Page 1
WP241 DUAL
AIR COMPRESSORS
Subject
TABLE OF CONTENTS
Page
GENERAL ..................................................................... 2
SPECIFICATIONS ............................................................... 2
APPLICATION .................................................................. 2
OPERATION ................................................................... 2
MAINTENANCE..............................................................
.......... 3
Maintenance Schedule ....................................................... 3
Lubrication .................................................................. 3
DrainingTank ................................................................. 4
Air Intake Filter ............................................................... 4
Filter Cartridge (at PRV) ......................................................... 4
Safety Relief Valves. ............................................................ 4
Belts (SeeFig.2). .. .......................................................... 4
Pressures .................................................................. 5
Wiring Options ............................................................... 5
Operational Check. 6
.........................................
TROUBLESHOOTING ............................................................ 7
Wrong Oil Pressure, ......................................................... 7
Oil Pressure Adjustment (See Fig. 6).
Oil Leaks ....................................................................
.................................................
7
Excessive Oil Consumption ....................................................... 8
Noisy Pump ................................................................. 8
Noisy Motor .................................................................. 8
Noise Not Locatable
............................................................ 8
Chart 1 -Motor Won’t Start. ....................................................... 9
Chart 2-Circuit Breaker Trips (Fuse Opens), ............................................ 10
Chart 3-Won’t Pump Air-Runs, but Tank Shows No Pressure Build-Up
Chart 4 -Won’t Pump Air-Builds Up Slowly, or Not Complete
................................
Chart S-Won’t Pump Air-Pump Slows, Stalls, or Trips Circuit Breaker (Fuse Opens)
.......................... 11
12
................... 13
Excessive Vibration ............................................................. 13
REPAIR ...................................................................... 14
Pump Removal and Replacement ..........
Oil Pump Replacement.
Belt Replacement ...
Motor Replacement.
................
................
.
..................
Intake and Exhaust Valves, Unloader .......
Pressure Regulating Valve (PRV) Station .....
. . . . . .
......
. . .
.
......
..................
...............
.........
..................
...............
. . . . . . . . . . . . . . . . . . . . . . . . . 14
.................................. 14
..................................
..................................
15
16
.................................. 15
..................................
........................
16
17
. . . . . . . . . . . . . . . . . . . . . . . . . . 17
.........
......................
......................
. . . . . . . . . . . . . . . 17
18
19
7
Rev. 4-80
Page 2
GENERAL
This sheet contains maintenance and repair information for the WP241 series air compressors. The WP241
Dual Air Compressor has two electric motor-driven pumps
mounted on a common storage tank, allowing automatic
alternating operation with standby capability.
IONS
PRESSURE RANGE: Cut-in pressure-70 lb/in2 (483
kPa), Cut-out pressure -90
lb/in2 (621 kPa).
MAXIMUM AMBIENT TEMPERATURE: 104
TANK CAPACITY: 30, 80, or 200 gallons (114,303, or
757 R).
Table 1. WP241 Dual Air Compressor Specifications.
Compressor WP241 Y WP241B WP241C WP241D
No. of Cylinders
RPM Compressor 500 410 460 480 460 400 570 550
Displacement ft3/min (l/min)
Delivery ft3/min. (l/min)
at 70 to 90 lb/in2
(483 to 621 kPa) One unit only
Tank Size Gal (l) 30 (114) 80 (303) 80 (303) 80 (303) 80 (303) 80 (303)
Intake
Size NPT-Compressor 1/4 3/4 3/4 1/2 3/4 1-1/4 1
Outlet Size-NPT-Compressor 1/4
Flywheel O.D. (in.) 10
Motor Pulley Pitch Dia. (in.)
Safety Valve-Receiver-NPT
Crankcase Oil Capacity
Lubrication System Splash Pressure Pump
11 1 1 2
1.1 (31)
2.8 3.2 3.6 3.2 3.6 3.6 5.1
4 oz (118 ml) 28 oz. (828 ml) 28 oz (828 ml) 22 oz (651 ml) 48 oz (1.4l) 2 qt (1.4l) 2 qt (1.9l)
WP241Y
1/3 (0.25)
115/60/1
-48
1.9 (54) 3.3 (93) 3.8 (108) 5.9 (167) 8.6 (144 12.6 (357)
3/4 3/4 1/2 3/4 1-1/4 3/4
14 14 12 14 16 16
WP241B
1/2 (0 .37)
208/60/3/60/3
-56
WP241C
3/4 (0.56)
230/60/3
-56
WP241D
1 (0.75)
460/60/3
-143T
WP241E WP241F WP241G WP241H WP241J
2 2 2 2 2
19.3 (547) 30.0 (849)
80 (303) 700 (757) 200 (757)
1-1/2 2
1-1/4 1-1/4
19.5 19.5
6.0 6.6
1/2 1/2 1/2 1/2
6 qt (5.7l) 6 qt (5.7l)
WP241E WP241F WP241G WP241H WP241 J
1-1/4 (1.12) 2 (1.49) 3 (2.24) 5 (3.73) 7-1/2 (5.60)
208/60/3 230/60/3 460/60/3 460/60/3 460/60/3
-145T -145T -182P -184T t -213T
F
(57 C).
61 0
APPLICATION
The WP241 Dual Air Compressors are used where
continual operation is a necessity. The motors are inter- maintenance, or be unable to maintain minimum storage
connected to operate on alternate cycles with standby tank pressure, the other motor provides backup by
capability. Should one motor fail, be shut down for
ing automatically.
start-
OPERATION
Air is drawn through the intake filter of the operating
motor-pump unit(s), compressed, and stored in the tank.
As the control system consumes air, the tank pressure
drops. When tank pressure drops to 70
lb/in2 (480 kPa),
75-7268
the motor energizes operating the compressor pump,
which restores tank pressure to 90 lb/in2 (620
tank pressure increases to 90
lb/in2 (620 kPa), a pressure
kPa).
switch stops the motor.
2
When
Page 3
MAINTENANCE SCHEDULE
WEEKLY
kW)
1. Check oil level and pressure on 1 hp (0.75
larger compressors. See LUBRICATION paragraph.
2. Drain water from tank or check automatic drain
operation. See DRAINING TANK paragraph.
3. Check tank and pressure relief valve (prv) pressure.
See PRESSURES paragraph.
4. Observe operation to confirm that pumps build up to
cut-off pressure and shut off. See OPERATIONAL
CHECK paragraph.
EVERY THREE MONTHS
1.
Change oil. See LUBRICATION paragraph.
2. Check intake filters. See AIR INTAKE FILTER paragraph.
and
LUBRICATION
Quincy
units use splash lubrication on the 1/3 to 3/4
kW)
hp (0.25 to 0.56
on 1 hp to 7-l/2 hp (0.75 to 5.6
pumps, remove and wipe off dipsticks; reinsert dipsticks;
remove again and read. If necessary, add oil through dipstick port. Use oil in accordance with Table 1. A high
quality, nondetergent automotive oil is satisfactory
(Table 2).
1-hp
On
checking oil level, check the oil pressure gage. Gage reading should be in the 10 to 20
range.
(100 kPa).
To change oil, stop both units.
(0.75
Recommended operating pressure is 15
units and pressurized lubrication
kW)
units, Stop both
kW)
units and larger, in addition to
lb/in2 (70 to 140
WARNING
kPa)
lb/in
2
3. Drain water from tank and filter bowls. See DRAINING TANK paragraph.
4. Check tension and condition of belts. See BELTS
paragraph.
5.
Check sequential operation. See OPERATIONAL
CHECK paragraph.
6. Check safety relief valves. See SAFETY RELIEF
VALVES paragraph.
7. Check filter cartridge on 7-l/2
FILTER CARTRIDGE paragraph.
EVERY YEAR
*Change
1.
paragraph.
2. *Change
FILTER CARTRIDGE paragraph,
3. Service motors. See LUBRICATION paragraph.
intake filters. See AIR INTAKE FILTER
prv filter on 7-l/2 hp (5.6
hp
(5.6
kW)
only. See
kW)
only. See
Personal injury could result from starting a unit
not containing oil.
Remove the drain plug and dipstick and allow oil to
drain completely. Ordinarily, a crankcase need not be
flushed. If flushing seems necessary, use a nonflammable
solvent (available at most auto parts stores). Replace
plug and refill according to Table 2. DO NOT OVERFILL! Overfilling causes excessive oil consumption and
contamination of the compressed air.
Lubricate the motor annually in accordance with
instruction on nameplate.
Table 2. Compressor Oil Requirements.
*Dirty operating environment may require changing these
items more often. The three-month checks will uncover
any need for more frequent replacement.
3
75-7268
Page 4
To drain tank, open drain cock, located in the middle
of the tank at one end. Allow a few seconds to purge the
tank
of water. Weekly draining is usually the minimum
requirement.
NOTE. The frequency of draining depends on climatic
conditions. In humid climates, daily draining
may be necessary.
Consider adding the
Honeywell
AK3485 automatic
drain kit.
Visually check the air intake filter on l/3- to
(0.25 to 1.49
kW)
compressors for build-up of foreign
2-hp
material on a routine basis. A dirty filter causes excessive
oil consumption, replace it.
The
3-hp
Air Maze
(2.24 kW) and larger units use the
filter silencer, which is checked for dirt by
Quincy
removing it from the unit and holding a strong light
against the intake openings. Light should be visible when
observing from the inside of the filter.
in
nonflammable
solvent or in warm, soapy water.
ash the filter
Check filter element condition by comparing tank
pressure to line pressure downstream from filter. If one
doesn’t exist, a gage tap may have to be installed in the
line
to read the pressure. The pressure difference should
not exceed 15
lb/in2 (100
kPa)
at any time. Filter ele-
ment should be replaced if the difference in pressure is
Fig. 1. Changing Filter Cartridge on
Safety relief valves are factory set to approximately
15 lb/in2 (100
compressor. Check each safety relief valve by pulling on
the ring to unseat it.
valves immediately. Safety relief’ valves are located next
to the pressure switch or on the tank.
approaching this limit. Subtract the line pressure reading
from the tank pressure. The difference should not exceed
lb/in2 (100 kPa).
15
Hand pressure should depress the belt about
(13 mm). Tighten the belt just enough to prevent slippage.
Adjust tension by loosening the motor hold-down bolts,
Allowing system pressure to drop to zero during
replacement
will
of element or gage tap installation
cause all
actuators in the system to assume
moving the motor until tension is correct, then retighten
the bolts. Insure that belt and pulleys are aligned. Replace
worn or frayed belts.
stem drawings for
Units.
-1/2
HP (5.60
7
kPa)
higher than the rated pressure of the
Replace or repair malfunctioning
.
6275
1/2
kW)
inch
To change a filter in the 7-l/2 hp (5.6 k
1.
to Fig.
Shut off air to filter at point (A) and bleed
down housing by manually operating drain trap (B).
Remove wing nut and clamp ring (C) from housing and
remove housing and automatic drain. Remove knurled
nut at bottom of filter and replace filter. Reassemble,
taking care that O-ring seal on bottom side of cover has
not been disturbed. Turn on air slowly, checking for
leaks.
PUMP 1/2”
FLYWHEEL
Fig. 2. Checking Belt Tension.
4
7.5-7268
Page 5
PRESSURES
During weekly checks, verify that the tank pressure is
in the 70 to 90
(480 to 620
range and each
prv pressure is at the proper setting.
WIRING
Dual Compressors usually have automatic alternation
between pumps after each pump cycle, and with automatic backup. See wiring options shown in Fig.
and
60HZ
SET PS-2
BELOW
CUT-IN PRESSURE
lb/in*
Fig. 4. Automatic Alternation with Automatic Backup.
For Single-Phase Internally Protected Motors
.
1
---0
PRESSURE SWITCHES
I *I
FUSES. FUSED DISCONNECT, OR CIRCUIT BREAKER
IF
-----
-----
---
M2
3
1
/
I
I
L2
COMP
#I
75-7268
IL----&’
MOTOR
STARTER
Fig.
Automatic Alternation with Automatic Backup. Three-Phase Motor with Low Voltage Control.
COMP
5
Page 6
PRESSURE
SWITCH
60HZ
ALTERNATOR
I
PRESSURE
SWITCH
SET PS-2 AND PS-3 TO OPERATE IN SEQUENCE, ABOUT 5-10
BELOW CUT-IN PRESSURE POINT OF PSl.
Fig.
Automatic Alternation with Backup and 11
OPERATIONAL CHECK
It is sufficient to confirm that both compressor pumps
have an off cycle and are not running continuously.
Switch over the manual alternation system or bleed air
from tank on automatic alternation system to confirm
startup and off cycle of both pumps.
I f-------
STARTER
_-i-
(35-70 kPa)
Isolated Control of Three-Phase Motors.
added devices or leaks. Increasing pump-up time with no
change in pressure range or off time indicates wear in the
compressor pump and may warrant closer observation as
it is usually followed by an increase in oil consumption.
Check backup operation by operating the safety relief
Measure the cut-in pressure, pump-up time, cut-out
pressure, and off time under normal operating conditions.
Pump-up time should be below 50 percent operation
(less on time than off time) and operate between 70 to
90
each pump using manual switch over if necessary.
(480 to 620
pressure. Check operation of
valve (see SAFETY RELIEF VALVE paragraph). The
second pump should cut in after the tank pressure has
dropped 5 to 10 lb/in2 (35 to 70
pressure for the first unit.
If wear is suspected, check the dead-ended pump-up
time (pumping up tank with the system off) against the
Record these figures for reference (a card attached to
the unit is handy). Decreasing off periods (with no change
in pressure range) indicate an increase in air consumption
with an increasing pump-up time. This could be due to
75-7268
value given in Table 3. If this time differs from the table
by more than 10 percent, troubleshoot according to
instructions given under WON’T PUMP AIR paragraph,
and take proper action.
6
below cut-in
Page 7
TROUBLESHOOTING
This section aids isolation of most common problems
and pinpoints causes.
Notify Honeywell Applications
Engineering (Arlington Heights) of any other problems
frequently encountered.
If oil pressure is low, check oil pump(s) and pressure
gage(s) by unscrewing the pressure gage(s) slowly until
oil seeps out around the threads during compressor(s)
operation. This indicates that oil pressure is reaching the
system and the pressure gage(s). The pumps require oil
pressure to operate intake valve unloaders and for lubrication. Lack of pumping ability indicates possible loss of
WRONG OIL PRESSURE
(0.75 kw) AND UP
oil pressure. If oil appears at the threads of the gage and
the oil pressure gage indicates no pressure, replace the oil
pressure gage. No oil appearing at the threads of the oil
gage indicates possible oil pump failure (see OIL PUMP
Oil pressure in the 10 to 20 lb/in2 (70 to 140
REPLACEMENT paragraph in the REPAIR section),
range is normal. The recommended operating pressure is
15
(100 kPa). There should be no pressure during
NOTE: A clogged oil intake filter will cause restricted
the off cycle.
OIL PRESSURE ADJUSTMENT
(See Fig. 6)
In cases of low (not zero) pressure, the cause may be
excessive wear in the pumping unit or a gage not in calibration. Check the pump-up time against Table 3 and listen
Check oil level before adjusting pressure
The oil
pressure is regulated by a spring-loaded ball mounted in
the bearing carrier on the same side as the dipstick,
for unusual knocks indicating worn bearings. If pump up
time is normal and no unusual noises are detected, recalibrate or replace the gage.
Loosen the adjustment lock nut before making any
adjustment. Turn the pressure adjusting screw slowly
clockwise (pressure increases) until the oil gage registers
approximately 15
(100 kPa). After adjustment,
tighten adjustment screw lock nut.
oil flow in the loop system and no air pressure
in the system. Clean or replace filter as necessary.
Table 3. Pump Up Time in
DIPSTICK
DRAIN PLUG
L PRESSURE ROTATION OF FLYWHEEL
I
OIL INTAKE FILTER (I TO 3 HP ONLY)
MAY BE REMOVED FOR CLEANING
AND INSPECTION OF CRANKCASE
ACCUMULATION
Fig. 6. Crankcase End View of l-HP (0.75
6280
Model.
OIL LEAKS
Oil leaks usually occur around screws and gaskets.
These are normally corrected by tightening screws or
replacing gaskets.
If unable to locate the source of the leak, clean the
unit as much as possible and sprinkle the suspected area
with talcum powder (avoid getting powder into intake).
After several hours, check powder to locate leak.
75-7268
Page 8
Excessive oil on the after cooler pipe or compressor
head usually indicates air leakage. Locate air leaks with
soap solution while the compressor is operating. While
the compressor is in the off cycle, check the unloaders
under pressure.
Excessive oil consumption is a difficult problem.
Before repair, take the following steps:
a. Confirm the Complaint-Oil at the tank drain does
not necessarily indicate high oil consumption.
Table 4 shows acceptable oil consumption in terms
of fill amount and time between refills.
Check pump-up and cycle pressures against the
values in Table 3. Differences greater than
per-
cent indicate worn parts (see WON’T PUMP
paragraph).
g. Remove valves and examine piston top for oil.
wetting is acceptable, but an accumulation of oil
indicates a defective pump.
The most common reason for a noisy pump is a loose
flywheel or motor pulley. Check for these first, then
check:
pressure-If low, check pump as described in
WRONG OIL PRESSURE paragraph. Lack of oil
pressure may have caused bearing damage.
assemblies -Make certain they are tight.
Oil capacity
in crankcase between high and low
Days running time between high and low dipstick
levels, based on three
oil per
air used
(31 ml oil per Ml air used) and 50 percent maximum duty cycle. Does not allow for spillage or
leakage.
Make certain proper grade of nondetergent oil is
being used (see Table 2) and compressors are not
being overfilled. Overfilling always causes high oil
consumption. Oil level should never be above the
high mark on the dipstick.
c. Check for leaks.
d. Check intake filter/piping and crankcase breather
valve(s) for cleanliness and obstruction.
e. Check for excessive oil pressure or high percent
operation (see LUBRICATION and PRESSURE
paragraphs in
section). If, after
performing the above, a unit is still considered an
oil consumer with no apparent external cause, then:
Wrist pin
connecting
bearings-Stop pump
and remove belts. Using the flywheel, rotate pump
back and forth about two inches (5 1 mm). If knock
is heard, a bad wrist pin or connecting rod bushing
probably exists. Inspect the rod bushings by
removing side plate and rod caps or remove head
and observe piston while rocking flywheel. Piston
should follow movement without play (except at
top and bottom dead center where piston appears
to hesitate). Inspect cylinder and head for carbon
build-up.
Bad main bearings-Check for end play by attempt-
ing to move flywheel in different directions. Listen
and feel for any play. End play on the crankshaft
is usually eliminated by removing one of the shims
beneath the bearing housing adjustment plate. A
slight drag, when turned by hand, is proper,
Check for a loose motor pulley. A low-pitch growl is
an indication
of low voltage.
If noise is slight, lubricate motor in accordance with
instructions on nameplate. Noise should disappear so
motor runs properly. Watch for dry bearings, as these
shorten motor life. To check bearings, stop motor,
remove belt and check for side play in motor shaft. Turn
motor by hand. Any side play or noise is an indication
of bad bearings. If bearings are bad, replace motor. End
play (movement or motor shaft in and out) is common
in this type of motor and is not an indication of wear.
Use a large screwdriver or similar implement. Place
the point end against suspected areas and the other against
the ear. Listen for abnormalities.
75-7268
8
Page 9
WARNING
Before using listening rod near spinning flywheel,
belts, etc, determine if it is long enough to avoid
moving parts.
In the l/2 and l/3 hp (0.37 and 0.25
a noise vibrating guard. Check the belt guard by applying hand
which cannot be traced to the pump is usually the check
CHART l-MOTOR WON’T START
CHECK CIRCUIT
BREAKER OR FUSE
CHECK PRESSURE
SWITCH,
TRACE WIRING
FIND FAULT
valve. (Larger units do not have a check valve.)
assemble the check valve and inspect. If cleaning does
not stop the noise, replace check valve.
I
Another noise which is not easily traceable is a
pressure to outside surfaces at different points.
DISCONNECT POWER,
COOL MOTOR
RECONNECT POWER
NO
REPLACE
MOTOR
REPLACE CAPACITOR,
STARTING SWITCH,
OR MOTOR
*ON l-HP (0.75 kW) OR SMALLER MOTORS, THERMAL OVERLOAD PROTECTORS MAY SHUT
MOTOR OFF AFTER A SHORT PERIOD OF TIME.
I
9
75-7268
Page 10
CHART 2-CIRCUIT BREAKER TRIPS (FUSE OPENS)
START
TROUBLESHOOTING
SEE
CHART 5
SEE
TROUBLESHOOTING
CHART 1
DISCONNECT POWER,
REINSTALL BELTS,
PLUG INTAKE (BY HAND),
RECONNECT POWER
TROUBLESHOOTING
YES
YES
NO
.
PROPERLY
*GROWL IS LOW VOLTAGE CLUE.
SEE
CHART 5 A
I
75-7268
10
Page 11
CHART 3-WON’T PUMP AIR
RUNS, BUT TANK SHOWS NO PRESSURE BUILD-UP
START
ISOLATE BUILDING
Al R SUPPLY
NO
TURN UNIT ON
*CRACKED DISCHARGE TUBE,
REPLACE
LOOK FOR AIR LEAK
BETWEEN PUMP AND
OUTLET VALVE*
YES
DISASSEMBLE
AND INSPECT
VALVES
,
REPAIR AS NEEDED,
SEE “PARTS LIST”
TANK, OPEN VALVE, ETC.
Page 12
UP SLOWLY, OR NOT COMPLETE
ISOLATE
BUILDING AIR
SUPPLY
.
(0.25 / 0.37
REMOVE DlSCtHARGE
TUBE, HAND BLOCK
_I.
HP
UP IIM
LOOK FOR AIR
LEAK BETWEEN
PUMP AND
OUTLET VALVE*
HP (0.56
I HM~ VALVES
REMOVE PISTON
CUP AND CLEAN
REPAIR 1
& UP
LINE
I
UNDERNEATH
SHUT OFF UNIT,
DISCONNECT COPPER LINE
REMOVE COVER BOLTS &
COVER (TAP WITH BLUNT
INSTRUMENT TO LOOSEN)
SLOWLY DEPRESS PISTON
TO FEEL RESISTANCE OF
RETURN SPRING AND
PISTON CONTACTING VALVE
NO
IN INTAKE
*CRACKED DISCHARGE TUBE, TANK, OPEN VALVE, E
75-7268
TC.
12
NORMAL
OPERATION
NO
VALVES, INSPECT
PISTON TOP AND
SEE “PARTS LIST”
Page 13
CHART 5-WON’T PUMP AIR
PUMP SLOWS, STALLS, OR TRIPS CIRCUIT BREAKER (FUSE OPENS)
CHECK FOR PLUGGED
DISCHARGE TUBE
DISCONNECT TUBE AT
COMPRESSOR PUMP
MOTOR DEt=ECTIVE,
REPLACE
NO
REPLACE OR REPAIR
PUMP, SEE “PUMP
REMOVAL & REPLACEMENT”
EXCESSIVE VIBRATION
This problem is usually due to omission of vibration
pads or an uneven weight distribution on the pads. Shut
unit off and apply weight to different corners of the unit.
Shim out excessive rocking. Use adjustable levelers for
uneven floors.
Belt guards often produce a vibrating noise even under
CLEAN OR
REPLACE
AND TEST
I
normal operating conditions. Readjust to eliminate or
reduce vibration noise.
Sometimes, even normal operation of the compressor
is considered excessive in noise or vibration. In such cases,
a remote air intake, adjustable pads, and air-line vibration
isolators may be required. Isolators are stocked by
Honeywell.
13
Page 14
REPAIR
PUMP REMOVAL
AND REPLACEMENT
If major repair is needed, order a Parts List for the
specific pump. See ORDERING INFORMATION paragraph in PARTS LIST section.
Shut off power to both units. Drain oil from faulty
unit, and bleed down tank. Remove belt guard, loosen
motor mounts and remove belt(s).
Remove discharge tube at pump end. If tube wraps
around crankshaft, remove both ends and any hold-down
straps.
If accessible, remove flywheel at this time. The l/2-hp
(0.27
and a puller will probably be necessary. All others use a
split hub and key. Remove flywheel by removing hub
bolts and nuts and driving a wedge into split.
line of 3/4 hp (0.56
unit is held on with a keyed shaft and setscrew
Remove pump intake filter and the unloader air supply
and up.
topple pump when the hold-down bolts are
Remove pump hold-down bolts, and pump. Remove flywheel if not done previously.
When installing new pump, be sure flywheel is in line
with motor pulley before removing wedge and tightening hub bolts.
NOTE: When removing discharge tube connector from
OIL PUMP REPLACEMENT
The oil pump is factory machined as an assembly, and
partial replacement is not possible. In the event the pump
(or crank bearing which is part of the pump) is faulty,
replace whole assembly. The assembly is held by four
bolts (see Fig. 7). Order the replacement oil gage sep-
arately if needed. After installation, adjust oil pressure
on replacement pump (see WRONG OIL PRESSURE
paragraph in TROUBLESHOOTING section).
old pump, loosely install the male coupling on
the discharge tube in the connection to prevent
collapse during removal.
75-7268
OIL PUMP
X1082-l
Fig. 7. Crankcase Group.
14
Page 15
BELT REPLACEMENT
(Refer to Fig. 2)
Disconnect electric power and loosen motor clamping
bolts. Slide motor towards pump. If the compressor has
a totally enclosed belt guard, remove it. Remove and
replace belt(s). Hold motor against belts when
ing so the belt(s) have no more than l/2 in. (13 mm)
total play. Make certain motor is square to belts. Reinstall
guard and turn on power.
NOTE: Sometimes new belts stretch excessively after
being installed. Recheck belt tension after one
week as stated in BELTS paragraph of MAINTENANCE section.
MOTOR REPLACEMENT
Before replacing motor, see NOISY MOTOR and
WON’T START paragraphs in TROUBLESHOOTING
section. If motor is defective, disconnect power and
replace. Use motor of identical type, hp, voltage, speed,
and frame when reinstalling motor. Reset belt tension,
see BELTS paragraph in MAINTENANCE section.
The 3/4-hp (0.56
unloaders on the intake valve(s). Some preliminary
checks on unloaders are described in CIRCUIT BREAKER
TRIPS (FUSE OPENS) paragraph in TROUBLESHOOTING section. The unloader for the l-hp (0.75
is shown in Fig. 9. All other units (3/4 hp, 0.56
l-l
Fig. 10.
Fig. 8. Unloader for l/3-HP (0.25
and larger units have automatic
hp, 1.1
and up) use the unloader shown in
DISCHARGE
/VALVE
ASS’Y
Unit.
unit
CAUTION
Many motors are dual voltage and/or reversible.
Check motor’s internal wiring against diagram on
motor or inside of wiring cover plate for proper
connections for voltage being used and/or rotation.
The compressor will pump air if rotated backwards
but will not cool properly.
INTAKE AND EXHAUST VALVES,
UNLOADER
Intake valves, exhaust valves and unloader mechanisms
can be disassembled for inspection, cleaning, or repair
for all compressor sizes except the l/2 hp (0.37
The l/2-hp (0.37
In the event the valves are deemed defective, replace
entire head assembly.
For the l/3-hp (0.25
locking nuts in the head. Remove valve parts for inspection See Fig. 8 for reassembly order.
unit has a head sealed assembly.
unit, remove the two valve
UNLOADER ASS’Y
INTAKE VALVE ASS’Y
Fig. 9. Air Unloading of Intake Valves--l HP (0.75
15
75-7268
Page 16
UNLOADER
ASSEMBLY
-HEAD
Fig. 12. Hydraulic Unloader Assembly-l-IHP (0.75
Units and Larger.
Fig. 10. Air Unloading of Intake
l-1/2 HP (1.1
and Up.
HP (0.56
The unloader pilot is located on the crankcase and is
connected to the unloader by a copper line. The l/2-
and
(0.37 and 0.56
units use a pilot that is
mechanically activated (see Fig. 11). All other units are
operated by oil pressure (see Fig. 12). Disassemble and
clean units if suspect. See PARTS LIST section for
repair kit numbers.
PRESSURE REGULATING VALVE
(PRV) STATION
The l/3- to
well
or PP902 PRV. For detailed maintenance
and repair information, see Form No. 75-2558.
The prv station used on the
combination of a Pall-Trinity-Micro Corp. filter, and a
Norgren regulator and relief valve (see Fig. 15 and
Table 3).
To perform maintenance and repair work on the prv
station, shut off air supply from tank. Bleed down the
system by manually operating the drain (push red button
on drain valve).
All valves and dampers return to the normal position when system is bled. Study job drawings for
critical problems before bleeding down system.
(0.25 to 1.5
CAUTION
units use a Honey-
(2.2
units is a
Fig. 11. Three-Way Valve Assembly-l/2- and 3/4-HP
(0.37 and 0.56
75-7268
Units.
The regulator and relief valve can now be replaced or
repaired with the appropriate repair kit (see PARTS
section).
After repairing or replacing, slowly turn air back on,
checking for leaks.
16
Page 17
PARTS LIST
INTAKE FILTERS
See Fig. 13 and 14.
R2373
Fig. 14. Quincy Air Maze Intake Filters.
FILTER-PRV ASSEMBLY
Fig. 13. Honeywell Intake Filter, Part No. J&3895-4.
Table 5. 7-l
Nomenclature 7-l/2 HP-WP241
Replacement element kit for
14003121-001. See Form 75-2558 for other
See Fig. 15 and Table 5.
HP Filter-PRV Parts List.
Refer all
Quincy Compressor
inquiries to
PRV is
parts.
Refer all inquiries to
Quincy Compressor
17
75-7268
Page 18
FRONT VIEW
6286
Fig. 15. Typical PALL-TRINITY-MICRO (PTM) Filter-PRV Assembly-for 7-l/2 HP (5.60
OTHER COMPRESSOR PARTS
Table 6. WP241 Duplex Air Compressor Parts List
Intake
Valve’
No.
Only
X2 Plain
-48 -56 -56
1 I
500 410 460 480 460 400 570 550 610
I -A-44 I -B-5
None
5993 7483X
8405 8405
106
3444 3444
108
1
1 I -B-45
7483X 8125 7483X
None None None None
Model Compressor
Motor
Motor Frame No
Motor Voitagc/Frcq/Phase
RPM- Compressor
V-Belt-Quantity, Type,
Unloader Dcvlce
Units.
2
(0 75) l-l/2(1
Part No AK38954
7970x 7970x 7970x 7970x 7970x 7970x
16
230
-B-54 2-B-60
7483X
325
3 (2 2)
2-B-60
7483X 718iY 7483X
None hone
FFH340
340
(3 7) 7-l/7
3-B-8
370
3-B-X
6)
75-7268
18
Page 19
ORDERING INFORMATION
PTM (Pall-Trinity-Micro) PARTS
(In United States)
When ordering parts, it is important to supply infor-
mation shown on the nameplate.
Order from local Quincy representative or:
Colt Industries
Quincy Compressor Division
Quincy, IL 62301
NOTE: Supply complete Quincy compressor serial
number as stamped on the nameplate of each
compressor when ordering parts or discussing
servicing or problems on a specific compressor.
See Fig. 16. A list of Quincy service depots is
included with the instructions packed with each
compressor.
Local distributor or:
Pall-Trinity-Micro Corporation
Cortland, NY 13045
Supply exact part number.
NORGREN PARTS
Local distributor or:
C .A. Norgren Company
Littletown, CO 80 120
Supply exact part number.
HONEYWELL PARTS
Local Honeywell Serviceline Center.
Supply part number and compressor model number,
Colt hdustries Quincy Compressor Division
DATE CODE 1
us A
6287
Fig. 16. Compressor Nameplate.
Mechanical devices must be serviced periodically if they are expected to give continued satisfactory performance,
and controls are not an exception. How accurate and how troublefree your control system will be in the years to
come depends largely on the maintenance given it. For best results, all devices in your system should be serviced
at one time.
Time and trouble can be saved by arranging with Honeywell for a maintenance agreement which will guarantee
expert, economical care, and insure maximum life and efficiency from your system.
19
75-7268
Page 20
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