FScurtis CA series, ES03, ES05, ES06, ES10 Installation And Operating Instruction Manual

CAP600AE

NOVEMBER, 2008

AIR COMPRESSOR

INSTALLATION AND OPERATING INSTRUCTION MANUAL

Before installing and operating this compressor, read and understand the safety precautions contained in LV-474 supplement to and part of CAP-600

IMPORTANT

Make a permanent record of the Model and Serial number of your machine here. You’ll save time and expense by including this reference identification on replacement part orders.

*CONSULT FACTORY FOR SPECIAL APPLICATIONS

WARNING

CURTIS-TOLEDO, INC. 1905 Kienlen Avenue St. Louis, MO 63133

REFER TO MODEL & SERIAL NUMBER. READ INSTAL. & OPERATION INSTR. DO NOT OPERATE LOW ER THAN 500 R.P.M. OR ABOVE MAX. AS STIPULATED BY PERFORMANCE DATA SHEET.

SERIAL NO.MODEL NO.

CURTIS-TOLEDO, INC.

1905 Kienlen Avenue, St. Louis, Missouri 63133

phone: 314-383-1300 fax: 314-381-1439

email:info@curtistoledo.com website: www.fscurtis.com

Sales representatives in principal cities

CAP-600

INSTALLATION

CONGRATULATIONS on your new Curtis

Challenge Air Compressor. Please examine the compressor for shipping damage(s) and if any are found report it immediately to the carrier.

Select a clean dry location with a rigid floor strong enough to support the compressor. If the compressor is to be located in an area where vibration is critical, properly engineered vibration mounts and flexible piping should be used. Remove the skid. NOTE: The compressor should never be operated on the shipping skid. Level the compressor so it can be bolted down securely. Before tightening the bolts, check to see that all four feet are resting on the foundation. Shim as necessary to eliminate stress on the receiver or base when the bolts are tightened. We suggest using a level for proper alignment.

Maximum ambient temperature in which the compressor and motor should be operated is 104°F. Therefore, adequate ventilation must be provided.

The suction openings of the compressor are equipped with a combination air filter-muffler to protect the compressor from normal dust and other harmful substances. If the air around the compressor is excessively hot, dusty, humid or contaminated with foreign gases (such as ammonia or acid fumes) move the filter-muffler to a remote point where the air is clean, cool and dry. Run a pipe to the compressor suction opening. If the run is over 50 feet in length, use a larger pipe to avoid excessive pressure drop. In order to fit the filter to the compressor, bush down the connections. Be sure piping and fittings are clean and free from dirt and chips. If the filter is installed outside, check to insure that it is located above the normal outside dust level, and that rain cannot enter the filter element. Where the relocation of the filter-muffler is not possible or feasible, an oil bath filter is recommended and is available from Curtis.

LIMITED SAFETY PRECAUTIONS

(Also see supplement LV-474)

The following safety precautions are recommended in the use of this compressor:

1. Use a totally enclosed OSHA-approved belt guard to cover the drive assembly. Where possible, place the flywheel toward the wall, and mount the unit a minimum distance of 2 feet from the wall for maintenance convenience.

2. Turn off & lock out the electrical disconnect switch before working on the unit to prevent the unit from starting unexpectedly

WARNING: Read and understand supplement LV-474 before installing and operating the compressor.

On basic or base mounted compressors run a discharge pipe to the receiver or optional aftercooler and bush up or down as necessary. The pipe should enter near the top of the receiver. Keep in mind that condensate may form in the discharge line; therefore, the lines should always be pitched to drain condensate away from the compressor. Always provide a safety relief valve in the discharge line between the compressor and inline shutoff valves. If more than one compressor pumps into a common system, a check valve in the discharge line of each compressor is recommended to prevent moisture from entering the cylinder head when one compressor is idle. A globe or gate valve installed in the discharge line will allow compressor isolation from plant air system for compressor maintenance. (Note: A safety relief valve should be located between the compressor and the globe/gate valve.)

Check the electrical supply for voltage, phase, and frequency to see that they match the nameplate stampings on the motor, magnetic starter, solenoids, and other controls. Use electrical wires of adequate size to carry the full load current of the motor without excessive voltage drop. Charts are available from Curtis (upon request) to provide information on this. The motor must always be protected by a starter with properly sized thermal overload(s). The starter should protect the motor from overheating and burnout due to an overload, low voltage or single phasing of a 3-phase circuit.

Failure to install the proper starter and overloads will void the motor manufacturers warranty. Follow the National Electric Code or

local electric code in providing wiring, fusing and disconnect switches. NOTE: Do not close the

disconnect switch to start the compressor until the procedures outlined under "Startup Procedures" have been completed.

3. Release all air pressure from the system before working on the unit and red tag all electrical control switches, for safety precaution.

4. Do not by-pass motor over-current protection.

5. Do not change the setting or in any way affect the operation of the safety valve.

6. Keep unit securely anchored so that movement will not put a strain on piping, wiring, or air receiver.

2

START-UP PROCEDURES

OIL RECOMMENDATION

Use Genuine CURTISLUBEPLUS Lubricants. Specially formulated for Curtis Reciprocating Air Compressors. NonDetergent type with anti-foam, anti-rust and oxidation inhibitors.

Recommended ISO68 RC-1000 Premium Reciprocating Compressor Lubricant, Part no. VO411-3, 12-quart case or VO411-2, 4 gallon case.

Recommended ISO100 RC-1000A Premium Reciprocating Compressor Lubricant Part no. VO421-3, 12-quart case or VO421-2, 4 gallon case.

CURTISLUBEPLUS Lubricants are available through your authorized Curtis distributor.

CAP-600

If the compressor is equipped with an automatic start-stop control (with pressure switch unloading), it is automatically unloaded upon starting, and will automatically load after attaining running speed. If the compressor is equipped with a constant speed control (pilot valve unloading), it is necessary to manually unload the compressor, if there is pressure in the discharge line, in order to achieve an unloaded start. The compressor must be manually loaded after the compressor has attained full running speed, there after, it functions automatically to maintain operating pressure until the unit is shut off. Close the disconnect switch and start the compressor. Observe the direction of rotation, which should be counterclockwise when viewed from the flywheel side of the compressor on all models. For single-phase units, the direction of rotation is determined by the motor nameplate instructions, and is adjusted at the factory. For three-phase units, if the rotation is incorrect, stop the unit and interchange any two of the three wires to the motor at the disconnect switch. This will reverse the direction of rotation of the motor and compressor.

PREVENTIVE MAINTENANCE

A good maintenance program will add years of service to your air compressor. The following is recommended as a minimum maintenance program. (TURN OFF POWER BEFORE SERVICING.)

LUBRICATION

1. For proper lubrication the compressor shall not be operated below the minimum or above the maximum R. P.M. recommended for the various models.

2. Maintain oil level mid-way between the upper and lower lines of the crankcase sight gage.

3. Stop compressor to add and gauge oil.

4. Do not fill above the upper line and do not operate compressor with oil level below the lower line.

DO NOT OVER FILL

5. Change oil at the first 100 hours of operation and 1000 hours thereafter, or as required. It may be necessary to change oil more frequent due to abnormal humid and contaminated conditions.

DAILY MAINTENANCE

1. Check and maintain oil level at centerline of sight glass and add oil as necessary.

2. Drain condensate from receiver unless it is equipped with an automatic tank drain, in which case the drain should be checked weekly to see that it is operating. See automatic tank drain instructions.

NOTE ILLUSTRATION:

WARNING: Read and understand supplement LV-474 before installing and operating the compressor.

3. Check for unusual noise or vibration (See "Trouble Shooting".)

WEEKLY MAINTENANCE

1. Clean the air filters. A clogged air filter can seriously affect the efficiency of the compressor and cause overheating and oil usage.

2. Clean all external parts of the compressor and driver. Be sure to clean the intercooler-finned surface on two-stage compressors. A dirty compressor will cause abnormally high discharge temperature and resulting oil carbonization on internal valve components

3. Check the safety valve manually (by pulling ring or lever) to see that it is not stuck.

MONTHLY MAINTENANCE

1. Inspect the entire air system for leaks.

2. lnspect condition of oil and change if necessary.

3. Check drive belt tension and tighten if needed.

EVERY 3 MOS. OR 1,000 HRS. OF OPERATION

1. Change oil.

2. lnspect valves. Clean the carbon from valves and head if necessary.

3. Check and tighten if necessary all bolts, nuts, etc.

4. Check unloader operation.

*CHECKING BELT TENSION

The v-belt(s) should be adjusted so that a declination of about 3/8 – 1/2 inch will be obtained when it is pushed by a finger at the middle point as shown in Figure 1.

CAUTION: Over tightening the v-belt(s) will result in overloading of the motor and belt failure, while a loose belt will be slipping and resulting in an unstable speed, overheating the belt and high amp draw.

3

Figure 1

VALVE INSPECTION AND MAINTENANCE

Valves should be inspected at regular intervals as recommended under "Maintenance" and cleaned or replaced when necessary. The valve can be serviced without disconnecting air piping or removing the head. (Be sure the power to the motor is disconnected and

all pressure released before starting to work on the compressor.)

On constant run models, it is necessary to remove the unloader piping before the valve plugs can be removed.

MODELS E-11 AND E-23 (Figures 2 and 3) A. Disassembly:

1. Unbolt the outlet valve push cover (70112- 11450).

2. Remove the outlet valve push cover packing (70112-

11650), spring (70112-41070) and valve plate (70112-

31030). CAUTION: Steps 1 and 2 are for outlet valve.

3. Remove the unloading connecting tube for Models E-11 and E-23.

4. Untighten four cylinder head fixed bolts.

5. Remove cylinder head carefully and turn it over.

6. Unbolt inlet valve receiver (70112-31020).

7. Remove valve spring (70112-31070) and valve plate (70112-31030).

Valves should be inspected approximately every 1,000 hours of operation. Inspect the valve seats on cylinder head for dents, cracks or wear. Replace all defective parts. Remove carbon deposits and wash all valve components in a suitable non-flammable cleaning fluid.

B. Assembly:

1. Place outlet valve plate (70112-31030) in position.

2. Place the outlet valve push cover packing (70112-

11650) in position.

3. Insert the spring (70112-41070) into outlet valve push cover (70112-11450).

4. Turn outlet valve push cover (70112-11450) in position carefully.

CAP-600

To change tension, loosen the motor hold-down bolts and slide the motor on the base, using a lever if necessary, or by turning the adjusting bolt at the end of the base.

Retighten motor hold-down bolts.

NOTE: Do not over tighten belts.

ELECTRIC MOTOR

Grease once a year with a good grade of lithium ball bearing grease, or as directed by the motor manufacturer.

5. Check the valves to see if they can move freely in their guides.

6. Turn over the cylinder head (70112-11010).

7. Place the inlet valve plate (70112-31030) in position.

8. Insert the small end of inlet valve spring (70112-

31070) into position of valve receiver (70112- 31020).

9. Screw inlet valve receiver in position.

10. Check the valves to see if they can move freely in their guides and do not pinch or bind between the seat and guard legs.

Figure 2

WARNING: Read and understand supplement LV-474 before installing and operating the compressor.

Figure 3

4

MODELS E-50, E-71 AND E-15 (Figures 4 and 5)

A. Disassembly of Inlet Valve Assembly (Figure 4).

1. Untighten the hex nut.

2. Remove unloading fork (70123-31080), unloading fork guide (70123-31090), unloading spring (70123-11230) and valve seat (70123-31010).

CAUTION:

1. If a vise is used to hold the valve assembly, be careful not to clamp the assembly too tight.

2. Valve assembly should be inspected approximately every 1,000 hours of operation.

3. Inspect the valve seat for dents, cracks or wear.

4. Replace all defective parts.

5. Valve seats that might be worn after years of operation can be re-lapped or re-ground, in this case the recess in which the valve guard legs fit must also be cut down accordingly to ensure a same valve lift.

6. Remove carbon deposits and wash all valve components in a suitable non-flammable cleaning fluid.

B. Reassembly of Inlet Valve Assembly

1. Place valve spring (70123-31070) and valve plate (70123-31030) on valve receiver (70123-31020).

2. Place valve seat (70123-31010), unloading fork guide 70123-31090), unloading spring (70123- 11230) and unloading fork (70123-31080) respectively.

3. Tighten the valve assembly by tightening the hex nut.

4. Check the valves to see if they can move freely in their guides and do not pinch or bind between the seat and guard legs.

C. Disassembly of Outlet Valve Assembly (Figure 5)

1. Untighten the hex nuts.

2. Remove valve receiver (70123-41020), valve spring (70123-41070) and valve plate (70123-31030).

CAUTION: Refer to disassembly of inlet valve assembly (paragraph B).

CAP-600

D. Reassembly of Outlet Valve Assembly

1. Place valve spring (70123-41070) in valve receiver 70123-41020).

2. Place valve plate (70123-31030) in valve receiver. (70123-41020).

3. Insert the sub-assembled part (assembled in step I and 2) into valve seat (70123-41010).

4. Tighten the hex nuts.

5. Check the valves to see if they can move freely in their guides and do not pinch or bind between the seat and guard legs.

FIGURE 4 (EXAMPLE SHOWN E-50)

WARNING: Read and understand supplement LV-474 before installing and operating the compressor.

FIGURE 5

5

(EXAMPLE SHOWN E-50)

VALVE ASSEMBLY INSTALLATION - E-50 MODEL (Figures 6 and 7)

1. Install valve assembly gasket (70123-11110)

2. Install valve assembly (70123-31000).

3. Install valve push cover (70123-11150).

4. Install head bolt and tighten evenly and securely.

It is strongly recommended that a Preventative Maintenance Kit & Valve/Gasket Maintenance Kit be kept on hand. In this manner, the valves can be used in turn to keep the compressor always in good condition and a minimum downtime.

FIGURE 6

CAP-600

PISTON RINGS (Rebuild Kit)

To inspect or replace piston rings as follows:

1. Remove cylinder head.

2. Remove cylinder.

3. Loosen the connecting rod bolts.

4. Push out the piston with piston rings and connecting

rod.

5. To remove the old rings, pry them out of their grooves

and slide them over the piston. Care should be taken not to damage the piston.

6. Inspect the ring grooves for nicks and carbon deposits.

Clean the ring grooves and remove the obstructions, which might prevent the rings from moving freely.

To install new rings on the piston as follows: (Be careful not to damage the piston and rings).

1. Install the oil control ring (70123-61050) first. Rotate

ring in groove to make sure it is free.

2. Install the Compression ring (70123-61030). Make sure

the "top" or "R" mark is exactly on top. If not, it might cause excessive oil consumption.

3. Repeat the process with other rings, if any.

4. Assemble connecting rod into the crankshaft. Be sure

that the connecting rod and its cap are in original pair and position, since the connecting rod cap and crankshaft pin bushing are selected fitted and are not interchangeable.

5. Check if the ring gaps are in proper positions (Figure 8).

FIGURE 8

WARNING: Read and understand supplement LV-474 before installing and operating the compressor.

6

CAP-600

• REBUILD KITS AIR COOLED SINGLE STAGE MODELS

PART

NO.

CF1237

1 70112-11461 Copper Gasket

ES05

CONSISTS OF:

PART

NO.

CF1299

ES03

CONSISTS OF:

1 70111-66140 Filter Element 1 70111-66140 Filter Element 2 70111-31030 Valve Disc 2 70112-31030 Valve Disc 1 70111-31070 Spring 1 70112-31070 Spring 1 70111-41070 Spring 1 70112-41070 Spring 1 70111-11461 Gasket 2 70112-61030 Comp. Ring 1 70111-11612 Head Gasket 1 70112-61050 Oil Ring 2 70111-61030 Comp. Ring 1 70112-11612 Head Gasket 1 70111-61050 Oil Ring 1 70112-51610 Crankcase Gasket 1 70111-57970 Bottom Cover Gasket 1 70112-57950 Front Cover Gasket 1 70111-57950 Front bearing cover gasket 1 70112-57960 Rear Cover Gasket 1 70111-57080 Front Oil Seal 1 70112-57080 Oil Seal 1 70111-57960 Rear Cover Gasket 12 92521-190800 Copper Washer

10 92521-190600 Copper Washer

ES06 ES10, ES10P ES20

PART

NO.

CF1302

CONSISTS OF:

2 70111-66140 Filter Element 2 70111-66140 Filter Element 3 70111-66140 Filter Element 4 70111-31030 Valve Disc 4 70112-31030 Disc 6 70112-31030 Disc 2 70111-31070 Spring 2 70112-31070 Spring 3 70112-31070 Spring 2 70111-41070 Spring 2 70112-41070 Spring 3 70112-41070 Spring 2 70111-11461 Gasket 4 70112-61030 Compression Ring 6 70112-61030 Compression Ring 2 70111-11612 Head Gasket 2 70112-61050 Oil Ring 3 70112-61050 Oil Ring 2 70121-51610 Crankcase Gasket 2 70112-11612 Head Gasket 3 70112-11612 Head Gasket 4 70111-61030 Comp. Ring 2 70112-51610 Crankcase Gasket 3 70112-51610 Crankcase Gasket 2 70111-61050 Oil Ring 1 70122-57950 Front Cover Gasket 1 70122-57950 Front Cover Gasket 1 70121-57950 Front Cover Gasket 1 70122-57960 Rear Cover Gasket 1 70122-57960 Rear Cover Gasket 1 70111-57960 Rear Cover Gasket 1 70122-57080 Front Oil Seal 1 70122-57080 Front Oil Seal 1 70121-57970 Bottom Cover Gasket 24 92521-190800 Copper Washer 26 92521-190800 Copper Washer

24 92521-190600 Copper Washer 2 70112-11461 Copper Gasket 3 70112-11461 Copper Gasket

PART

NO.

CF1238

CONSISTS OF:

PART

NO.

CF1239

CONSISTS OF:

PART

NO.

CF1246 REBUILD KIT INCLUDES:

2 70123-66140 Filter Kit 4 70123-31030 Disc 2 70123-31070 Spring 2 70123-41070 Spring 4 70123-61030 Compression Ring 4 70123-61050 Oil Ring 6 70123-31030 Disc 6 70124-31030 Disc 6 70125-31030 Disc 3 70125-31030 Disc I / V 4 70123-11110 Seat Gasket 3 70123-31070 Spring 3 70124-31070 Spring 3 70125-31070 Spring 3 70125-31070 Spring 2 70123-11612 Head Gasket 3 70123-41070 Spring 3 70124-41070 Spring 9 70125-41074 Spring 9 701212A1-41075 Spring 2 70123-51610 Crankcase Gasket 6 70123-11110 Seat Gasket 6 70124-11110 Seat Gasket 6 70125-11110 Seat Gasket 6 70125-11110 Seat Gasket 1 70123-57950 Front Cover Gasket 3 70123-11612 Head Gasket 3 70124-11612 Head Gasket 3 70125-87510 Manifold Gasket 3 70125-41030 Disc O / V 1 70123-57960-01 Rear Cover Gasket 3 70125-11610 Head Gasket 3 70125-11612 Head Gasket 1 70123-57080 Front Oil Seal ** 70125-11612 Head Gasket

*2 70123-61081 Bushing

2 70123-61090 Set, Rod Bearing

26 92521-191000 Copper Washer

1 70123-57080 Front Oil Seal 1 70124-57950 6 70123-61030 Compr.Ring 6 70124-61030 Compr.Ring 6 70125-61030 Compression Ring 6 70125-61030 Compression Ring 6 70123-61050 Oil Ring 6 70124-61050 Oil Ring 6 70125-61050 Oil Ring 6 70125-61050 Oil Ring *3 70123-61081 Bushing 3 70124-61080 Bushing *3 70125-61081 Bushing *3 70125-61081 Bushing 3 70123-61090 Set, Rod Bearing 6 70124-61090 Set, Rod Bearing 3 70125-61090 Set, Bearing 6 70125-61090 Set, Bearing 3 70123-51610 Crankcase Gasket 3 70124-51610 Crankcase Gasket *3 70135-51610 Crankcase Gasket *3 70135-51610 Crankcase Gasket 1 70123-57950 1 70133-57960

ES-30 ES-50 ES-100 ES-150 ES-150A

CONSISTS OF:

PART

NO.

CF1252

3 70123-66140 Filter Element 3 70123-66140 Filter Element 3 70123-66140 Filter Element 3 70123-66140 Filter Element

CF1245

CF1244 REBUILD KIT INCLUDES: CF1242 REBUILD KIT INCLUDES: CF1244 REBUILD KIT INCLUDES: CF1244 REBUILD KIT INCLUDES:

34

CONSISTS OF:

PREVENTATIVE MAINTENANCE KIT INCLUDES

VALVE / GASKET MAINT. KIT INCLUDES

92521-191000

Frt. Brg. Cvr. Gasket Rear Brg. Cvr. Gasket

Copper Washer

PART

NO.

CF1252

CF1243

1 70134-57080 Front Oil Seal 1 70135-57950 Frt. Brg.Cvr Gasket 1 70135-57950 Frt. Brg.Cvr Gasket 1 70134-57960 34

CONSISTS OF:

PREVENTATIVE MAINTENANCE KIT INCLUDES

VALVE / GASKET MAINT. KIT INCLUDES:

Frt. Brg. Cvr. Gasket

92521-191000

Rear Brg. Cvr. Gasket

Copper Washer

PART

NO.

CF1252

CF1241

1 70134-57080 Front Oil Seal 1 70134-57080 Front Oil Seal

1 70134-57960 Rear Brg.Cvr Gasket 1 70134-57960 Rear Brg.Cvr Gasket 24 92521-191000 Copper Washer 24 92521-191000 Copper Washer

CONSISTS OF:

PREVENTATIVE MAINTENANCE KIT INCLUDES

VALVE / GASKET MAINT. KIT INCLUDES:

PART

NO.

PREVENTATIVE MAINTENANCE

CF1252

KIT INCLUDES

VALVE / GASKET MAINT. KIT INCLUDES:

CF1320

CONSISTS OF:

* WARNING – THESE ITEMS INTERCHANGE WITH PARTS ON SERIAL #3020000 & HIGHER ONLY. CONTACT FACTORY FOR EARLIER SERIES.

** USE WITH SERIAL #A311XXXX AND LATER 70135-11610 REPLACES 70125-11610

.

7

CAP-600

• REBUILD KITS AIR COOLED TWO STAGE MODELS

E-11 E-23

PART

NO.

CF1250 1 70111-66140 Filter Element CF1251 2 70111-66140 Filter Element

2 70112-31030 Disc 4 70112-31030 Disc 2 70162-32030 Disc 2 70111-31030 Disc 1 70112-31070 Spring 2 70112-31070 Spring 1 70162-42070 Spring 2 70112-41070 Spring 1 70112-41070 Spring 1 70172-32070 Spring 1 70162-32070 Spring 1 70172-42070 Spring 2 70112-61030 Compression Ring 4 70112-61030 Compression Ring 1 70112-61050 Oil Ring 2 70112-61050 Oil Ring 2 70162-62030 Compression Ring 2 70111-61030 Compression Ring 2 70162-62050 Oil Ring 2 70111-61050 Oil Ring 1 70112-11612 Head Gasket (1st) 2 70112-11612 Head Gasket (1st) 1 70162-12610 Head Gasket (2nd) 1 70111-11612 Head Gasket (2nd) 2 70112-51610 Crankcase Gasket 3 70112-51610 Crankcase Gasket 1 70122-57950 Front Cover Gasket 1 70122-57950 Front Cover Gasket 1 70122-57960 Rear Cover Gasket 1 70122-57960 Rear Cover Gasket 1 70122-57080 Front Oil Seal 1 70122-57080 Front Oil Seal 24 92521-190800 Copper Washer 32 92521-190800 Copper Washer 1 70112-11461 Copper Gasket 1 70111-11461 Copper Gasket 2 70112-11461 Copper Gasket

CONSISTS OF:

PART

NO.

CONSISTS OF:

PART

NO.

CF1306

1 70152-66141 Element

CF1307

4 70152-31030 Disc 2 70152-32030 Disc 4 70152-31070 Spring 2 70152-32070 Spring 1 70152-11612 Head Gasket 1 70152-31120 Seat Gasket 1 70152-11622 Seat Gasket

CF1308 REBUILD KIT INCLUDES:

1 70152-51610 Case Gasket 1 70152-57960 Rear Cover Gasket 2 70152-61030 Comp. Ring 1 70152-61050 Oil Ring 1 70152-61080 Bushing (L.P.) 1 70152-62080 Bushing (H.P.) 2 70152-61090 Rod Bearing Set 3 70152-62030 Compression Ring 1 70152-62050 Oil Ring 1 70152-57950 Front Cover Gasket 1 70127-57080 Front Oil Seal 6 92521-190800 Copper Washer

E-35

CONSISTS OF:

PREVENTATIVE MAINTENANCE

KIT INCLUDES:

VALVE/GASKET MAINT KIT

INCLUDES:

E-57 E-50 E-71 E-15

PART NO. CONSISTS OF:

CF1291

CF1292

CF1293 REBUILD KIT INCLUDES: CF1254 REBUILD KIT INCLUDES: CF1256 REBUILD KIT INCLUDES: CF1258 REBUILD KIT INCLUDES:

26 92521-191000 Copper Washer 34 92521-191000 Copper Washer 34 92521-191000 Copper Washer 1 93503-NK28/30 Needle Bearing ***

PREVENTATIVE MAINTENANCE KIT

1 70153-66142 Element 2 70123-66140 Element 2 70123-66140 Element 2 70123-66140 Element

4 70153-31032 Disc 6 70123-31030 Disc 4 70124-31030 Disc 4 70125-31030 Disc 2 70153-32032 Disc 3 70123-31070 Spring 2 70123-31030 Disc 2 70175-42030 Disc 4 70153-31072 Spring 3 70123-41070 Spring 2 70124-31070 Spring 2 70125-31070 Spring 2 70153-32072 Spring 6 70123-11110 Seat Gasket 1 70123-31070 Spring 1 70124-31070 Spring 1 70153-31120 Head Gasket 3 70123-11612 Head Gasket 2 70124-41070 Spring 6 70125-41070 Spring 1 70153-11612 Seat Gasket 1 70123-41070 Spring 1 70124-41072 Spring 1 70153-11622 Seat Gasket 4 70124-11110 Seat Gasket 4 70125-11110 Seat Gasket

2 70123-11110 Seat Gasket 2 70124-11110 Seat Gasket 2 70124-11612 Head Gasket 4 70125-87510 Manifold Gasket 1 70123-11612 Head Gasket 2 70125-11610 Head Gasket 1 70124-11612 Head Gasket ** 70135-11610 Head Gasket

1 70153-57951 Front Bearing Gasket 1 70123-57950 Front Bearing Gasket 1 70124-57950 Front Bearing Gasket 4 70125-61030 Compression Ring 2 70124-61030 Compression Ring 4 70123-61030 Compression Ring 4 70124-61030 Compression Ring 4 70125-61050 Oil Ring 2 70124-61050 Oil Ring 4 70123-61050 Oil Rings 4 70124-61050 Oil Ring 3 70124-61030 Compression Ring 3 70153-62030 Compression Ring 3 70112-61030 Compression Ring 3 70123-61030 Compression Ring 2 70124-61050 Oil Ring 1 70153-62050 Oil Ring 1 70112-61050 Oil Ring 2 70123-61050 Oil Ring 2 70125-61081 Bushing 1 70153-61081 Bushing (L.P.) 2 70123-61081 Bushing 2 70124-61080 Bushing 3 70125-61090 Rod Bearing (2 Halves) 1 70153-62081 Bushing (H.P.) 1 93503TA1725 Needle Bearing 1 70174-62081 Bushing 3 70135-51610 Gasket 4 70153-61090 Rod Bearing (Halves) 6 70123-61090 Rod Bearing (Halves) 3 70124-51610 Gasket 1 70134-57080 Oil Seal 1 70153-51611 Case Gasket 3 70123-51610 Crankcase Gasket 1 70134-57080 Oil Seal 1 70135-57950 Front Bearing Gasket 1 70123-57080 Oil Seat 1 70123-57080 Oil Seal 6 70124-61090 Bearing (Halves) 1 70134-57960 Rear Bearing Gasket 1 70153-57961 Rear Bearing Gasket 1 70133-57960 Rear Bearing Gasket 1 70134-57960 Rear Bearing Gasket 24 92521-191200 Copper Washer

1 70173-62080 Bushing 1 70175-62080 Bushing ****

INCLUDES

VALVE/GASKET MAINT KIT

INCLUDES:

PART

NO.

CF1315

CF1253

CONSISTS OF:

PREVENTATIVE MAINTENANCE

KIT INCLUDES:

VALVE/GASKET MAINT KIT

INCLUDES:

PART

NO.

CF1315

CF1255

CONSISTS OF:

PREVENTATIVE MAINTENANCE

KIT INCLUDES:

VALVE/GASKET MAINT KIT

INCLUDES:

PART

NO.

CF1315

CF1257

CONSISTS OF:

PREVENTATIVE MAINTENANCE

KIT INCLUDES:

VALVE/GASKET MAINT KIT

INCLUDES:

* WARNING – THESE ITEMS INTERCHANGE WITH PARTS ON SERIAL #3020000 & HIGHER ONLY. CONTACT FACTORY FOR EARLIER SERIES.

** USE WITH SERIAL #A311XXXX AND LATER 70135-11610 REPLACES 70125-11610 *** USE WITH SERIAL #A409XXXX AND LATER **** USE FOR UNITS PRIOR TO SERIAL #A409XXXX

.

8

CAP-600

RING SETS & GASKET SETS

SINGLE STAGE

QUANTITY

MODEL PART NO. DESCRIPTION

ES03

ES05

ES06

ES10

ES20

ES30

ES50

ES100

ES150 & ES150A

CF1297 CF1298

CF1259 CF1276

CF1300 CF1301

CF1260 CF1277

CF1261 CF1278

CF1262 CF1279

CF1263 CF1280

CF1264 CF1281

CF1265 CF1282

*CF1311

Ring set Gasket set

Ring set Gasket set *Gasket set

REQ’D

1 1

2 1

3 1

2 1

3 1

3 1 1

TWO-STAGE

MODEL PART NO. DESCRIPTION

CF1266

E11

E23

E35

E50

E57

E71

E15

* USE WITH SERIAL #A311XXXX AND LATER

CF1267 CF1283

CF1268 CF1269 CF1284 CF1303 CF1304 CF1305

CF1270 CF1271 CF1285

CF1288 CF1289 CF1290

CF1272 CF1273 CF1286

CF1274 CF1275 CF1287

*CF1313

Ring set (LP) Ring set (HP) Gasket set

Ring set (LP) Ring set (HP) Gasket set Ring set(LP) Ring set(HP) Gasket set

Ring set(LP) Ring set(HP) Gasket set

Ring set(LP) Ring set(HP) Gasket set *Gasket set

QUANTITY

REQ’D

1 1 1

2 1 1 1 1 1

2 1 1

1 1 1

2 1 1

2 1 1 1

9

MODEL ES-03

AIR COOLED, SINGLE STAGE, SINGLE CYLINDER

CAP-600

Description QTY PART NO.

VALVES

1. Inlet & Outlet Valve Plate 2 70111-31030

2. Inlet Valve Spring 1 70111-31070

3. Inlet Valve Receiver 1 70111-31020

4. Inlet Valve Snap Ring 1 93610-130225

5. Outlet Valve Spring 1 70111-41070

6. Outlet Valve Push Cover Gasket 1 70111-11461

7. Outlet Valve Push Cover 1 70111-11450

8. Manual Unloader Assembly 1 70111-11300

9. CYLINDERS

9A. Cylinder Head Assembly (Includes Valves) 1 70111-11000-4024 9B. Cylinder Head (Bare Casting) 1 70111-11010

10. Cylinder Head Bolt (Not Shown) 4 (Hardware Item)

11. Cylinder Head Gasket 1 70111-11612

12. Cylinder & Crankcase 1 70111-57010-4024

13. Compression Ring 2 70111-61030

14. Oil Control Ring 1 70111-61050

15. Piston 1 70111-61011

16. Piston Pin 1 70111-61120

17. Piston Pin Snap Ring 2 70111-61070

18. Connecting Rod Assembly 1 70111-61200

19. Connecting Rod Bolt 2

20. Oil Splash Dipper 1 70111-61282

21. Oil Splash Dipper Bolt 1 91507-2304010

22. Oil Splash Dipper Bolt Washer (Not Shown) 1 92522-130400

CRANKCASE AND CRANK ASSEMBLY

(furnished on conn. Rod only)

23. Crankshaft 1 70111-56010

24. Front Bearing Cover 1 70111-57030

25. Front Bearing Cover Gasket 1 70111-57950

26. Front Cover Bolts (Not Shown) 4 91501-1306016

27. Front Bearing #6203 1 93501-6203

28. Rear Bearing Cover 1 70111-57060

29. Rear Bearing Cover Gasket 1 70111-57960

30. Rear Bearing #6201 1 93501-6201

31. Rear Bearing Cover Bolts (Not Shown) 3 93501-1306016

32. Front Oil Seal 1 70111-57080

33. Compressor Pulley 1 70111-76010

34. Compressor Pulley Thrust Washer 1 70111-76210

35. Compressor Pulley Thrust Bolt 1 91501-1306020

36. Crankcase Bottom Cover (Not Shown) 1 70111-57220

37.

38. Compressor Pulley Pin NA (Not Required)

39. Oil Level Gauge And Cover 1 70111-57700

40. Gauge Cover Seal 1 70111-57730

41. Crankcase Oil Plug (1/4” PT) 1 90112-100202

42. Breather Assembly 1 70191-57600-4024 AIR STRAINER ELEMENT

43. Air Strainer Assembly 1 70111-66001

44. Air Strainer Element (Not Shown) 1 70111-66140

10

Description QTY PART NO. CRANKCASE AND CRANK ASSEMBLY

Crankcase Bottom Cover Gasket (Not Shown)

1 70111-57970

MODEL ES-06

AIR COOLED, SINGLE STAGE, TWO CYLINDER

CAP-600

DESCRIPTION QTY PART NO. DESCRIPTION QTY PART NO.

VALVES

1. Inlet And Outlet Valve Plate 4 70111-31030 29 Front Bearing Cover Bolt 4 91501-1306016

2. Inlet Valve Spring 2 70111-31070 30 Front Bearing #6204 1 93501-6204

3. Inlet Valve Receiver 2 70111-31020 32 Rear Bearing Cover 1 70111-57060

4. Inlet Valve Snap Ring 2 93610-130225 33 Rear Bearing Cover Gasket 1 70111-57960

5. Outlet Valve Spring 2 70111-41070 34 Rear Bearing Cover Bolt (Not Shown) 3 91501-1306016

6. Outlet Valve Push Cover Gasket 2 70111-11461 35 Rear Bearing #6203 1 93501-6203

7. Outlet Valve Push Cover 2 70111-11450 36 Crankcase Bottom Cover (Not Shown) 1 70121-57220 37 Crankcase Bottom Cover Bolt (Not Shown) 1 70121-57970

CYLINDERS, CRANKCASE AND CRANK ASSEMBLY

8a. Cylinder Head Assy. (Includes Valves) 2 70111-11000-4024 39 Front & Rear Cover Bolt Washer (Not Shown) 10 92521-190600 8b. Cylinder Head (Bare Casting) 2 70111-11010 40 Compressor Pulley Pin 1 70112-56060

9. Cylinder Head Gasket 2 70111-11612 41 Compressor Pulley 1 70121-76011

10 Cylinder Head Bolt 8 91501-1306055 42 Compressor Pulley Thrust Washer 1 70112-76210 11 Cylinder 2 70121-51010 43 Compressor Pulley Thrust Bolt 1 91501-1306025 12 Cylinder To Case Gasket 2 70121-51610 44 Oil Level Gauge & Gauge Cover 1 70111-57700 13 Cylinder To Case Bolt (Not Shown) 8 91501-1306016 *44A Oil Level Gauge Assy 1 70704-57700 14 Cylinder To Case Bolt Washer (Not Shown) 16 92521-190600 45 Oil Level Gauge Cover Seal 1 70111-57730 15 Compression Ring 4 70111-61030 *45A Oil Level Gauge “O” Ring 1 93602-8126026 16 Oil Control Ring 2 70111-61050 46 Crankcase Oil Plug (1/4” NPT) 1 90112-100202 17 Piston 2 70111-61011 47 Breather Assembly 1 CCC1357 18 Piston Pin 2 70111-61120 19 Piston Pin Snap Ring 4 70111-61070 48 Auto – Unloader Assembly 2 70112-11201 20 Connecting Rod Assembly 2 70111-61200 49 Unloading Elbow* (Includes Nut & Sleeve) 1 VA786

21 Connecting Rod Bolt 4 22 Oil Splash Dipper 2 70121-61282

23 Oil Splash Dipper Bolt 2 91507-2304010 51 Air Strainer Assembly 2 70111-66001 24 Oil Splash Dipper Lock washer 2 92522-130400 52 Air Strainer Element (Not Shown) 2 70111-66140 25 Crankshaft 1 70121-56010 53 Compressor Body Discharge Pipe Assembly 1 70121-87100 26 Crankcase 1 70121-57010-4024 54 Outlet Pipe Elbow 1 70121-87010 27 Front Bearing Cover 1 70121-57030 55 Outlet Pipe Tee 1 70121-87020

56 Outlet Pipe Tee Nut 1 79922-130404

(Furnished On Conn, Rod Only)

* START S/N AS 4030001

28 Front Bearing Cover Gasket 1 70121-57950

38 Crankcase Bottom Cover Washer (Not Shown) 4 (Hardware Item)

UNLOADERS(* Indicates Not Included On Basic Units)

50 Unloading Tee* (Includes Nut & Sleeve) 1 VA787

AIR STRAINER ASSEMBLY & DISCHARGE PIPING

11

AIR COOLED, SINGLE STAGE MODELS

ES-05, ES-10 & ES-20

CAP-600

12

CAP-600

MAIN PARTS LISTING FOR

SINGLE STAGE MODELS

ES-05, ES-10 & ES-20

VALVES

1. Inlet And Outlet Valve Plate 2 70112-31030 4 70112-31030 6 70112-31030

2. Inlet Valve Spring 1 70112-31070 2 70112-31070 3 70112-31070

3. Inlet Valve Receiver 1 70112-31020 2 70112-31020 3 70112-31020

4. Inlet Valve Snap Ring 1 93610-130232 2 93610-130232 3 93610-130232

5. Outlet Valve Spring 1 70112-41070 2 70112-41070 3 70112-41070

6. Outlet Valve Push Cover Gasket 1 70112-11461 2 70112-11461 3 70112-11461

7. Outlet Valve Push Cover 1 70112-11450 2 70112-11450 3 70112-11450

CYLINDER AND CYLINDER HEADS

16A. Cylinder Head Assembly 1 16B. Cylinder Head 1 70112-11010 2 70112-11010 3 70112-11010

17. Cylinder & Head Gasket 1 70112-11612 2 70112-11612 3 70112-11612

18. Cylinder 1 70112-51010 2 70112-51010 3 70112-51010

19. Cylinder And Case Gasket 1 70112-51610 2 70112-51610 3 70112-51610

20. Compression Ring 2 70112-61030 4 70112-61030 6 70112-61030

21. Oil Control Ring 1 70112-61050 2 70112-61050 3 70112-61050

22. Piston 1 70112-61011 2 70112-61011 3 70112-61011

23. Piston Pin 1 70112-61120 2 70112-61120 3 70112-61120

24. Piston Pin Snap Ring 2 70112-61070 4 70112-61070 6 70112-61070

25. Connecting Rod Assembly 1 70112-61200-1 2 70112-61200-1 3 70112-61200-1

26. Connecting Rod Bolt 1 70112-61250 4 70112-61250 6 70112-61250

27. Oil Splash Dipper 1 70111-61282 2 70122-61282 2 70122-61282

27A. Oil Splash Dipper 1 70132-61290

28. Oil Splash Dipper Bolts 1 91507-2304010 2 91507-2304010 3 91507-2304010

29. Cylinder Head Bolt 4 (Hardware Item) 8 (Hardware Item) 12 (Hardware Item)

CRANK ASSEMBLY

39. Crankcase 1

40. Crankshaft 1 70112-56010 1 70122-56010 1 70132-56010

41. Front Bearing Cover 1 70112-57030 1 70122-57030 1 70122-57030

42. Front Bearing Cover Gasket 1 70112-57950 1 70122-57950 1 70122-57950

43. Rear Bearing Cover 1 70112-57060 1 70122-57060 1 70122-57060

44. Rear Bearing Cover Gasket 1 70112-57960 1 70122-57960 1 70122-57960 45A. Bearing – Front 1 93501-6205 1 93501-6205 1 93501-6205 45B. Bearing – Rear 1 93501-6204 1 93501-6204 1 93501-6204

46. Front Oil Seal 1 70112-57080 1 70122-57080 1 70122-57080

47. V-Pulley Pin 1 70112-56060 1 70112-56060 1 70112-56060

48. Compressor Pulley 1 70112-76010 1 70122-76011 1 70122-76011

49. Compressor Pulley Thrust Washer 1 70112-76210 1 70112-76210 1 70112-76210

50. Compressor Pulley Thrust Bolt 1 91501-1308025 1 91501-1308025 1 91501-1308025

51. Breather Assembly 1

52. Oil Gauge & Gauge Cover 1 70111-57700 1 70111-57700 1 70111-57700

٭52 A Oil Level Gauge Assembly - 1 70704-57700 1 70704-57700

53. Gauge Cover Seal 1 70111-57730 1 70111-57730 1 70111-57730

٭53 A Oil Level Gauge “O” Ring - 1 93602-8126026 1 93602-8126026

54. Crankcase Oil Plug 1 90112-100202 1 90112-100202 1 90112-100202

54A. Oil fill cap - - 1 54B. “O” Ring - - 1 93601-810016

UNLOADERS

55. Auto – Unloader Assembly 1 70112-11201

56. Auto – Unloader Spring 1 70112-11230 2 70112-11230 3 70112-11230

57. Auto – Unloader Piston 1 70112-11221 2 70112-11221 3 70112-11221

58. O-Ring (Unloader) 1 93601-810004 2 93601-810004 3 93601-810004

AIR STRAINER

61. Air Strainer Element (not shown) 1 70111-66140

62. Air Strainer Assembly 1 70111-66001 2 70111-66001 3 70111-66001

63. Discharge Piping Assembly 1 (Not Required) 2 70122-87100 2 70132-87100

64. Outlet Pipe Joint A - 1 70122-87010 1 70122-87010

65. Outlet Pipe Joint B - 1 70122-87020 1 70132-87020

66. Outlet Pipe Joint C - - 1 70132-87030

QTY

REQ’D

MODEL ES05

70112-11000-4024

70112-57010-4024

CCC1375

• ES10, START S/N AS 4030043

• ES20, START S/N AS 4030061

QTY

REQ’D

2

1

2 70112-11201

2 70111-66140

MODEL ES10

70112-11000-4024

70122-57010-4024

CCC1375

QTY

REQ’D

3

1

3 70112-11201

3 70111-66140

MODEL ES20

70112-11000-4024

70132-57010-4024

CCC1375

70101-57190-4010

13

AIR COOLED SINGLE STAGE

t

MODELS ES-30, ES-50, ES-100

CAP-600

VALVE ASSEMBLIES

VALVE &

UNLOADERS

Description

Inlet Valve Assembly, 1 Outlet Valve Assembly, 1 Breather Assembly 1

s

Stage 2 70123-31000 3 70123-31000 3 70124-31000

s

Stage 2 70123-41000 3 70123-41000 3 70124-41000

Qty.

Req.

MODEL

ES30

70103-57600-4024

Qty.

Req.

70103-57600-4024

1

MODEL

ES50

Qty.

Req.

MODEL

ES100

1 70124-57600

MAIN PARTS LISTING FOR MODELS

ES-30, ES-50, ES-100

Item

Description

No.

1. Inlet Valve Seat 2 70123-31010 3 70123-31010 3 70124-31010

2. Inlet Valve Receiver 2 70123-31020 3 70123-31020 3 70124-31020

3. Inlet & Outlet Valve Plate 4 70123-31030 6 70123-31030 6 70124-31030

4. Inlet Valve Spring 2 70123-31070 3 70123-31070 3 70124-31070

5. Inlet Valve Unloading Fork Guide 2 70123-31090 3 70123-31090 3 70124-31090

6. Unloading Spring 2 70123-11230 3 70123-11230 3 70124-11230 7A. Valve Gasket 4 70123-11110 6 70123-11110 6 70124-11110

Qty. Req.

MODEL

ES30

Qty.

Req.

MODEL

ES50

Qty.

Req.

MODEL

ES100

14

CAP-600

t

MAIN PARTS LISTING FOR MODELS

ES-30, ES-50 & ES-100 (Continued)

Qty.

Req.

7B Inlet Valve Unloading Fork 2 70123-31080 3 70123-31080 3 70124-31080

8. Locknut 2 92518-230800 3 92518-230800 3 92518-230800

10. Outlet Valve Seat 2 70123-41011 3 70123-41011 3 70124-41011

11. Outlet Valve Receiver 2 70123-41020 3 70123-41020 3 70124-41020

12. Outlet Valve Spring 2 70123-41070 3 70123-41070 3 70124-41070

13. Outlet Valve Bolt 2 70123-41810 3 70123-41810 3 70124-41810

14. Nut (Outlet Valve) 4 92502-130800 6 92502-130800 6 92502-130800

15. Inlet Valve Push Cover, 1

(Cont’d)

16. O – Ring G 40 2 93602-810040 3 93602-810040 3 93602-810055

17. Viton O – Ring G 40 (Outlet Valve) 2 93602-870040 3 93602-870040 3 93602-870055

18. Unloading Piston, 1

VALVES & UNLOADERS

19. O – Ring P 20 2 93601-810020 3 93601-810020 3 93601-810021

20. Outlet Valve Push Cover, 1 21A. Cylinder Head Assembly 2 70123-11000 3 70123-11000 -

21. Cylinder Head (1

22. Cylinder & Head Gasket, 1

23. Cylinder (1

s

) 2 70123-51012 3 70123-51012 3 70124-51011

s

Stage 2 70123-11150 3 70123-11150 3 70124-11150

s

Stage 2 70123-11220 3 70123-11220 3 70124-11220

s

Stage 2 70123-11450 3 70123-11450 3 70124-11450

) 2 70123-11010 3 70123-11010 3 70124-11010

s

Stage 2 70123-11612 3 70123-11612 3 70124-11612

23A. S/N 3020000 THRU A311XXXX 2 70123-51011 3 70123-51011 3 70124-51011

24. Cylinder & Case Gasket 2 70123-51610 3 70123-51610 3 70124-51610

25. Compression Ring (1

26. Oil Control Ring (1

27. Piston (1

s

) 2 70123-61011 3 70123-61011 3 70124-61011-1

s

) 4 70123-61030 6 70123-61030 6 70124-61030

s

) 4 70123-61050 6 70123-61050 6 70124-61050

27A. S/N 3020000 & later use 2 70123-61011 3 70123-61011 3 70124-61011

28. Piston Pin Snap Ring 4 70123-61070 6 70123-61070 6 70124-61070

29. Piston Pin (1

CYLINDERS

30. Connecting Rod Piston Pin Bushing (1

31. Connecting Rod Assembly, 1

s

) 2 70123-61120 3 70123-61120 3 70124-61120

s

) 2 70123-61081 3 70123-61081 3 70124-61080

Stage 2 70123-61200 3 70123-61200 3 70124-61201

31A. S/N 3020000 & later use 2 70123-61201 3 70123-61201 3 70124-61201

32. Connecting Rod Crank Pin Metal 4 70123-61090 6 70123-61090 6 70124-61090

33. Connecting Rod Bolt 4 70123-61250 6 70123-61250 6 70125-61250 34A. Oil Splash Dipper H.P. - 1 70122-61290 1 70134-62290

34. Oil Splash Dipper 2 70122-61282 2 70122-61282 2 70134-61281

35. Oil Splash Dipper Bolt 2 91507-2304012 3 91507-2304012 3 91507-2305016

42. Crankshaft 1 70123-56010 1 70133-56011 1 70134-56010

43. Counterweight - - 2 70134-56030

44. Lockwasher - - 2 70124-56830

45. Bolt - - 2 70124-56810

46. Crankcase 1 70123-57010-4024 1 70133-57010-4024 1 70134-57010-4024

47. Front Bearing Cover 1 70123-57030 1 70133-57030 1 70134-57031

48. Front Bearing Cover Gasket 1 70123-57950 1 70123-57950 1 70124-57950

49. Rear Bearing Cover 1 70123-57061 1 70133-57060 1 70134-57061 49A. S/N 3020000 & later use 1 70123-57061 1 70133-57061 1 70134-57061

50. Rear Bearing Cover Gasket 1 70123-57960-01 1 70133-57960 1 70134-57960

51. Front Bearing 1 93501-6206 1 93501-6206 1 93502-32210

52. Rear Bearing 1 93501-6206 1 93501-6206 1 93502-32210

53. Front Oil Seal 1 70123-57080 1 70123-57080 1 70134-57080

54. V – Pulley Pin 1 70123-56061 1 70123-56061 1 70134-56060 55A. Compressor Fan 1 (Not Required) 1 (Not Required) 1 70124-76310 55B. Compressor Pulley 1 70123-76010 1 70133-76010 1 70134-76011

56. Compressor Pulley Washer 1 70123-76210 1 70124-76210 1 70124-76210

57. Compressor Pulley Set Bolt 1 91501-1312030 1 91501-1312030 1 91501-1312040

58. O-Ring (oil level glass) 1 93602-81260-3065 1 93602-81260-3065 - -

59. Screw in Oil Level Glass 1 70A109B1-57702 1 70A109B1-57702 - -

60. Crankcase Oil Cap 1 CCC1257 1 CCC1257 1 CCC1257

61. Crankcase Oil Plug 1 90112-100404 1 90112-100404 1 90112-100404

62. Oil Level Glass Gasket 1 701210A1-57730 1 701210A1-57730 1 701210A1-57730

63. Oil Level Glass Assy. 1 701210A1-57700 1 701210A1-57700 1 701210A1-57700

CRANKCASE & CRANK ASSEMBLY

64. Oil Level Glass, Push Cover 1 701210A1-57740 1 701210A1-57740 1 701210A1-57740

65. Screw, Metric Pan Head 4 VH1470 4 VH1470 4 VH1470 66A Air Strainer Assembly 2 70123-66000 3 70123-66000 3 70123-66000

67. Air Strainer Filter 2 70123-66140 3 70123-66140 3 70123-66140

69. Outlet Pipe Joint B 1 70123-87020 1 70133-87020 1 70134-87020

70. Compressor Body Discharge Piping Assy. 1 70123-87100 2 70133-87101 2 70134-87100 70A. S/N 3020000 & Later Use 1 70123-87101 2 70133-87101 2 70134-87101

71. Outlet Pipe Joint A 1 70123-87010 1 70123-87010 1 70124-87010

73. Outlet Pipe Joint C - 1 70133-87030 1 70134-87030

74. Gasket (Manifold) - - -

75. Breather Assembly 1 CCC1375 1 CCC1375 1 CCC1375

MODEL

ES30

15

Qty.

Req.

MODEL

ES50

Qty.

Req.

MODEL

ES100

AIR COOLED SINGLE STAGE

t

MODELS ES-30A, ES-50A, ES-100A

CAP-600

Description

VALVE ASSEMBLIES

Inlet Valve Assembly, 1 Outlet Valve Assembly, 1 Breather Assembly 1 701105A1-57600 1 701105A1-57600 1 701210A1-57601

MAIN PARTS LISTING FOR MODELS

ES-30A, ES-50A, ES-100A

Item

Description

No.

1. Inlet Valve Seat 2 701208A1-31010 3 701208A1-31010 3 701210A1-31010

VALVE &

UNLOADERS

2. Inlet Valve Receiver 2 701208A1-31020 3 701208A1-31020 3 701210A1-31020

3. Inlet & Outlet Valve Plate 2 701208A1-31030 6 701208A1-31030 6 501210A1-31030

4. Inlet Valve Spring 2 701208A1-31070 3 701208A1-31070 3 701210A1-31070

5. Inlet Valve Unloading Fork Guide 2 701208A1-31090 3 701208A1-31090 3 701210A1-31090

6. Unloading Spring 2 701208A1-11230 3 701208A1-11230 3 701210A1-11230 7A. Valve Gasket 4 701208A1-11110 6 701208A1-11110 6 701210A1-11110

Qty.

s

Stage 2 701208A1-31000 3 701208A1-31000 3 701210A1-31000

s

Stage 2 701208A-41000 3 701208A1-41000 3 701210A1-41000

Req.

Qty.

Req.

14A

MODEL

ES30A

MODEL

ES30A

Qty.

Req.

Qty. Req.

MODEL

ES50A

MODEL

ES50A

Qty. Req.

MODEL

ES100A

MODEL

ES100A

MAIN PARTS LISTING FOR MODELS

t

ES-30A, ES-50A & ES-100A (Continued)

Qty.

Req.

7B. Inlet Valve Unloading Fork 2 701208A1-31080 3 701208A1-31080 3 70210A1-31080

8. Locknut 2

10. Outlet Valve Seat 2 701208A1-41011 3 701208A1-41011 3 701210A1-41011

11. Outlet Valve Receiver 2 701208A1-41020 3 701208A1-41020 3 701210A1-41020

12. Outlet Valve Spring 2 701208A1-41070 3 701208A1-41070 3 701210A1-41070

13. Outlet Valve Bolt 2 701208A1-41810 3 701208A1-41810 3 9152613-1110050-5608

14. Nut (Outlet Valve) 4 9250113-150800-532 6

15. Inlet Valve Push Cover, 1

s

Stage 2 701208A1-11150 3 701208A1-11150 3 701210A1-11150

16. O – Ring G 40 (G55 ES100) 2 9360281-310394 3 9360281-310394 3 9360281-310544

17. Viton O – Ring G 40 (Outlet Valve) 2 9360287-310394 3 9630287-310394 3 9360287-310544

18. Unloading Piston, 1

19. O – Ring P 20 (P21 ES100) 2 9360181-240198 3 9360181-240198 3 9360187-240208

VALVES & UNLOADERS (Cont’d)

20. Outlet Valve Push Cover, 1 21A. Cylinder Head Assembly 2 70123-11000 3 70123-11000 -

21. Cylinder Head (1

22. Cylinder & Head Gasket, 1

23. Cylinder (1

s

Stage 2 701208A1-11220 3 701208A1-11220 3 701210A1-11220

s

Stage 2 701208A1-11450 3 701208A1-11450 3 701210A1-11450

s

) 2 701208A2-11010 3 701208A2-11010 3 701210A2-11010

s

Stage 2 701208A1-11020 3 701208A1-11020 3 701210A1-11020

) 2 701208A2-51010 3 701208A2-51010 3 701210A2-51010

23A. S/N 3020000 THRU A311XXXX 2 701208A1-51010 3 701208A2-51010 3 701210A2-51010

24. Cylinder & Case Gasket 2 701208A1-51030 3 701208A1-51030 3 701210A1-51030

25. Compression Ring (1

26. Oil Control Ring (1

27. Piston (1

s

) 2 701208A1-61012 3 701208A1-61012 3 701210A1-61011

s

) 4 701208A1-61030 6 701208A1-61030 6 701210A1-61030

s

) 4 701208A1-61050 6 701208A1-61050 6 701210A1-61050

27A. S/N 3020000 & later use 2 70123-61011 3 70123-61011 3 701210A1-61011

28. Piston Pin Snap Ring 4 701208A1-61070 6 701208A1-61070 6 701210A1-61070

29. Piston Pin (1

CYLINDERS

30. Connecting Rod Piston Pin Bushing (1

31. Connecting Rod Assembly, 1

s

) 2 701208A1-61120 3 701208A1-61120 6 701210A1-61120

s

) 2 70123-61081 3 70123-61081 3 70124-61080

Stage 2 701208A1-61201 3 701208A1-61201 3 701210A1-61201

31A. S/N 3020000 & later use 2 701208A1-61201 3 701208A1-61201 3 701210A1-61201

32. Connecting Rod Crank Pin Metal 4 70123-61090 6 70123-61090 6 70124-61090

33. Connecting Rod Bolt 4 70123-61250 6 70123-61250 6 70125-61250 33A. Oil Splash Dipper H.P. - 1 70130FA1-61290 1 701310A1-61290

34. Oil Splash Dipper 2 70120FA1-61282 2 70120FA1-61282 2 701310A1-61281

35. Oil Splash Dipper Bolt 2

42. Crankshaft 1 701208A1-56011 1 701308A1-56011 1 701310A1-56010

43. Counterweight - - 2 701310A1-56030

44. Lockwasher - - 2 701210A1-56830

45. Bolt - - 2 701210A1-56810

46. Crankcase 1 701208A2-57010 1 701308A2-57010 1 701310A2-57010

47. Front Bearing Cover 1 701208A1-57030 1 701308A1-57030 1 701310A1-57031

48. Front Bearing Cover Gasket 1 701208A1-57040 1 701208A1-57040 1 701210A1-57040

49. Rear Bearing Cover 1 701208A1-57061 1 701308A1-57061 1 701310A1-57061 49A. S/N 3020000 & later use 1 701208A1-57061 1 701308A1-57061 1 701310A1-57061

50. Rear Bearing Cover Gasket 1 701208A1-57070 1 701308A1-57070 1 701310A1-57070

51. Front Bearing 1 9350104-6206 1 9360112-6306 1 9354501-32210

52. Rear Bearing 1 9350104-6206 1 9360112-6306 1 9354501-32210

53. Front Oil Seal 1 701208A1-57080 1 701208A1-57080 1 701310A1-57080

54. V – Pulley Pin 1 701208A1-56061 1 701208A1-56061 1 701310A1-56060 55A. Compressor Fan 1 (Not Required) 1 (Not Required) 1 70121071-76311 55B. Compressor Pulley 1 701208A1-76010 1 701308A1-76010 1 701310A1-76011

56. Compressor Pulley Washer 1 701208A1-76210 1 70124-76210 1 701210A1-76210

57. Compressor Pulley Set Bolt 1

58. O-ring (Oil Level Glass) 1

59. Screw In Oil Level Glass 1

60. Crankcase Oil Cap 1 CCC1257 1 CCC1257 1 CCC1257

61. Crankcase Oil Plug 1 9156310-400800 1 9156310-400800 1 9156310-400800

62. Oil Level Glass Gasket 1 701210A1-57730 1 701210A1-57730 1 701210A1-57730

63. Oil Level Glass Assembly 1 701210A1-57700 1 701210A1-57700 1 701210A1-57700

CRANKCASE & CRANK ASSEMBLY

64. Oil Level Glass, Push Cover 1 701210A1-57740 1 701210A1-57740 1 701210A1-57740

65. Screw, Metric Pan Head 4 VH1470 4 VH1470 4 VH1470 66A Air Strainer Assembly 2 701208A1-66000 3 701208A1-66000 3 701312A1-66000

67. Air Strainer Filter 2 701208A1-66140 3 701208A-66110 3 701208A1-66110

69. Outlet Pipe Joint B 1 70123-87020 1 70133-87020 1 70134-87020

70. Compressor Body Discharge Piping Assy. 1 70123-87100 2 701308A1-87101 2 70134-87100 70A. S/N 3020000 & Later Use 1 701208A1-87101 2 701308A1-87101 2 701310A1-87101

71. Outlet Pipe Joint A 1 701208A1-87011 1 70123-87010 1 70124-87010

73. Outlet Pipe Joint C - 1 70133-87030 1 70134-87030

74. Gasket (Manifold) - - -

75. Breather Assembly 1 CCC1375 1 CCC1375 1 CCC1375

MODEL

ES30A

9251313-150800-532

9151313-1104012-5602

9150113-1112030-5608 93602-81260-3065 70A109B1-577002

Qty.

Req.

9251313-150800-532

3

9250113-150800-532

9151313-1104012-5602

3

9150113-1112030-5608

1

93602-81260-3065

1

70A109B1-577002

1

MODEL

ES50A

Qty.

Req.

MODEL ES100A

3 9251313-151000-532

9250113-121000-532

6

9151313-1105016-5602

3

9150113-1112040-5608

1

-

15A

CAP-600

AIR COOLED, SINGLE STAGE MODEL

t

ES-150

CAP-600

DESCRIPTION

VALVE

ASSEMBLIES

Inlet Valve Assembly, 1 Outlet Valve Assembly, 1 Breather Assembly 1 70124-57600

MAIN PARTS LISTING FOR MODEL ES-150

VALVE &

UNLOADERS

DESCRIPTION

1. Inlet Valve Seat 3 70125-31010

2. Inlet Valve Receiver 3 70125-31021

3. Inlet & Outlet Valve Plate 6 70125-31030

4. Inlet Valve Spring 3 70125-31070

5. Inlet Valve Unloading Fork Guide 3 70125-31090

6. Unloading Spring 3 70125-11230

7A. Valve Gasket 6 70125-11110

Qty.

s

Stage 3 70125-31000

s

Stage 3 70125-41000

Req.

Qty.

Req.

16

MODEL

ES150

MODEL

ES150

MAIN PARTS LISTING FOR MODEL CAP-600

t

ES-150 (Continued)

VALVES & UNLOADERS

CYLINDERS

DESCRIPTION Qty. Req. MODEL ES150

7B Inlet Valve Unloading Fork 3 70125-31080

8. Locknut 3 92517-231200

10. Outlet Valve Seat 3 70125-41011

11. Outlet Valve Receiver 3 70125-41025

12. Outlet Valve Spring 3 70125-41074

13. Outlet Valve Bolt 3 70124-41810

14. Nut (Outlet Valve) 6 92502-131000

(Cont’d)

15. Inlet Valve Push Cover, 1

s

Stage 3 70125-11151

16. O – Ring G 65 3 93602-810065

17. Viton O – Ring G 65 (Outlet Valve) 3 93602-870065

18. Unloading Piston, 1

19. O – Ring P 22A 3 93601-870022A

20. Outlet Valve Push Cover, 1 21A. Cylinder Head Assembly 70135-11000A

21. Cylinder Head (1 21B. S/N A311XXXX AND LATER 3 70135-11011

22. Cylinder & Head Gasket, 1 22A. S/N A311XXXX AND LATER 3 70135-11612

23. Cylinder (1

s

Stage 3 70125-11220

s

Stage 3 70125-11451

s

) 3 70125-11010

s

Stage 3 70125-11612

s

) 3 70135-51011 23A. S/N 3020000 THRU A311XXXX 3 70135-51010 23B. S/N A311XXXX AND LATER 3 70135-51011

24. Cylinder & Case Gasket 3 70135-51610

25. Compression Ring (1

26. Oil Control Ring (1

27. Piston (1

s

) 3 70125-61010

s

) 6 70125-61030

s

) 6 70125-61050

27A. S/N 3020000 & later use 3 70135-61010-1

28. Piston Pin Snap Ring 6 70125-61070

29. Piston Pin (1

30. Connecting Rod Piston Pin Bushing (1

31. Connecting Rod Assembly, 1

s

) 3 70125-61120

s

) 3 70125-61081

Stage 3 70125-61200

31A. S/N 3020000 & later use 3 70125-61200

32. Connecting Rod Crank Pin Metal 6 70125-61090

33. Connecting Rod Bolt 6 70125-61250 34A. Oil Splash Dipper H.P. -

34. Oil Splash Dipper 3 70135-61281

35. Oil Splash Dipper Bolt 3 92501-130800

42. Crankshaft 1 70135-56011

43. Counterweight 2 70135-56031

44. Lockwasher 2 70135-56830

45. Bolt 2 70135-56811

46. Crankcase 1 70135-57010-4024

47. Front Bearing Cover 1 70135-57030

48. Front Bearing Cover Gasket 1 70135-57950

49. Rear Bearing Cover 1 70134-57061 49A. S/N 3020000 & later use 1 70134-57061

50. Rear Bearing Cover Gasket 1 70134-57960

51. Front Bearing 1 93502-30310

52. Rear Bearing 1 93502-32210

53. Front Oil Seal 1 70134-57080

54. V – Pulley Pin 1 70134-56060 55A. Compressor Fan 1 70135-76310 55B. Compressor Pulley 1 70135-76011

56. Compressor Pulley Washer 1 70124-76210

57. Compressor Pulley Set Bolt 1 91501-1312050

60. Crankcase Oil Cap 1 CCC1257

61. Crankcase Oil Plug 1 90112-100404 62 Oil Level Glass Gasket 1 701210A1-57730

63. Oil Level Glass Assembly 1 701210A1-57700

64. Oil Level Glass, Push Cover 1 701210A1-57740

65. Screw, Metric Pan Head 4 VH1470 66A. Air Strainer Assembly 3 70123-66001

67. Air Strainer Filter 3 70123-66140

69. Outlet Pipe Joint B 1 70135-87021

70. Compressor Body Discharge Piping Assy. 2 70135-87100 (Long) 70A. S/N 3020000 & Later Use 2 70135-87200 (Short)

71. Outlet Pipe Joint A 1 70135-87011

73. Outlet Pipe Joint C 1 70135-87031

74. Gasket (Manifold) 3 70125-87510 Discharge Piping Assembly 1 70135-87700 Discharge Piping Assembly 1 70135-87800 Discharge Piping Assembly 1 70135-87900

75. Breather Assembly 1 CCC1258

17

AIR COOLED SINGLE STAGE MODEL ES-150A

CAP-600

18

MAIN PARTS LISTING FOR

MODEL ES150A

ITEM

NO.

1 2 92521-191000 COPPER WASHER 22 3 70134-57061

4 4a 4b

5 70134-57590

6 70134-57960

7

8

9 70124-57740 OIL GLASS & COVER 1 9a 70124-57700 OIL COVER 1 10 70124-57750 OIL COVER GLASS 1 11 70124-57730 GAUGE COVER SEAL 1 12 13 14 93502-30310 BEARING #30310 1 15 70135-56011 CRANKSHAFT 1 16 701312A1-56032 17 70135-56830 CT R WGT LK WASHER 2 18 70135-56811 CT R WGT MGT BOLT 2 19 70134-56060 V-PULLEY KEY 1 20 93502-32210 BEARING #32210 1 21 70135-57950 22 70134-57080 FRONT OIL SEAL 1 23 70135-57030 24 70135-76011 25 70135-76310 COMP PULLEY FAN 1 26 27 28 70124-76210 29 30 31 70135-51610 CYL & CASE PACKING 3 32 70135-51810 CYL & CASE BOLT 12 33 70135-61281 OIL SPLASH DIPPER 3 34 35 70125-61090 36 70125-61200 CONN.ROD ASS’Y 3 37 70125-61250 38 50135-61081 39 70125-61070 40 70125-61120 PISTON PIN 3 41 70135-61010-1 PISTON 3 42 70135-61050 OIL CONT ROL RING 6 43 70135-61030 COMPRESSION RING 6 44 70135-51011 CYLINDER 3 45 46 70135-11610 CYL & HEAD PACKING 3 47 48 70135-11011 CYLINDER HEAD 3 49 70125-11110 50 70125-31023

PART

NO.

91501-1310025

70131B81-57670 70131BA1-57670 CCC1697

70123-57190-4010

91507-2305016

90112-100404

70135-57010-4024

92522-130800 91501-2308030

92522-131200 91501-1312050

92501-130800

92501-131200

91501-1312035

DESCRIPTION QTY BOLT, M10 X 25 10

REAR BEARING COVER

TUBE & BRTHR. ASSY. 1 TUBE, BREATHER 1 BREATHER, ASSY. 1

REAR COVER OIL BAFFLE REAR BRG CVR PACKING

CRANKCASE OIL CAP 1 GAUGE SET BOLT 4

CRANKCASE OIL PLUG 1 CRANKCASE 1

CRANKSHAFT CTR. WGT.

FRONT BEARING GASKET

FRONT BEARING COVER COMPRESSOR PULLEY

WASHER 6 BOLT 6

PULLEY THRUST WASHER

SPRING WASHER 31 BOLT 1

NUT 3

CONN.ROD CRANK PIN METL

CONN.ROD ASS’Y BOLT

CONN.ROD CRANK PIN METL

PISTON PIN SNAP RING

NUT 12 BOLT 18

I/O VALVE SEAT GASKET

INLET VALVE RECEIVER

CAP-600

ITEM

NO.

51 70125-31070 INLET VALVE SPRING 3 52 70125-31030 PLAT E, INLET VALVE 3

1

53 70125-31010 INT E R VALVE SEAT 3 54 70125-31090 55 70125-11230 UNLOADING SPRING 3

56 70125-31080 I.VALVE UNLOAD FORK 3 1 1

57

58

59 70125-11220 UNLOADING PISTON 3

60 93602-810065 O-RING G#65 3

61 70125-11151 I. VALVE PUSH COVER 3

62

63 90112-100101 SCREW PLUG 3

64 70124-41810 BOLT 3

65 70125-41012 OUT LET VALVE SEAT 3

66

67 70125-41025

68 92501-231000 NUT 6 2

69 93602-870065 VITON O-RING G#65 3

70 70125-11451

71

72 70135-87101 1

73

74 70135-87201 1

1

75

76 70125-41030 PLAT E, OUTLET VALVE 3

77 70125-41001 OUT LET, VALVE ASSY. 3

78 70125-31000 INLET , VALVE ASSY. 3

79 70123-66001 AIR ST RAINER ASSY. 3 1

80 70123-66140 AIR ST RAINER FILTER 3

6 6

3 6

6 3

PART

NO.

92517-231200 93601-810022A

91501-1310025

701212A-41075 OUTLET VALVE SPRING

701312A1-87032

701312A1-87022

701312A2-87011

DESCRIPTION QTY

I. VALVE UNLOAD FORK GUIDE

SLOTTED NUT 3 O-RING P#22A 3

BOLT 24

OUTLET VALVE RECEIVR

O. VALVE PUSH COVER

DIST. MANIFOLD #C 1

COMP.BODY DIS. PIPING ASSEMBLY

DIST. MANIFOLD #B 1

COMP.BODY DIS. PIPING ASSEMBLY

DIST. MANIFOLD #A 1

3

9 3

3

1

19

AIR COOLED SINGLE STAGE MODEL ES-150B

CAP-600

18A

ITEM

NO.

91501-1310025

1

9252615-101000-0

2

701310A1-57061 REAR BEARING COVER

3

70131B81-57670

4

70131BA1-57670

4a

CCC1697

4b

701310A1-57590 REAR COVER OIL BAFFLE

5

701310A1-57070 REAR BRG CVR GASKET

6

70123-57190-4010

7

VH1470

8

701210A1-57740

9

701210A1-57700

9a

70124-57750

10

701210A1-57730

11

9156310-400800

12

701312A3-57010

13

9354504-30310

14

701312A1-56011

15

701312A1-56032 CRANKSHAFT CTR. WGT.

16

701312A1-56830

17

701312A1-56811

18

701310A1-56060

19

9354501-32210

20

70135-57950 FRONT BEARING GASKET

21

701310A1-57080

22

701312A1-57030 FRONT BEARING COVER

23

701312A1-76011 COMPRESSOR PULLEY

24

70131283-76310

25

9253113-100800-8

26

9150113-1108030-5202

27

701210A1-76210

28

9253113-101200-8

29

9150113-1112050-5608

30

701312A1-51030

31

701312A1-51810

32

701312A1-61281

33

9250113-120800-538

34

701212A1-61090

35

701212A1-61200

36

70125-61250 CONN.ROD ASS’Y BOLT

37

501312A1-61081

38

701212A1-61070 PISTON PIN SNAP RING

39

701212A1-61120

40

701312A1-61010

41

701212A1-61050

42

701212A1-61030

43

701312A3-51010

44

92501-131200

45

701312A3-11020

46

9250113-121200-538

47

701312A3-11010

48

701212A1-11110

49

PART

NO.

DESCRIPTION QTY

BOLT, M10 X 25 10 COPPER WASHER 10

TUBE & BRTHR. ASSY. 1 TUBE, BREATHER 1 BREATHER, ASSY. 1

CRANKCASE OIL CAP 1 GAUGE SET BOLT 4 OIL GLASS & COVER 1 OIL COVER ASSY 1 OIL COVER GLASS 1 GAUGE COVER SEAL 1 CRANKCASE OIL PLUG 1 CRANKCASE 1 BEARING #30310 1 CRANKSHAFT 1

CTR WGT LK WASHER 2 CTR WGT MGT BOLT 2 V-PULLEY KEY 1 BEARING #32210 1

FRONT OIL SEAL 1

COMP PULLEY FAN 1 WASHER 6 BOLT 6

PULLEY THRUST WASHER

SPRING WASHER 1 BOLT 1 CYL & CASE PACKING 3 CYL & CASE BOLT 12 OIL SPLASH DIPPER 3 NUT 3

CONN.ROD CRANK PIN METL

CONN.ROD ASS’Y 3

CONN.ROD CRANK PIN METL

PISTON PIN 3 PISTON 3 OIL CONTROL RING 6 COMPRESSION RING 6 CYLINDER 3 NUT 12 CYL & HEAD GASKET 3 BOLT 12 CYLINDER HEAD 3

I/O VALVE SEAT GASKET

MAIN PARTS LISTING FOR

MODEL ES150B

ITEM

NO.

701212A1-31023 INLET VALVE RECEIVER 3

50

701212A1-31070

51

1

1 1

2

1 1

1

501212A1-31030

52

701212A1-31010

53

701212A1-31090

54

701212A1-11230

55

701212A1-31080

56

9250413-151200-532

57

9360187-350217

58

701212A1-11220

59

9360287-310644

60

701212A1-11151

61

91501-1310025

62

90112-100101

63

70124-41810

64

701212A1-41012

65

701212A1-41075 OUTLET VALVE SPRING

66

701212A1-41025 OUTLET VALVE RECEIVR

67

92501-231000

68

9360287-310644

69

701212A1-11451 O. VALVE PUSH COVER

70

701312A1-87032

71

70135-87101

72

701312A1-87022

73

701312A2-87100

74

701312A2-87011

75

70125-41030

76

701212A1-41001

77

701212A1-31000

78

701312A1-66000

79

701208A1-66110

80

6 6

3 6

6

PART

NO.

CAP-600

DESCRIPTION QTY

INLET VALVE SPRING 3 PLATE, INLET VALVE 3 INTER VALVE SEAT 3

I. VALVE UNLOAD FORK GUIDE

3 UNLOADING SPRING 3 I.VALVE UNLOAD FORK 3 SLOTTED NUT 3 O-RING P#22A 3 UNLOADING PISTON 3 O-RING G#65 3 I. VALVE PUSH COVER 3 BOLT 3 SCREW PLUG 24 BOLT 3 OUTLET VALVE SEAT 3

3

9 NUT 3 VITON O-RING G#65 6

3 DIST. MANIFOLD #C 3

COMP.BODY DIS. PIPING ASSEMBLY

1 DIST. MANIFOLD #B 1

COMP.BODY DIS. PIPING ASSEMBLY

1 DIST. MANIFOLD #A 1

PLATE, OUTLET VALVE 1 OUTLET, VALVE ASSY. 3 INLET, VALVE ASSY. 3 AIR STRAINER ASSY. 3 AIR STRAINER FILTER 3

19A

AIR COOLED TWO STAGE MODELS E-11 & E-23

CAP-600

20

MAIN PARTS LISTING FOR

t

d

t

d

TWO STAGE MODELS E-11 & E-23

VALVES

1. Inlet & Outlet Valve Plate (1

2. Inlet Valve Spring (1

3. Inlet Valve Receiver (1

4. Inlet Valve Snap Ring (1

5. Outlet Valve Spring (1

6. Outlet Valve Push Cover Gasket (1

7. Outlet Valve Push Cover 1 70112-11450 2 70112-11450

8. Inlet & Outlet Valve Plate (2

9. Inlet Valve Spring (2

10. Inlet Valve Receiver (2

11. Inlet Valve Snap Ring (2

12. Outlet Valve Spring (2

14. Outlet Valve Push Cover Gasket (2

15. Outlet Valve Push Cover (2

CYLINDERS

16. Cylinder Head (1

17. Cylinder & Head Gasket (1

18. Cylinder (1

19. Cylinder & Case Gasket 2 70112-51610 3 70112-51610

20. Compression Ring (1

21. Oil Control Ring (1

22. Piston (1

23. Piston Pin (1

24. Piston Pin Snap Ring 4 70112-61070 6 70112-61070

25. Connecting Rod Assembly (1

26. Connecting Rod Bolt 2 70112-61250 3 70112-61250

27. Oil Splash Dipper 70122-61282 2 70122-61282 27A. Oil Splash Dipper - 1 70132-61290

28. Oil Splash Dipper Bolt 2 91507-2304010 3 91507-2304010

29. Cylinder Head Bolt 8 91501-1308025 12 91501-1308025

30. Cylinder Head (2

31. Cylinder & Head Gasket (2

32. Cylinder (2

34. Compression Ring (2

35. Oil Control Ring (2

36. Piston (2

37. Piston Pin (2

38. Connecting Rod Assembly (2

39. Crankcase 1 70122-57010-4024 1 70132-57010-4024

40. Crankshaft 1 70122-56010 1 70132-56010

41. Front Bearing Cover 1 70122-57030 1 70122-57030

42. Front Bearing Cover Gasket 1 70122-57950 1 70122-57950

43. Rear Bearing Cover 1 70122-57060 1 70122-57060

44. Rear Bearing Cover Gasket 1 70122-57960 1 70122-57960

45. Bearing 2 93501-6205 2 93501-6205

46. Front Oil Seal 1 70122-57080 1 70122-57080

47. V–Pulley Pin 1 70112-56060 1 70112-56060

48. Compressor Pulley 1 70122-76011 1 70132-76010

49. Compressor Pulley Thrust Washer 1 70112-76210 1 70112-76210

50. Compressor Pulley Thrust Bolt 1 91501-1308025 1 91501-1308025

51. Breather Assembly 1 CCC1375 1 CCC1375

52. Oil Gauge & Gauge Cover 1 70111-57700 1 70111-57700

٭52 A. Oil Level Gauge Assy. 1 70A109B1-57701 1 70704-57700

53. Gauge Cover Seal 1 70111-57730 1 70111-57730

٭53 A. Oil Level Gauge “O” Ring 1 93602-8126026 1 93602-8126026

54. Crankcase Oil Plug 1 90112-100202 1 90112-100202 54A. Oil fill cap - 1 70101-57190-4010 54B. “O” Ring - 1 93601-810016

55. Auto-Unloader Assembly 2 70112-11201 3 70112-11201

56. Auto-Unloader Spring 2 70112-11230 3 70112-11230

57. Auto-Unloader Piston 2 70112-11221 3 70112-11221

58. O-Ring (Unloader) 2 93601-810016 3 93601-810016 AIR STRAINER ASSEMBLY

61. Air Strainer Filter (not shown) 1 70111-66141 2 70111-66141 63A. Discharge Piping Assembly - 1 70132-87100 63B. Discharge Piping Assembly 1 70172-87300 1 70172-87300

64. Air Strainer Assembly 1 70111-66001 2 70111-66001

65. Outlet Pipe Joint #A 2 70122-87010 3 70122-87010 65A. Outlet Pipe Joint #B 1 70132-87020

• E11, START S/N AS4040633

• E23, START S/N AS4030313

s

) 1 70112-51010 2 70112-51010

s

) 1 70112-61011 2 70112-61011

s

) 1 70112-61120 2 70112-61120

n

) 1 70162-52010 1 70172-52010

n

) 1 70162-62010 1 70172-62010-1

n

) 1 70162-62120 1 70172-62120

CRANK ASSEMBLY

UNLOADERS

s

) 2 70112-31030 4 70112-31030

s

) 1 70112-31070 2 70112-31070

s

) 1 70112-31020 2 70112-31020

s

) 1 93610-130232 2 93610-130232

s

) 1 70112-41070 2 70112-41070

n

) 1 70162-32070 2 70172-32070

n

) 1 70162-32020 1 70111-31020

n

) 1 70162-42070 1 70172-42070

) 1 70112-11010 2 70112-11010

s

) 2 70112-61030 4 70112-61030

s

) 1 70112-61050 2 70112-61050

) 1 70162-12010 1 70172-12010

n

) 2 70162-62030 2 70111-61030

n

) 2 70162-62050 2 70111-61050

s

) 1 70112-11461 2 70112-11461

n

) 2 70162-32030 2 70111-31030

) 1 93610-130222 1 93610-130225

n

) 1 70162-12650 1 70111-11461

n

) 1 70112-12450 1 70111-11450

s

) 1 70112-11612 2 70112-11612

s

) 2 70112-61200-1 2 70112-61200-1

n

) 1 70162-12610 1 70111-11612

n

) - 1 70182-62200

Qty.

Req.

MODEL E11

Qty.

Req.

CAP-600

MODEL E23

21

AIR COOLED, TWO STAGE CAP600

t

d

t

d

MODELS E-50 & E-71

DESCRIPTIONS Qty. Req. Inlet Valve Assembly, 1

Inlet Valve Assembly, 2 Outlet Valve Assembly, 1

VALVE

Outlet Valve Assembly, 2

ASSEMBLIES

Breather Assembly 1 70103-57600-4024 1 70124-57600-4010

DESCRIPTIONS

1. Inlet Valve Seat 2 70123-31010 1 70123-31010 2 70124-31010 1 70123-31010

2. Inlet Valve Receiver 2 70123-31020 1 70123-31020 2 70124-31020 1 70123-31020

3. Inlet & Outlet Valve Plate 4 70123-31030 2 70123-31030 4 70124-31030 2 70123-31030

4. Inlet Valve Spring 2 70123-31070 1 70123-31070 2 70124-31070 1 70123-31070

5. Inlet Valve Unloading Fork Guide 2 70123-31090 1 70123-31090 2 70124-31090 1 70123-31090

6. Unloading Spring 2 70123-11230 1 70123-11230 2 70124-11230 1 70123-11230

7. Inlet Valve Unloading Fork 2 70123-31080 1 70123-31080 2 70124-31080 1 70123-31080

8. Slotted Nut 2 92502-230800 1 92502-230800 2 92502-230800 1 92502-230800

9. Cotter Pin (not shown) 2 93701-130220 1 93701-130220 2 93701-130220 1 93701-130220

10. Outlet Valve Seat 2 70123-41011 1 70123-41011 2 70124-41011 1 70123-41011

VAVLES & UNLOADERS

11. Outlet Valve Receiver 2 70123-41020 1 70123-41020 2 70124-41020 1 70123-41020 12A. Seat Gaskets 4 70123-11110 2 70123-11110 4 70124-11110 2 70123-11110

MODEL

s

Stage 2 70123-31000 2 70124-31000

n

Stage 1 70173-32000 1 70173-32000

s

Stage 2 70123-41000 2 70124-41000

n

Stage 1 70123-41000 1 70123-41000

E50

Qty. Req.

MODEL

E71

MAIN PARTS LISTING FOR

TWO STAGE MODELS E-50 & E-71

MODEL E50 MODEL E71

Qty

Req’d

st

1

Stage

22

Qty

Req’d

2nd Stage

Qty

Req’d

1st Stage

Qty

Req’d

2nd Stage

CAP-600

MAIN PARTS LISTING FOR

TWO STAGE MODELS E-50 & E-71 (CONTINUED)

MODEL E-50 MODEL E-71

12B Outlet Valve Spring 2 70123-41070 1 70123-41070 2 70124-41070 1 70123-41070

13 Outlet Valve Bolt 2 70123-41810 1 70123-41810 2 70124-41810 1 70123-41810 14 Nut (Outlet Valve) 2 92502-230800 1 92502-230800 2 92502-230800 1 92502-230800 15 Inlet Valve Push Cover 2 70123-11150 1 70123-11150 2 70124-11150 1 70123-11150 16 O-ring G-40(Inlet Valve) 2 93602-810040 1 93602-810040 2 93602-810055 1 93602-810055 17 Viton O-ring G-40 (Outlet Valve) 2 93602-870040 1 93602-870040 2 93602-870055 1 93602-870040 18 Unloading Piston 2 70123-11220 1 70123-11220 2 70124-11220 1 70123-11220 19 O-ring P-20 2 93601-810020 1 93601-870020 2 93601-810021 1 93601-870020 20 Outlet Valve Push Cover 2 70123-11450 1 70123-11450 2 70124-11450 1 70123-11450

Valves & Unloaders

20A Iinterstage Safety Valve (E71 only) - N/A - N/A 1 93132-15006-40101 - N/A

21 Cylinder Head (1st) 2 70123-11010 2 70124-11010

22 Cylinder & Head Gasket 2 70123-11612 1 70123-11612 2 70124-11612 1 70123-11612 23 Cylinder (1st) 2 70123-51012 2 70124-51011

23A S/N A311xxxx & Later Use 2 70123-51012 2 70124-51011

24 Cylinder & Case Gasket 2 70123-51610 1 70123-51610 2 70124-51610 1 70124-51610 25 Compression Ring (1st) 4 70123-61030 4 70124-61030 26 Oil Control Ring (1st) 4 70123-61050 4 70124-61050 27 Piston (1st) 2 70123-61011 2 70124-61011-1

27A S/N 3020000 & Later Use 2 70123-61011 2 70124-61011-1

28 Piston Snap Ring 4 70123-61070 2 70123-61070 4 70124-61070 2 70124-61070 29 Piston Pin (1st) 2 70123-61120 2 70124-61120

30 Con’cting Rod Pist. Pin Bushing 2 70123-61081 1 70173-62080 2 70124-61080 1 70174-62081 30A Bushing S/N 3020000 & Later use 2 70123-61081 30B Nedl Brg.S/N A303XXXX&LatrUse 1 93503-RNA6903R

30C Nedl Brg.(2nd)S/N A405XXXX&Latr 1 93503-TA1725

31 Connecting Rod Assy 2 70123-61200 1 70173-62200 2 70124-61201 1 70174-62202

Cylinders

31B

32 Connecting Rod Crank Pin Metal 4 70123-61090 2 70123-61090 4 70124-61090 2 70124-61090

33 Connecting Rod Bolt 4 70125-61250 2 70125-61250 4 70125-61250 2 70125-61250

34 Oil Splash Dipper 2 70122-61282 1 70132-61290 2 70134-61281 1 70134-61290

35 Oil Splash Dipper Bolt 2 91507-2304012 1 91507-2304012 2 91507-2304012 1 91507-2304012

36 Cylinder Head (2nd) 1 70123-11010 1 70174-12010

37 Cylinder (2nd) 1 70173-52010 1 70174-52011

37A Cyl (2nd),S/N 3020000 & Later Use 1 70174-52011

38 Compression Ring (2nd) 3 70112-61030 3 70123-61030

39 Oil Control Ring (2nd) 1 70112-61050 2 70123-61050

40 Piston (2nd) 1 70173-62010-1 1 70174-62010-1

41 Piston Pin (2nd) 1 70173-62120 1 70174-62120

42 Crankshaft 1 70133-56011 1 70134-56010

43 Crankshaft, Counterweight - 1 70134-56030

44 Counterweight Lock Washer - 2 70124-56830

45 Counterweight Mtg. Bolt - 2 70124-56810

46 Crankcase 1 70133-57010-4024 1 70134-57010-4024

47 Front Bearing Cover 1 70133-57030 1 70134-57030

48 Front Bearing Cover Gasket 1 70123- 5795 0 1 70124-57950

49 Rear Bearing Cover 1 70133-57061 1 70134-57061

49A Rear Brg Cvr, S/N 3020000 & Later 1 70133-57061 1 70134-57061

50 Rear Brg Cvr Gasket 1 70133-57960 1 70134-57960

51 Front Bearing 1 93501-6306 1 93502-32210

52 Rear Bearing 1 93501-6306 1 93502-32210

53 Front Oil Seal 1 70123-57080 1 70134-57080

54 V-Pulley Pin 1 70123-56061 1 70134-56060

55A Compressor Fan - 1 70124-76310 55B Compressor Pulley 1 70133-76010 1 70134-76011

56 Compressor Pulley Washer 1 92521-232000 1 70124-76210

57 Compressor Pulley Set Bolt 1 91501-1312030 1 91501-1312040

58 O-Ring (Oil Level Glass) 1 93602-81260-3065 - - - -

59 Screw In Oil Level Glass 1 70A109B1-57702 - - - -

60 Crankcase Oil Cap 1 CCC1257 1 CCC1257

61 Crankcase Oil Plug 1 90112-100404 1 90112-100404

62 Breather Assembly 1 CCC1375 1 CCC1258

66A Air Strainer Assembly 2 70123-66000 2 70123-66000

Crankcase & Crank Assembly

67 Air Strainer Filter 2 70123-66140 2 70123-66140

69 Outlet Pipe Joint B 1 70123-87020 1 70174-87020

70A Comp.body.discharg.pipe.assy. 1st 1 70133-87101 short 1 70134-87101 short 70B Comp.body.discharg.pipe.assy. 1st - - 70C Comp.body.discharg.pipe.assy.2nd - - 70D Comp.body.discharg.pipe.assy.2nd 1 70173-87300 long 1 70174-87300 long

71 Outlet Pipe Joint A 2 70123-87010 3 70124-87010

72 Outlet Pipe Joint D 1 70173-87010

73 Outlet Pipe Joint C

74 Gasket Manifold - -

75 Oil Level Glass Gasket 1 701210A1-57730 1 701210A1-57730

76 Oil Level Glass Assembly 1 701210A1-57700 1 701210A1-57700

77 Oil Level Glass Push Cover 1 701210A1-57740 1 701210A1-57740

78 Screw, Metric Pan Head 4 VH1470 4 VH1470

DESCRIPTION

nd

Conn. Rod Assy., 2 A405XXXX & Later Use

Stage S/N

QTY

1 70173-62200

1st Stage

QTY

23

2nd Stage

QTY

1st Stage

QTY

2nd Stage

AIR COOLED, TWO STAGE

t

d

t

d

MODEL E-15

CAP-600

VALVE ASSEMBLIES

VAVLES & UNLOADERS

MAIN PARTS LISTING FOR TWO STAGE MODEL E-15

Description

1. Inlet Valve Seat 2 70125-31010 1 70124-31010

2. Inlet Valve Receiver 2 70125-31022 1 70124-31020

3. Inlet & Outlet Valve Plate 4 70125-31030 2 70175-42030

4. Inlet Valve Spring 2 70125-31070 1 70124-31070

5. Inlet Valve Unloading Fork Guide 2 70125-31090 1 70124-31090

6. Unloading Spring 2 70125-11230 1 70124-11230

7. Inlet Valve Unloading Fork 2 70125-31080 1 70124-31080

8. Slotted Nut 2 92502-230800 1 92502-230800

9. Cotter Pin (not shown) 2 93701-130220 1 93701-130220

10. Outlet Valve Seat 2 70125-41011 1 70124-41010

11. Outlet Valve Receiver 2 70125-41021 1 70175-42020 12A. Seat Gaskets 4 70125-11110 2 70124-11110

Description

Inlet Valve Assembly, 1 Inlet Valve Assembly, 2 Outlet Valve Assembly, 1 Outlet Valve Assembly, 2

Qty.

s

Stage 2 70125-31000

n

Stage 1 70175-32000

s

Stage 2 70125-41000

n

Stage 1 70175-42000

Req.

MODEL

E15

Breather Assembly 1 70124-57600-4010

MODEL E15

Qty

Req’d

st

1

Stage

Qty

Req’d

nd

2

Stage

24

CAP-600

t

d

t

d

t

d

MAIN PARTS LISTING FOR

TWO STAGE MODEL E-15 (Continued)

DESCRIPTION

Qty

Req’d

st

1

Stage

12B. Outlet Valve Spring 2 70125-41071 1 70124-41072

13. Outlet Valve Bolt 2 70124-41810 1 70124-41810

14. Nut (Outlet Valve) 2 92501-231000 1 92501-231000

15. Inlet Valve Push Cover 2 70125-11151 1 70175-12150

16. O-Ring G-65 (Inlet Valve) 2 93602-810065 1 93602-870055

17. Viton O-Ring G-65 (Outlet Valve) 2 93602-870065 1 93602-870055

18. Unloading Piston 2 70125-11220 1 70124-11220

VALVES &

UNLOADERS

19. O-Ring P-20 2 93601-810022A 1 93601-870021

20. Outlet Valve Push Cover 2 70125-11451 1 70175-12450 20A. Outlet Valve Push Cover Push Pipe 1 70124-11120

21. Cylinder Head (1

s

) 2 70125-11010

21A. S/N A31XXXX & Later Use 2 70135-11010

22. Cylinder & Head Gasket 2 70125-11612 1 70124-11612 22A. S/N A311XXXX & Later Use 2 70135-11612

23. Cylinder (1

s

) 2 70125-51010

23A. S/N A311xxxx & Later Use 2 70135-51011

24. Cylinder & Case Gasket 2 70135-51610

25. Compression Ring (1

26. Oil Control Ring (1

27. Piston (1

s

) 2 70135-61010-1

s

) 4 70125-61030

s

) 4 70125-61050

27A. S/N 3020000 & Later Use 2 70135-61010-1

28. Piston Snap Ring 4 70125-61070 2 70125-61070

29. Piston Pin (1

30. Connecting Rod Piston Pin Bushing (1 30D. Needle Bearing (2

31. Connecting Rod Assembly, 1 31C. Connecting Rod Assembly, 2

CYLINDERS

32. Connecting Rod Crank Pin Metal 4 70125-61090 2 70125-61090

s

) 2 70125-61120

n

) S/N A409XXXX & Later Use 1 93503-NK28/30

s

) 2 70125-61081 1 70175-62080

s

Stage 2 70125-61200 1 70175-61200

n

Stage 1 70175-62201

33. Connecting Rod Bolt 4 70125-61250 2 70125-61250

34. Oil Splash Dipper 2 70135-61281 1 70135-61281

35. Oil Splash Dipper Bolt 2 92501-130800 1 92501-130800

36. Cylinder Head (2

37. Cylinder (2

38. Compression Ring (2

39. Oil Control Ring (2

40. Piston (2 40A. Piston (2

41. Piston Pin (2 41A. Piston Pin (2

n

) 1 70175-12010

n

) 1 70175-52010

n

) 3 70124-61030

n n n

) 2 70124-61050 ) 1 70175-62010-1 ), S/N A409XXXX & Later Use 1 70175-62011-1

n

) 1 70175-62120

n

), S/N A409XXXX & Later Use 1 70175-62121

42. Crankshaft 1 70135-56011

43. Crankshaft Counterweight 1 70135-56030

44. Counterweight Lock Washer 2 70124-56830

45. Counterweight Mounting Bolt 2 70135-56811

46. Crankcase 1 70135-57010-4024

47. Front Bearing Cover 1 70135-57030

48. Front Bearing Cover Gasket 1 70135-57950

49. Rear Bearing Cover 1 70134-57061 49A. Rear Bearing Cover, S/N 3020000 & Later Use 1 70134-57061

50. Rear Bearing Cover Gasket 1 70134-57960

51. Front Bearing 1 93502-30310

52. Rear Bearing 1 93502-32210

53. Front Oil Seal 1 70134-57080

54. V-Pulley Pin 1 70134-56060 55A. Compressor Fan 1 70135-76310 55B. Compressor Pulley 1 70135-76011

56. Compressor Pulley Washer 1 70135-76210

57. Compressor Pulley Set Bolt 1 91501-1312050

60. Crankcase Oil Cap 1 CCC1257

61. Crankcase Oil Plug 1 90112-100404

62. Breather Assembly 1 70124-57600-4010 66A Air Strainer Assembly 2 70123-66000

67. Air Strainer Filter 2 70123-66140

69. Outlet Pipe Joint B 1 70175-87021 70A. Compressor Body Discharge Piping Assembly, 1

CRANKCASE AND CRANK ASSEMBLY

70B. Compressor Body Discharge Piping Assembly, 1 70C. Compressor Body Discharge Piping Assembly, 2 70D. Compressor Body Discharge Piping Assembly, 2

s

1 70135-87100(long)

s

1

n

1

n

1 70175-87300(long)

70135-87200(short) 70175-87400(short)

71. Outlet Pipe Joint A 1 70175-87010

72. Outlet Pipe Joint D (not shown) 1 70125-87020

73. Outlet Pipe Joint C 1 70175-87030-4010

74. Gasket Manifold 4 70125-87510 75 Oil Level Glass Gasket 1 701210a1-57730 76 Oil Level Glass Assembly 1 701210a1-57700 77 Oil Level Glass Push Cover 1 701210a1-57740 78 Screw, Metric Pan Head 4 VH1470

MODEL E15

Qty

Req’d

2nd Stage

25



CAP 600

AIR COOLED, TWO STAGE

MODEL E

-

25

25A

CAP-600

MAIN PARTS LISTING FOR

TWO STAGE MODEL E-25

Item

No.

Description

Qty

Req.

1 CRANKCASE 1 2 OIL SIGHT GLASS GASKET 1 3 OIL SIGHT GLASS ASSY. 1 4 OIL SIGHT GLASS PUSH COVER 1 5 OIL SIGHT GLASS BOLT; M5 x L20, Gr.8.8 4 6 BOLT M12*1.25*L10 1 7 OIL NOZZLE 2 8 PIPE 1

9 PIPE CAP 1 10 CRANK SHAFT 1 11 FRONT & REAR BEARING 2 12 REAR BEARING COVER GASKET 1 13 REAR BEARING COVER 1 14 REAR OIL SEAL 1 15 CENTRIFUGAL FAN LOCK WASHER; M10 12 16 CENTRIFUGAL FAN BOLT; M10 X L30, Gr.8.8 12 17 FIX PLATE 1 18 PRESSURE SWITCH 1 19 O-RING (OIL FILL CAP) 1 20 OIL FILL CAP 1

70131EB2-57010

70124-57730 70124-57700 70124-57740

91507-2305020

9152813-1Z12010 703213A1-561070 9011023-1604604 9092017-1304000

70131EB2-56010

93501-33112

70178-57070 70131EB2-57060 70131EB2-57090

92521-231000 91501-2310030-8 70131EB2-57930

93301-990005

93601-810018

70123-57190

21 CYLINDER – CASE GASKET (2ND) 22 CONNECTING ROD CRANK PIN 6 23 CONNECTING ROD BOLT 6 24 LOCKWASHER (M12) 6 25 NUT; (M12) 6 26 CONNECTING ROD 3 27 CONNECTING ROD – PISTON PIN NEEDLE BEARING 3 28 PISTON PIN SNAP RING 6

70178-61090 70178-61250

92522-131200

92501-131200-8

70131EB2-61210

93501-3230

93610-130032

29 PISTON (2ND) 30 PISTON (2ND) 31 OIL CONTROL RING (2ND) 32 COMPRESSION RING (2ND) 33 CYLINDER BOLT (1ST); M16 x L46, Gr. 8.8 12 34 CYLINDER LOCK WASHER; M16 x L46, Gr. 8.8 13 35 CYLINDER NUT; M16 12

91525-1316045-8

92522-131600

92501-131600

36 CYLINDER (2ND) 37 VALVE – CYLINDER GASKET (2ND) 1 38 INLET & OUTLET VALVE GASKET (2ND) 2 39 OUTLET VALVE BOLT; M10 X L50, Gr. 8.8 1

9152613-1110050

40 OUTLET VALVE SEAT (2ND) 41 OUTLET VALVE SPRING (2ND) 42 OUTLET VALVE RECEIVER (2ND) 1 43 OUTLET VALVE PLATE (2ND) 44 NUT; M10 (Outlet Valve) 6

92501-231000

45 INLET VALVE RECEIVER (2ND) 46 INLET VALVE PLATE (2ND) 47 INLET VALVE SPRING (2ND) 48 INLET VALVE SEAT (2ND) 49 INLET VALVE UNLOADER FORK (2ND) 1 50 UNLOADER SPRING 3

70125-11230

Model E-25

st

Stage

1

Qty

Req.

nd

2

Stage

1 70178-52030

70131EB2-62120

1

70131EB2-62010

1

70178-62050

2

70178-62030

3

1

70178-52010 70178-31240 70125-11110

70125-41011

1

70125-41074

3

701212A1-41026 501212A1-41032

1

70125-31023

1

50125-31030

1

70125-31070

1

70125-31010

1

70125-31080

25B

MAIN PARTS LISTING FOR CAP600

TWO STAGE MODEL E-25

Item

Description

No.

51 INLET VALVE UNLOADER FORK GUIDE 52 LOCKNUT; M12 (Inlet Valve) 53 AIR OUTLET JOINT 54 CYLINDER HEAD (2ND) 55 CYLINDER HEAD BOLT SPRING WASHER; M12 56 CYLINDER HEAD BOLT; M12 x L35; Gr. 8.8 57 O-RING P 22A (Unloader) 58 UNLOADER PISTON 59 O-RING G65 (Outlet Valve) 60 O-RING G65 (Inlet Valve) 61 INLET VALVE PUSH COVER (2ND) 62 OUTLET VALVE PUSH COVER (2ND) 63 OUTLET VALVE PUSH COVER BOLT; M10 x L25, Gr. 8.8 64 PISTON PIN (1ST) 65 PISTON (1ST) 66 OIL CONTROL RING (1ST) 67 COMPRESSION RING 2 (1ST) 68 COMPRESSION RING 1 (1ST) 69 CYLINDER – CASE GASKET (1ST) 70 CYLINDER (1ST) 71 VALVE - CYLINDER GASKET (1ST) 72 INLET & OUTLET VALVE GASKET (1ST) 73 INLET VALVE RECEIVER (1ST) 74 INLET VALVE SPRING (1ST) 75 INLET VALVE PLATE 1 (1ST) 76 INLET VALVE PLATE 2 (1ST) 77 INLET VALVE SEAT (1ST) 78 INLET VALVE STUD 79 OUTLET VALVE SEAT (1ST) 80 OUTLET VALVE SPRING (1ST) 81 OUTLET VALVE RECEIVER (1ST) 82 OUTLET VALVE STUD 83 INLET VALVE UNLOADER FORK (1ST) 84 CYLINDER HEAD (1ST) 85 O-RING G85.7 86 INLET VALVE PUSH COVER (1ST) 87 OUTLET VALVE PUSH COVER (1ST) 88 OUTLET VALVE PUSH COVER BOLT; M10 x L30, Gr. 8.8 89 OIL SEAL 90 FRONT OIL SEAL PUSH COVER 91 FRONT OIL SEAL PUSH COVER BOLT; M8 x L25, Gr. 8.8 92 CENTRIFUGAL FAN 93 LOCK WASHER, M6 94 BOLT; M6 x L10, Gr. 8.8 95 COMPRESSOR PULLEY 96 COMPRESSOR PULLEY THRUST WASHER 97 V-PULLEY PIN 98 COMPRESSOR PULLEY BOLT; M16 x L30, Gr. 8.8 99 INTERCOOLER – HEAD GASKET

100 PIPING-INTERCOOLER LOCK WASHER; M10

Model E-25

Qty

Req

1 70125-31090 1 92517-231200 1 70131EB1-87021

1 70181EB3-12010 18 92522-131200 18 9150113-1112035

3 93601-870022A 3 70125-11220 1 93602-870065 1 93602-810065

1 70125-11151

1 70125-11451

8 91501-1310025-8 2 70178-61120 2 70131EB2-61010 4 70178-61050 4 70178-61030-2 2 70178-61030-1 2 70178-51030 2 70181EB3-51010 2 70181EB3-11202 4 70181EB3-31110 2 70181EB3-31020 6 70181EB3-31070 2 70181EB3-31050 2 70181EB3-31030 2 70181EB3-31010 2 70181EB3-31810 2 70181EB3-41010 6 70181EB3-41070 2 70181EB3-41020 2 70131BA4-41810 2 70181EB3-31080 2 70181EB3-11010 2 9360287-310857 2 70181EB3-11150 2 70181EB3-11450

16 CT55-1310030

1 70178-57080 1 70178-57240 4 91501-2308025-8

1 70A81EB1-76300 12 92522-130600 12 91513-1306010

1 70178-76010

1 70178-76210

1 70718-56060

1 91501-2316045-8

1 70178-71020 14 92522-13100

st

1

Stage

Qty

Req

2nd Stage

25C

MAIN PARTS LISTING FOR CAP600

TWO STAGE MODEL E-25

Item No.

Description

101 PIPING-INTERCOOLER BOLT; M10 x L30, Gr. 8.8 102 PIPING- INTERCOOLER GASKET 103 DISCHARGE PIPING ASSEMBLY 104 MIDDLE INTERCOOLER ASSEMBLY 105 COMPRESSOR FAN 106 COMPRESSOR FAN WASHER, M8 107 COMPRESSOR FAN LOCK WASHER, M8 108 COMPRESSOR FAN BOLT; M8 x L30, Gr. 8.8 109 PIPING-HEAD GASKET 110 DISCHARGE PIPING ASSEMBLY 111 GEAR PUMP COUPLING 112 BOLT; M6*15 113 NUT; M6 114 GEAR PUMP HOUSING GASKET 115 GEAR PUMP HOUSING 116 STEEL BALL 117 BALL VALVE RECEIVER 118 PRESSURE GAUGE (0~10K) 119 BALL VALVE SPRING 120 REGULATOR SEALING 121 REGULATOR ADJUST NUT 122 REGULATOR ADJUST BOLT 123 GEAR PUMP SHAFT 124 DRIVE GEAR RING 125 DRIVE GEAR 126 DIRVEN GEAR 127 O-RING 128 GEAR PUMP HOUSING COVER 129 LOCK WASHER, M10 130 BOLT; M10*30 131 COPPER PIPE JOINT 132 PUMP CONNECTING TUBE 133 STRAINER PLUG 134 FEED OIL FILTER ASSEMBLY 135 BREATHER ASSEMBLY (RUBBER) 136 BREATHER TUBE 137 ELBOW 45º 138 NIPPLE ½ 139 AIR FILTER ASSEMBLY



Model E-25

Qty

Req

14 91513-1310030-8

2 70178-87090 1 70178-87100 1 70131EB1-71000C 1 70178-76310 6 92521-230800 6 92522-130800 6 91501-92308030-8 2 70178-87130-1 1 70178-87200 1 703213A1-27110 1 91501-2306015 1 92501-130600 1 703213A1-27020 1 70131EB2-27010 1 9980113-20036 1 703213A1-28090 1 9320611-2032213 1 703213A1-28080 1 703213A1-28110 1 703213A1-28130 1 703213A1-28120 1 703213A1-27070 1 703213A1-27130 1 703213A1-27050 1 703213A1-27060 1 9360281-31044 1 70131EB2-27030 3 92522-131000 3 91501-2310030 1 7992013-2204050 1 70131EB2-27080 1 703213A1-28530 1 703213A1-28500 1 701312A1-57601 1 70131BA1-57670 1 9010311-1304304 1 9011013-1304304 2 70178-66000

st

1

Stage

Qty

Req

2nd Stage

25D

AIR COOLED TWO STAGE MODEL E-35

CAP-600

26

MAIN PARTS LISTING FOR

t

d

t

d

t

d

AIR COOLED TWO STAGE MODEL E-35

(FORMERLY B-1)

DESCRIPTION QTY PART NO.

1. Discharge Elbow 1 70123-87050

2. Discharge Elbow Nut (Not Shown) 1 79922-130606

3. Cylinder Head Bolt 6 91501-1310085

4. Spring Washer 6 92522-130800

5. Cylinder Head 1 70152-11010

6. Unloading Tee * # 1 79922-150101

7. Bolt 2 91521-1306025

8. Spring Washer 2 92522-130600

9. Upper Cover 1 70153-11270

10. Upper Cover Gasket 1 70153-11641 Unloader Assembly (1

11.

16)

12. Unloading Piston 1 70153-11222

13. Unloading Spring 1 70153-11231

14. Unloading Cylinder 1 70153-11211

15. Unloading Fork (1

16. Bolt 1 91501-1306015

17. Cylinder Head Valve Seat Gasket 1 70152-11612

18. Valve Plate Assembly (Includes 19-27) 1 70152-31000

19. Valve Seat Bolt 3 91521-1305012

20. Valve Seat (Upper) 1 70152-31010

21. Valve Seat Gasket 1 70152-31120

22. Valve Plate (1

23. Valve Plate Spring (1

24. Valve Plate (2

25. Valve Plate Spring (2

26. Valve Seat (Bottom) 1 70152-31020

27. Nut 1 92501-230500

28. Cylinder-Valve Seat Gasket 1 70152-11622

29. Cylinder 1 70152-51010

30. Cylinder Crankcase Gasket 1 70152-51610

31. Bolt 11 91501-1310030

32. Copper Washer 6 92521-190800

33. Crankcase Oil Cap 1

34. Oil Cap O-Ring 1 93601-810016

35. Crankcase 1 70152-57010

36. Bearing #6025 (Front & Rear) 2 93501-6205

37. Rear Cover Gasket 1 70152-57960

38. Rear Cover 1 70152-57060

39. Rear Cover Bolt 3 91521-1308030

40. Copper Washer 7 92521-190800

41. Oil Level Gauge & Gauge Cover 1 70111-57700

42. Gauge Cover Seal 1 70111-57730

43. Crankcase Oil Plug (1/4” NPT) 1 90112-100303

44. Inter-Cooler Bolt 3 91521-1308050

45. Gasket 1 70152-71612

46. Inter-Cooler Body 1 70152-71110

46A. Gasket, Copper 1 70152-12280

s

)(Includes 12-

s

) 1 70152-31080

s

) 4 70152-31030

s

) 4 70152-31070

n

) 2 70152-32030

n

) 2 70152-32070

1 70152-11201

70101-57190-4010

*Includes Nut(S) and Sleeve(S) #Not Supplied On Basics

CAP-600

DESCRIPTION QTY PART NO.

47. Inter-Cooler Body Gasket 1 70152-71622

48. Inter-Cooler Cover 1 70152-71160

49. Spring Washer 4 92522-130600

50. Bolt 4 91501-1306016

51. Compression Ring (1

52. Oil Control Ring (1

53. Piston (1

s

) 1 70152-61010

54. Piston Snap Ring 4 70152-61070

55. Connection Rod Assembly (1

56. Piston Pin Bush (1

57. Connecting Rod Assembly (2

58. Piston Pin Bush (2

59. Crank Pin Metal (Rod Bearing 2 Halves) 2 70152-61090

60. Crankshaft 1 70152-56010

61. Piston Pin (1

62. Compression Ring (2

63. Piston Pin (2

64. Oil Control Ring (2

65. Piston (2

n

) 1 70152-62010

66. Breather Assembly 1

67. V-Pulley Pin 1 70112-56060

68. Nut (Connecting Rod) 4 92501-130800

69. Spring Washer (Connecting Rod) 4 92522-130800

70. Bolt (Connecting Rod) 4 70152-61250

71. Front Cover Gasket 1 70152-57950

72. Front Cover 1 70152-57030

73. Front Oil Seal 1 70127-57 080

74. Copper Washer 7 92521-190800

75. Bolt 4 91501-1310030

76. Compressor Pulley 1 70152-76010

77. Compressor Pulley Thrust Washer 1 70112-76210

78. Bolt 1 91501-1308025

79. Unloading Elbow * # 1 79926-150101 Unloader Assembly (2

80.

85)

81. Unloader Cover (2

82. Viton O-Ring Unloader (2

83. Unloading Piston (2

84. Unloading Spring (2

85. Unloader Body 1 70153-12200

86. Air Strainer Assembly (Includes 87-92) 1 70152-66001

87. Air Strainer Cover Gasket 1 70152-66131

88. Air Strainer Cover 1 70153-66120

89. Air Strainer Bolt 1 70152-66160

90. Air Strainer Element 1 70152-66141

91. Nut (Self Lock) Air Strainer 1 92522-230600

92. Air Strainer Body 1 70152-66011

93. Intercooler Safety Valve (Not Shown) 1 VV431

s

) 2 70152-61030

s

) 1 70152-61050

s

) 1 70152-61080

n

) 1 70152-62080

s

) 1 70152-61120

n

) 1 70152-62120

n

) 1 70152-62050

n

) 1 70103-11271

n

) 1 70152-12221

n

) 1 70103-11230

) 1 70152-61200

n

) 1 70152-62200

) 3 70152-62030

CCC1375

n

)(Includes 81-

n

) 1 93601-870009

1 70152-12200

27

AIR COOLED TWO STAGE MODEL E-57, E57A CAP600



28

MAIN PARTS LISTING FOR

t

d

t

d

t

d

AIR COOLED TWO STAGE MODEL E-57 & E-57A

(FORMERLY B-2)

DESCRIPTION QTY PART NO.

1. Discharge Elbow 1 VA15EJE

2. Discharge Elbow Nut (Not Shown) 1 79922-130707

3. Cylinder Head Bolt 6 91501-1310085

4. Spring Washer 6 92522-131000

5. Cylinder Head 1 70153-11011

6. Unloading Tee * # 1 VA787

7. Bolt 2 91521-1306025

8. Spring Washer 2 92522-130600

9. Upper Cover 1 70153-11270

10. Upper Cover Gasket 1 70153-11631

11. Lower Unloader Gasket 1 70153-11641

Unloader Assembly (1st)(Includes 13-17)

12.

1 70153-11201

13. Unloading Piston 1 70153-11222

13A. Viton O-Ring Unloader (1ST) 1 93601-870015

14. Unloading Spring 1 70153-11231

15. Unloading Cylinder 1 70153-11211

16. Unloading Fork 1 70153-31080

17. Bolt 1 91501-1306016

18. Cylinder Head Valve Seat Gasket 1 70153-11612

19. Valve Plate Assembly (Includes 20-28) 1 70153-31001

20. Valve Seat Bolt 3 91521-1305012

21. Valve Seat (Upper) 1 70153-31011

22. Valve Seat Gasket 1 70153-31120

23. Valve Plate (1

24. Valve Plate Spring (1

25. Valve Plate (2

26. Valve Plate Spring (2

s

) 4 70153-31032

s

) 4 70153-31072

n

) 2 70153-32032

n

) 2 70153-32072

27. Valve Seat (Bottom) 1 70153-31021

28. Nut 2 92501-230500

29. Cylinder-Valve Seat Gasket 1 70153-11622

30. Cylinder 1 70153-51011

31. Cylinder Crankcase Gasket 1 70153-51611

32. Bolt 6 91501-1310030

33. Copper Washer 6 92521-191000

34. Crankcase Oil Cap 1 CCC1257

35. Oil Cap O-Ring 1 93601-810018

36. Crankcase 1 70153-57011

37. Bearing #6026 (Front & Rear) 2 93501-6206

38. Rear Cover Gasket 1 70153-57961

39. Rear Cover 1 70153-57061

40. Rear Cover Bolt 3 91521-1308030

41. Copper Washer 3 92521-190800

42. Oil Level Gauge & Gauge Cover 1 70111-57700

43. Gauge Cover Seal 1 70111-57730

44. Crankcase Oil Plug (1/4” NPT) 1 70153-12350

45. Inter-Cooler Bolt 3 91521-1308055

46. Gasket 1 70153-71611

47. Inter-Cooler Body 1 70153-71111

48. Inter-Cooler Body Gasket 1 70153-71622

49. Inter-Cooler Cover 1 70153-71161

50. Spring Washer 6 92522-130600

51. Bolt 6 91501-1306016 * Includes Nut(S) And Sleeve(S) # Not Supplied On Basics

** S/N A4081331 & Later

*** S/N AS07030318 & Later

52. Compression Ring (1

53. Oil Control Ring (1

54. Piston (1

55. Piston Pin Snap Ring 4 70153-61071

56. Connection Rod Assembly (1

56A. Connecting Rod Assembly (1

57. Piston Pin Bush (1

58. Connecting Rod Assembly (2

59. Piston Pin Bush (2 59A. Piston Pin Needle Bearing (2 59B. Piston Pin Needle Bearing (1

60. Connecting Rod Bearing (2 Halves) 2 70153-61090

61. Crankshaft 1 70153-56011

62. Piston Pin (1

63. Compression Ring (2

64. Piston Pin (2

65. Oil Control Ring (2

66. Piston (2

67. Breather Assembly 1

68. V-Pulley Pin 1 70123-56061

69. Nut (Connecting Rod) 4 92501-230800

70. Spring Washer (Connecting Rod) 4 92522-130800

71. Bolt (Connecting Rod) 4 70153-61250

72. Front Cover Gasket 1 70153-57951

73. Front Cover 1 70153-57030

74. Front Oil Seal 1 70123-57080

75. Copper Washer 4 92521-190800

76. Bolt (Front Cover) 4 91501-1310030

77. Compressor Pulley 1 70153-76011

78. Compressor Pulley Thrust Washer 1 70123-76210

79. Compressor Pulley Bolt 1 91501-1310030

80. Unloading Elbow * # 1 VA786

81.

82. Unloader Cover (2

83. Viton O-Ring Unloader (2

84. Unloading Piston (2

85. Unloading Spring (2

86. Unloader Body (2

87. Air Strainer Assembly (Includes 88-93) 1 70153-66002

88. Air Strainer Cover Gasket 1 70153-66132

89. Air Strainer Cover 1 70153-66121

90. Air Strainer Bolt 1 70153-66160

91. Air Strainer Element 1 70153-66142

92. Nut (Self Lock) Air Strainer 1 92507-230600

93. Air Strainer Body 1 70153-66012

94. Intercooler Safety Valve (Not Shown) 1 VV431

95. Gasket, Copper 1 70152-12280

96. HHCS, ¼-20 X ½” LG 2 VH12FD

97. Lock washer, split ¼” 2 VH35F

98. Plate, Cover, Flange 1 CA2323

99. Gasket, Plate Cover 1 CA2312

DESCRIPTION QTY PART NO.

s

) 2 70124-61030

s

) 1 70153-61011

n

) 1 70153-62011

Unloader Assembly (2nd)(Includes 82-86)

) 2 70124-61050

s

) 1 70153-61211

s

) 1 70153-61081

n

) 1 70153-62081

s

) 1 70153-61121

n

) 1 70153-62121

n

) 1 70153-62050

n

) 1 70103-11271

n

) 1 70153-12222

n

) 1 70103-11231

n

) 1 70103-11211

)*** 1 70153-62211

n

) 1 70153-62211

n

) ** 1 93503-TA2420

s

)*** 1 93503-TA2420

) 3 70153-62030

n

) 1 93601-870009

CAP-600

CCC1258

1 70153-12201

29

CAP-600

INSPECTION & MAINTENANCE OF

E-57 VALVE ASSEMBLY

INSTRUCTION FOR E-57 COMPRESSOR MODEL HEAD VALVE ASSEMBLY INSPECTION AND MAINTENANCE.

Model E-57 valve assembly inspection and maintenance instruction.

1. Inspect valve assemblies every 1000 hours of operation or as necessary to maintain efficient operation.

2. Turn off power, red tag power supply switch (caution: Maintenance in progress – DO NOT START). Drain all air pressure from system before starting work.

3. Disconnect air piping from head.

Remove valve package.

A1. Loosen and remove head bolts. On constant run models, remove upper tubing from unloader cylinder. A2. Remove cylinder head to expose valve assembly. A3. Remove valve assembly, head to valve package gasket and valve package to cylinder gasket. Use new gaskets in re-assembly. Note conditions of cylinders, clean out any foreign material and cover with clean shop cloth while open. A4. Refer to parts breakdown for description of valve package. A5. Secure valve assembly package, loosen and remove socket head bolts to separate the upper and lower valve seats. This will expose the valve springs and valve plates. CAUTION: Do not interchange upper and lower valve seats A6. Thoroughly clean and wash all valve seats and parts with a suitable non-flammable cleaning fluid. CAUTION: Use care to not scratch or deform valve parts in the cleaning. A7. Carefully inspect the valve seats, plates and springs for dents, cracks, wear, and any reason to prevent proper and efficient operation. A8. Replace all parts not in proper condition.

Assemble valve assembly package.

B1. Secure lower valve plate in flat position with spring slots “up”. B2. Refer to parts breakdown for valve package breakdown. B3. Place valve springs and valve plates in proper positions over slots in seat. Use tag wire or string for tie to hold in position for completing assembly. B4. Secure upper valve seat in flat position with spring slots up B5. Use new valve seat gasket. B6. Place valve seat gasket in position on lower valve plate. B7. Place upper valve seat with valve springs and plates tied in position on top of lower valve seat with new valve seat gasket in place between the two seats. B8. Start center and then two end valve plates socket head bolts, tighten finger tight being careful not to damage seat gasket, use socket head wrench to torque the three bolts uniformly to secure the top valve seat to the lower valve seat using care to avoid damage to the gasket, and valve springs and plates from moving out of position. B9. Remove ties to free valve springs and plates B10. Check to be sure valve springs and valve plates are in proper position and the plates are free to flex when manually touched with blunt instrument.

Assemble valve assembly package into compressor.

C1. Use new gaskets, valve package to cylinder and cylinder head to valve package. Select gaskets by part numbers from parts breakdown. C2. Remove shop cloth to expose open cylinder bores. Remove any foreign matter from cylinder bores and top of cylinder. C3. Place gasket on top of cylinder, place and align valve package, place gasket on top of valve package and align holes for head bolts. C4. Place clean head on top of valve package with gasket and align with cylinder bolt holes. C5. Insert cylinder head bolts using care to avoid damage to the gaskets, start each bolt threading evenly to contact head surfaces. C6. Torque head bolts equally, follow torque specifications on page 20. C7. Attach and tighten copper tubing of constant running compressors. C8. Assemble and tighten discharge tubing. C9. Check oil level in crankcase C10. Close and tighten valve or the connections used to drain air pressure from system. C11. Remove all tools and make area safe to start compressor. C12. Turn on power at main switch and inspect to see that unit is operating properly. C13. Stay with unit for normal pump up to cut out pressure. C14. If unit has performed through a running cycle properly put on line for duties and remove red tag from power supply switch. C15. Make entry in equipment maintenance log.

30

CAP-600

VALVE PLATES DESIGNS FOR E-57 COMPRESSOR

31

CAP-600

CM-FT.

TORQUE

INLET & OUTLET

VALVE PUSH COVERS

SIZE

BOLT

CM-FT.

TORQUE

100-6.8

180-13.0

180-18.0

225-16.3 225-16.3

M8-1.25

180-13.0

280-20.25

300-21.7

225-16.3 225-16.3

M8-1.25

280-20.25

300-21.7

280-20.25

225-16.3

M8-1.25

280-20.25

320-23.1

M10-1.5

L

28-120.25

280-20.25

225-16.3

M8-1.25

H

REAR COVER

FRONT COVER

ROD BOLTS

SIZE

BOLT

CM-FT.

TORQUE

SIZE

BOLT

CM-FT.

TORQUE

SIZE

BOLT

CM-FT.

TORQUE

M6-1

100-6.8

M6-1

135-9.7

M6-1

100-6.8

180-13.0

M6-1

M8-1.25

135-9.7

180-13.0

M6-1

M8-1.25

120-8.7

200-14.5

M8-1.25

180-13.0

M8-1.25

180-13.0

M8-1.25

200-14.5

M8-1.25

180-13.0

M8-1.25

180-13.0

M8-1.25

200-14.5

M8-1.25

180-13.0

M8-1.25

180-13.0

M8-1.25

200-14.5

M8-1.25

180-13.0

M8-1.25

180-13.0

M8-1.25

200-14.5

M10-1.5

M8-1.25

180-13

280-20.25

M10-1.5

M8-1.25

180-13

280-20.25

M10-1.5

M8-1.25

200-14.5

280-20.25

M10-1.5

280-20.25

M8-1.5

280-20.25

M8-1.5

280-20.25

M8-1.25

M10-1.5

300-21.7

M8-1.5

M10-1.5

300-21.7

280-20.25

M8-1.5

M8-1.25

280-20.25

M10-1.5

300-21.7

320-23.11

M8-1.5

M10-1.5

300-21.7

320-23.1

M8-1.5

M10-1.5

350-25.3

280-20.25

M10-1.5

320-23.1

M10-1.5

320-23.1

M10-1.5

350-25.3

BOLT TORQUES FOR CHALLENGE AIR COMPRESSORS

CYLINDER-CASE

HEAD BOLTS

SIZE

BOLT

TORQUE

SIZE

BOLT

CM-FT.

120-8.7

M6-1

ES03

M8-1.25

200-14.5

M8-1.25

ES05

M6-1

120-8.7

M6-1

ES06

M8-14.5

200-14.5

M8-1.25

ES10

M8-1.25

200-14.5

M8-1.25

E11

M8-1.25

200-14.5

M8-1.25

ES20

32

M8-1.25

200-14.5

M8-1.25

E23

M10-1.5

M8-1.25

300-21.7

200-14.5

M10-1.5

M8-1.25

E35

ES30

M10-1.5

300-21.7

M10-1.5

ES50

M10-1.5

300-21.7

M10-1.5

E50

M10-1.5

320-23.1

M10-1.5

E57

M10-1.5

320-23.1

M10-1.5

ES100

M10-1.5

320-23.1

M10-1.5

E71

M10-1.75

320-23.1

M10-1.5

ES150

M10-1.75

320-23.1

M10-1.5

E15

CAP-600

BOLT TORQUES

MODEL

NO.

ES03 8 96 - ES05

ES06 ES10 E11 ES20 E23 E35

E57 23 276 - ES30 30 360 - -

FLYWHEEL BOLTS FAN BOLTS

TORQUE

FT.-LBS.

12 144 - -

TORQUE

IN.-LBS.

TORQUE

FT.-LBS.

TORQUE

IN.-LBS.

ES50 E50

E71 ES100

E15 ES150

40 480 - -

45 540 24 288

50 600 24 288

33

CAP-600

OIL CAPACITIES

MODEL

NUMBER

HORSEPOWER

ES03 1/4 – 1/2 500 1/2 PINTS

ES05 1/2 500 1/2 PINTS

ES06 3/4 500 10 OUNCES

ES10 1 500 1¼ PINTS

ES20 2 – 3 500 1¾ PINTS

ES30 3 – 5 500 1¼ PINTS

MIN

RPM

OIL CAPACITY

ES50 5 – 7½ 500 1½ QUARTS

ES100 7½ - 10 500 2½ QUARTS

ES150

ES150A

15 500 5 QUARTS

E11 1 500 1¼ PINTS

E23 2 – 3 500 1¾ PINTS

E35 3 – 5 500 2½ PINTS

E50 5 500 1½ QUARTS

E57 5 – 7½ 500 2 QUARTS

E71 10 500 2½ QUARTS

E15 15 500 5 QUARTS

34

TROUBLESHOOTING

Flywheel rotation in wrong direction Incorrect connection of motor terminal Re-arrange terminal connection. Overheating of bearings 1. Insufficient lubrication.

Flywheel rotation slows down 1. Heavy lubrication oil.

Severe vibration Bent crankshaft Remove & Replace Abnormal noise 1. Loose valve assembly.

WHEN COMPRESSOR CAN BE STARTED

Pressure cannot be built up or only up to a certain extent

Inaccuracy of pressure gauge Pressure gauge damaged. Replace. Excessive oil consumption 1. Worn piston ring

Slipping of belts 1. Working pressure too high.

Overheating of electric motors 1. Overloading of motor due to

CANNONT BE STARTED

Unit will not start 1. Breakdown of electric current.

WHEN COMPRESSOR

Fuse tends to blow 1. Incorrect size.

CURTIS-TOLEDO

SYMPTOMS CAUSES REMEDIES

1. Add lubrication oil.

2. Bad lubrication system.

3. Crankshaft bearings to tight.

2. Drop in voltage.

3. Belts slipping.

2. Piston hits cylinder cover.

3. Worn connecting rod bearing.

1. Worn valve plate.

2. Valve springs have lost their temper.

3. Dirt on the valve plate.

4. Leaks from safety valve.

5. Leaks from bolt holes.

6. Uneven valve seat surface.

7. Excessive blow by on piston rings.

8. Bad packing (gasket to thick).

9. Excessive air leaks.

2. Worn piston.

3. Worn cylinder.

2. Improper belt tension.

3. Worn belt.

excessive working pressure (higher than stipulated pressure).

2. Burnt piston.

3. Burnt bearing metals.

4. Drop of voltage.

2. Line failure.

3. Malfunction of motor

2. Wrong connections

3. Overloading of motor.

4. Overloading of motor due to leaks of outlet valve.

5. Crankshaft too tight.

2. Remove and examine the system.

3. Readjust load on bearings.

1. Refill with lighter lubrication oil.

2. Contact power company or install a transformer.

3. Tighten belts

1. Tighten valve bolt and lock nut.

2. Check piston & rod assembly for excessive wear.

3. Replace bearing.

1. Repair or replace valve plate.

2. Replace valve springs.

3. Remove and clean it.

4. Repair or replace safety valve.

5. Tighten the nuts even with packing.

6. Remove and lap the surface.

7. Replace with new ones

8. Replace packing (gasket).

9. Eliminate air leaks.

1. Replace.

2. Replace.

3. Replace.

1. Lower working pressure.

2. Adjust belt tension.

3. Replace with new ones.

1. Lower working pressure.

2. Rebuild compressor.

3. Rebuild compressor.

4. Contact power company or install a transformer

1. Contact power company.

2. Examine the line. Replace with new wiring.

3. Contact motor manufacturer.

1. Replace with correct size.

2. Change connections.

3. Eliminate the loading.

4. Remove and repair outlet valve.

5. Remove crankshaft and examine it for cause.

CUSTOMER SERVICE (314) 383-1300

CAP-600

35

CAP-600

RECOMMENDED STATEMENT ON DRYERS AND FILTERS

Liquid water occurs naturally in air lines as a result of compression. Moisture vapor in ambient air is concentrated when pressurized and condenses when cooled in downstream air piping.

Compressed air dryers reduce water vapor concentration and prevent liquid water formation in compressed air lines. Dryers are necessary companion to air filters, aftercoolers, and automatic tank drains for improving the productivity of compressed air systems.

Water and water vapor removal increases the efficiency of air operated equipment, reduces contamination and rusting, increases service life of pneumatic equipment and tools, prevents air line freeze ups, and reduces product rejects. The use of dryer’s filters is recommended when this moisture related problems are reported to our factory or distributor service departments.

Troubleshooting guide Symptom: Liquid water present in compressed air lines. Problem: Water vapor condensation from cooling and

compression occurs naturally

Solution: Remove the water vapor from compressed air prior to

distribution through the air system. Check operation of after-cooler and moisture separator. Install a compressed air dryer sized for the flow and dryness level required.

(Note: filters may also be required to remove

particles, liquid oil aerosols, or for oil vapor removal. Change cartridges as recommended by filter manufacturer.)

Check all drain traps routinely to insure their proper operation.

Maintain them regularly.

36

TWO STAGE

H.P. Size

3 3VT6 947 10.66 20 x 50 60 12’ – 24” 2’ – 8” 5 5E23VT6 1000 11.3 20 x 50 60 11’ – 47” 2’ – 1” 5 5E1HT6 1100 15.81 20 x 50 60 7’ – 46” 1’ – 20” 5 5E1VT6 1100 15.81 20 x 50 60 7’ – 46” 1’ – 20” 5 5E1HT8 1100 15.81 20 x 48 80 10’ – 21” 1’ – 46” 5 5E1VT8 1100 15.81 20 x 48 80 10’ – 21” 1’ – 46” 5 5HT6 968 20.58 20 x 50 60 5’ – 56” 1’ – 1” 5 5VT6 968 20.58 20 x 50 60 5’ – 56” 1’ – 1” 5 5HT8 968 20.58 20 x 66 80 7’ – 54” 1’ – 21” 5 5VT8 968 20.58 20 x 48 80 7’ – 54” 1’ – 21” 5 5E2HT6 900 21.47 20 x 50 60 5’ – 25” 0’ – 56” 5 5E2VT6 900 21.47 20 x 50 60 5’ – 25” 0’ – 56” 5 5E2HT8 900 21.47 20 x 66 80 7’ – 14” 1’ – 14”

5 5E2VT8 900 21.47 20 x 48 80 7’ – 14” 1’ – 14” 7 1/2 7E2HT8 1100 26.24 20 x 66 80 6’ – 16” 1’ – 05” 7 1/2 7E2VT8 1100 26.24 24 x 48 80 6’ – 16” 1’ – 05” 7 1/2 7HT8 764 29.57 20 x 66 80 5’ – 22” 0’ – 55”

10 10HT8 977 37.81 20 x 66 80 4’ – 11” 0’ – 43” 10 10HT12 977 37.81 24 x 70 120 6’ – 17” 1’ – 5” 10 10VT12 977 37.81 30 x 47 120 6’ – 17” 1’ – 5” 15 15HT12 855 54.55 24 x 70 120 4’ – 28” 0’ – 46”

TWO STAGE

H.P. Size

COMPRESSOR PUMP-UP TIME

Compressor

Model No. R.P.M.

GASOLINE ENGINE DRIVEN

Compressor

Model No. R.P.M.

Piston

Displ.

C.F.M.

Piston

Displ.

C.F.M.

Tank size Approx. Time Required

Size

(in)

Tank size Approx. Time Required

Size

(in)

Gal

0 to 175 PSIG

To Pump From:

Min. – Sec.

To Pump From:

Min. – Sec.

CAP-600

145 to 175 PSIG

Min. – Sec.

145 to 175 PSIG

Min. – Sec.

10 10E2GT3 910 21.7 16 x 41 30 2’ – 42” 0’ – 28” 10 10GT3 950 20.2 16 x 41 30 3’ – 1” 0’ – 31” 10 10GT6 950 20.2 20 x 50 60 6’ – 3” 1’ – 2” 13 13E2GT3K 910 21.7 16 x 41 30 2’ – 42” 0’ – 28” 13 13GT3K 950 20.2 16 x 41 30 3’ – 1” 0’ – 31” 13 13GTGK 950 20.2 20 x 50 60 6’ – 3” 1’ – 2” 13 13E2GT3HE 910 21.7 16 x 41 30 2’ – 42” 0’ – 28”

37

SINGLE STAGE

H.P. Size

3 3HS6 945 15.97 20 x 50 60 6’ – 16” 1’ – 15”

3 3VS6 945 15.97 20 x 50 60 6’ – 16” 1’ – 15”

5 5ES20VS6 1000 16.9 20 x 50 60 6’ – 4” 1’ – 13”

5 5HS6 945 20.13 20 x 50 60 4’ – 8” 0’ – 50”

5 5VS6 945 20.13 20 x 50 60 4’ – 8” 0’ – 50”

5 5HS6 945 20.13 20 x 66 80 5’ – 31” 1’ – 6”

5 5VS8 945 20.13 24 x 48 80 5’ – 31” 1’ – 6” 7 1/2 7HS8 945 30.14 20 x 66 80 3’ – 35” 0’ – 43” 7 1/2 7VS8 945 30.14 24 x 48 80 3’ – 35” 0’ – 43”

10 10HS8 866 50.4 20 x 66 80 2’ – 7” 0’ – 25” 10 10HS12 866 50.4 24 x 70 120 3’ – 10” 0’ – 38” 10 10VS12 866 50.4 30 x 47 120 3’ – 10” 0’ – 38” 15 15HS12 855 81.74 24 x 70 120 2’ – 2” 0’ – 24”

COMPRESSOR PUMP-UP TIME

Compressor

Model No. R.P.M.

Piston

Displ.

C.F.M.

Tank size Approx. Time Required

Size

(in)

Gal

0 to 100 PSIG

To Pump From:

Min. – Sec.

CAP-600

80 to 100 PSIG

Min. – Sec.

38

NOTES

39

CAP-600

CURTIS – TOLEDO, INC.

1905 KIENLEN AVE., ST. LOUIS, MO 63133

TEL. (314) 383-1300 FAX (314) 381-1439

E-MAIL: info@curtistoledo.com

www.curtistoledo.com

FScurtis CA series, ES03, ES05, ES06, ES10 Installation And Operating Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual