Honeywell WP241Y, WP241B, WP241C, WP241D, WP241E Service Data

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

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.

SPECIFB

PRESSURE RANGE: Cut-in pressure-70 lb/in2 (483

kPa), Cut-out pressure -90

IONS

MAXIMUM AMBIENT TEMPERATURE: 104

lb/in2 (621 kPa).

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 1.6 (45) 2.9 0 (82) 4.7 (13.3) 5.4 (153) 5.9 (269) 13.3 (377) 16.0 (453) 24.3 (688) 40.0 (1l33)

1.1 (31)

2.8 3.2 3.6 3.2 3.6 3.6 5.1

1 1/4 1/4 1/4 1/4 1/4

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

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

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.

HAND PRESSUR

PUMP 1/2” (13mm) APPROXIMATE

FLYWHEEL

Fig. 2. Checking Belt Tension.

4

7.5-7268

PRESSURES

During weekly checks, verify that the tank pressure is
in the 70 to 90
prv pressure is at the proper setting.

lb/in2

(480 to 620

kPa)

range and each

II5VAC

60HZ

WIRING

OPTiONS

Dual Compressors usually have automatic alternation
between pumps after each pump cycle, and with auto­matic backup. See wiring options shown in Fig.

FUSES. FUSED DISCONNECT, OR CIRCUIT BREAKER

I+

IF

SPiClFlED

----a

---0

PRESSURE SWITCHES

r-

3,4

and

-----

-----

__----

7

*

SET PS-2

(35-70 kPd

BELOW
CUT-IN PRESSURE

5-10

lb/in*

6278-

Fig. 4. Automatic Alternation with Automatic Backup.

For Single-Phase Internally Protected Motors

Ody

.

COMP

#I

1

75-7268

:

I

ji

I

i

I *I

--I*

I

M2

3

Qs

I

L2

MOTOR
STARTER

---

/

TI ’

r--

L-4

I

IL----&’

L-------i

1

COMP

*2

6277-l

Fig. 3. Automatic Alternation with Automatic Backup. Three-Phase Motor with Low Voltage Control.

5

j+.-

115VAC

PRESSURE

SWITCH

60HZ

r----7

ALTERNATOR

-1

I

I

COMP+rl

1 SWITCH

PRESSURE

SWITCH

*

SET PS-2 AND PS-3 TO OPERATE IN SEQUENCE, ABOUT 5-10
BELOW CUT-IN PRESSURE POINT OF PSl.

Fig.

5.

Automatic Alternation with Backup and 11 SV Isolated Control of Three-Phase Motors.

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-

I f-------

STARTER

COMP*2

--L--L-.

LB/IN2

(35-70 kPa)

6279-l

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

lb/in2

(480 to 620

each pump using manual switch over if necessary.

kPa)

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

kPa)

below cut-in

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

IHP

(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

kPa)

REPLACEMENT paragraph in the REPAIR section),

range is normal. The recommended operating pressure is

15

lb/in2

(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

lb/in2

(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

Min:Sec.

DIPSTICK01 L PRESSURE ROTATION OF FLYWHEEL

xE

DRAIN PLUG

/

Fig. 6. Crankcase End View of l-HP (0.75

-)

~~~~i%JR:fii’%TS

I

OIL INTAKE FILTER (I TO 3 HP ONLY)

MAY BE REMOVED FOR CLEANING

AND INSPECTION OF CRANKCASE

ACCUMULATION

6280

kW)

Model.

WP241H

WP241J

8:45
5:45

2:lS

1:30

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

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.

XCESSSV NSUAA

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.

f.

Check pump-up and cycle pressures against the

values in Table 3. Differences greater than 10 per-
cent indicate worn parts (see WON’T PUMP

AIR

paragraph).

g. Remove valves and examine piston top for oil.

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:

Oil

pressure-If low, check pump as described in

WRONG OIL PRESSURE paragraph. Lack of oil

pressure may have caused bearing damage.

Valve

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 oz oil per

100,00C1 ft3

air used
(31 ml oil per Ml air used) and 50 percent maxi­mum duty cycle. Does not allow for spillage or
leakage.

b.

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

MAINTENANCE

section). If, after
performing the above, a unit is still considered an
oil consumer with no apparent external cause, then:

Wrist pin OY connecting

rod

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

r‘--p

WARNING

~1

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

kW)

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

TO

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.

Dis-

DISCONNECT POWER,

COOL MOTOR

RECONNECT POWER

NO

+

REPLACE

MOTOR

c

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

*

A

I1033

9

75-7268

CHART 2-CIRCUIT BREAKER TRIPS (FUSE OPENS)

START

0

TROUBLESHOOTING

SEE

CHART 5

,

SEE

TROUBLESHOOTING

CHART 1

4

1 YES

DISCONNECT POWER,

REINSTALL BELTS,

PLUG INTAKE (BY HAND),

RECONNECT POWER

TROUBLESHOOTING

t

YES

YES

SEE

CHART 5 A

-\

NO

4

.

PROPERLY

*GROWL IS LOW VOLTAGE CLUE.

I

I034

75-7268

10

CHART 3-WON’T PUMP AIR

-

RUNS, BUT TANK SHOWS NO PRESSURE BUILD-UP

START

9

ISOLATE BUILDING

Al R SUPPLY

NO

TURN UNIT ON

j YES

*CRACKED DISCHARGE TUBE,

REPLACE

+

LOOK FOR AIR LEAK

BETWEEN PUMP AND

OUTLET VALVE*

TANK, OPEN VALVE, ETC.

YES

4

DISASSEMBLE

AND INSPECT

VALVES

c

,

REPAIR AS NEEDED,

SEE “PARTS LIST”

11035

11

7.5-7268

CHART4-BUILDS

UP SLOWLY, OR NOT COMPLETE

,

ISOLATE

BUILDING AIR

SUPPLY

.

*

1/3

&

l/2

(0.25 / 0.37

REMOVE DlSCtHARGE

TUBE, HAND BLOCK

n I- CI

HP

kW)

_I.

REPAIR 1

L

UP IIM

1

3/4

HP (0.56

1

LOOK FOR AIR

LEAK BETWEEN

PUMP AND

OUTLET VALVE*

kW)

& UP

ZIPPER

I\

I HM~ VALVES

I

REMOVE PISTON
CUP AND CLEAN

UNDERNEATH

LINE

L

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

1

*CRACKED DISCHARGE TUBE, TANK, OPEN VALVE, E

75-7268

TC.

12

L

NORMAL

OPERATION

*

NO

VALVES, INSPECT

PISTON TOP AND

REPAI R AS NEEDED,

SEE “PARTS LIST”

11036

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

v

NO

REPLACE OR REPAIR

PUMP, SEE “PUMP

REMOVAL & REPLACEMENT”

I

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

1 CHECK VALVE

I

J

]

I1037

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

75-7268

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

kW)

unit is held on with a keyed shaft and setscrew
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.

Remove pump intake filter and the unloader air supply

line of 3/4 hp (0.56

If flywheel has not been removed, its weight may

topple pump when the hold-down bolts are

kW)

and up.

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

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.

retighten-

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 /2 hp, 1.1

Fig. 10.

Fig. 8. Unloader for l/3-HP (0.25

kW)

and larger units have automatic

kW;

and up) use the unloader shown in

kW)

Unit.

kW)

DISCHARGE

i

/VALVE

ASS’Y

‘I

unit

kW;

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.

kW)

unit has a head sealed assembly.

kW)

unit, remove the two valve

kW).

UNLOADER ASS’Y

INTAKE VALVE ASS’Y

Fig. 9. Air Unloading of Intake Valves--l HP (0.75

6282

kW).

15

75-7268

zii3x

UNLOADER
ASSEMBLY

-HEAD

6283

Fig. 10. Air Unloading of Intake

kW),

l-1/2 HP (1.1

kW)

Valves--3/4

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

3/4-hp

(0.37 and 0.56

kW)

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.

Fig. 12. Hydraulic Unloader Assembly-l-IHP (0.75

kW)

Units and Larger.

PRESSURE REGULATING VALVE

(PRV) STATION

The l/3- to

well

PP901

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).

2-hp

(0.25 to 1.5

kW)

units use a Honey-

or PP902 PRV. For detailed maintenance

3-11~

(2.2

kW)

units is a

Fig. 11. Three-Way Valve Assembly-l/2- and 3/4-HP

(0.37 and 0.56

75-7268

kW)

Units.

CAUTION

All valves and dampers return to the normal posi­tion when system is bled. Study job drawings for
critical problems before bleeding down system.

The regulator and relief valve can now be replaced or
repaired with the appropriate repair kit (see PARTS

LJST

section).

After repairing or replacing, slowly turn air back on,

checking for leaks.

16

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 /2 HP Filter-PRV Parts List.

Nomenclature 7-l/2 HP-WP241

Replacement element kit for

14003121-001. See Form 75-2558 for other

See Fig. 15 and Table 5.

Refer all
Quincy Compressor

inquiries to

PI?901 -PI?902

PRV is

prv

parts.

Refer all inquiries to
Quincy Compressor

17

75-7268

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

WP241Y WP24lB WP241C WP241D WP241E WP241F WP241G WP241H WP241J

Qumcy Model

Model Compressor
Motor

Motor Frame No
Motor Voitagc/Frcq/Phase
RPM- Compressor
V-Belt-Quantity, Type,

L,ength (In )
Air

Unloader Dcvlce

Unloader

rkk

Horsepower (kW)

Intake

Fdter

Valve’

Valve4

No.

i-

Only

FFHX2 FFlIlOh

X2 Plain

l/3 (0

-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

Loadless

‘5)

l/2 (0 37) 3/4 (0 56)1 (0 75) l-l/2(1

S/60/ 1

‘08/60/3 ‘30/60/3 460/60/3 208/60/3 230/60/3 460/60/3 460/60/3 460/60/3

1

3444 3444

FFIIl08 FFII210

108

Loadiess2 IO Loadlegs 2

1

-B-5

1 I -B-45

Iloneywell

7483X 8125 7483X
None None None None

kW)

Units.

.*

EFIJ216 FFH230

16

Loadless

-14x

Part No AK38954

7970x 7970x 7970x 7970x 7970x 7970x

-145T -145T

I

-B-54 2-B-60

230

Loadless

1)

2(1 5)

7483X

FFII325

325

Loadless

3 (2 2)

-182T

2-B-60

7069%

7483X 718iY 7483X

None hone

FFH340
340

Loadless

5

(3 7) 7-l/7 (S 6)

184T

3-B-8

1

70704 7071*

FF11370

370

Loadless

.71:-y - -

3-B-X

1

VCXlC

75-7268

18

ORDERING INFORMATION

PTM (Pall-Trinity-Micro) PARTS

(In United States)

When ordering parts, it is important to supply infor-

mation shown on the nameplate.

QUINCY PARTS

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.

~~

Colt hdustries Quincy Compressor Division

QUWKY, ~IIIIKHS

us A

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,

DATE CODE 1

j

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

SALES AND

ALABAMA GEORGIA

alrmingham, AL Aflanfa GA

(2051323

2431

Mob#le, AL
(205)

479 8572

ALASKA

Anchorage, AK

(907)

274 0551

ARIZONA

Phoenix AZ

(602) 249 7155

Turcon, AZ
(602)

795 4209

ARKANSAS

Litfle Rock AH

(501)

372 0166

CALIFORNIA

lWlrl% CA

(714)

557 643,

LOS Angeles CA

(213)

726

6161

Sacramento CA

1916)

485 0581

San mego CA

(714)

292 531 I

Ssn Franc~sco CA
(415)

957 2674

COLORADO

Denver (Engelwoodj CO

1303)

779 6295 or

1

800 332 7031 [Toll Free)

CONNECTICUT

Hartford CT

12031

762 3100

DISTRICT OF COLUMBIA

Ws.h,ngto” D C
(703)

827 3705

FLORIDA

Jackronv,lle FL

(904)

396 6971

Miami FL

(305)

592 8140

Orisndo FL
(3051 894 3131

Tampa, FL

(813)

870 3733

west

Palm Beach FL

(305)

683 1990

SERVHCE

HAWAII

IDAHO

ILLINOIS

INDIANA

IOWA

KANSAS

(McLean

VA

KENTUCKY

LOUISIANA

MAINE

(404) 32,

Honolul” HI

(808)

aoire

(208)

Chicago North

(312)

ChIcago South (Lanrenq)
(312)

Elgin IL
(312)

Lanrlng IL
(3121474 9300

Peoria
(309)

Fort Wayne IN

(2191

ind,a”apolls IN
(317)
X

Esttendorf

3705

Davenport IA

(319)

Des
(515)

Wlfchlta KA

(316)

Lo”ls”,iis KY

15021459 5970

aaron Rouge

(504)

New Orlsanr LA

(504)

Schrevaport

(318)

Portland ME

(207) 775

2495

537 5514

ID

375 1618

674 9770x354

5684200

697 7880

ii

692 0610 X 220

492 9654

243

0831

281

or 248

IA

Utscs

Ridge Rd

359 3441

MO,“% IA

288 3601

522 3431

924 8626

833 7241

LA

222 5325

3501

-

(il”coi”woo<

Lh

MARY LAND

Baltimore MU

(301

I 828 0900 x 247

MASSACHUSETTS

8”SfO” (Newton) MA

(617)

969 0250

MICHIGAN

Ustroit (FarmIngron Hails) MI

1313)

478 1600

Grand

31 IL

IL

Rap,& M,

(6161 247

4811

sag,naw Ml
(517)

792

8707

MINNESOTA

Minneapohs (Ed,na) MN

(612)

8303880

D”iUfh

MN

(218) 727 040,

MlSSlSSlPPl

Jackson

MS

[phone] NORTH DAKOTA

1601)

MISSOURI

Kansas CliY h”o

(8161

St

Lo”!* MO

(314)

MONTANA

Mlsrouia MT

(406)

NEBRASKA

Omaha
(4021331 3200

NEW HAMPSHIRE

Bedford NH

(603)

NEW JERSEY (419) 473 972, x

Mt Laurs, NJ

16091 234 2224

Parslp~any NJ
(201)

Wsrrfield, NJ
(201)

NEW MEXICO

Albuquerque NM Tulsa

(505)

or

833 724, Fargo

3584200

576 2566

728 7442

N8

625 6502

263 2225

233 9200

345 1656

NEW YORK

NORTH CAROLINA

OHIO

OREGON

Porrisnd OR

(503)

OKLAHOMA

Oklahoma Clfy OK

(405)8482811

($18)

Albsny

NY

(518)

456 7000

Buffalo

NY

(716)

835 2770

Long Idand NY

(2121392 4300

PlaInvIew

NY

(516)

931

,500

Roches*er NY

1716)

424 2700

Syracuse NY

13151451 4000

White

P,a,nes

NY

(914) 948 7511

Charlotte NC

(704)

364 4770

Greensboro NC

(919)

292

1556

NO

1701)

235 422,

Akron OH

1216)

733 2244

Canton OH

(216)

454 6960

Cincinnati OH

1513)

948 4185

Cleveland OH
(216) 361

7373

Colurnb”s

OH

16141 486 5971 X

Dayton OH

(5131

237 4035

Toiedo OH

YO”“gsfOL+” OH

1216)

747 0072

235 8411

OK

437 5934

PENNSYLVANIA

Hdrrlsburg PA

(717)

564 8000

Phiiadelphla

iValley

(215)

666 8302

Pittsburgh PA
(412)

928 4236

wllces

Barre PA

17171654

247,

RHODE ISLAND

Providence R,

(401)

438 6000

SOUTH CAROLINA

Col”mbla SC

(803)

28.8 1825 or

1803)

779 3240

Grsenvills

SC

1803) 288

7825

SOUTH DAKOTA

SIOUX

Fail* SD

(6051

336 0986

TENNESSEE

Memphis TN

(901)

345 6222

Nashville TN

1615)

385 3400 or

1 800

341

2314 (Toil Free1

TEXAS

ALIst,” TX

(512)

478

1788

El Paso TX
I91 5) 533 9924

Ft Worfh TX
(214)

263 2311

Ho”ston TX
(713)

780

6603

1 800 392 2328 (Toil

Lubbock TX

(806)

762 5202

San

Anton,*

TX

1512)

341 4691

JTAH

Salt Lake CltY

801)487

0681

VIRGINIA

tvlcl.sari (Wastungton u c I “A

(703)

8213705

Forge)

or

Free)

Richmond “A

PA

(804)

1

800 522

Roanok “A

(703)

Virginia aeach iNo,

(804)

WASHINGTON

SGatrls

(206)

233 2030

Spokane WA
(509)

328 4250

WEST VIRGINIA

Charleston WV

(513)

Clarksl?urg

(304)

623 655,

WISCONSIN

Apl3ie*on WI

(414)

Mad,*“”
(608)

Miiwa”kee
(414) 771

WYOMING

Carper WY

(307)

1 800 443 8446 (?Oll Freei

285

8111

3807 (Toll Free)

989 5201

461 0265

WA

948 4185

WV

4491

733

WI

222

1400

WI

6300

265 9374 or

or

tii

CANADA

ALBERTA

Calgary

Edmonton

BRlTlSH COLUMBIA

VWlCOUWr

INTERNATIONAL

-Honeywell Limited - Honeywell Limit&, 740 Ellesmere Road - Scarborough, Ont

-

SUBSIDIARIES AND AFFlLlATESt

ARGENTINA

BUENOS AIRES

AUSTRALIA

WATERLOO, N.S.W.

Adelaide
CC3tlbWf.Z
Darwn

Hobart
Melbourne
Perth
Queensland

Townsv~lle

Wollongong

AUSTRIA

VIENNA

Graz

Innsbruck

Klagenfurt
Llfl2

BELGIUM

BRUSSELS
Gent

LiegelGrlvegnee

Luxembourg

HONEYWELL*Minneapolis,

BRAZIL

SAO PAU LO

RIO de Janeiro

DENMARK

COPENHAGEN

Aarhus

FINLAND

ESPOO

Kuop~o
Tampere

FRANCE

BOIS

D’ARCY
Bordeaux

L1lle
Lyon
Marseilles
Nantes

StrasbOurQ

GERMANY

OFFENBACH/M

BErll”
Bonn
Duueldorf

Hamburg

Minnesota

MANITOBA

WinnlWQ

NEW BRUNSWICK

Mormon

Hannovsr

Llngs
Ma”“he,lT
M”“,Ch
Nurnberg
Stuttgart

nhag

HONG KONG

I RAN

TEHERAN

ITALY

MILAN

BOIOQ”~
FlC3”Ie
Padova
Rome
TOr,“O

JAPAN t

TOKYO

Chlba

AIN

Fukuoka
Fukuyama
HimI?]
Hiroshima
Kashims
Kitakyushu

55408*Scarborough, OntarioCubsidiaries

NEWFOUNDLAND

St John I

NOVA SCOTIA

Hallfax

B”

Kokura
Nap&h
Nagoya
Nlhama

Ft Washmgton, Pa (USA)
Los Angeles, Calif. (USA)

Otta

Okayama
Osaka
Sapporo

Tokuyama
Tomekomal
Toyama
Yokkalch!

GREECE

Aftlens

MEXICO

MEXICO CITY D.F

Monterrey

NETHERLANDS

AMSTERDAM

Schiphal Centrum

and Affiliates Around the World.*Printed in U.S.A.

ONTARIO

Hamilton

London

ottawcu
Sudbury

Toronto

WIndsor

NEW ZEALAND t

AUCKLAND

ChrIstchurch
DUnedIn
WellIngton

NORWAY

BERGEN

Sandvlka

Stavang%r

Tromro

Trondheim

PUERTO RICO

San Ju,irl

SINGAPORE t

SOUTH AFRICA

JOHANNESBURG
Capetown

Durban

Port Eluabsth

Pretoria

SPAIN

MADRID
Barcelona

Gljon

QUEBEC

MO”Ti?.3
Ouebsc

SASKATCHEWAN

Regina

Saskatoon

SWEDEN

STOCKHOLM
Goteborg

Malrno

Sundfvall

SWITZERLAND

ZURICH

Base

Bern

G%S3Va

TAIWAN t

TAIPE,

UNITED KINGDOM

LONDON Brackns,,

Belfast
Blrml”ghSm
CardIf+
Cheadie Huime
DUbilrY (Rep lrsiand,

East Kllbride (Scotla,xl)

Maldenhedd

Mlddlssbrough
Motherwell
Sheffteld

VENEZUELA

CARACAS

MarfY.2ibO
V&flClR