ex Head Capscrew M8X35 ockwasher 8 at Washer lywheel 10 5 1 A w 110240 710102 02 crew Bolt M3X8 ylinder Head Iron Hem LAPR A 010087 tc te B 010038 W 010039 M D 010040 4 1 APO JE 2 180058 003 180070 4 stas 0 5 11
16. bstantial equipment and property damage if the warning is ignored Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial equipment and property damage if the warning is ignored Caution is used to indicate the presence of a hazard that will or can cause personal injury or equipment and property damage if the warning is ignored Notice is used to notify people of installation operation or maintenance of information that is important but not hazard related Section Symbols on the compressor Pump Operation Manual Warning Hot surfaces Do not touch Warning The unit is operated by remote control and might start without warning Note Instructions for the operating personnel must be read Prohibited Never open the valve before the air hose connection to the compressed air network is connected Forbidden TO remove protective covering and safety devices Danger Hot or noxious gases outlet unbreathable Danger High voltage disconnect power source before servicing Section Pump Operation Manual Danger Spray injury Section Pump Operation Manual Safety Guide Compressor Safety Precautions DANGER An air compressor is a dynamic piece of machinery needing the same common sense safety precautions that should be observed with any operating machinery Careless operation or maintenance is hazardous to personnel y WARNING
17. ck oil level and top up if necessary fe Check suction filter monthly and clean if necessary Replace suction filter 2000 cartridge Check safety valve 2000 Check cooler for 500 monthly soiling and clean if necessary Change oil 1 000 Check V belt for 2 000 damage and replace if necessary 12 Pump Operation Manual Section III List of Maintenance and service work fin cooler jas oO o 2 Q oO Q change Check safety Oil Check replace air filter element Check top Clean check Replace air filter up oil level BO paz U D OQ O Date Pump Operation Manual Section III fin cooler jas oO Tj O 2 Q oO K O change Check safety Oil Check replace air filter element Check top Clean check Replace air filter up oil level BO Ja 9 D a O Date 14 Pump Operation Manual Section III fin cooler jas oO Tj O 2 Q oO K O change Check safety Oil Check replace air filter element Check top Clean check Replace air filter up oil level BO Ja 9 D a O Date 15 Pump Operation Manual Section III fin cooler jas oO Tj O 2 Q oO K O change Check safety Oil Check replace air filter element Check top Clean check Replace air filter up oil level
18. d middle fingers on the other The piston should not rock of its own weight Drive roll pin into wrist pin when piston and wrist pin holes are in line and piston is assembled to connecting rod If replacement of a needle bearing ever becomes necessary be sure to press in the new bearing so that the small hole through casting lines up with oil hole in rod Wrist pin should also be replaced Section III Pump Operation Manual E Connecting Rod Crankshaft Tap cap when insert bearings are assembled to rod and cap to make sure bearing is making contact and tighten rod bolts with lock washers in place to prevent loosening torque 25 foot pounds The combined piston and connecting rod should turn slowly on the crankshaft of their own weight if bearing adjustment incorrect It will be noted that ends of the inserts extend slightly above the parting line of the rod and cap and under no circumstance should these ends of the inserts be filed F Reinstall crankshaft with pistons and connecting rods attached being careful not to damage oil feeder ring when fitting within base lugs and being sure there are no burrs or dirt on the pulley end of the crankshaft that might cut the oil seal G If oil seal is to be replaced slide over the crankshaft and press into place in the base the lip or seal side toward the crankcase Do not hammer directly on the seal H Replace valve parts in sequence indicated in explode drawing being careful not to force any pa
19. e seat gasket K To dismantle valves place valve in a soft jaw vise and remove center screw Valves are now free to take apart Clean all parts thoroughly Valve plates and seats must be smooth and flat and can sometimes be resurfaced by rubbing on fine emery cloth held on a smooth surface Badly worn parts including springs which lose tension after considerable use should be replaced Fitting and Reassembling Clean all parts thoroughly before assembling A Crankshaft Base Be sure base is cleaned to remove all metal chips and dirt Insert crankshaft and oil feeder ring only into base assemble end cover and tighten end cover bolts evenly End cover gaskets or shims are furnished in three thicknesses and the proper combination must be selected so that crankshaft can be spun in the bearings without end play Also see that oil feeder ring turns freely within the guide lugs in the base Then remove crankshaft B Piston Cylinder Check fit before assembling pistons to connecting rods Pistons without rings should slide through the cylinder of their own weight and holding the skirt of the piston with the two thumbs there should be no appreciable side motion at any point of piston travel Scored cylinders or pistons should be replaced C Wrist Pins should be tap fit by hammer See that roll pin holes are im line D Wrist Pin Needle Bearing Fit so that piston can be rocked with three fingers the thumb on one side and index an
20. ecessary replace or tighten threaded parts C Compressor too small for equipment being operated Check air requirements and add to compressor capacity consult dealer D Leaking head valves Remove hold down covers and remove valves for examination Repair or replace faulty valves Valves can be removed from head by tapping valve screw with hammer handle or piece of wood to loosen valve from head before lifting valve Clean all parts thoroughly Valves and seats must be flat and smooth and sometimes can be Section III Pump Operation Manual resurfaced by rubbing on fine emery cloth held on a smooth flat surface Badly worn parts including springs which lose tension after considerable use should be replaced Reassemble valve parts in sequence indicated in explode drawing Examine valve gaskets carefully and replace if doubtful of condition Be careful that nothing falls into the cylinder that could get caught between top of piston and cylinder head Before reassembling valve look into cylinder through valve opening while turning flywheel by hand 2 Excessive Oil Consumption Oil Pumping usually results from using the wrong type or an inferior grade of oil Replacing worn or stuck piston rings will help correct this condition but contrary to popular belief worn rings do not affect pumping efficiency appreciably Piston rings can be replaced by removing cylinder while the heads are off Remove rings and clean grooves in piston
21. ied out Prior to switching on again check whether anyone else is working on the compressor For your own safety never omit a safety step Otherwise you will risk injury from restarting electric shock or parts which may fly off Section III Pump Operation Manual Check oil level Check oil level every week and top up if necessary fill the oil tank with oil until the sight glass is 1 4 to 3 4 full Oil sight glass WARNING Use the same brand oil Check and clean compressor valves if compressor fails to pump air or seems slow in filling up tank disconnect unit from power source and remove valves and clean thoroughly using compressed air and a soft wire brush After cleaning exceptional care must be taken that all parts are replaced in exactly the same position and all joints must be tight or the compressor will not function properly When all valves are replaced and connections tight close hand valve at tank outlet for final test Valve gaskets should be replaced each time valves are removed from pump Replace springs discs and seats when worn or damage Valves must be reinstalled in original position Incorrect valve replacement may result in overpressure of the cylinder head resulting in catastrophic failure injury or death Valve gaskets should be replaced each time valve are serviced Checking the safety valve DANGER Section III Pump Operation Manual The safety valve must respond when the com
22. more head valves failing to seat properly Remove hold down cover valve cage and valve Clean reseat or replace valves C Blown cylinder head gasket Replace after cleaning all traces of old gasket from head and cylinder D Restriction in head intercooler or check valve if used Remove and clean E Lack of oil Check oil level if necessary remove side plate to see that oil feeder ring is free to turn F Dirt in cylinder fins Blow out with air G Poor ventilation and high room temperature If compressor cannot be moved check possibility of piping intake to cooler location 7 Compressor Has No Or Insufficient Output A Suction filter soiled Clean suction filter B Suction and pressure valves worn or defective Replace valves C Vent unloading valve does not close Check whether the vent unloading valve closes when the compressor is running overhaul or replace valve if necessary 8 Safety Valve Of The First Stage Blows Off A Suction and pressure valves of the second stage defective or worn Replace valves B Seal between valve and cylinder head defective Replace seal 9 Oil Foam in The Crankcase A Last stage piston worn Operate compressor with final stage valve head removed If oil collects at rim of cylinder piston clearance ok If oil flows continuously out of cylinder replace piston and liner B Last stage outlet valve defective Replace Section III Pump Operation
23. ng on Remove the electrical fuses in order to avoid accidents e Depressurize the compressor Disconnect from the compressed air network by closing the ball valve on the compressed air outlet Perform maintenance or servicing work Only allow skilled and qualified welders to perform welding work on compressed air receivers After welding work on compressed air receivers new constructional and hydrostatic pressure tests are to be carried out e Prior to switching on again check whether anyone else is working on the compressor For your own safety never omit a safety step Otherwise you will risk injury from restarting electric shock or parts which may fly off Section III Pump Operation Manual Bolt torque chart LP amp HP Hold Down Bolt 8 8 13 5 End Cover Bolt 110 M12X110 Cylinder to Base Bolt Disassembling Pump Before dismantling a pump for overhauling it is advisable to obtain a set of valve parts piston rings and gaskets in addition to other required parts A Loosen motor slide toward pump and remove belts Drain oil from crankcase and if desired remove complete pump from plat form B Remove flywheel bolt and remove pulley using a wedge or wheel puller if required Remove key File edges of key way smooth to remove sharp edges which could cut oil seal during removal C Remove air inlet filter from head D Remove cylinder head from cylinder by removing cap screws E Before removing cylinder mark
24. or cleaning parts Exercise cleanliness during maintenance and when making repairs Keep dirt away from parts and exposed openings by covering with a clean cloth or Kraft paper Install pressure relief valves in any isolatable piping in the plant system Do not operate the compressor in areas where there is the possibility of ingesting flammable or toxic gases Check pipe for any signs of wear or deterioration before each use and make certain that all connections are secure Observe the prescribed maintenance intervals Only use genuine LP COMPRESSOR parts Only use LP COMPRESSOR compressor oils and operating material recommended by LP COMPRESSOR Strictly observe the effluent disposal laws of your local authority when disposing of condensate Make sure to investigate the code requirements to ensure compliance prior to operating the compressor The owner lessor or operator of this compressor is hereby notified and forewarned that any failure to observe these safety precautions may result in injury death and or property damage TRADE SECRET CONFIDENTAL AND PROPRIETARY SHEET 1 OF 1 EXCLUSIVELY OWNED BY LAPLANTE COMPRESSOR LTD ANY COPYING USE OR DISCLOSURE WITHOUT THE WRITTEN PERMISSION OF LAPLANTE COMPRESSOR LTD IS STRICTLY PROHIBITED THIS MATERIAL IS PROTECTED UNDER l TRADE SECRET AND UNFAIR COMPETITION LAWS THE EXPRESSION OF THE INFORMATION IS PROTECTED UNDER FEDERAL COPYRIGHT
25. pressor pressure increases too high The inter stage pressure relief valve is provided to protect against inter stage over pressure and is factory set for maximum pressure of 75 PSIG If the pressure relief valve pops open it indicates trouble Shut down the unit immediately and determine and correct the malfunction Inspect the head valves Serious damage can result if not corrected and can lead to complete destruction of the unit Tampering with the inter stage pressure relief valve or plugging the opening destroys the protection provided and voids all warranty The valve must be able to blow off the entire delivery quantity of the compressor As it is rarely or never operated it is of utmost importance for the safety of the compressor that the valve is regularly checked Check the valve once a year or after 2000 operating hours This is the only maintenance work which has to be performed while the compressor is running Make sure that all safety devices are correctly installed Never perform this work with the safety device removed Danger of injury or death WARNING Do not readjust Test safety valve on compressor A ring is located at the free end of the safety valve Pull the ring by hand Never remove the lead seal at the head of the valve If you now pull the ring further the safety valve should blow off increasingly more air If the valve blows off correctly dropt hand tight in its seating and complete the check e If
26. rchase order for repair The purchase order should refer to the item and trucker claim Section Pump Operation Manual 6 We will accept the shipment back repair under normal conditions and return it within 7 seven working days 7 We will invoice the customer for the repair which will then become part of your claim The Invoice must be presented to the trucking claim department along with their claim form 8 We suggest if the trucker does not pay within 30 days that you call and or write the ICC making a formal complaint of poor service Also advise LP COMPRESSOR in writing for follow up If damage can be repaired at the receiving point follow Procedure 1 steps 1 through 4a Repair the unit and make out a detailed invoice to the trucker showing labor hours labor rate materials used and cost of materials Storage In some cases it may necessary to store the compressor for extended periods of several months before placing the unit in operation When this is required do the following Cover and seal all machine openings to prevent the entrance of water and dirt Cover all openings in open drip proof motors to prevent the entrance of rodents If the storage conditions are below freezing drain off the tank traps and attendant piping We do not recommend outside storage Cover with a waterproof tarpaulin that can easily be removed for in storage maintenance While in storage every two to three months rotate the compressor and
27. rts together when tightening this center screw and locknut Torque 28 foot pounds After assembly depress valve plate to insure that the valve works freely I Install key and pulley after cylinder head intercooler and after cooler are connected J Turn pulley over by hand several times to insure that no interference of any kind exists K Running in for a few hours without the head assembly is recommended if a pump has been completely overhauled especially if new pistons and or cylinders have been installed Valves Valves are generally considered to be maintenance items and require care by the user They are the most important part of the compressor and the importance of proper care and maintenance cannot be over emphasized All valves should be removed from the cylinder head at the end of the first two or three months of operation and examined for cleanliness and carbon formation Clean with safety solvent and blow off with compressed air Depending on what is found at this inspection the next inspection should not be more than 4 to 6 months later These 2 inspections will guide you in scheduling periodic cleaning times which will pay off many times over in providing trouble free service and reduced down time Troubleshooting 1 Slow Pumping Or Insufficient Pressure Can Be Caused By A Clogged inlet filter Disassemble and clean thoroughly B Leaks in air lines valves fittings etc Locate using soapy water if n
28. sing dry air filters All compressors are available with a common air filter with under pressure display for all cylinders Clean air filter Nearly 1500 operating hours or 1 year Check air filter and clean if necessary After undoing the snap fasteners lift the cover off and take out the filter cartridge If the filter is soiled clean as follows Clean the cartridge on the outside by an inclined air blast at max 3 5 bar The cartridges can be cleaned up to three times before being replaced with new ones Nearly 1500 operating hours or 1 year to change the filter element Clean the filter casing Carefully inspect the cartridge for damage Only use completely intact filters cartridges Examine cover seal and replace with a new one if damaged Insert filter cartridge replace casing cover and close with fastening clamps 11 Section III Pump Operation Manual Cleaning the air filter Maintenance intervals We recommend servicing and maintaining your compressor at the following intervals The hours of operation refer to average working conditions Other intervals may apply depending on these conditions Please contact LP COMPRESSOR in this event Please record each maintenance task in the table on the last pages of these instructions This may help LP COMPRESSOR Service to locate faults if any occur Maintenance work Maintenance intervals dependent on usage or Operating hours weekly monthly weekly Che
29. ssaressnseserseresesncessserseesesesis rre aooiie iiaae re CAI AAA cc a AAA ME 7 SAFETY INFORMATION iaa o a OZ ad 8 CHECK OMA dia 8 CHECK AND CLEAN COMPRESSOR VAL VES ca da 10 CHECK TUE SAFETY Vi sia 11 CHANGE AAN AR EEC 14 CHECK AND CHANGE AIR FILTER MI O oo ouasssscccsccassessvccscnossesescecsscccscassessncsscecsenscescneasessucsanecavsssancctorsccasdesesccanseaasssenentes 14 MAINTENANCE SCHEDULE occur E ii id 15 LIST OF MAINTENANCE AND SERVEER SRK AF uuu aaa eo oaza wawie UD SNE DSN NS ENS NEDEN DENNES SKE ODS DSN ao waka aaa DSN DE SDS NED SN DEN Des Dennes sene 16 Section Pump Operation Manual Introduction These operating instructions form part of the machine and must be made available to the compressor operating personnel at all times In order to receive maximum performance and long life from your compressor the following instructions should carefully read and all points regarding installation and operation of the unit should be noted and observed careful reading of this manual prior to connecting anything to the motor or compressor will pay dividends in long term trouble free operation Section Pump Operation Manual Unpacking and Handling Occasionally damage will occur during shipping Be sure to carefully inspect the unit before unpacking and after unpacking BEFORE you sign the receiver If any has occurred document it with the trucking firm immediately Contact your LP COMPRESSOR
30. top of pistons nearest flywheel so that they can be reinstalled in same position Remove cylinder by removing bolts Cylinder can be removed easily by twisting slightly back and forth while pulling upward Care should be taken that connecting rod and piston does not become damaged from striking metal when cylinder is removed The condition of cylinder pistons rings and bearing fits can then be checked F Remove end cover and slide crankshaft with connecting rods pistons etc out Section III Pump Operation Manual of base being careful not to damage the oil feeder ring Place pulley end of crankshaft in a vice using a soft jaws to prevent damage G To remove pistons Remove roll pins by driving them into the wrist pins and push out wrist pins Remove roll pins from wrist pins H When removing connecting rods see that rods and caps are kept in matched sets noting the position with reference to the crankshaft of the identification marks on one side of each so that the connecting rod can be replaced in the same position it originally occupied I Drive oil seal out of base only if replacement is necessary with evenly spaced blows from inside J To dismantle head remove low pressure hold down covers and high pressure hold down covers by removing cap screws Lift out low pressure cages and high pressure cages Low pressure valves and high pressure valves can be lifted out as well as the low pressure seat gasket 15 fig 4 and high pressur
31. y tested and set However damage occurring afterwards e g during transport cannot be excluded Therefore the compressor should always be subjected to a trial run during commissioning and carefully monitored WARNING Before start pump must be do the following job first Check power supply and Check oil level top up if necessary Check fastener and piping connection For 3 phase power Ensure no problem start up pump to check rolling direction counter clockwise is right if not please change 2 of 3 phase power wiring If all items are ok start the pump in operating Section III Pump Operation Manual Parts Kits About parts kits of pump include 4 sets 1 Overhaul Kit Includes1 each of filer element and ring set valve set gasket set 2 Ring Set Includes 1 set of piston rings 3 Valve Set Includes 1 set of inlet valve and outlet valve 4 Gasket Set Includes1 each of gasket For each pumps you can find the relevant parts kits number and describe in the explode drawings and bom list section Safety information f DANGER Please observe the following instructions when performing any maintenance cleaning repair work when relocating the compressor plant prior to installing and dismounting component parts receivers fittings and screw connections e Always isolate the compressor at the main switch prior to per forming any maintenance work Secure the main switch against accidental switchi
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