Powerex OPS, OPS030, OPS010, OPT Series, OPT050 Series Manual

Oilless Reciprocating Air Compressor Pumps

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product
described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in
personal injury and/or property damage! Retain instructions for future reference.

Description

GENERAL

Powerex utilizes cutting-edge compressor technology
to provide the most advanced oilless reciprocating air
compressor in the industry. The Powerex reciprocating
compressor is available in single and two stage models.
Continuously lubricated, sealed bearings provide oil-free
compressed air and long compressor life. The onboard fan,
finned flywheel and temperature reducing composite piston
create lower operating temperatures.

DRY TYPE INLET FILTER

The inlet filter on the oilless compressor assures 99% of
particulate free air, down to 10 micron, is admitted to the
unit. Change every 2500 hours or more often in dirty locations
(See Figure 5).

PISTON AND PISTON RINGS

The Powerex oilless reciprocating compressor pistons are
made of a high-strength, self-lubricating composite using the
most advanced technology available. These heat reducing
pistons eliminate the effect of excessive grease leakage at
the wrist pin bearing. PTFE rings reduce wear and provide
self lubrication. Piston rings should be replaced every 10,000
hours of operation (See Figure 12).

BEARING REGREASE

The wrist pin bearings of the OPS and OPT oilless compressors
are needle bearings protected by two outer lip seals. This
needle bearing becomes impacted and requires regreasing at
5,000 hours (See Figure 15).

BEARING SEALS

The wrist pin bearing lip seals prevent the lubricating grease
from leaking from the bearing area. The two lip seals on each
connecting rod require replacement every 10,000 hours (See
Figure 16-22 or page 9).

Specifications (Series)

Product OPS / OPT Series Powerex Air Compressor

Performance
Specifications

Lubrication Grease-filled Bearing

Pressure Settings Cut-In: 90 psig Cut-Out: 120 psig

Pumps

See Page 2

Cut-In: 125 psig Cut-Out: 145 psig
(High Pressure Unit)

Powerex • 150 Production Drive • Harrison, OH 45030 • USA
1-888-769-7979 • www.powerexinc.com

IN258607AV 1/12

Oilless Reciprocating Air Compressor Pumps

Specifications (Performance)

Model HP

OPS010 1

1.5

OPS030 2

3

OPT050 5 145 16.5 800 2 (1) 4.13 x

OPT100 7.5

10

OPT150 15 145 47.0 1140 3 (2) 4.13 x

Max.

PSIG

145 3.6

145 7.6

145 27.5

Safety Guidelines

This manual contains information that is very important
to know and understand. This information is provided for
SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help

SCFM @

100 PSIG RPM

5.3

10.1

35.0

625
885

845
1115

855
1090

No. of

Cyl. Bore Stroke

1 2.56 2.56 11.2 1 GR-A 24

2 2.56 2.36 13.8 1 GR-B 46

(1) 2.95

3 (2) 3.54 x

(1) 2.95

(1) 2.95

Installation

INSTALLATION SITE

1. The oilless compressor must be located in a clean, well lit

recognize this information, observe the following symbols.

Danger indicates an imminently

hazardous situation which, if

not avoided, WILL result in death or serious injury.

Warning indicates a potentially

hazardous situation which, if

not avoided, COULD result in death or serious injury.

Caution indicates a potentially

minor or moderate injury.

Notice indicates important

information, that if not

followed, may cause damage to equipment.

2. The area should be free of excessive dust, toxic or

3. Never install the compressor where the ambient

4. Clearance must allow for safe, effective inspection and

5. If necessary, use metal shims or leveling pads to level the

Flywheel

O.D. Drive

3.35 16.9 2 GR-B 97

3.35 18.3 2 GR-B 138

3.35 19.6 2 GR-B 141

Weight

(lbs.)

and well ventilated area.

flammable gases and moisture.

temperature is higher than 105° F or where humidity is
high.

maintenance.

compressor. Never use wood to shim the compressor.

Minimum Clearances

Breathable Air Warning

This compressor / pump is NOT equipped and should NOT
be used “as is” to supply breathing quality air. For any
application of air for human consumption, you must fit
the compressor/pump with suitable in-line safety and
alarm equipment. This additional equipment is necessary
to properly filter and purify the air to meet minimal
specifications for Grade D breathing as described in
Compressed Gas Association Commodity Specification
G 7.1 - 1966, OSHA 29 CFR 1910. 134, and/or Canadian
Standards Associations (CSA).

DISCLAIMER OF WARRANTIES
In the event the compressor / pump is used for the purpose
of breathing air application and proper in-line safety and
alarm equipment is not simultaneously used, existing
warranties are void, and Powerex disclaims any liability
whatsoever for any loss, personal injury or damage.

Above 24 inches

Drive belt side 12 inches

Other side 20 inches

VENTILATION

1. If the oilless compressor is located in a totally enclosed
room, an exhaust fan with access to outside air must be
installed.

2. Never restrict the cooling fan exhaust air.

3. Never locate the compressor where hot exhaust air from
other heat generating units may be pulled into the unit.

WIRING

Refer to the general safety guidelines manual. All electrical
hook-ups must be performed by a qualified electrician.
Installations must be in accordance with local and national
electrical codes.

Use solderless terminals to connect the electric power source.

2

Oilless Reciprocating Air Compressor Pumps

Installation (Continued)

PIPING

Refer to the general safety guidelines manual.

1. Make sure the piping is lined up without being
strained or twisted when assembling the piping for the
compressor.

2. Appropriate expansion loops or bends should be installed
at the compressor to avoid stresses caused by changes in
hot and cold conditions.

3. Piping supports should be anchored separately from the
compressor to reduce noise and vibration.

4. Never use any piping smaller than the compressor
connection.

5. Use flexible hose to connect the outlet of the compressor
to the piping so that the vibration of the compressor
does not transfer to the piping. Make sure the flexible

hose is rated for proper pressure and temperature before

installing.

SAFETY VALVES

A safety valve must be installed in the manifold or tank
where the compressor pump is installed. The flow capacity of
the safety valve must be equal to or greater than the capacity
of the compressor.

1. The pressure setting of the safety valve must be no
higher than the maximum working pressure of the tank.

2. Safety valves should be placed ahead of any possible
blockage point in the system, i.e. shutoff valve.

3. Avoid connecting the safety valve with any tubing or
piping.

4. Manually operate the safety valve every six months to
avoid sticking or freezing.

5. The safety valve must be ASME approved.

HOURMETER

The hourmeter on the oilless compressor indicates the
actual number of hours the unit has been in operation. The
hourmeter is also used to determine maintenance and service
timing. An hourmeter must be installed with every

oilless compressor.

Operation

Powerex oilless compressors operate at a standard pressure
of 120 PSIG. Two stage compressors operate at a maximum
of 145 PSIG and are equipped for continuous run operation.
Compressor RPM’s are established by Powerex based on
horsepower and operating pressure.

BEFORE START UP

1. Make sure all safety warnings, labels and instructions
have been read and understood before continuing.

2. Be sure all pressure connections are tight.

3. Check to be certain all safety relief valves, etc., are
correctly installed.

4. Make sure the inlet filter is properly installed.

5. Visually check the rotation of the compressor pump.
If the rotation is incorrect, have a qualified electrician
correct the motor wiring.

START-UP AND OPERATION

1. Follow all the procedures under “Before start-up” before
attempting operation of the compressor.

2. Switch the electric source breaker on.

3. Open the tank discharge valve completely.

4. Check that the compressor operates without excessive
vibration, unusual noises or leaks.

5. Close the discharge valve completely.

6. Check the discharge pressure. Also make sure the air
pressure rises to the designated pressure setting by
checking the discharge pressure gauge.

7. Check the operation of the pressure switch or the pilot
valve for continuous run units by opening the stop
valve and confirming the compressor starts or reloads as
pressure drops.

Switch the breaker off if the compressor is not to be used for
a long period of time.

CONDENSATE DRAIN VALVE

A condensate drain valve must be installed on any tank
to allow removal of the liquid which will collect during
compressor operation.

Drain liquid from

tank daily.

3

Oilless Reciprocating Air Compressor Pumps

Maintenance Schedule

Operating Hours

Item Action needed 500 2500 5000 10,000 15,000 20,000 Remarks

Tank Drain moisture Daily Drain tank daily

Inlet Air Filter Replace

Blower Fan Clean

Fan Duct Clean

Compressor Fins Clean

Bearings Replace

Compression Rings Replace

Wrist Pin Bearings Regrease Note 4

Piston Set Replace

Cylinder Inspect

Unloader Set Replace

Gasket Set Replace

Bearing Seal Wrist Pin Replace

V-belt Inspect, Replace Note 3

l Inspect
s Replace

Notes:

1. Inspect and perform maintenance periodically according to maintenance schedule.

2. The maintenance schedule relates to the normal operating conditions. If the circumstances and load condition are adverse,
shorten the cycle time and do maintenance accordingly.

3. The tension of the V-belt should be adjusted during the initial stage (500H) and inspected every 2,500 hours afterwards.
Proper belt tension for 1 to 3 HP units is 2-3 lbs./.5 inch deflection; for 5 to 15 HP units, 4-6 lbs./.5 inch deflection.

4. See page 8.

l s

l l l l

l l l l

l

l l s

l s l s

s s s s

s s

l l l l

l s l s

s s

s

l s s s s

Every 2500 hours or less

Every 2500 hours or less

2500 Hours - Air Filter Element Replacement

1. Remove wing nut.

2. Remove canister and wipe inside clean with dry cloth.

3. Remove and discard filter cartridge.

4. Install new filter cartridge. Do not attempt to clean and reuse filter cartridge.

5. Wipe inside clean with dry cloth.

Figure 5 - Air Filter Replacement

4

5000 Hours - Valve Inspection /
Replacement

Per OSHA regulations, ALL

power must be locked out

before performing any maintenance.

INSPECT VALVE SET

1. Remove head bolts from cylinder head.

2. Remove cylinder head and valve set. If it is difficult to
remove by hand, insert screwdriver between cylinder and
valve set and remove (See Figure 6 and 7).

INSPECTION AND MAINTENANCE

1. Check if exhaust valve (A) sticks to seat or is damaged
(See Figure 8).

2. Check if there is breakage, gouge or damage to
appearance of intake valve (B).

3. Lift intake valve 10 mm (3/8 inch) and check if there is
peeling and/or wear on coating surface of valve set (C).

Lifting intake valve too much

can cause damage to intake

valve.

4. Replace intake valve set if valve plate or valves are worn
or wear is over 0.5 mm (0.020 inches) in depth.
If exhaust valve rises upwards, clean seat surface of
foreign matter.

5. Clean the whole valve set taking care not to damage seat
surface and remove dust.

6. If viton seals (upper and lower) reach inspection time,
replace them. Even if its not time to inspect, be sure to
replace if they do not protrude from groove or seal has
hardened or been damaged.

7. Be sure to replace plastic seat in cylinder (See Figure 10).

8. Install valve set while paying attention to black plastic
seat of intake valve installed in cylinder (so that you do
not drop seat or insert tip of valve under seat).

9. Install cylinder head and tighten head bolts with
designated torque.

NOTES:

• Whenusingvalvesetagain,replaceupperandlower

viton seals.

• Whenreplacingvalveset,replacewithupperandlower

viton seals (valve set with packing set). You cannot reuse
disassembled valve set.

We are not responsible for any problems caused by reuse of
disassembled valve set.

Oilless Reciprocating Air Compressor Pumps

Figure 6

Figure 7

(B)

Check for
peeling or
wear (C)

REASSEMBLY

Assemble in reverse order of disassembling. Tighten each
section with designated tightening torque (See Chart on
page 6).

5

Figure 8

(A)

(A)

Oilless Reciprocating Air Compressor Pumps

Cylinder Inspection / Replacement

Per OSHA regulations, ALL

power must be locked out

before performing any maintenance.

INSPECTION / REPLACEMENT

1. Remove cylinder head and valve set. Pay attention not
to lose semicircular (black plastic) seat inserted at top
surface of cylinder (see Figure 9).

2. Remove cylinder bolts and pull off cylinder slowly. Make
sure piston does not drop down and get damaged. Note
cylinder orientation.

3. Inspect cylinder surface. If treated area is worn and metal
is exposed, replace. If there are several vertical scratches
at a narrow distance, replace (see Figure 10).

NOTE: Blackish streaks you can feel with your nail or finger
are not damage but sliding marks of piston and piston ring.
You do not need to replace the piston set or cylinder even
if there are several marks on the whole diameter of the
cylinder.

REASSEMBLY

1. Assemble in reverse order of disassembling cylinder.

2. Direction of cylinder is set so that semicircular spot
facing, to which seat (black plastic) is inserted, faces
toward flywheel side.

3. Tighten cylinder bolts with designated torque (refer to
chart below).

Figure 9

Replace if it
is scratched

Seat

Model

OPS010 / OPS030 156 in. lb. 156 in. lb.

OPT050 / OPT100 / OPT150 295 in. lb. 156 in. lb.

Cylinder Bolt

Torque

Head Bolt

Torque

Cylinder

Figure 10

6

Figure 11

Oilless Reciprocating Air Compressor Pumps

10,000 Hours - Piston Ring
Replacement

Per OSHA regulations, ALL

power must be locked out

before performing any maintenance.

INSPECTION / REPLACEMENT

1. Remove cylinder head tubing and cylinder bolts.

2. Pull cylinder and head assembly off slowly. Do not allow
piston to drop out of cylinder and get damaged.

3. Remove piston rings. Do not use ring tool to remove
ring. Expand by hand only wide enough to remove from
piston. Note orientation of each for proper replacement.

NOTE: Expanding ring too much and deforming can cause
wear and leakage. (See Figure 12). Mark upper surface (not
lower surface) of removed ring for easy distinction.

4. Inspect lower surface (A) and outer side surface (B) of
ring (See Figure 13). Measure thickness (C) of ring with
calipers. Replace if foreign matter enters (A, B) or deep
damage is found or (C) dimension is less than 2.5 mm
(0.10 inches) at any point around the rings circumference.

NOTE: Clean the whole ring and ring groove with soft clean
cloth.

Ring and piston dust build up

in the ring groove can cause

knocking. This is sometimes mistaken for bad valve or bearing.

Figure 12

Figure 13

Piston

O-ring

Figure 14

(A)(C)

Piston rings

Wrist pin

(B)

REASSEMBLE: Pay attention to the fit of the piston and wrist
pin fit. There should be no axial play or looseness in the wrist
pin area.

NOTE: Do not separate piston from connecting rod when
inspecting piston or ring. If you remove piston from
connecting rod, you may damage oil seal of connecting rod

and needle bearing.

PISTON INSPECTION/REPLACEMENT

1. Inspect for appearance; if there is deep damage or crack
on top of piston or at pin boss, replace piston.

2. Remove piston ring and inspect for breakage or droop of
ring land; if damage is found, replace piston.

3. Remove o-rings on both sides of wrist pin. Push wrist pin
to one side

NOTE: Install bearing retention sleeve in grease kit/piston set.
The retention sleeve is to prevent the needle bearing from
falling out of the bearing area. On the HP cylinder only.

4. Remove wrist pin; remove piston.

5. Install o-ring in flywheel side of new piston (see Page 8).

6. Install piston onto con rod. Slide wrist pin into place.
Install second o-ring. Make sure piston is in proper
direction (see Page 8).

7. Install rings in proper grooves (for inspection) and proper
gap orientation.

7

Oilless Reciprocating Air Compressor Pumps

10,000 Hours - Piston Ring
Replacement (Continued)

WRIST PIN BEARING REGREASE

1. Remove cylinder/head assembly and piston.

3. For high pressure wrist pin bearings, replace wrist pin
(#91924680). (OPT Pumps Only)

4. Replace cylinder/head assembly and piston as in
procedures above.

5. Tighten all fittings and bolts to designated torques.

2. For low pressure wrist pin bearings, fill needle area with
IP634500AJ Powerex approved grease.

Piston Orientation Chart for Oilless OPS / OPT Series

Pump Compressor Model Bore No. Cylinders

OPS010 65 mm 1 1

OPS030

OPT050

65 mm

LP 105 mm 1 1 Flywheel side

1 1

No. of Piston Rings

per Piston Mark on Top of Piston

Flywheel side

Fan Side

Flywheel side

Fan Side

HP 75 mm 1 2

LP 90 mm 2 1 Flywheel side

OPT100

HP 75 mm 1 2

LP 105 mm 2 1 Flywheel side

OPT150

HP 75 mm 1 2

Small end of connecting rod

Wrist pin

Small end of connecting rod

Figure 15

NOTE: The orientation in which the pistons are reinstalled
is very important. Improper placement will cause premature
wear of the ring and piston.

Fan Side

Fan Side

Fan Side

NOTE: When removing HP piston on two-stage pumps,

remove piston and then insert retention sleeve having
the same diameter of wrist pin or piston to small end of
connecting rod. If not, you may drop or lose needles from the
bearing, as HP needle bearing does not have support.

Fit piston by referring the

piston surface and list on above chart.

marking on the top of the

NOTE: Gradually insert wrist pin while turning it. Inserting
with force can damage oil seal of needle bearing.

* FOR LOW PRESSURE

WRIST PIN BEARINGS
ONLY

Oilless Reciprocating

Grease

6 Grams

#IP634500AV

Powerex

Oilless

Reciprocating

Grease

6 Grams

#IP634500AJ

8

Oilless Reciprocating Air Compressor Pumps

Wrist Pin Bearing Seal Replacement (Replace Every 10,000 Hours)

REPLACING OIL SEAL

Figure 16

1. Insert the plastic retention sleeve which protects the
needle bearing from dropping out.

Figure 18

3. Clean both surfaces where oil seals are removed.

Pushing Board

Figure 20

5. Press the oil seal with a C-clamp into the small bearing
end.

6. Repeat on opposite side.

Figure 17

2. Remove the two oil seals by using a screwdriver.

Figure 19

4. Push the oil seal into the small bearing end horizontally.

Figure 21

7. Apply a small volume of adhesive at several points.

Figure 22

8. Remove the retention sleeve inserted at the first step.

NOTE: You may use a “C” clamp or two large washers and
bolt with nut through the bearing. Then apply pressure
to install the seals. This makes it easy to replace the seals
without removing the crankshaft.

9

Oilless Reciprocating Air Compressor Pumps

20,000 Hours - Connecting Rod,
Wrist Pin and Crankshaft

Per OSHA regulations, ALL

power must be locked out

before performing any maintenance.

REPLACE CONNECTING ROD SET AND CRANKSHAFT
AS A SET

Pressing bearing into connecting rod and connecting rod
set into crankshaft requires special fixtures. Without such
fixtures, the squareness and parallelism of each part will be
affected.

REMOVE CYLINDER/HEAD ASSEMBLY AND PISTONS IN
THIS ORDER

1. Bearing at large end of connecting rod: Replace if it does
not move or feels stuck holding and moving small end of
connecting rod.

2. Bearing of crankshaft: Replace if you feel some resistance
when slowly turning shaft.

3. Bearing at wrist pin: Check for breakage of needle
bearing and damage of cage.

Figure 23

DISASSEMBLING: CRANKSHAFT SET

1. Remove cylinder/head, assemblies and pistons.

2. Remove bolts from bearing cap and remove bearing cap.

3. Lightly tap shaft fan side with non-shock hammer (avoid
metal hammer) and remove crankshaft. After bearing
leaves the crankcase bore, pull connecting rod out as
illustrated and remove it from crankcase (See Figure 23).

REASSEMBLY

1. Heat bearing housing of crankcase with industrial dryer
or simple burner just the same as disassembling.

2. Insert crankshaft set into crankcase in reverse order of
disassembling and insert bearing into housing.

3. Tap shaft from pulley side with non-shock hammer and
insert it inwards.

4. Fit bearing case. Grease bearing housing of bearing case.

5. Replace pistons and cylinder/head assemblies per the
inspection procedure listed previously.

10

Notes

Oilless Reciprocating Air Compressor Pumps

11

Oilless Reciprocating Air Compressor Pumps

Figure 24 - Replacement Parts Illustration for OPS010

12

Oilless Reciprocating Air Compressor Pumps

Ref. Part Number for Model
No. Description OPS010 Quantity

1 Cylinder 91000560 1

6 Cylinder head 91003630 1

16 Elbow (Unloader) 96800261 1

18 Unloader cap 91052041 1

27 Bolt (cylinder head) 96137835 4

33 Bolt (cylinder) 96137825 8

34 Bolt (bearing cap) 96137620 8

47 O-ring 91146550 1

51 Flywheel pulley 91201552 1

52 Parallel pin 91271550 1

62 Hex blot (fan, flywheel) 96992857 1

67 Piston set 91903640 1

67-1 Piston ring 91246640 1

72 Intake filter set 91906550 1

72-1 Intake filter ST073923AV 1

84 Screw (dust cover) 96131508 2

99 Seat (intake valve) 91301560 1

197 Lip seals wrist pin 97190162 2

200 Unloader set 91931561 1

500 Gasket set 91936640 1

600 Valve set with gasket 91933640 1

13

Oilless Reciprocating Air Compressor Pumps

Figure 25 - Replacement Parts Illustration for OPS030

14

Oilless Reciprocating Air Compressor Pumps

Ref. Part Number for Model
No. Description OPS030 Quantity

1 Cylinder 91000560 2

6 Cylinder head 91003640 2

16 Elbow (unloader) 96800261 1

17 Tee union assembly 96803261 1

20 Intake joint (1) 91345561 1

21 Intake joint (2) 91346571 1

24 Spring guide set 91932561 2

27 Bolt (cylinder head) 96137835 8

30 Flange (breather) 91176661 1

31 Bolt 96995831 20

33 Bolt (cylinder) 96137825 8

34 Bolt (bearing cap) 96137620 8

38 Filter (crank case) 91348690 1

47 O-ring 91146560 1

51 Flywheel pulley 91202560 1

52 Woodruff key 96600013 1

53 Hex nut 96994016 2

59 Fan 91220560 1

60 Cover (fan) 91134560 1

61 Hex bolt (fan, flywheel) 96992857 2

67 Piston set 91903640 2

67-1 Piston ring 91246640 2

72 Intake filter set 91907570 1

72-1 Intake filter ST073905AV 1

78 O-ring 96630032 2

79 Intake pipe 91407560 1

82 Screw (filter) 96131508 2

87 Tube 91909400 1

99 Seat (intake valve) 91301560 2

109 O-ring (intake joint) 96639906 2

193 Fan guard 91135560 2

195 Bolt (intake joint 1) 91095570 1

196 Bolt (intake joint 2) 91095560 1

197 Lip seals wrist pin 97190162 4

200 Unloader set 91931561 2

500 Gasket set 91936640 2

600 Valve set with gasket 91933640 2

15

Oilless Reciprocating Air Compressor Pumps

Figure 26 - Replacement Parts Illustration for OPT050

16

Oilless Reciprocating Air Compressor Pumps

Ref. Part Number for
No. Description Model OPT050 Qty.

1 Cylinder (LP) 91000680 1

2 Cylinder (HP) 91947680 1

3 Liner 91177680 2

6 Cylinder Head (LP) 91004690 1

7 Cylinder Head (HP) 91014680 1

14 Elbow (Intercooler) 91415690 2

17 Tee Union Ass’y 96803261 2

18 Unloader Cap 91052451 2

20 Intake Joint 91345660 1

24 Spring Guide Set 91949694 2

27 Bolt (Cylinder Head) 96137850 10

30 Flange (Breather) 91176661 1

31 Bolt (Unloader Cap) 96995831 26

33 Bolt (Cylinder) 96137130 8

34 Bolt (Bearing Cap) 96137830 10

38 Filter (Crank Case) 91348690 1

47 O-ring 91146430 1

51 Flywheel Pulley 91201660 1

52 Woodruff Key 96600016 1

53 Hex Nut 96994016 4

54 Washer 96991512 1

59 Fan 91220690 1

60 Cover (Fan) 91134660 1

61 Hex Bolt (Fan, Flywheel) 96992817 2

67 Piston Set (LP) 91903680 1

67-1 Piston Ring (LP) 91236681 1

68 Piston Set (HP) 91910673 1

68-1 Piston Ring (HP) 91930680 1

68-2 Wrist Pin (Prepacked) 91924680 1

72 Intake Filter Set 91907660 1

72-1 Intake Filter ST073905AV 1

Ref. Part Number for
No. Description Model OPT050 Qty.

82 Screw (Filter) 96235304 2

87 Unloader Tube 91420661 1

99 Seat (Intake Valve) 91301691 2

108 Intercooler Flange 91403690 1

109 O-ring (Intake joint) 96639906 2

110 Connecting Pipe 91400660 1

120 Bolt (Intercooler) 91435692 2

143 O-Ring (Connecting Pipe) 96632825 1

145 O-Ring (Connecting Pipe) 96632835 1

157 Hex. Bolt (Intercooler) 96996460 6

165 Nut (Intercooler) 96994015 6

171 Connecting Pipe Set 91955721 1

173 Intercooler 91404680 1

174 Intercooler Flange (1) 91405690 1

175 Intercooler Flange (2) 91406690 1

176 Gasket (Intercooler) 91432690 2

193 Fan Guard 91144660 2

196 Bolt (Intake Joint) 91344690 2

197 Lip seals wrist pin 97191000 4

200 Unloader Set 91932682 2

500 Gasket Set (LP) 91936680 1

550 Gasket Set (HP) 91937681 1

600 Valve Set with Gasket (LP) 91933681 1

650 Valve Set with Gasket (HP) 91934683 1

17

Oilless Reciprocating Air Compressor Pumps

Figure 27 - Replacement Parts Illustration for OPT100 and OPT150

18

Oilless Reciprocating Air Compressor Pumps

Ref. Part Number for Model
No. Description OPT100 OPT150 Quantity

1 Cylinder (LP) 91000670 91000680 2
2 Cylinder (HP) 91947680 91947680 1
6 Cylinder head (LP) 91004670 91004690 2
7 Cylinder head (HP) 91014680 91014680 1
14 Elbow (Intercooler) 91415690 91415690 4
17 Tee union assembly 96803261 96803261 2
18 Unloader cap 91052451 91052451 3
20 Intake joint (1) 91345691 91345691 1
21 Intake joint (2) 91346690 91346690 1
24 Spring guide set 91949694 91949694 3
27 Bolt (Cylinder head) 96137850 96137850 16
31 Bolt (Unloader cap) 96995831 96995831 30
33 Bolt (Cylinder) 96137130 96137130 12
34 Bolt (Bearing cap) 96137830 96137830 10
38 Filter (Crank case) 91348690 91348690 1
47 O-ring (Bearing cap) 91146690 91146690 1
51 Flywheel pulley 91201590 91201690 1
52 Woodruff key 96600016 96600016 1
53 Hex nut 96994016 96994016 6
54 Washer (Intercooler) 96991512 96991512 1
59 Fan 91220690 91220690 1
60 Fan cover 91134690 91134690 1
61 Hexagon bolt (Fan) 96992817 96992817 1
62 Hexagon bolt (Flywheel) 96992833 96992833 1
63 Hexagon nut (Intake joint) 96382086 96382086 1
67 Piston set (LP) 91903670 91903680 2
67-1 Piston ring (LP) 91236671 91236681 2
68 Piston set (HP) 91910673 91910673 1
68-1 Piston rings (HP) 91930680 91930680 1
68-2 Wrist pin set (prepacked) 91924680 91924680 1
72 Intake filter set 91907590 91907690 1
72-1 Intake filter ST073907AV ST073907AV 1
78 O-ring (Intake pipe) 96630032 96630032 2
79 Inlet pipe 91407691 91407691 1
82 Bolt (Crankcase filter) 96131508 96131508 4
87 Unloader tube 91420690 91420690 1
96 Unloader tube 91419600 91419600 1
99 Wear pad, valve 91301691 91301691 3
108 Intercooler Joint 91403690 91403690 1
109 O-ring ( Intercooler Joint ) 96639906 96639906 3
110 Connecting Pipe 91402680 91402680 1
120 Bolt ( Intercooler) 91435692 91435692 4
131 Cover Bracket 91413690 91413690 2
143 O-ring ( Connecting Pipe ) 96632825 96632825 2
145 O-ring ( Connecting Pipe ) 96632835 96632835 1
157 Hex bolt ( Intercooler ) 96996460 96996460 6
165 Nut ( Intercooler ) 96994015 96994015 6
171 Connecting Pipe Set ( 1 ) 91955780 91955890 1
172 Connecting Pipe Set ( 2 ) 91955790 91955900 1
173 Intercooler 91404680 91404680 2
174 Intercooler Flange ( 1 ) 91405690 91405690 2
175 Intercooler Flange ( 2 ) 91406690 91406690 2
176 Gasket ( Intercooler ) 91432690 91432690 4
193 Fan Guard 91135690 91135690 2
195 Bolt ( Intake Joint 1 ) 91343690 91343690 1
196 Bolt ( Intake Joint 2 ) 91344690 91344690 2
197 Lip seals wrist pin 97191000 97191000 6
200 Unloader Set 91932682 91932682 3
500 Gasket Set ( LP ) 91936670 91936680 2
550 Gasket Set ( HP ) 91937681 91937681 1
600 Valve Set with Gasket ( LP ) 91934691 91933681 2
650 Valve Set with Gasket ( HP ) 91934683 91934683 1

19

Oilless Reciprocating Air Compressor Pumps

Powerex Limited Warranty

Warranty and Remedies.

(a) General. Powerex warrants each Compressor System, Vacuum System, Vacuum Pump, Compressor Air-End, or Powerex branded

Accessory (collectively “Products”, individually each a “Product”) to be free from defects in material and workmanship (“Defects”)
at the date of shipment. EXCEPT AS SET FORTH BELOW, NO OTHER WARRANTY, WHETHER EXPRESS OR IMPLIED, INCLUDING ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL EXIST IN CONNECTION WITH THE SALE OR USE
OF SUCH PRODUCTS. TO THE EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED. All claims under this
warranty must be made in writing and delivered to Powerex, or such claim shall be barred. Upon timely receipt of a claim, Powerex shall
inspect the Product claimed to have a Defect, and Powerex shall repair, or, at its option, replace, free of charge, any Product which it
determines to have had a Defect at the time of shipment from Powerex; provided, however, that if circumstances are such as to preclude
the remedying of Defect by repair or replacement, Powerex shall, upon return of the Product, refund to buyer any part of the purchase
price of such Products paid to Powerex. Freight for returning Products to Powerex for inspection shall be paid by buyer. The warranties
and remedies herein are the sole and exclusive remedy for any breach of warranty or for any other claim based on any Defect, or non­performance of the Products, whether based upon contract, warranty or negligence.

b) Initial Period of Warranty – Parts and Labor. Powerex warrants and represents all Products shall be free from Defects for the
first twelve (12) months from the date of shipment by Powerex, or five thousand (5,000) hours of use, whichever occurs first. During
such warranty period, Powerex shall be fully liable for all Defects in the Products (the “Product Defects”), i.e., all costs of repair or
replacement, which may include “in and out” charges, so long as the Products are located in the continental United States, and the
Products are reasonably located and accessible by service personnel for removal. “In and out” charges include the costs of removing a
Product from buyer’s equipment for repair or replacement.

(c) Additional Period of Warranty – Parts Only (No Labor). In addition to the above, Powerex warrants each Powerex branded
Compressor Air-End, and Vacuum Pump shall be free of Defects for a period of thirty-six months from the date of shipment of Product, or
10,000 hours of use, whichever occurs first. Supplier’s repair or replacement of any Product shall not extend the period of any warranty of
any Product. This warranty applies to the exchange of part(s) found to be defective by an Authorized Powerex Service Center only.

(d) Coverage. The above mentioned warranty applies to Powerex manufactured units or systems only.

(e) Exceptions. Notwithstanding anything to the contrary herein, Powerex shall have no warranty obligations with respect to Products:

(i) that have not been installed in accordance with Powerex’s written specifications and instructions;

(ii) that have not been maintained in accordance with Powerex’s written instructions;

(iii) that have been materially modified without the prior written approval of Powerex; or

(iv) that experience failures resulting from operation, either intentional or otherwise, in excess of rated capacities or in an otherwise

improper manner.

(f) The warranty provided herein shall not apply to: (i) any defects arising from corrosion, abrasion, use of insoluble lubricants, or
negligent attendance to or faulty operation of the Products; (ii) ordinary wear and tear of the Products; or (iii) defects arising from
abnormal conditions of temperature, dirt or corrosive matter; (iv) any OEM component which is shipped by Powerex with the original
manufacturer’s warranty, which shall be the sole applicable warranty for such component.

Limitation of Liability. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, NOTWITHSTANDING ANYTHING TO THE CONTRARY
HEREIN, UNDER NO CIRCUMSTANCES SHALL POWEREX BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTAL, PUNITIVE, SPECULATIVE OR
INDIRECT LOSSES OR DAMAGES WHATSOEVER ARISING OUT OF OR IN ANY WAY RELATED TO ANY OF THE PRODUCTS OR GOODS SOLD
OR AGREED TO BE SOLD BY POWEREX TO BUYER. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, POWEREX’S LIABILITY IN ALL
EVENTS IS LIMITED TO, AND SHALL NOT EXCEED, THE PURCHASE PRICE PAID.

Warranty Disclaimer. Powerex has made a diligent effort to illustrate and describe the Products in this literature accurately; however,
such illustrations and descriptions are for the sole purpose of identification, and do not express or imply a warranty that the Products are
merchantable, or fit for a particular purpose, or that the Products will necessarily conform to the illustrations or descriptions.

Product Suitability. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use of Products for
certain purposes, which may vary from those in neighboring areas. While Powerex attempts to assure that its Products comply with such
codes, it cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a
Product, please review the Product applications, and national and local codes and regulations, and be sure that the Product, installation,
and use will comply with them.

Claims. Claims pertaining to the Products, with the exception of warranty claims, must be filed with Powerex within 6 months of the
invoice date, or they will not be honored. Prices, discounts, and terms are subject to change without notice or as stipulated in specific
Product quotations. All agreements are contingent upon strikes, accidents, or other causes beyond our control. All shipments are
carefully inspected and counted before leaving the factory. Please inspect carefully any receipt of Products noting any discrepancy or
damage on the carrier’s freight bill at the time of delivery. Discrepancies or damage which obviously occurred in transit are the carrier’s
responsibility and related claims should be made promptly directly to the carrier. Returned Products will not be accepted without prior
written authorization by Powerex and deductions from invoices for shortage or damage claims will not be allowed. UNLESS OTHERWISE
AGREED TO IN WRITING, THESE TERMS AND CONDITIONS WILL CONTROL IN ANY TRANSACTION WITH POWEREX any different
or conflicting terms as may appear on any order form now or later submitted by the buyer. All orders are subject to acceptance by
Powerex.

Powerex • 150 Production Drive • Harrison, OH 45030 • USA
1-888-769-7979 • www.powerexinc.com

20