V64103-3en0217

OPERATING INSTRUCTIONS
CTN10-16
Screw compressor

Version 1.10

F019684-

EN © 2015 Gardner Denver Oy

1. Introduction ............................................................................................................................ 1
1.1 Storing the books ......................................................................................................... 1
1.2 Warranty terms............................................................................................................. 1
1.3 Log book....................................................................................................................... 1
1.4 Inquiries........................................................................................................................ 1

2. Safety ...................................................................................................................................... 2
2.1 Safety during installation and preparations for use ...................................................... 2
2.2 Safety during operation ................................................................................................ 3
2.3 Safety during maintenance........................................................................................... 3
2.4 Safety signs.................................................................................................................. 4

3. Main components .................................................................................................................. 5

4. Handling instructions ............................................................................................................ 7

4.1 Storing the compressor ................................................................................................ 7
4.2 Lifting instructions (diagram) ........................................................................................ 7
4.2.1 Lifting the compressor with lifting wire.................................................................. 7
4.2.2 Lifting the compressor using forklift truck ............................................................. 8
4.3 Decommissioning ......................................................................................................... 8
4.3.1 WEEE (Waste Electrical and Electronic Equipment Directive) label .................... 8

5. Operating instructions .......................................................................................................... 9

5.1 First start-up of the compressor .................................................................................. 9

6. Operating principles ............................................................................................................ 10

6.1 Screw unit................................................................................................................... 10
6.2 Air compressing process ............................................................................................ 10
6.3 Oil circulation and the compressed air circuit............................................................. 11
6.3.1 Oil circulation...................................................................................................... 11
6.3.2 Compressed air circuit........................................................................................ 12
6.4 Compressor control system........................................................................................ 12
6.5 Capacity control.......................................................................................................... 13
6.6 Temperature sensor ................................................................................................... 13

7. Maintenance instructions ................................................................................................... 14

7.1 Before maintenance ................................................................................................... 14
7.2 After maintenance ...................................................................................................... 14
7.3 Service chart .............................................................................................................. 15
7.4 Adding and changing oil ............................................................................................. 16
7.4.1 Adding oil ........................................................................................................... 16
7.4.2 Changing oil ....................................................................................................... 17
7.5 Replacing the oil filter ................................................................................................. 17
7.5.1 Removing the oil filter......................................................................................... 18
7.5.2 Installing the oil filter........................................................................................... 18
7.6 Replacing the air filter................................................................................................. 18
7.7 Replacing the oil separator cartridge.......................................................................... 19
7.8 Checking for oil leaks ................................................................................................. 20
7.9 Checking the condition of hoses ................................................................................ 20
7.10 Cleaning the cooler .................................................................................................. 21
7.11 Replacing the belts................................................................................................... 22
7.12 Replacing the pulley and the conical sleeve ............................................................ 22
7.12.1 Removing the pulley of the motor..................................................................... 22
7.12.2 Installing the pulley and the conical sleeve of the motor .................................. 23
7.13 Testing the pressure relief valve .............................................................................. 25
 7.14 Oil recommendations ............................................................................................... 25
7.14.1 Recommended lubricants................................................................................. 25
7.14.2 Oil specifications .............................................................................................. 26
7.14.3 General guidelines for oil change intervals for mobile use............................... 26

8. Troubleshooting .................................................................................................................. 27

9. Technical Appendixes ......................................................................................................... 30

Declaration of Incorporation of CT and CTN

Declaration of Incorporation
(Machinery Directive 2006/42/EC, part B, Annex II) of CT- and CTN-compressors
Type: Oil-Flooded Screw Compressor (called “CT” in the following text)

This CT-compressor was Gardner Denver Oy

manufactured from: P.O.Box 516
FIN-33101 Tampere
Finland

The CT concerned is an air compression unit without an electric starter, type: CT3, CT6, CT12, CT25,
CTN2, CTN3 or CTN25. The CT name plate shows the model, the part number and the serial number
of the CT. This compressor is allowed to compress air and separately specified gases. The maximum
allowed operational temperature is 120°C.

The relevant technical documentation is compiled in accordance with part B of Annex VII of the
Machinery Directive. All the relevant information of the CT will be transmitted, in writing, in response to
a reasoned request by the national authorities. This shall be done without prejudice to the intellectual
property rights of the manufacturer of the CT.

Documenting unit: Gardner Denver Oy, Tampere

Engineering Manager, sustaining: Harri Väänänen

The following essential health and safety requirements of Directive 2006/42/EC, Annex I, are applied
and fulfilled:

• Principles of safety integration:

The incorporation of the CT in the pressurized air system shall be carried out only by qualified
personnel. Qualified personnel is, as a general rule, The Gardner Denver Service personnel or the
Service personnel authorized by Gardner Denver. The Service personnel should wear appropriate
clothing and eye protection during the assembly of the CT and the air system. Safety footwear and
safety glasses should be compulsory in all workshops. Safety helmets must be worn if there is any
risk of falling objects. Gloves are recommended.

• Materials and product:

The CT is essentially made of cast iron. Remainder of mineral compressor oil (used in test run)
could be inside the CT.

• Handling:
The packaging of the CT is done for safe transportation with a minimized risk of damaging during
transportation. The installation and commissioning of the CT should be done within 3 months after
delivery. If the CT should be stored over a long time period, please contact authorized distributor
of Gardner Denver for appropriate preservation.

Gardner Denver Oy
P.O.Box 516
FIN-33101 Tampere
Finland
Declaration of Incorporation of CT and CTN

The CT can only be moved and lifted by using of standard lifting gear. Eye bolts for attaching of
lifting tackle have already been installed or are enclosed. Install a minimum of two eye bolts to lift
the CT.

All openings and holes of the CT are covered and plugged during shipping. After removing covers
do not grasp into the CT! Be careful that no foreign particles or pollution could fall into the CT
during the assembly job or could end into the oil circuit.

• Protection against mechanical hazards

During the installation of the CT into the pressurized air network normally it’s required to
disassemble specific protective devices like coupling guard or V-belt guard. These specific
protective devices must be reassembled before commissioning of the compressor. Oil must be
filled in again according to the user manual. Follow the instructions of the compressor user
manual when commissioning the compressor.

• Risk of uncontrolled movements:

During the assembly job the compressor unit must be isolated from the main power supply.

• Risk of other hazards:

The essential health and safety requirements, mentioned in the user manual of the compressor
(machinery), must be fulfilled when the CT is incorporated into the pressurized air network and
first and foremost when the pressurized air network is commissioned or re-commissioned.

In particular the compressor discharge temperature and the discharge pressure must be
monitored with sensors, connected to the pressurized air control system, tripping ALARM or
SHUTDOWN when critical limits are reached.

The CT must not be put into service until the pressurized air network (final machinery) into which it is
to be incorporated has been declared in conformity with the provisions of Directive 2006/42/EC.

Tampere 15.12.2016
(Place) (Date)

(Signature)

Jussi Nurminen, Managing director

(Name, position in company)

Gardner Denver Oy
P.O.Box 516
FIN-33101 Tampere
Finland
1. Introduction

1. Introduction

Gardner Denver wishes you welcome among the users of Gardner Denver screw compressors!

This manual gives you instructions on correct and safe operation and maintenance of your screw
compressor.

Read these and other instructions with the compressor carefully before using your screw
compressor. This ensures correct preparations and use from the very beginning.

1.1 Storing the books

All the instructions in this manual have been provided to guarantee a long life and reliable operation of your
screw compressor.

Always keep the manual available near the compressor. Make sure that the compressor is operated and
serviced according to the instructions.

1.2 Warranty terms

Get acquainted with the Gardner Denver warranty terms, which are enclosed with the manuals for the
compressor. Fill in the warranty registration card with care and return it to the seller as instructed.

The warranty becomes void if the terms are not observed or if other than original Gardner Denver spare
parts are used. Use only the recommended AEON oil types in order to ensure undisturbed operation.

All the service and maintenance duties, which are not covered in this manual should be made only by
trained and qualified service personnel authorized by Gardner Denver or its representative.

1.3 Log book

There is a log book enclosed with the manuals for the compressor. Always fill it in after any maintenance or
repair work.

1.4 Inquiries

When making inquiries concerning your screw compressor, always quote the complete type specification
and the serial number as they are given on the data plate of the compressor.

Gardner Denver reserves the right to change the construction and manuals of the compressors without
prior notice.

1
2. Safety

2. Safety

The general safety instructions concerning the compressor are presented in this chapter.

Read also the safety instructions for transportation, installation, operation and maintenance
presented separately in each section of the manual.

Always read the safety instructions before starting to work.

The instructions concerning safety are marked with this symbol.

In addition to these instructions, the local regulations in your country may impose additional requirements
that must be observed.

2.1 Safety during installation and preparations for use

The noise level of the compressor, which is presented in the "Technical data" on page 31, is determined
according to ISO2151 and ISO3744. The noise level may rise higher if the walls surrounding the installing
location reflect sound. Take this into consideration, when choosing the best location for the compressor.

Observe the local regulations concerning the use of ear protectors.

The intake air for the compressor must be clean and cool. Prevent the used and hot cooling air
circulating back to the cooling air intake. Make sure that foreign objects cannot get into the compressor
with the intake air. The intake air must not contain any explosive or inflammable gases or harmful
substances.

Do not exceed compressor's rated maximum pressure, capacity or rotation speed. For more details see
"Technical data" on page 31.

Use pneumatic hoses that can hold the working pressure. Pay special attention to the hose mountings.
The pressure in the hoses must be removed before disconnecting. A whipping hose may cause
unpredictable damage.

The pressure vessels in the pressurized air network must be in accordance with the pressure vessel
regulations.

Only authorized and qualified personnel should make the electrical connections.

The condensate water contains oil. It should be disposed of according to the local regulations on waste oil.

2
2. Safety

2.2 Safety during operation

Do not blow pressurized air against the skin.

Use only the recommended AEON oil types. Do not mix different types of oil.

Do not use the compressor in EX classified environment.

2.3 Safety during maintenance

While doing maintenance, the compressor must always be stopped and disconnected from the electrical
mains connection. The shut-off valve of the pressurized air network must also be closed. Make sure that
there is no pressure in the air/oil receiver before starting maintenance.

Use only original Gardner Denver spare parts.

Do not repair the receiver by welding.

All alterations must comply with the pressure vessel regulations PED 97/23/EC.

Do the regular checkups and maintenance of the compressor in order to ensure undisturbed operation.

Maintenance and service operations other than described in this manual must be left to service personnel
authorized by Gardner Denver.

3
2. Safety

2.4 Safety signs

Read User Manual before starting the compressor Wear ear protectors

Warning: hot surface Warning: risk of electric shock

Warning: compressor is remotely controlled and

Warning: moving parts
may start without warning

Warning: risk of hot exhaust fumes/hot air

General meaning of geometric shapes, safety colors and contrast colors for the safety signs

Graphical symbol
Geometric shape Meaning Safety color Contrast color
color

Mandatory action Blue White White

Circle

Warning Yellow Black Black

Equilateral triangle

4
3. Main components

3. Main components

The screw compressor is an oil-cooled single stage screw compressor. The pressurized air is produced
with a screw air end driven by an electric motor. Oil is separated from the compressed air in an oil
separation receiver. Oil is cooled before injecting into the air end.

10
3 8
4

9 5 7 2

Main components CTN10

No. Part Function

1 Motor Rotates air end

2 Thermostat valve Prevents cold oil from entering the cooler

3 Inlet valve Controls air output

4 Air filter Cleans the inlet air

5 Air end Compresses air

6 Discharge valve Maintains minimum receiver pressure, non-return valve

7 Safety valve Protection against over pressure

8 Oil cooler Cools oil

9 Oil filter Purifies oil

10 Belts Transmits the power

5
 3. Main components

8 10
3
4
1

9 5 2 7

Main components CTN16

No. Part Function

1 Motor Rotates air end

2 Thermostat valve Prevents cold oil from entering the cooler

3 Inlet valve Controls air output

4 Air filter Cleans the inlet air

5 Air end Compresses air

6 Discharge valve Maintains minimum receiver pressure, non-return valve

7 Safety valve Protection against over pressure

8 Oil cooler Cools oil

9 Oil filter Purifies oil

10 Belts Transmits the power

6
4. Handling instructions

4. Handling instructions

4.1 Storing the compressor

If the compressor is stored for a long period of time, the stockroom must be dry and warm. Check the
functioning of the belt tightening before starting the compressor first time after the storing.

If the compressor is stored unused for over 12 months, please contact an authorised Gardner Denver
retailer before using the equipment again.

4.2 Lifting instructions (diagram)

Lifting and transporting the compressor requires caution. Check the compressor’s centre of gravity from
Dimensional drawings.

The water separator (if available) must be removed before lifting the compressor.

Do not go under the equipment when lifting the compressor.

4.2.1 Lifting the compressor with lifting wire

Lifting points
Lifting points

Lifting the compressor with lifting wire

7
 4. Handling instructions

4.2.2 Lifting the compressor using forklift truck

Insert the forks under the compressor in the directions shown in the following figure.

Lifting the compressor with a forklift truck

4.3 Decommissioning

When the compressor is decommissioned, the compressor oil, the oil filter and the oil separator elements
must be disposed of in accordance with local hazardous waste regulations.

Decommissioning

4.3.1 WEEE (Waste Electrical and Electronic Equipment Directive) label

The WEEE label means the product must be disposed of separately from other waste.
Appropriate recycling of the product helps to maintain a cleaner environment. For
more information about recycling the product, please contact your local authorised
Gardner Denver retailer.

8
5. Operating instructions

5. Operating instructions

5.1 First start-up of the compressor

Temperature sensor/gauge must be installed before first start -up !

The first start-up must be performed by qualified personnel.

1. Check for sufficient oil level in the receiver. For more information, see "Adding and changing
oil" on page 16 and "Oil recommendations" on page 25.

2. Open the shut-off valve of the compressed air network.

3. Make sure the screw elements rotate in the correct direction before starting the compressor .

Wrong rotation direction will damage the screw unit.

Correct rotation direction must always be ensured after the power supply or motor cables have been
disconnected and reconnected. Please look from the air end the arrow indicating the correct rotation
direction.

Do not control the air flow in the compressed air network using the shutter valve. Misuse of the shutter valve
may cause a rapid deflation of the system and increases oil consumption.

Temperature gauge (thread M14)

Temperature sensor (thread M10x1)

Temperature sensor/gauge placement

9
 6. Operating principles

6. Operating principles

6.1 Screw unit

Main components of the screw

unit

1. Housing

2. Female rotor

3. Male rotor

4. Discharge flange

5. Shaft seal

6. Bearing cover

Screw unit

6.2 Air compressing process

Rotors

In a screw compressor the air is compressed in the air end driven by a motor.

The meshing rotors take air in between the ridges as they pass the inlet opening. When the rotors turn, the
connection to the inlet opening closes and the space between the ridges starts to decrease. At the end of
the compression phase, the desired pressure has been reached and the connection to the receiver opens.

The air in the air end is cooled by oil that is injected into it. The oil cools also the air end. In addition, the oil
lubricates the bearings and seals the clearances between the rotors and the rotor housing.

10
6. Operating principles

6.3 Oil circulation and the compressed air circuit

Oil circulation and the compressed air circuit

6.3.1 Oil circulation

From the compressor air end the mixture of pressurized air and oil mist is ducted into the oil separating
receiver, where oil is separated from the pressurized air. The separating process has two phases.

Main part of the oil is separated in the cyclone (10) in the receiver, where the centrifugal effect is utilized.
The separated oil flows to the bottom of the receiver (11). The remainder of the oil is separated from the air
by means of oil separator (1). The oil separated in the oil separator is led back into circulation through the
oil return pipe (2). The return pipe is provided with an orifice plate (3) that prevents excess air recirculation
back into the compressor air end.

The internal pressure forces the oil back to the circulation through the oil cooler (8) and the oil filter (4).The
oil circulation is controlled by an oil thermostat valve (5). The oil thermostat valve controls the oil flow to the
oil cooler and to the oil cooler by-pass.

The forced oil circulation is maintained by the pressure difference between the receiver and the
compressor air end. To quarantee oil circulation whenever the compressor produces pressurized air, the
discharge valve (6) prevents the receiver pressure from dropping below the set minimum level (5 bar).

11
 6. Operating principles

6.3.2 Compressed air circuit

The compressed air is led out through the discharge valve (6). Alternatively (option) the compressed air is
led from the discharge valve to the after-cooler (7), where it´s temperature drops.

The pressure relief valve (9) protects the receiver against overpressure. It opens at a certain pressure,
preventing the receiver pressure from rising dangerously high.

6.4 Compressor control system

Compressor control system

The control system adjusts compressor output in accordance with the current air consumption and
maintains uniform pressure. It also cuts the power consumption for each cubic meter of pressurized air as
low as possible.

The output control range is continuous, and ranges from zero to full output capacity. Output is adjusted by
opening and closing the intake valve. The intake valve is controlled automatically by a control valve that
measures compressor pressure and regulates it so that it remains within a set fluctuation range (normally 1

12
6. Operating principles

bar). The fluctuation range limits the allowed output pressure, which may fluctuate because of changing air
consumption.

When the motor is stopped, the blow-down valve depressurises the receiver.

6.5 Capacity control

The pilot valve capacity control is factory set at max. operating pressure of the compressor.If the pressure
setting needs ajustment see the instructions below.

Correct operating pressure of the compressor including modulating control needs to be adjusted by having
intake valve totally open at normal working pressure (100% air capacity) and totally closed at maximum
pressure ( 0% air capacity).

First start the compressor. To adjust the cotrol valve pressure setting first loosen the lock nut (A). Start
closing the shut-off valve in the network gradually. See the pressure reading simultaneously from the
manometer. Do not exceed the max. pressure of the compressor ! If the setting is too low tighten the screw
(B) until correct pressure is reached. For lower pressure loosen the screw. For max. 8 bar compressor
control valve should start throttling at 7,3-7,5 bar. Remember to tighten the locking nut (A) after
adjustments.

Do not exceed the maximum pressure of the compressor ! See compressor data sheet to check maximum
pressure.

.
B

Capacity control

6.6 Temperature sensor/gauge

Temperature sensor/gauge must be installed before first start -up !

Compressor must never be used without temperature sensor. Misuse may cause
serious damage !

At 100°C the temperature alarm lights and at 115°C the compressor will stop.

Temperature sensor/gauge must be installed by Sandvik.

13
 7. Maintenance instructions

7. Maintenance instructions

Maintenance and service operations other than those described in this manual must be left to service
personnel authorized by Gardner Denver.

Always wear protective clothes and gloves during the maintenance.

Use only original Gardner Denver spare parts. The use of other spare parts may cause compressor damage.

7.1 Before maintenance

Before any maintenance operations, switch off the compressor with the main switch and make sure that the
compressor cannot be accidentally started.

There are hot surfaces in the compressor immediately after stopping.

1. Stop the compressor and make sure that there is no pressure in the receiver. Wait for 2
minutes after stopping for the blow-down function to empty the receiver.

2. Turn the power off at the main switch and make sure that the compressor cannot be
accidentally started.

3. Close the shut-off valve between the compressed air network and the compressor.

4. Open the pressure relief valve’s cap with 4 to 5 turns.

The space between the discharge valve and the system shut-off valve stays under pressure when the
compressor is stopped and the shut-off valve is closed. Release the pressure before starting maintenance.

7.2 After maintenance

1. Close the pressure relief valve.

2. Open the shut-off valve between the compressed air network and the compressor.

3. Start the compressor.

14
7. Maintenance instructions

7.3 Service chart

Record all maintenance operations in a maintenance log.

In the case of extreme operating conditions, it is advisable to halve the service intervals. The compressor’s
rapid cycling between unloading and loading will shorten the service intervals. Please contact an authorized
distributor of Gardner Denver for more information.

The maintenance intervals below are recommended for portable equipment and correspond approximately to
the maintenance interval of the motor and other components.

Service chart

Action 1 2 3 4 5 6 7 8 9

Check the correct running temperature *** x

Check the cooling air fan x
Check the oil level* x
Check for oil leaks x x x
Replace the oil filter x x
Check and retighten main motor cables x x
Change oil, see "Oil recommendations" on page 25 x
Replace the air filter x x
Change the belts x
Clean the cooler externally x x
Clean the compressor externally with a cloth x x x
Replace the oil separator cartridge x x
Clean the oil return line and replace the screen x x
Check the operation of the pressure relief valve x
Replace the seal kit of the inlet valve x
Replace the discharge valve x
Replace the oil hoses x x
Replace the blow-down valve x
Replace the seal kit of the pilot valve x
Replace the oil thermostat x
Replace the motor bearings x
Replace the shaft seal kit x
Replace the air end x
Check functioning of the thermometer safety limits** x

1) Daily 6) As required
2) After the first 50h 7) Every 3 years / 5000h
3) Every 500h 8) Every 5 years / 10 000h
4) Every 1000h 9) Every 10 years / 20 000h
5) Once a year
* Stop the compressor before checking the oil level. Wait until the oil is separated from the air, about 10 min.
** Thermometer´s functionality is tested by using a heater (operation range 0-120 °C) to heat the sensor to the temperature
limits. Do not use fire.
***standard thermostat will adjust running temperature to be min 70 °C. However, the correct running temperature must be 50...55
degree °C above the ambient temperature to avoid condensate into the system.

15
 7. Maintenance instructions

7.4 Adding and changing oil

Use only recommended AEON oil types. Do not mix different oils.

Oil is hot just after the compressor has stopped.

Do not open the oil filling plug or cooler drain plug if the system is pressurized.

Dispose used oil according to the waste oil regulations.

7.4.1 Adding oil

1. See "Before maintenance" on page 14 for precautions.

2. Open the oil filling plug (1) and add new oil until the oil-checking glass is filled. Note! Do not
over fill.

3. Close the oil filling plug (1).

4. Close the pressure relief valve (2) and open the network shut-off valve.

Adding oil

16
7. Maintenance instructions

7.4.2 Changing oil

1. Run the compressor until oil temperature is +40...+50°C.

2. See "Before maintenance" on page 14 for precautions before starting the work.

3. Open the oil filling plug (1) and the oil drain plug (3). Drain oil into a suitable receiver. Close the
oil drain plug (3).

Changing oil

4. Replace the oil filter, see "Replacing the oil filter" on page 17.

5. Add new oil and close the oil filling plug (1).

6. Close the pressure relief valve (2) and open the network shut-off valve.

7. (Start the compressor and let it run for 5 minutes. Stop the compressor and wait for a while so
that oil settles and the pressure drops. Add new oil again. Repeat this two times.

7.5 Replacing the oil filter

Allow the compressor to cool down before replacing the oil filter.

Dispose the used oil filter in accordance with local hazardous waste regulations.

Only use original Gardner Denver spare parts. The use of other spare parts may cause compressor damage.

17
 7. Maintenance instructions

7.5.1 Removing the oil filter

1. See "Before maintenance" on page 14 for precautions.

2. The oil filter is installed on the air end. Use a protective cloth, as some oil will drain out when
the filter is removed.

3. Remove the filter by rotating it counterclockwise.

Oil filter

Replacing the oil filter

7.5.2 Installing the oil filter

1. Lubricate the oil filter sealing ring with clean oil.

2. Install the filter by tightening it up clockwise by hand.

7.6 Replacing the air filter

The air filter cannot be cleaned or reused.

Remove the filter with caution. Make sure that particles do not get into the inlet air channel.

Use only original Gardner Denver spare parts. The use of other spare parts may compressor damage.

1. See "Before maintenance" on page 14 for precautions.

2. Remove the air filter cover (3) and the old filters(2).

18
7. Maintenance instructions

3. Clean the air filter housing (1).

4. Install the new air filters (2) and its cover (3) back to their places.

1 2 3 4

Replacing the air filter

Note! Install particle remover (4) always downwards.

7.7 Replacing the oil separator cartridge

Allow the compressor to cool down before the replacement.

Dispose the used oil separation cartridge in accordance with local hazardous waste regulations.

Use only original Gardner Denver spare parts. The use of other spare parts may cause compressor damage.

1. See "Before maintenance" on page 14 for precautions before starting to replace the oil
separator cartridge.

2. Remove the oil separator cartridge cover (1).

3. Remove the oil separator cartridge (2).

4. Clean orifices (3) in the hose ends.

5. Replace the filter strainer (4) and clean the oil separator housing.

6. Lubricate the O-ring (5) of the separator cartridge and install new separator cartridge (2) by
hand.

19
 7. Maintenance instructions

Replacing the oil separator cartridge

7.8 Checking for oil leaks

Visually check the compressor for oil leaks, in particular around the compressor unit, the oil cooler and the
oil hoses.

7.9 Checking the condition of hoses

Check all hoses for cracks, blisters, tears, leaks, and stiffness. Replace as required

Remove the pressure in the hoses before disconnecting.

Always use original pneumatic hoses that are rated to withstand the working pressure and temperature. Pay
particular attention to the hose installings as a lose hose can flail and cause unpredictable damage.

20
7. Maintenance instructions

7.10 Cleaning the cooler

A clogged cooler increases the output air temperature and may lead to a compressor stoppage.

Cleaning the cooler

Clean the cooler with pressurized air, see the picture. For a more effective cleaning, brush the cooler from
underneath. Note! Do not use a metal wire brush.

If the cooler is very dirty, remove it from the compressor and clean the outside with mild detergent.

For more information on cleaning the cooler, please contact an authorized distributor of Gardner Denver.

21
 7. Maintenance instructions

7.11 Replacing the belts

The weight of the motor keeps the belts correctly tensioned.

A ( 0,24 : 1 )

Screw

Replacing the belts

1. See "Before maintenance" on page 14 for more details.

2. Untighten the screw counterclockwise until the belts are loose enough. (The screw pushes the
motor up so that belts loosen.)

3. Change the belts.

4. Return the screw to its original position.

7.12 Replacing the pulley and the conical sleeve

7.12.1 Removing the pulley

Remove the two screws and insert one into the removal hole. Tighten the screw evenly until the sleeve
comes off the hub. Remove the loose pulley manually from the shaft, taking care not to damage the shaft
(do not hammer). Sleeve comes off with the pulley.

22
7. Maintenance instructions

Removing the pulley

7.12.2 Installing the pulley and the conical sleeve

Inserting the conical sleeve to the pulley

1. Remove protective grease from the sleeve and the pulley hub. Fix the sleeve to the pulley and
align the holes.

2. Grease the two fixing screws (1), insert them into the holes shown in the figure, and tighten
lightly. Threads are in the pulley.

Installing the pulley

23
 7. Maintenance instructions

3. Clean the shaft, and install the pulley with the sleeve on it. Note that the sleeve fastens first,
after which the pulley can still be moved a bit in relation to the sleeve. Bear this in mind when
aligning the pulleys.

4. Tighten the screws to equal tightness with a spanner.

5. Knock the sleeve lightly with a drift, and retighten the screws. Repeat this a few times to
make sure the sleeve is firmly fixed in place.

6. Check the tightness of the screws from time to time.

7. Fill the extraction holes e.g. with grease to protect them against dirt.

Sleeve Tightening
torque (Nm)
1610 20

2012 31

2517 49
NOTE! Sleeve type is marked on the end of the sleeve

24
7. Maintenance instructions

7.13 Testing the pressure relief valve

All adjustment and repair operations of the pressure relief valve must be performed by qualified
maintenance technicians. All local regulations must be observed.

The compressor must be stopped and secured from automatic restart before attempting this procedure.

The opening pressure of the pressure relief valve must be tested in a separate pressurized air line. The
pressure relief valve has been tested at the manufacturer's site before shipping out the compressor. If the
valve has been replaced, it needs to be tested for proper operation. This procedure can be performed only
by a qualified mechanican.

The operation of the valve can be tested by turning the cap (1) counter-clockwise 1 to 2 turns. Always
tighten up the pressure relief valve cap properly to avoid damage caused by vibration.

Testing the pressure relief valve

7.14 Oil recommendations

These oil recommendations are for Gardner Denver screw compressors in industrial use.

7.14.1 Recommended lubricants

Gardner Denver compressors are factory filled with AEON lubricants. These lubricants are formulated to
the highest quality standards and are factory authorized, tested and approved for use in screw
compressors. AEON lubricants are available through your authorized Gardner Denver compressor
distributor.

25
 7. Maintenance instructions

7.14.2 Oil specifications

Recommended lubricants for the compressor:

• Gardner Denver AEON 3000 (mineral oil) factory first fill.

• Gardner Denver AEON 9000 SP (synthetic oil) by request.

Recommended lubricants for the compressor

Package size AEON 3000* order no. AEON 9000 SP order no.

3 X 5 litres pack 033 891 44 -

20 litres 033 891 42 897 560 89

209 litres 033 891 43 897 676 89

* first fill

7.14.3 General guidelines for oil change intervals for mobile use

For recommended oil change intervals, please see the table below.

Recommended oil change intervals

Running temperature of AEON 9000 SP oil change

AEON 3000 oil change interval
the compressor interval

70–87°C 500 hours 1 000 hours

88–92°C 500 hours 1 000 hours

≥ 93°C 300 hours 500 hours

Operating temperature of the compressor can be seen in temperature gauge. (Not supplied).

Specific AEON lubricants are recommended for use in this equipment. Other lubricants will cause:

• shortened life time of oil filter, oil separating cartridges and oil
• varnishing and blockage of oil circuit
• increased oil consumption
• excessive oil carryover and compressor damage

Do not mix different types of oil

Note! If wrong oil type has been used or oil circuit is varnished, please contact an authorized distributor of Gardner
Denver for oil circuit cleaning instructions.

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8. Troubleshooting

8. Troubleshooting

Troubleshooting table

Problem Possible cause and repair

• Check the condition and suitability of

the protection devices for the voltage
No power supply supply. Please contact an authorized
distributor of Gardner Denver for more
details.

Find out the cause of overheating:

• oil filter clogged
• wrong oil type or oil level too low
• cooler clogged, clean externally
Compressor stopped due to
• recirculation of hot cooling air
overheating.
• cooling air volume insufficient
• ambient temperature too high
COMPRESSOR IS • oil separator cartridge clogged
STOPPED AND FAILS TO • oil thermostat valve faulty
START • Check the wiring of the motor and the
Electrical fault
tightness of the cable connectors

• Check that the maximum pressure is

not exceeded
• Check the supply voltage
• Check the oil level to between min-
max
• Check the oil separator cartridge, max.
Motor overloaded.
0.7 bar over the network pressure at
load
• Check discharge valve, min. pressure
5 bar
• Check the temperature and volume of
the cooling air at the inlet, clean motor

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 8. Troubleshooting

Troubleshooting table

Problem Possible cause and repair

Air filter clogged • Replace

Oil separator cartridge • Replace

clogged

Inlet valve faulty • Repair or replace

Discharge valve or • Repair or replace

condensate drain faulty

Leaks in the compressed • Check and repair the leaks

OUTPUT IS INSUFFICIENT air system

Incorrect pressure settings • Readjust

• Ensure sufficient cooling air circulation

Ambient temperature too
• Ensure that the inlet air is from the
high
coolest possible place

• Prevent the flow of cold cooling air to

After-cooler frozen
the compressor

Pressure relief valve open • Close the cap of the valve by hand

Oil return line clogged • Clean

Oil separator cartridge • Replace

faulty

Oil separator cartridge • Replace

clogged

• See "Oil recommendations" on page

Wrong oil type
25.
OIL CONSUMPTION IS TOO
HIGH Discharge temperature too • Find out and eliminate the cause
high.

Leakage • Check and repair

Oil level too high • Lower the oil level

• Readjust the pressure limits

• Please contact an authorized
Rapid pressure loss
distributor of Gardner Denver for more
details

• Replace the seal kit

Inlet valve seal is leaking • Inspect the check valve function of the
inlet valve and the blow-down line
INLET VALVE LEAKS OIL
AFTER STOPPING • Lower oil level, check oil quality /
Oil foaming too much
check rapid pressure loss

Check oil separation • Repair

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8. Troubleshooting

Troubleshooting table

Problem Possible cause and repair

Cooler clogged • Clean the outside

Ambient temperature too • Check cooling air circulation

high

Oil level too low • Add oil

• See "Oil recommendations" on page

COMPRESSOR IS Wrong oil type
25.
OVERHEATED.
Oil filter clogged. • Replace

Oil thermostat element not • Replace

functioning

Oil separation cartridge • Replace

clogged

Pressure in the receiver • Wait until pressure drops

COMPRESSOR STARTS Supply voltage too low • Check the supply voltage
TOO SLOWLY
• See "Oil recommendations" on page
Wrong oil type
25.

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 9. Technical Appendixes

9. Technical Appendixes

Technical data

Dimensional drawings

30