Unlok

Instruction Manual and Replacement Parts List
GSA Units
High Pressure Breathing Air Compressor Unit
C-D/DV/Navy
June 1, 2010 2nd Edition, Rev. 2 Chg. 4 MNL-0237

©1997 - 2010 Bauer Compressors, Inc.
BAUER Compressors, Inc. Phone: (757) 855-6006
1328 Azalea Garden Road Fax: (757) 855-6224
Norfolk, Virginia 23502-1944 www.bauercomp.com
C-D/DV/Navy
This information is believed to be accurate by Bauer Compressors, Inc., as of it’s date of publication, but
Bauer offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set
forth herein. Bauer shall not be liable for inaccuracies in, or consequences resulting from, your use of this
information. All information supplied is in connection with sales of Bauer’s products, and is thus subject
to Bauer’s standard terms and conditions of sale. Bauer reserves the right to change this information and
has no obligation to update these materials. This information is copyrighted by Bauer Compressors, Inc.,
and Bauer reserves to itself all rights to this publication. Bauer’s customers have no right to reproduce,
rewrite, modify, license or permit anyone else’s use of this information, without the express written per-
mission of Bauer Compressors, Inc.
^ WARNING
This Instruction Manual and Replacement Parts List contains safety information and instructions
for the C-D/DV/Navy High Pressure Breathing Air Compressor Unit.
You must read, understand and follow all safety precautions and instructions.
Editions, Revisions and Changes

• An Edition is the original or a complete rewriting of the entire Manual.
• A Revision occurs whenever a complete Section or Appendix is rewritten or added.
• A Change occurs when individual pages, drawings or tables are changed
Page i 2nd Edition, Rev. 2 Chg. 4

MNL-0237
1st Edition: April 1997
Rev Chg Date Notes Auth

0 0 April 1997 JB
2nd Edition: January 2002
Rev Chg Date Notes Auth

0 0 Jan. 2002 JH
Addition of Moisture Indicator, Frame & Supplemental Man-

1 0 Apr. 2002 JD
ual for ENG-0045. Deletion of SCUBA Fill Hose Parts List
1 1 July 2002 Deletion of OIL-0001 from recommended oil JD
1 2 July 2003 Correcting Item indexing of Figure 7-1 JD
1 3 Jan. 2004 Change to OIL-0015, Add HAN-0048 JD
1 4 Aug. 2004 Added MSDS for Molsiv Adsorbents JD
1 5 Feb. 23, 2005 Added Separator Clamp, Changed Fill Hose Assembly parts JD
1 6 July 22, 2005 Typographical Error Corrections JD
1 7 Jan. 31, 2006 Update and correction to current as built JD
1 8 Apr. 11, 2006 Calibration of Safety Valves & GAG-0010W/CAL JD
1 9 July 12, 2006 Changed P/N of 3rd Stage Intake Valve JD
1 10 Aug. 17, 2006 Corrected Oil Pressure Specification to 750 psi JD
1 11 Jan. 1, 2007 Corrected reference to further paragraphs. JD
1 12 May 30, 2007 Cross References updated, Introduction added JD
1 13 Jan. 16, 2008 Updated Final Safety Valve P/N from 011523 to 065410-330 CLA
1 14 Feb.29, 2008 Added Vibration Isolator replacement to Drive Chapter CLA
1 15 June 26, 2008 Corrected 3rd Stage Valve Replacement Procedure SS
2 0 Oct. 6, 2008 Updated to Standard Manual Format CLA

2 1 Oct. 17, 2008 Added Drive Section with Parts List SS
2 2 Nov. 14, 2008 Updated Specifications SS
2 3 Oct. 7, 2009 Updated Block P/Ns SS
2 4 June 1, 2010 Updated Block P/Ns SS
June 1, 2010 Page ii

C-D/DV/Navy
EFFECTED PAGES of CHANGES
Edit./Rev. / Chg. Effected Pages Edit. / Rev. / Chg. Effected Pages

1st Edition All Rev. 1, Chg. 7 All
2nd Edition All Rev. 1, Chg. 8 62
Revision 1 62, 61, 68 & Appendix G Rev. 1, Chg. 9 31
Rev. 1, Chg. 1 3 Rev. 1, Chg. 10 4
Rev. 1, Chg. 2 73 Rev. 1, Chg. 11 5
Rev. 1, Chg. 3 12 & 70 Rev. 1, Chg. 12 1—8
Rev. 1, Chg. 4 MSDS Sheets Rev. 1, Chg. 13 59, Item 11
Rev. 1, Chg. 5 27, added page 62 Rev. 1, Chg. 14 64, Item 8
Rev. 1, Chg. 6 21 — 24 Rev. 1, Chg. 15 28
Revision 2 All Rev. 2, Chg. 3 35, 39

Rev. 2, Chg. 1 63 — 65 Rev. 2, Chg. 4 33
Rev. 2, Chg. 2 6
Page iii 2nd Edition, Rev. 2 Chg. 4

MNL-0237
TABLE OF CONTENTS
CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION
1.1 HOW TO USE THIS MANUAL......................................................................................................................................... 1
1.1.1 Manual Safety Notices ....................................................................................................................................................... 1
1.2 HOW TO USE THE REPLACEMENT PARTS LIST .................................................................................................... 2
1.3 HOW TO USE THE APPENDIX....................................................................................................................................... 3
1.4 DESCRIPTION AND SPECIFICATIONS ....................................................................................................................... 4
1.4.1 Unit Description ................................................................................................................................................................. 4
1.5 THEORY OF OPERATION .............................................................................................................................................. 5
1.5.1 Drive................................................................................................................................................................................... 5
1.5.2 Air Flow ............................................................................................................................................................................. 5
1.5.3 Cooling ............................................................................................................................................................................... 5
1.6 C-D/DV/NAVY SPECIFICATIONS .................................................................................................................................. 6
CHAPTER 2: - - - - - - - - - - - - - - - - - - - - - - - OPERATION
2.1 INITIAL USE ....................................................................................................................................................................... 7
2.1.1 General ............................................................................................................................................................................... 7
2.1.2 Preoperational Tasks .......................................................................................................................................................... 7
2.2 ROUTINE USE .................................................................................................................................................................. 10
2.2.1 Prestart Checks................................................................................................................................................................. 10
2.2.2 Diesel Engine Start-up Procedure .................................................................................................................................... 10
2.2.3 Post Start Procedures........................................................................................................................................................ 11
2.2.4 Bottle Fill Procedures....................................................................................................................................................... 12
2.2.5 Shutdown Procedures....................................................................................................................................................... 13
CHAPTER 3: - - - - - - COMPRESSOR BLOCK - KC-FH CAPITANO

3.1 MAINTENANCE AND PARTS ....................................................................................................................................... 14
3.1.1 Description ....................................................................................................................................................................... 14
3.1.2 Component Location ........................................................................................................................................................ 14
3.1.3 Lubrication System (See Figure 3-2) ............................................................................................................................... 14
3.1.3.1 Type of Oil.................................................................................................................................................................... 15
3.1.3.2 Oil Level Check............................................................................................................................................................ 15
3.1.3.3 Oil Change .................................................................................................................................................................... 16
3.1.3.4 Venting the Oil Pump ................................................................................................................................................... 17
3.1.3.5 Oil Pressure Regulator.................................................................................................................................................. 18
3.1.4 Intake Filter ...................................................................................................................................................................... 19
3.1.4.1 Description.................................................................................................................................................................... 19
3.1.4.2 Intake Filter Maintenance ............................................................................................................................................. 19
3.1.5 Intermediate Separator ..................................................................................................................................................... 19
3.1.5.1 Maintenance.................................................................................................................................................................. 20
3.1.6 Cooling ............................................................................................................................................................................. 21
3.1.6.1 Maintenance.................................................................................................................................................................. 21
3.1.7 Compressor Valves and Heads......................................................................................................................................... 21
3.1.7.1 Functional Description. ................................................................................................................................................ 21
3.1.7.2 General Instructions for Changing the Valves.............................................................................................................. 21
3.1.7.3 Tolerances and Limits ................................................................................................................................................ 23
June 1, 2010 Page iv

C-D/DV/Navy
3.1.7.4 Changing the 1st Stage Valves .....................................................................................................................................24
3.1.7.4.1 Removing the 1st Stage Pressure Valve .......................................................................................................................24
3.1.7.4.2 Removing the 1st Stage Inlet Valve .............................................................................................................................25
3.1.7.4.3 Reassembly of the 1st Stage Valves .............................................................................................................................25
3.1.7.5 Changing the 2nd Stage Valves ....................................................................................................................................26
3.1.7.5.1 Removing the 2nd Stage Pressure Valve. .....................................................................................................................26
3.1.7.5.2 Removal of the 2nd Stage Inlet Valve ..........................................................................................................................27
3.1.7.5.3 Reassembly of the 2nd Stage Valve Head and Valves .................................................................................................27
3.1.7.6 Changing the 3rd Stage Valve ......................................................................................................................................29
3.1.7.6.1 :Removal of the 3rd Stage Pressure Valve ...................................................................................................................29
3.1.7.6.2 Removal of the 3rd Stage Inlet Valve...........................................................................................................................30
3.1.7.6.3 Reassembly of the 3rd Stage Valves.............................................................................................................................30
3.1.8 Replacement Parts List .....................................................................................................................................................31
3.1.8.1 Troubleshooting and Repair..........................................................................................................................................45
3.1.8.1.1 Troubleshooting Table ..................................................................................................................................................45
3.1.8.1.2 Repair............................................................................................................................................................................46
3.2 MANUAL CONDENSATE DRAIN SYSTEM ...............................................................................................................47
3.2.1 Description .......................................................................................................................................................................47
3.2.2 Operation ..........................................................................................................................................................................47
3.2.3 Unloaded start...................................................................................................................................................................47
CHAPTER 4:- - - - - - - - - - - - - - MAINTENANCE SCHEDULE

4.1 C-D/DV/NAVY MAINTENANCE INTERVALS ...........................................................................................................48
4.1.1 Maintenance Records ......................................................................................................................................................49
CHAPTER 5:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

5.1 PURPOSE ...........................................................................................................................................................................50
5.1.1 General .............................................................................................................................................................................50
5.2 P1 PURIFICATION SYSTEM .........................................................................................................................................50
5.2.1 Component Description....................................................................................................................................................51
5.2.1.1 Coalescing Oil/Water Separator. ..................................................................................................................................51
5.2.1.2 Condensate Drain Valve ...............................................................................................................................................51
5.2.1.3 Moisture Indicator.........................................................................................................................................................52
5.2.1.4 Purification Chamber ....................................................................................................................................................52
5.2.1.4.1 Purifier Cartridge ..........................................................................................................................................................52
5.2.1.5 Vent Valve ....................................................................................................................................................................52
5.2.1.6 Pressure Maintaining Valve..........................................................................................................................................52
5.2.1.7 Safety Valve..................................................................................................................................................................52
5.2.2 Maintenance .....................................................................................................................................................................53
5.2.2.1 Cartridge Operating Life...............................................................................................................................................53
5.2.2.2 Calculating the Maximum Purification Cartridge Operating Hours.............................................................................53
5.2.2.3 Calculating the Adjusted Purification Cartridge Operating Hours ...............................................................................53
5.2.2.4 Adjusted Cartridge Operating Hours ............................................................................................................................53
5.2.2.5 Coalescing Oil/Water Separator ...................................................................................................................................55
5.2.2.6 Moisture Indicator.........................................................................................................................................................56
5.2.2.7 Purification Chamber ....................................................................................................................................................57
5.2.2.8 Cartridge Leaking after Installation ..............................................................................................................................57
5.2.3 Replacement Parts List .....................................................................................................................................................59
Page v 2nd Edition, Rev. 2 Chg. 4

MNL-0237
CHAPTER 6: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

6.1 DIVE UNITS ...................................................................................................................................................................... 63
6.1.1 Maintenance of the V-belt and Sheave ............................................................................................................................ 63
6.1.1.1 Checking the Sheave..................................................................................................................................................... 63
6.1.1.2 Checking the V-belt...................................................................................................................................................... 64
6.2 REPLACEMENT PARTS LIST ...................................................................................................................................... 65
CHAPTER 7: - - - - - - - - - - - - - - - - - - - - MISCELLANEOUS
7.1 VALVES.............................................................................................................................................................................. 66
7.1.1 Nonadjustable Valves....................................................................................................................................................... 66
7.1.2 Pressure Maintaining Valve ............................................................................................................................................. 66
7.1.3 Safety Valves.................................................................................................................................................................... 67
7.1.3.1 Safety Valve Adjustment.............................................................................................................................................. 67
7.2 CALIBRATION OF SAFETY VALVES AND PRESSURE GAUGES ....................................................................... 67
7.3 FILL HOSE REPLACEMENT PARTS LIST................................................................................................................ 68
CHAPTER 8: - - - - - - - - - - - - - - - - - - - - - - - - APPENDIX
8.1 MAINTENANCE REFERENCE DATA ......................................................................................................................... 69
8.1.1 Tightening Torque Values................................................................................................................................................ 69
8.1.1.1 Torque Sequence Diagrams.......................................................................................................................................... 69
8.1.2 Approved Lubricants Chart.............................................................................................................................................. 70
8.1.3 Glossary of Abbreviations and Acronyms ....................................................................................................................... 70
8.2 SAFETY PRECAUTIONS................................................................................................................................................ 71
8.2.1 General ............................................................................................................................................................................. 71
8.2.2 Safety Warning Labels ..................................................................................................................................................... 73
8.3 LONG TERM STORAGE AND PRESERVATION ...................................................................................................... 73
8.3.1 General ............................................................................................................................................................................. 73
8.3.2 Preparations...................................................................................................................................................................... 73
8.3.2.1 Units Equipped with a Filter System ............................................................................................................................ 74
8.3.3 Preserving the Compressor............................................................................................................................................... 74
8.3.4 Preventive Maintenance During Storage.......................................................................................................................... 74
8.3.5 Lubrication Oils for Preservation ..................................................................................................................................... 74
8.3.6 Reactivating the Compressor Unit ................................................................................................................................... 75
8.4 INSTALLATION............................................................................................................................................................... 75
8.4.1 Unpacking and Handling.................................................................................................................................................. 75
8.4.2 Ventilation........................................................................................................................................................................ 76
8.4.2.1 Outdoor Installation ...................................................................................................................................................... 76
8.4.2.2 Indoor Installation......................................................................................................................................................... 76
8.4.2.3 Natural Ventilation ....................................................................................................................................................... 76
8.5 REPRODUCIBLE MAINTENANCE RECORD FORMS ............................................................................................ 77
8.5.1 Scheduled Maintenance Form ......................................................................................................................................... 77
8.5.2 Record of Operating Hours .............................................................................................................................................. 80
8.6 ADDITIONAL DATA ....................................................................................................................................................... 81
8.7 DRIVE MOTOR SUPPLEMENT.................................................................................................................................... 81
June 1, 2010 Page vi

C-D/DV/Navy
LIST OF FIGURES
CHAPTER 1:- - - - - - - - - - - - - - - - - - - - - INTRODUCTION
Figure 1-1 Compressor Identification Plate ..............................................................................................................................2
Figure 1-2 C-D/DV/NAVY Air Compressor ............................................................................................................................4
Figure 1-3 Air Flow Diagram....................................................................................................................................................5
CHAPTER 2:- - - - - - - - - - - - - - - - - - - - - - - OPERATION

Figure 2-1 Compressor Oil Dipstick .........................................................................................................................................7
Figure 2-2 Purification Cartridge Installation ...........................................................................................................................8
Figure 2-3 Fill Hose ..................................................................................................................................................................8
Figure 2-4 Hose Connection......................................................................................................................................................9
Figure 2-5 Air Intake Hose........................................................................................................................................................9
Figure 2-6 Moisture Indicator and Bleed Valve........................................................................................................................9
Figure 2-7 Manual Drains .........................................................................................................................................................9
Figure 2-8 Fuel Valve..............................................................................................................................................................11
Figure 2-9 START/STOP Control ..........................................................................................................................................11
Figure 2-10 Recoil Starter .........................................................................................................................................................11
Figure 2-11 Decompression Lever ............................................................................................................................................11
Figure 2-12 Final Relief Valve..................................................................................................................................................12
Figure 2-13 Filling Storage Bottles ...........................................................................................................................................13
CHAPTER 3:- - - - - - COMPRESSOR BLOCK - KC-FH CAPITANO

Figure 3-1 KC-FH Capitano Compressor Block, Front View.................................................................................................14
Figure 3-2 Lube Oil Circuit.....................................................................................................................................................15
Figure 3-3 Compressor Oil Dipstick .......................................................................................................................................16
Figure 3-4 Oil Dipstick Markings ...........................................................................................................................................16
Figure 3-5 Venting the Oil Pump ............................................................................................................................................17
Figure 3-6 Oil Pressure Regulator...........................................................................................................................................18
Figure 3-7 Intake Filter............................................................................................................................................................19
Figure 3-8 3rd Stage Intermediate Separator...........................................................................................................................20
Figure 3-9 Valve Operation.....................................................................................................................................................21
Figure 3-10 Permissible Tolerances ..........................................................................................................................................23
Figure 3-11 Checking the Piston ...............................................................................................................................................23
Figure 3-12 1st Stage Valve Head and Valves..........................................................................................................................24
Figure 3-13 2nd Stage Valves ...................................................................................................................................................26
Figure 3-14 Peening the Inlet Valve..........................................................................................................................................28
Figure 3-15 3rd Stage Valve Head and Valves .........................................................................................................................29
Figure 3-16 Removing the 3rd Stage Pressure Valve ...............................................................................................................30
Figure 3-17 Crankcase Assembly..............................................................................................................................................31
Figure 3-18 1st Stage Valve Head and Valves..........................................................................................................................34
Figure 3-19 2nd Stage Valve Head and Valves.........................................................................................................................35
Figure 3-20 3rd Stage Valve Head and Valves .........................................................................................................................37
Figure 3-21 Intermediate Separator...........................................................................................................................................38
Figure 3-22 Intake Filter............................................................................................................................................................39
Figure 3-23 Cooling System......................................................................................................................................................41
Figure 3-24 Lubrication System................................................................................................................................................43
Figure 3-25 Manual Condensate Drains....................................................................................................................................47
CHAPTER 4:- - - - - - - - - - - - - - MAINTENANCE SCHEDULE

There are no Figures in this Chapter
Page vii 2nd Edition, Rev. 2 Chg. 4

MNL-0237
CHAPTER 5: - - - - - - - - - - - - - - - - PURIFICATION SYSTEM

Figure 5-1 Purification Dataplate............................................................................................................................................ 50
Figure 5-2 P1 Purification System .......................................................................................................................................... 51
Figure 5-3 Moisture Indicator ................................................................................................................................................. 52
Figure 5-4 Correction Factor for Cartridge Operating Hours ................................................................................................. 54
Figure 5-5 Example Record of Adjusted Operating Hours..................................................................................................... 54
Figure 5-6 Oil and Water Separator ........................................................................................................................................ 55
Figure 5-8 Purifier Cartridge Replacement............................................................................................................................. 57
Figure 5-9 Oil/Water Separator............................................................................................................................................... 59
Figure 5-10 P1 Purification Chamber ....................................................................................................................................... 61
CHAPTER 6: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

Figure 6-1 Dive Unit Drive ..................................................................................................................................................... 63
Figure 6-2 Tensioning ............................................................................................................................................................. 63
Figure 6-3 C-D/DV/Navy Drive ............................................................................................................................................. 65
CHAPTER 7: - - - - - - - - - - - - - - - - - - - - MISCELLANEOUS
Figure 7-1 Pressure Maintaining Valve .................................................................................................................................. 66
Figure 7-2 Safety Valves......................................................................................................................................................... 67
Figure 7-3 Calibration Label, LBL-0300 ................................................................................................................................ 67
Figure 7-4 Fill Hose Assembly ............................................................................................................................................... 68
CHAPTER 8: - - - - - - - - - - - - - - - - - - - - - - - - APPENDIX
Figure 8-1 6 Bolt and 4 Bolt Torque Sequence....................................................................................................................... 69
June 1, 2010 Page viii

C-D/DV/Navy
CHAPTER 1: INTRODUCTION
1.1 How To Use This Manual
This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod-
ucts listed on the front cover.
All instructions in this manual should be observed and carried out as written to prevent damage or prema-
ture wear to the product or the equipment served by it.
If your unit is equipped with nonstandard accessories and or options, supplemental information is nor-
mally included in other documentation; i.e. OEM Manuals or additional Bauer Manuals.
While every effort is made to ensure the accuracy of the information contained in this manual, Bauer
Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the con-
sequences thereof.
1.1.1 Manual Safety Notices
Important instructions concerning the endangerment of personnel, technical safety or operator safety will
be specially emphasized in this manual by placing the information in the following types of safety
notices.
^ DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This is limited to the most extreme situations.
^ WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
injury.
^ CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. It may also be used to alert against unsafe practices.
NOTICE
NOTE advise of technical requirements that require particular attention by the operator or the mainte-
nance technician for proper maintenance and utilization of the equipment.
Page 1 2nd Edition, Rev. 2 Chg. 4

MNL-0237
1.2 How to Use the Replacement Parts List
• A lozenge ♦ in the Item Number column indicates the part number for a complete assembly.
• a dagger (†) in the Qty column with or without an ellipse (…) in the Part Number column means the
part is illustrated for assembly purposes only and is not available for sale as an individual component.
This part can be obtained by ordering the complete assembly.
• AR in the Qty column means that the item is cut or manufactured to the size which the customer spec-
ifies.
• A dash (—) in the Item Number column indicates that there is more than one part number applicable
to the preceding Item Number.
• The letters in the columns labeled Kit indicate the number of operating hours when the part is to be
replaced; a = replaced every 1,000 hours, b = replaced every 2,000 hours and c= replaced every 4,000
hours.
• NS in the Item Number column indicates the part is not illustrated but is available.
When placing an order for spare parts, please provide the following information to ensure delivery of the
correct parts. The model number, date of manufacture and serial number can be found of the compressor
unit identification plate on the compressor unit frame.
Information Example
Model Number TCom-25
Serial Number 32165
Date of Manufacture 02/2005
Quantity required 2
Part Number N04860
Part Description Valve
Figure 1-1 Compressor Identification Plate
BAUER COMPRESSORS, INC. BAUER

NORFOLK, VIRGINIA U.S.A COMPRESSORS
MODEL NO. BLOCK NO.

SERIAL NO. PRESSURE PSIG
CAPACITY CFM CHG. RATE CFM
MOTOR HP SPEED RPM
VOLTS PH HZ AMPS
DATE OF MANUFACTURE
LBL-004
June 1, 2010 Page 2

C-D/DV/Navy
^ WARNING
The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe
conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-
threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Bauer
Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are installed.
1.3 How to Use the Appendix

Information contained in the Appendix to this manual includes the following.
• The safety instructions applicable to this product. They must be read, understood and complied with
prior to operating the product.
• The instructions for installing this product. They must be read, understood and complied with prior to
operating the product.
• The instructions for long term storage (over 90 days) of this product.
• Reproducible Forms
• Reference Data
• Torque Values
• Torque Sequence
• Conversion Formulas
• Approved Lubricants
• Glossary of Abbreviations & Acronyms
• Additional Documents

MNL-0237
1.4 Description and Specifications
1.4.1 Unit Description
The Diving Version high pressure air-compressor unit is used for application in the high pressure range,
up to 5000 psig (345 bar), to compress and purify air for breathing air purposes. These units feature three-
stage, three-cylinder, air-cooled KC-FH high pressure air compressor blocks. The Diving Version com-
pressor units are designed with the engine and compressor arranged horizontally in a lightweight frame
for portability. The drive belt and sheaves are enclosed by a belt guard.
Standard equipment includes an intermediate filter after the 2nd stage, a P1 purification system, a CO and
Moisture Indicator, a diesel engine and an hourmeter.
These compressor units are comprised of the following major assemblies:
• Compressor block • Drive engine
• Frame and belt guard assembly • Manual condensate drain valves
• P1 purification system • Prefilter assembly
• Two fill hose assemblies • Hourmeter
The design of this compressor unit is indicated in the following illustration.
Figure 1-2 C-D/DV/NAVY Air Compressor
1 2
3 4 5 6 7 8
1. Belt guard 5. Purification Cartridge

2. Compressor block 6. Heavy-duty caster
3. 6 HP diesel engine 7. Tubular unit frame
4. Moisture Indicator 8. Lift Handles
June 1, 2010 Page 4

C-D/DV/Navy
1.5 Theory of Operation
1.5.1 Drive
The drive motor of the C-D/DV/Navy is a 6 horsepower, Yanmar diesel motor. The drive shaft of the
motor transfers its power through use of a sheave and V-belt to the compressor’s combination flywheel
and cooling fan. The compressor’s flywheel rotates the compressor’s driveshaft, which operates the pis-
tons and oil pump.
1.5.2 Air Flow
(See Figure 1-3). The air is drawn in through intake filter (1), compressed to the final pressure in cylin-
ders (2, 3, 4,) and cooled by intercoolers (5, 6) and aftercooler (7). The safety valves (8,9, 10) protect
from overpressure in the individual stages. The compressed air is filtered by intermediate separator (11)
and oil/water separator (12). The intermediate separator (11) and oil and water separator (12) are drained
by condensate drain valves (13). The compressed air proceeds from the oil water separator to the purifica-
tion chamber (14) and is filtered through a purification cartridge (15). The compressed air exits the puri-
fication assembly (16) where it proceeds to the pressure maintaining valve and air outlet.
Figure 1-3 Air Flow Diagram
10
7
15 1
14
12 9 2
4 3
13 5
11
16 13
1. Intake Manifold 7. Aftercooler 12. Oil and Water Separator

2. 1st Stage Cylinder 8. 1st Stage Safety Valve 13. Manual Condensate Drain Valve
3. 2nd Stage Cylinder 9. 2nd Stage Safety Valve 14. Purification Chamber
4. 3rd Stage Cylinder 10. Final Pressure Safety Valve 15. Purification Cartridge
5. 1st Stage Intercooler 11. Intermediate Separator 16. Air Outlet
6. 2nd Stage Intercooler
1.5.3 Cooling
The C-D/DV/Navy is air cooled by the combination flywheel/cooling fan. The cooling fan blows air
across the cylinder cooling fins, the inter-coolers and after-coolers. The C-D/DV/Navy is designed to
operate in ambient temperature ranges of 32° F — 115° F.

MNL-0237
1.6 C-D/DV/NAVY Specifications

All specifications are subject to change without prior notice.
Medium air
Charging Rate 6.0 scfm (170 l/min.)1
Free Air Delivery 5.0 scfm (140 l/min.)2
Inlet pressure atmospheric
Operating pressure, max. 5,000 psig (345 bar)
Ambient temperature range 32 to 115 °F (0 to 45 °C)
Approximate weight 265 lbs
Compressor block KC-FH (Capitano)

No. of stages 3
No. of cylinders 3
Cylinder bore, 1st stage 2.76 in (70 mm).
Cylinder bore, 2nd stage 1.42 in. (36 mm)
Cylinder bore, 3rd stage 0.58 in. (14 mm)
Piston Stroke 1.58 in. (40 mm)
Intermediate pressure, 1st stage 44 - 58 psig
Intermediate pressure, 2nd stage 464 - 551 psig
Final pressure, 3rd stage 5,000 psig
Direction of rotation when facing flywheel CCW
Compressor speed 1,250 RPM
Oil capacity 1.8 qts.(1.7 ltr)
Oil Pressure approx. 725 psig (50 bar)
Recommended oil BAUER OIL-0015 (TEP 2190)
Compressor Drive Diesel Engine
Bauer Part # Fuel Cap. Oil Cap. Power Speed Cylinders

ENG-0045 0.92 gal (3.5 l) 1.16 qt. (1.1 l) 6.0 hp (4.5 kw) 3,600 rpm 1
1. Based on recharging an 80 cubic foot tank from 500 to 3000 PSIG
2. Referenced to standard inlet conditions of 68°F and 36% humidity at 14.70 psia.
June 1, 2010 Page 6

C-D/DV/Navy
CHAPTER 2: OPERATION
2.1 Initial Use
2.1.1 General
The safety, unpacking, handling and installation instructions applicable to this product are contained in
the Appendix. They must be read, understood and complied with prior to operating the product.
Observe and maintain an ambient temperature range of 32° F to 115° F. The area in which the compressor
unit is installed should be well lit and easily accessible to facilitate servicing and routine maintenance.
2.1.2 Preoperational Tasks
Before activating the compressor unit for the first time the following tasks must be completed.
1. Visually check the oil dipstick shown in Figure 2-1 to verify the amount of oil in the crankcase. The
oil dipstick is located just to the left of the intake filter. The oil level should fall between the mini-
mum and maximum marks.
Figure 2-1 Compressor Oil Dipstick
^ CAUTION
Do not overfill the compressor with oil.
2. Using a Bauer purification wrench (Bauer part number WRH-0005) remove the purification cham-
ber cap and install the purification cartridges as shown in Figure 2-2. Make sure all dust caps are
removed, the O-rings are lubricated, the cartridge seats properly and the chamber vent valve is
closed. Reseal the purification chamber cap using the purification wrench.

MNL-0237
Figure 2-2 Purification Cartridge Installation
Pull
Up
3. Ensure the fill hose (Figure 2-3) is connected to the adapter that attaches to the pressure maintaining
valve as seen in Figure 2-4. Tighten the fitting hand tight plus one half of a turn being careful not to
cross thread or strip the threads on the hose connection.
Figure 2-3 Fill Hose
June 1, 2010 Page 8

C-D/DV/Navy
Figure 2-4 Hose Connection Figure 2-5 Air Intake Hose
4. Once the hose connections are secured install the compressor air intake hose (See Figure 2-5) to the
intake filter, located on the 1st stage of the compressor. Secure the hose with a proper sized hose
clamp. Ensure that the compressor air intake is supplied with fresh air. The intake air must not con-
tain any exhaust fumes or flammable vapors such as paint solvents, which may cause an internal
fire. Make sure that the intake air is unobstructed and moisture in the intake air is kept to a mini-
mum. It is important that units draw in clean air. The quality of the incoming air determines the
quality of the compressed air.
5. Bleed off any internal pressure by opening the bleed valve and manual drain valves. Then Close
them prior to starting the unit. The bleed valve is located at the outlet side of the purification cham-
ber (See Figure 2-6). The manual drain valves are on the bottom of the intermediate separator and
the bottom of the oil/water separator (See Figure 2-7).
Figure 2-6 Moisture Indicator and Bleed Valve Figure 2-7 Manual Drains
Manual Drains

MNL-0237
6. The last step before the initial start of the compressor is to visually inspect the moisture indicator,
(See Figure 2-6) for evidence of cartridge saturation. Under normal conditions the element in the
moisture indicator is blue and changes to pink with elevated levels of moisture.
2.2 Routine Use

2.2.1 Prestart Checks
1. Ensure that all scheduled maintenance is completed. Refer to Chapter 4, Maintenance Schedule.
2. Check compressor oil level. Refer to Paragraph 2.1.2
3. Read and understand the Yanmar Engine Manual supplied with this manual.
4. Check compressor drive engine oil level. Refer to the Yanmar Engine Manual.
5. Visually inspect the moisture indicator, for evidence of cartridge saturation, See Figure 2-6. Under
normal conditions the element in the moisture indicator is blue and changes to pink with elevated
levels of moisture.
2.2.2 Diesel Engine Start-up Procedure

1. Complete all pre-start checks.
2. Verify that all connections downstream of the compressor are secure.
3. Open the bleed valve and manual drain valves to relieve any internal pressure then close them.
4. Check the fuel level and refill the fuel tank if required.
5. Open the fuel valve. (See Figure 2-8).
6. Move the START/STOP control to the START position (See Figure 2-9)
7. Pull recoil starter handle until resistance is felt then return it slowly (See Figure 2-10).
^ CAUTION
Do Not Attempt To Start The Engine Until Step 7 Is Completed!
Failure to complete this step could result in damage to the recoil starter.
8. Push down the Decompression Lever and release it. (See Figure 2-11). This relieves the pressure in
the engine allowing the engine to start unloaded.
9. Quickly pull recoil starter handle out to its full length. Repeat this process as many times as neces-
sary to start engine. Do not use excessive force as this might damage the recoil starter internal com-
ponents.
June 1, 2010 Page 10

C-D/DV/Navy
Figure 2-8 Fuel Valve Figure 2-9 START/STOP Control
Figure 2-10 Recoil Starter Figure 2-11 Decompression Lever
2.2.3 Post Start Procedures

1. Listen to the unit as it operates. A loud knocking sound may be heard until the final stage pressure is
equalized. If excessive knocking or vibrations are observed or they continue past ten seconds, shut
down the compressor.
2. The compressor flywheel should be rotating counterclockwise. If it is not, shut down the compres-
sor and contact the Bauer Customer Service Department.
3. Allow the compressor to build pressure until the Final Relief Valve lifts. This confirms that the sys-
tem has no leaks. The Final Relief Valve is located on top of the Oil and Water Separator. (See Fig-
ure 2-12).
4. Once Step 3 is completed the compressor is ready to fill bottles.
5. The manual condensate drain valves must be opened and the condensate allowed to drain for 6 sec-
onds every 15 minutes while the compressor is operating.

MNL-0237
6. Due care must be taken to ensure that any oil which is drained with the condensation is disposed of
properly.
7. For compressor troubleshooting See Paragraph 3.1.8.1.1.
Figure 2-12 Final Relief Valve
2.2.4 Bottle Fill Procedures

1. Attach approved storage bottles to the fill hose assembly. Use only bottles approved for the
intended service.
^ CAUTION
Minimum bend radius for the fill hose is 1½ inches. Less than this will cause damage to or failure of
the fill hose. Place the bottle so that the bend radius of the hose is greater than 1½ inches.
2. Adjust the fill pressure regulator to the proper fill pressure. Never exceed the storage bottle rating.
3. With the proper storage bottle connected, open the fill valve then the bottle valve.
4. After the bottle is filled close the bottle valve first then the fill valve.
5. Open the Vent valve to vent the fill hose assembly.
6. Carefully disconnect the fill hose assembly and remove the filled bottle.
7. Repeat Step 1 through Step 6 as necessary.

C-D/DV/Navy
Figure 2-13 Filling Storage Bottles
1.
2.
1. 2.
Attaching the Fill Yoke Opening Sequence Closing Sequence
2.2.5 Shutdown Procedures

1. Verify all bottle valves and fill valves are closed.
2. Move the START/STOP control to the STOP position. (See Figure 2-9).
3. Close the fuel valve. (See Figure 2-8)
4. After shutting down the compressor drive, open the condensate drain valves to relieve any remain-
ing pressure and drain any moisture from the intermediate separators and the oil and water separa-
tor.
5. Close the condensate drain valves after all pressure is released.
6. If the compressor is to remain idle for six months or longer, refer to Appendix, Long Term Storage
for preservation instructions.

MNL-0237
CHAPTER 3: COMPRESSOR BLOCK - KC-FH CAPITANO
3.1 Maintenance and Parts
3.1.1 Description
The KC-FH Capitano compressor is used to compress air up to 5,000 psi.
This compressor is a three stage, three cylinder air cooled, oil lubricated reciprocating compressor. The
cylinders are arranged in a “W” configuration, the 1st stage cylinder is in the center, 2nd stage on the
right and 3rd stage on the left looking from the filter side. These compressor blocks are particularly suit-
able for continuous operation because of their rugged design and corrosion resistant intermediate filter
and cooler assemblies.
3.1.2 Component Location
Figure 3-1 KC-FH Capitano Compressor Block, Front View
5 6 7 8 9 10
11
4 12
3
13
2
1
14
1. Manual Condensate Drain Valve 8. Intake Filter

2. 2nd Stage Intercooler 9. 1st Stage Cylinder
3. 2nd Stage Intermediate Separator 10. Oil and Water Separator
4. Oil Pressure Regulator 11. 1st Stage Safety Valve
5. 3rd Stage Cylinder 12. 2nd Stage Cylinder
6. Oil Filler Cap and Dipstick 13. 1st Stage Intercooler
7. 2nd Stage Safety Valve 14. Oil Drain Plug
3.1.3 Lubrication System (See Figure 3-2)

The compressor is provided with force-feed lubrication for the third stage. The oil pump (1) is driven by
a cam on the crankshaft. It pumps oil into the oil pressure regulator (2) at the 3rd stage. The oil pressure
regulator maintains the proper working pressure.
Any oil not needed by the 3rd stage cylinder returns to the crankcase through the feedback tube (3). The
oil, splashed by the drive gear, lubricates the other moving parts, such as the crankshaft, connecting rods,

C-D/DV/Navy
cylinders and pistons, and returns into the oil sump. The cylinder and piston of the 1st stage are addition-
ally lubricated by oil vapors from the crankcase vent feedback line (4).
Figure 3-2 Lube Oil Circuit
3
4
2 1
3.1.3.1 Type of Oil

For proper care and maintenance of the compressor, using the correct oil is of vital importance. Due to the
thermal load on the compressor only high quality oil should be used. You are recommended to restrict
oils to those which have been approved by us and are listed in Section 1.4.
3.1.3.2 Oil Level Check
Check the oil level daily before starting the compressor.
1. Vent any residual air pressure from the system by opening and then closing the manual condensate
drain valves.
2. Open the filler cap slowly, allowing any residual pressure to vent from the crankcase.
3. Remove the cap/dipstick from the oil filler neck. (See Figure 3-3)
4. Wipe the dipstick with a lint-free cloth.
5. Return the oil cap/dipstick to the filler neck completely, then remove and note the oil level on the
dipstick. The oil level must be between the marks on the dipstick (See Figure 3-4).
6. Add or drain oil as necessary.
^ CAUTION
The oil level must not exceed the maximum level mark on the dipstick, as this will cause
excessive lubrication of the compressor and may result in coking of the valves.

MNL-0237
Figure 3-3 Compressor Oil Dipstick Figure 3-4 Oil Dipstick Markings
Max.
Min.
3.1.3.3 Oil Change

(See Figure 3-1)
1. Run the compressor until it is warm.
2. Shutdown compressor.
3. Remove the cap from the oil filler neck.
4. Drain oil while it is still warm by removing the oil drain plug.
5. Reinstall the oil drain plug.
6. Slowly pour new oil through the oil filler neck until the level reaches the maximum mark on the
dipstick.
7. Wait a few minutes and adjust the oil level if necessary before putting the unit into operation.
8. Dispose of the used oil in a safe manner complying with all local waste disposal codes.
9. Check the operation of the oil pump. It is working properly if no bubbles are visible in the oil pres-
sure regulating valve sight glass. If bubbles are visible then the oil pump must be vented.

C-D/DV/Navy
Figure 3-5 Venting the Oil Pump
3.1.3.4 Venting the Oil Pump

If little or no oil pressure builds up after starting the unit, especially after maintenance or repair work,
venting the oil pump will be necessary. Refer to Figure 3-5 and proceed as follows:
1. With the compressor and the inlet supply shut off, the power disconnected (if applicable) and the
crankcase vented, remove the tube nut and tube (1) from the oil pump.
2. Turn the compressor by hand until bubble-free oil emerges from the fitting. This should only take a
few seconds.
3. Position the tube and tube nut (1) and retighten.

MNL-0237
Figure 3-6 Oil Pressure Regulator
3.1.3.5 Oil Pressure Regulator

(See Figure 3-6)
The oil pressure regulator is mounted on the 3rd stage cylinder. The regulator valve can be adjusted by
removing the cap nut (1) and turning the set screw (2) in the oil pressure regulator block (3). Adjustment
should only be performed by a trained technician. The oil pressure regulator should be adjusted while the
unit is in operation.
NOTICE
Turning the screw clockwise increases pressure; counterclockwise reduces pressure.
Use an oil pressure gauge connected to the oil pressure regulator test connector (4) to read the oil pres-
sure. For units with an installed oil pressure gauge, observe the oil pressure indicated on the instrument
panel.

C-D/DV/Navy
3.1.4 Intake Filter

3.1.4.1 Description
A dry, micronic filter is used to filter the intake air. See Figure 3-7.
Figure 3-7 Intake Filter
3.1.4.2 Intake Filter Maintenance

The filter cartridge must be cleaned and changed at regular intervals. See the Maintenance Schedule for
the recommended interval.
1. Clean the filter cartridge with a brush or by blowing air from the inside of the cartridge to the out-
side.
2. Turn the cartridge 90° when replacing it. Change the cartridge filter after it has been turned three
times and thus is dirty on all sides.
3. Clean the inside of the filter body with a damp cloth. take care to prevent dust from entering the
intake pipe.
4. Replace the O-rings if necessary.
3.1.5 Intermediate Separator

An intermediate separator is mounted on the compressor after the 2nd stage. This separator is designed to
remove oil and water which accumulates due to the cooling of the air after the compression process. Sep-
aration is achieved by means of centrifugal action. In the separator the centrifugal action is provided by a
vortex plate additionally a sintered metal filter is provided to remove dirt contamination.

MNL-0237
Figure 3-8 3rd Stage Intermediate Separator
Filter Head
Knurled Nut
Distribution Plate
Baffle Funnel
Filter Insert
Center Screw
^ WARNING
Dynamic Loading
The rapid depressurizing and repressurizing of the intermediate separator during condensate draining
subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury
or death the intermediate separator must be replaced after 85,000 load cycles. A load cycle equals one
depressurization- repressurization. The Bauer recommended frequency of condensate draining is every
fifteen minutes and is a balance between maximizing the life of the oil and water separator chamber and
maintaining the quality of the delivered air.
3.1.5.1 Maintenance
Proper operation of the compressor requires that the intermediate separator be properly serviced. See the
Maintenance Schedule, Section 4 for the correct interval. See Figure 3-8 and proceed as follows:
1. Remove piping connected to the filter head.
2. Screw off the knurled nut.
3. Remove filter head along with the sintered metal filter.
4. Remove the center screw and separate the sintered metal filter, baffle cone, and vortex plate from
the filter head.

C-D/DV/Navy
5. Use hot soapy water to clean the filter insert, rinse and blow it dry with compressed air.
3.1.6 Cooling
The cylinders of the compressor, the intermediate coolers and the after cooler are air cooled. For this pur-
pose the compressor is equipped with a fanwheel which draws the cooling air through the unit. The fan-
wheel is driven by the drive motor V-belt and is also used as the compressor flywheel.
3.1.6.1 Maintenance
When dirty, clean the finned tubes, valve heads and cylinders by blowing off the dirt and dust with low
pressure compressed air (80 -125 psi)
3.1.7 Compressor Valves and Heads
3.1.7.1 Functional Description.
Figure 3-9 Valve Operation
Intake Discharge
The intake and pressure valves are fitted inside the valve heads. Note that the valves are operated by the
flow of the medium. On the intake stroke, the intake valves open and the medium flows into the cylin-
ders. At the start of the pressure stroke the intake valve closes and the medium opens the pressure valve.
3.1.7.2 General Instructions for Changing the Valves
• Always replace valves as a complete set.
• Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in Varsol and
clean with a soft brush.
• Check the individual components for excessive wear. If the valve seat or valve discs are dented,
replace the valves.
• Check the valve space in the valve heads for dirt, and clean if necessary.
• Use only satisfactory gaskets and O-rings during reassembly.
• Observe the correct sequence when reassembling.

MNL-0237
• After finishing all maintenance work on the valves, turn the compressor manually using the flywheel
and check whether all items have been correctly installed.
• 30 minutes after restarting the compressor, stop the unit, let it cool down to ambient temperature, and
retighten valve studs and cap nuts. Otherwise the gasket set may cause a leak.
• Remove and check the valves every 1000 operating hours, unless otherwise specified in the Mainte-
nance Schedule.
• Replace the valves every 2000 operating hours to avoid fatigue failure, unless otherwise specified in
the Maintenance Schedule.

C-D/DV/Navy
3.1.7.3 Tolerances and Limits
Figure 3-10 Permissible Tolerances Figure 3-11 Checking the Piston
max 1.0 mm Flush

or 3/64"
Valve Plates
17+0.1 mm
17+0.1 mm
43/64+.004"
43/64+.004"
Valve Body
max 0.2mm
or 1/128"
Valve Seats Valve Cover
Table 3-1: 1st Stage Pressure Valve Limits

Specified Length - 24 mm
Pressure Valve Spring
Limit - 21 mm
Minimum - 1.0 mm
Pressure Valve Stroke
Maximum - 1.25 mm
Valve Seat Bore Diameter - 12.5 mm
Table 3-2: 2nd Stage Pressure Valve Limits Table 3-3: 2nd Stage Inlet Valve Limits
Specified length - 10.5 mm
Specified length - 24 mm
Pressure valve spring Inlet valve spring Limit - 9 mm
Limit - 21 mm
Minimum - 0.8 mm Minimum - 1.0 mm

Pressure valve stroke Inlet valve stroke
Maximum - 1.05 mm Maximum - 1.25 mm
Valve seat bore Diameter - 8.0 mm Valve seat bore Diameter - 12.5 mm
Table 3-4: 3rd Stage Valve Limits

Minimum - 0.8 mm
Inlet valve stroke
Maximum - 1.2 mm
Minimum - 0.9 mm
Pressure valve stroke
Maximum - 1.2 mm

MNL-0237
Figure 3-12 1st Stage Valve Head and Valves
17
16
15
14
13 1
5
12
2
11
3
10
6 4
9
8
7
1. Valve Head 7. Valve Gasket 13. Disc Spring

2. O-ring 8. Valve Seat 14. Pressure Valve Cover
3. O-ring 9. Valve Plate 15. Set Screw
4. Intake Valve Plate 10. Compression Spring 16. Gasket
5. Pressure Valve Assembly 11. Pressure Valve Body 17. Dome Nut
6. Pressure Valve 12. O-ring
3.1.7.4 Changing the 1st Stage Valves

3.1.7.4.1 Removing the 1st Stage Pressure Valve
See Figure 3-12 and proceed as follows:
1. Remove the dome nut (17) and gasket (16). Inspect the gasket and replace it if it is damaged.
2. Unscrew and remove the socket set screw (15) and pressure valve cover (14).
3. Remove the disc spring (13) and the O-ring (12). The O-ring should be undamaged and non-porous.
Replace it if it is damaged.
4. Extract the pressure valves assembly (6).
5. Discard the valve gasket (7) and replace it with a new one.
6. Inspect the valve components for wear or damage. See Figure 3-10 and Table 3-1. If the tolerances
have been exceeded or damage has occurred then the valve assembly (5) should be replaced.

C-D/DV/Navy
7. Inspect the valve seat (8). The sealing surface must be in good condition, devoid of pitting or
cracks. The maximum valve seat width is 3/64” (1.0 mm).
8. Clean and inspect the valve plate (9). The maximum acceptable groove depth must not exceed 1/
28” (0.2 mm).
9. Check the tolerance of the inside diameter of the valve body (11). The valve body must not show
any grooves at ID 17 = 0.1 mm.
10. The valve spring (10) is serviceable if it shows no outside scuffing and the spring ends have not
picked up on the next coil.
3.1.7.4.2 Removing the 1st Stage Inlet Valve

1. Remove all tubing connections to the valve head.
2. Inspect the O-ring (2). Replace it if it is damaged.
3. Unscrew and remove the socket head screws and lift valve head (1) from cylinder.
4. The valve plate (4) rests free on the piston cylinder, it is not spring operated.
5. Inspect the valve plate (4). It should be flat and free of grooves. The maximum concentric groove
depth should not exceed 0.002” (0.05 mm).
6. The top of the piston should be flush with the valve seat. (See Figure 3-11).
7. Inspect the O-ring (3). It should be undamaged and non-porous. Replace it if necessary.
3.1.7.4.3 Reassembly of the 1st Stage Valves

1. Place the valve plate (4) and O-ring (3) into the valve seat of the piston cylinder.
2. Apply a temperature resistant non-age hardening RTV sealing compound to the surface of the valve
head (1).
3. Replace valve head (1) on cylinder and install socket head cap screws. Torque socket head cap
screws to 18 ft.-lbs (25 Nm).
NOTICE
To avoid damage to the valve body (11), the valve head must be installed and torqued
before the 1st stage pressure valve set screw (15) is tightened.
4. Install the pressure valve assembly (6) and tighten set screw (15).
5. Position the gasket (16) and tighten the dome nut (17).
6. Replace all tubing connections to the valve head.

MNL-0237
Figure 3-13 2nd Stage Valves
17
18 16
15
14
13
1 12
7
11
6
10
5
2 8
5
4
9
3
7
1. Valve Head 8. Pressure Valve Assembly 15. Pressure Valve Cover

2. Inlet Valve Assembly 9. Pressure Valve Seat 16. Socket Set Screw
3. Inlet Valve Cover 10. Pressure Valve Plate 17. Gasket
4. Compression Spring 11. Compression Spring 18. Dome Nut
5. Inlet Valve Plate 12. Pressure Valve Body 19. Safety Valve
6. Inlet Valve Seat 13. O-ring
7. Valve Gasket 14. Spring Washer
3.1.7.5 Changing the 2nd Stage Valves
3.1.7.5.1 Removing the 2nd Stage Pressure Valve.
1. Remove the dome nut (18) and the gasket (17). Inspect the gasket. The gasket should be replaced if
it is damaged.
2. Unscrew and remove the socket set screw (16) and the pressure valve cover (15).
3. Remove the spring washer (14) and the o-ring (13). The o-ring should be in perfect condition:
undamaged and non-porous. Replace it if necessary.
4. Extract the pressure valve assembly (8).

C-D/DV/Navy
5. Discard the valve gasket and replace it with a new gasket.
6. Inspect the valve seat (9). The sealing surface must be in good condition: devoid of pitting or crack-
ing. The maximum valve seat width is 3/64” (1.0 mm).(See Figure 3-10).
128” (0.2 mm). (See Figure 3-10)
8. Check the tolerance of the inside diameter of the valve body (12). The valve body must not show
any grooves at ID 17 + 0.1 mm. (See Figure 3-10).
9. The valve spring (11) is reusable if it shows no outside scuffing and the spring ends have not picked
up on the next coil.
10. The limits shown in Table 3-2 should also be checked. If the tolerances have been exceeded then
the valve assembly (8) should be replaced.
3.1.7.5.2 Removal of the 2nd Stage Inlet Valve

To remove the 2nd stage inlet valve, it is necessary to first dismantle the valve head. Refer to Figure 3-13
and proceed as follows.
1. Remove the tube nuts, tubes and ferrules from the tube connections to the valve head (1).
2. Unscrew and remove the socket head cap screws.
3. Lift the valve head off the piston cylinder.
4. Unscrew the valve cover (3) from the bottom of the valve head (1) using the valve tool provided
with the compressor unit.
5. Extract the inlet valve assembly (2) and discard the valve gasket (7). Replace the old gasket with a
new gasket.
6. Inspect the valve seat (6). The sealing surface must be in good condition: devoid of pitting or crack-
ing. The maximum valve seat width is 3/64” (1.0 mm). (See Figure 3-10).
128” (0.2 mm). (See Figure 3-10).
8. Check the tolerance of the inside diameter of the valve cover (3). It must not show any grooves at
ID 17 + 0.1 mm. (See Figure 3-10).
9. The valve spring is reusable if it shows no outside scuffing and the spring ends have not picked up
on the next coil.
10. The limits shown in Table 3-2 should also be checked. If any of these tolerances have been
exceeded, the valve assembly (2) should be replaced
3.1.7.5.3 Reassembly of the 2nd Stage Valve Head and Valves

To reassemble the valve head and valves, refer to Figure 3-13 and proceed as follows.
1. Before fitting the inlet valve to the valve head, grease the inlet valve plate slightly and place it cor-
rectly on the valve seat to make reassembly easier.

MNL-0237
2. After having assembled the inlet valve, peen the valve head twice, once on each side of the valve, to
lock the threads in place.
Figure 3-14 Peening the Inlet Valve
3. Apply a temperature-resistant, non-age hardening RTV sealing compound to the sealing surface of
the valve head.
4. Torque the valve head cap screws to 18 ft lb. (25 Nm) in accordance with the sequence shown in
Appendix A before tightening the socket set screw (3) in order to avoid damage to the valve body
(8).
5. Tighten the socket set screw (3) with the appropriate size hex key.
6. Position the gasket (2) and dome nut (1) and tighten it with an open end wrench.
7. Reinstall the tube connections (13) to the valve head (22).

C-D/DV/Navy
3.1.7.6 Changing the 3rd Stage Valve
See Figure 3-15 and proceed as follows
Figure 3-15 3rd Stage Valve Head and Valves
1
9
2
1. Dome Nut 4. O-ring 7. Valve Head

2. Gasket 5. Pressure Valve 8. Valve Head Cover
3. Set Screw 6. Inlet Valve 9. Valve Head Screw
3.1.7.6.1 :Removal of the 3rd Stage Pressure Valve

1. Remove the dome nut (1) and the gasket (2). Unscrew the socket set screw (3) three or four turns. If
the gasket is damaged, replace it with a new gasket.
2. Remove the valve head screws (9) that secure the valve head (7), then remove the valve head cover
(8).
3. Place two screwdrivers into the groove of the pressure valve body (See Figure 3-16) and lift out the
pressure valve (5) together with the o-ring (4). If necessary, loosen the valve first, using a 13 mm
open-end wrench on the flat surfaces.
4. Check the o-ring. It should be in perfect condition (undamaged and non-porous). Replace it if nec-
essary.

MNL-0237
5. If the pressure valve does not close tightly, it should be replaced. The bore diameter of the valve
seat should be 4.0 mm.
Figure 3-16 Removing the 3rd Stage Pressure Valve
3.1.7.6.2 Removal of the 3rd Stage Inlet Valve

1. Remove the tube connections to the valve head (7).
2. Unscrew and remove the socket head cap screws (9).
3. Remove the valve head cover (8).
4. Extract the inlet valve (6) using the valve tool provided with the unit.
5. The inlet valve should be replaced if it no longer closes tightly. The bore diameter of the valve seat
should be 4.0 mm.
3.1.7.6.3 Reassembly of the 3rd Stage Valves

1. Reassemble the inlet valve (6) in the reverse sequence of its removal.
2. Insert the pressure valve (5) with the O-ring (4) into the valve head (7).
3. Position the valve head cover (8). Do not use a sealing compound on the third stage valve head.
4. Insert and torque the valve head cap screws (9) to 18 ft-lb. (25 Nm = 2.5 kgm) in accordance with
the sequence shown in the Appendix before tightening the socket set screw (3) in order to avoid
damage to the valve body (8).
5. Screw in the set screw (3) by hand. Fit the Copper Gasket (2) and the Cap Nut (1) and tighten with
an open end wrench.
6. Reinstall the tube connections to the valve head (7).

C-D/DV/Navy
3.1.8 Replacement Parts List
Figure 3-17 Crankcase Assembly
42
2
41
35
3
1 2
43
36 42
44 48
47 2
39
40 45 47 49
9 51 50
4 37 33
46 53
5 31 26
10 33 54
6 38
42 2 7 55
30 52 27
11 14 25
56 ,1 28
8 2,
13 24
34 27
58 59 29
60 65
57 61 62 63 68 67 32 16
64 66 17
17
19
22
23 21
15
20
Item Qty Part No. Description Notes

1 6 SCR-0025 Hex head cap screw
2 18 WAS-0021 Flat washer
3 1 014998 Bracket for cooler
4 1 N00220 Shaft seal
5 1 014878 Bearing cover
6 1 N03705 O-ring
7 1 N03703 Roller bearing
8 1 014030 Crankshaft assembly, complete Items 9 - 13
9 1 N00166 Shaft key
10 † 001529 Shim
11 1 SCR-0138 Socket head cap screw
12 1 WAS-0001 Split lock washer
13 1 NUT-0119 Hex lock nut
14 1 N03702 Roller bearing
15 1 014874 Crankcase

MNL-0237
Figure 3-17 (cont.) Crankcase Assembly

16 1 003196 Drive cam
17 1 014888 Hold-down plate)
19 1 N03726 O-ring
20 1 058159 Filter mount
22 1 073270 Oil drain pipe
23 1 N03707 Hex head pipe plug
24 1 014892 Crankcase vent filter assembly Items 25 - 29
25 AR N03736 Flexible tube
26 1 N03737 Male connector
27 † N03207 Crankcase vent filter
28 1 N03712 O-ring
29 1 N00293 Copper gasket
30 1 072887 Connecting rod 1st stage
31 1 072884 Connecting rod 2nd stage
32 1 072885 Connecting rod 3rd stage
33 3 004180 Shaft spacer
34 8 N00215 Stud
35 1 014886 Dipstick rod
36 1 N03521 O-ring
37 1 014887 Oil fill tube
38 1 012560 Flange gasket
40 2 N03026 Wave washer
41 1 006540 1st stage piston cylinder 70 mm
43 1 001867 Piston cylinder gasket
44 1 069948 Piston assembly, 1st stage Items 46 - 49
45 1 010704 1st stage piston 70 mm
46 † — Piston pin 1st stage
47 † — Retaining ring
48 1 N03856 Piston ring set 70 mm
49 1 010875 2nd stage piston cylinder 36 mm
50 1 003110 Piston cylinder gasket 36 mm
51 1 069949 Piston assembly, 2nd stage Items 53 - 56
52 † — Piston, 2nd stage 36 mm
53 1 N04158 Piston ring set 36 mm

C-D/DV/Navy
Figure 3-17 (cont.) Crankcase Assembly

54 † — Piston pin 2nd stage
56 1 065094 Finned cooling plate
57 1 078043 Floating piston assembly(mod 8) Items 58 - 59
58 1 N23755 O-ring
59 2 N02320 O-ring
60 1 121632 Piston cylinder(mod 8) 14 mm
61 1 N04064 O-ring
62 1 056141 Guide cylinder 45 mm
63 1 001866 Guide cylinder gasket 45 mm
64 1 069950 Piston assembly, 3rd stage Items 65 - 67
65 1 N00823 Guide piston 45 mm
66 † — Piston pin 3rd stage
68 4 N04065 Stud

MNL-0237
Figure 3-18 1st Stage Valve Head and Valves
17
16
15
14
13 1
5
12
2
11
3
10
6 4
9
8
7

♦ 1 014906 Valve head assembly, 1st stage Complete
1 1 014907 Valve head
2 1 N01539 O-ring
3 1 N02169 O-ring
4 1 009884 Inlet valve plate
5 1 014583 Pressure valve assembly Items 6 - 17
6 1 012840 Pressure valve Items 7 - 11
7 1 000240 Valve gasket
8 † — Valve seat
9 † — Valve plate
10 † — Compression spring
11 † — Pressure valve body
12 1 N03521 O-ring
13 1 014332 Disc spring
14 1 014124 Pressure valve cover
15 071064 Socket set screw
17 1 N00084 Dome nut

C-D/DV/Navy
Figure 3-19 2nd Stage Valve Head and Valves
17
18 16
15
14
13
1 12
7
11
6
10
5
2 8
5
4
9
3
7

♦ 1 014696 Valve head assembly Complete
2 1 012841 Intake valve assembly
3 † — Inlet valve cover
4 † — Compression spring
5 † — Valve plate
6 † — Inlet valve seat
7 2 000240 Valve gasket
8 1 012835 Pressure valve assembly Complete
9 † — Pressure valve seat
10 † — Compression spring, Cylindrical
11 † — Pressure valve body
12 1 N03521 O-ring
13 1 014332 Disc spring

MNL-0237
Figure 3-19 (cont.) 2nd Stage Valve Head and Valves

14 1 014124 Pressure valve cover
15 1 071064 Socket set screw
18 1 010670 Safety Valve

C-D/DV/Navy
Figure 3-20 3rd Stage Valve Head and Valves
1
9
2

♦ 1 069954 Valve head assembly Complete
1 1 N03623 Dome nut
3 1 071065 Socket set screw
4 1 N02789 O-ring
5 1 014121 Pressure valve
6 1 081409 Intake valve
8 1 014118 Valve head cover
9 6 N01282 Socket head cap screw

MNL-0237
Figure 3-21 Intermediate Separator
11
12
3
8
9
10

♦ 1 067612 Intermediate Separator
1 1 013930 Filter Head
2 1 012784 Vortex Plate
3 1 012785 Baffle Cone
4 1 N02726 Sintered Metal Filter
5 1 012786 Center Screw
6 1 N03556 O-ring
7 1 014150 Filter Housing
8 1 013937 Threaded Collar
9 1 N01316 Gasket NSN 5530-01-461-4899
10 1 ADP-0021SS Adapter
11 1 011656 Safety Valve NSN 4820-01-460-8443
12 1 004479 Gasket

C-D/DV/Navy
Figure 3-22 Intake Filter
1 2 3 4 5 6
10 7 9 7 8

♦ 1 013758 Intake Filter Assembly Items 2 - 7
1 † — Intake Filter Cover
2 1 010528 Compression Spring
3 1 N04451 O-ring
4 1 N00070 Filter Element
5 1 013757 O-ring
6 † — Intake Filter H ousing
♦ 1 HOS-0163 Inlet Hose Assembly with Prefilter Items 7 - 10
7 3 CMP-0025 Worm Gear Hose Clamp
8 10 ft TUB-R-00083 Flexible Tube
9 1 ADP-0314 Reducing Adapter
10 1 057691 Prefilter

This page is inserted to provide proper page sequencing
8 9 1 2
6 5 7
10
3
4
C-D/DV/Navy
Figure 3-23 Cooling System
18
15
1
24
2
15
11
3 6
8
5 19
4 2
10 17
15 20
21
16
15 14
11 10
7
15
22
12
10 7
9 15
15 23

2 5 WAS-0001 Split lock washer
3 1 012754 Cooling fan/compressor flywheel
5 1 013666 Cooling fan hub
6 1 069960 Aftercooler
8 1 014998 Cooler bracket
9 8 013662 Tube clamp 3-groove
12 4 013663 Intercooler bracket
13 † — Intercooler 2nd stage
14 2 014370 P-clamp

MNL-0237
Figure 3-23 (cont.) Cooling System

19 1 069957 Connecting tube 1st stage to intercooler
21 † — Intercooler 1st stage
22 1 014624 Intercooler assembly 1st stage, air-cooled
23 1 058991 Intercooler assembly 2nd stage, air-cooled

C-D/DV/Navy
Figure 3-24 Lubrication System
3
11
10 17
9
4 8
12 16
8 5 13
6 15
1 7 18
14
20
2
23 21
24
25 22

1 1 002010 Oil pump gasket
2 1 N00083 Oil pump
3 1 058138 Oil pressure regulator Items 4 - 21
4 1 072439 Ball valve assembly Items 5 - 7
5 † 058119 Ball valve seat
6 † N02768 Precision ball
7 1 ---- Ball guide
8 4 N07091 O-ring
9 1 057132 Square flange
11 1 N04530 Tube plug
12 1 002623 Compression spring
13 11 058121 Valve plate
14 1 058102 Oil pressure regulator body
16 1 056302 Glass tube

MNL-0237
Figure 3-24 (cont.) Lubrication System

17 1 056301 Oil sight glass fitting
18 1 N02969 Slotted set screw
22 2 N03407 Socket head cap screw
23 1 069966 Oil supply tube

C-D/DV/Navy
3.1.8.1 Troubleshooting and Repair

3.1.8.1.1 Troubleshooting Table
Trouble Cause Remedy
No oil pressure 1. Low oil level 1. Check oil level

2. Vapor Lock at Oil Pump 2. Vent Oil Pump
1. Last stage piston worn 1. Operate compressor with final

2. Last stage pressure valve stage valve head removed. If
Oil foam in crankcase defective oil flows continuously out of
cylinder, replace piston and
sleeve.
2. Replace last stage valves.
1. Condensate drain valves or 1. Tighten and reseal.

fittings leaking. 2. Replace
2. Premature opening of final 3. Replace
Compressor output insufficient safety valve. 4. Replace
3. Piston rings worn 5. Tighten
4. Excessive piston clearance
5. Pipes leaking
1. Intermediate pressure too 1. Service and clean valves.

high 2. Service and clean valves.
Safety valves between stages 2. Valves not closing properly 3. Service and clean valves.
releasing pressure 3. Relief Valve not set prop-
erly
1. Insufficient cooling air. 1. Check for adequate ventilation

Compressor running too hot. 2. Intake or outlet valve not 2. Check and clean valves,
closing properly replace as necessary
1. Improper maintenance of 1. Service filters, change purifier

filters, purifier cartridge cartridge.
Oil residue in delivered air saturated. 2. Change to proper oil and clean
2. Wrong oil type valves.

MNL-0237
3.1.8.1.2 Repair
Preventive maintenance usually involves replacing the valves, gaskets, and sealing rings as well as carry-
ing out the maintenance work. Repair work can be carried out on the compressor block to a certain extent
but a certain level of experience and skill is necessary. It should be noted however that no repair should
be carried out on the crankshaft nor on the bearings. Also safety valves are not repaired but always
replaced.

C-D/DV/Navy
3.2 Manual Condensate Drain System
3.2.1 Description
The purpose of the manual condensate drain system is to provide a means to drain the filters of accumu-
lated condensation.
The manual condensate drain system consists of the following items:
1. Manual condensate drain valves on the intermediate filter and the oil and water separator.
2. Interconnecting tubing.
The manual drains on the intermediate and final separators should be tubed to a condensate collection
tank.
NOTICE
Condensate drained from the separators may be mixed with oil. Ensure that any oil which is drained with
the condensate is disposed of in accordance with local, state and federal regulations.
Figure 3-25 Manual Condensate Drains
1 2
1. Intermediate Separator Drain

2. Final Separator Drain
3.2.2 Operation
The manual condensate drain valves must be opened and the condensate allowed to drain every 15 min-
utes while the compressor is operating.
3.2.3 Unloaded start
On shut-down, open the intermediate and final separator manual condensate drain valves to drain con-
densation and remove pressure from the block. Close the drain valves after start up.
This operation performs two functions:
1. As pressure builds, the separators are cleared of accumulated condensation.
2. There is no load on the compressor during start-up.

MNL-0237
CHAPTER 4: MAINTENANCE SCHEDULE
4.1 C-D/DV/Navy Maintenance Intervals
Maintenance Intervals in Hours of Operation
Maintenance Task Operator

8 50 130 500 1000 2000 3000 17500 or Service
Technician
Check compressor oil level Operator
Manually drain condensate Operator
Check for oil pump venting Operator
Check for leaks Operator
Check for abnormal sounds Operator
Check for abnormal vibrations Operator
Check for short cycling Operator
Check for damage to unit Operator
Check moisture indicator Operator
Retorque valve head fasteners Operator
Inspect all hoses Operator
Inspect all guards Operator
Inspect fanwheel Operator
Inspect all drive belts Operator
Replace intake filter element Technician
Test all safety valves Technician
Change oil (petroleum) Technician
Change oil (synthetic) Technician
Clean all cooling fins Technician
Check for corrosion Technician
Clean intermediate separators Technician
Replace compressor valves Technician
Inspect pistons and rings Technician
Replace oil and water separator Technician

C-D/DV/Navy
^ CAUTION
All maintenance intervals refer to normal operating conditions. Operating the compressor under
extreme conditions like high temperatures, humidity or continuous operation may shorten the
intervals significantly. If in doubt, please contact the Bauer service department.
4.1.1 Maintenance Records

We recommend that all maintenance work be recorded, showing the date and details of the work carried
out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to
make a claim against the warranty, it will help to have proof that regular maintenance has been carried out
and that the damage has not been caused by insufficient maintenance. For this purpose Maintenance
Record Sheets are included in the Appendix and may be copied as required. Additionally a form for
recording operating hours is included and may be copied also.

MNL-0237
CHAPTER 5: PURIFICATION SYSTEM
5.1 Purpose
The purpose of all Bauer breathing air purification systems is to remove oil, water, taste and odor from
the compressed air stream before final delivery. For this reason Bauer purification systems are installed
immediately before the compressed air delivery point. Refer to the compressor unit purification dataplate
on the purifier cartridge to determine your purification system specifications (See Figure 5-1).
Figure 5-1 Purification Dataplate
PURIFICATION
CARTRIDGE TO BE
SYSTEM
INSTALLED
MODEL NO.
MAX. PRESSURE psig CARTRIDGE FOR

AIR PROCESSED cu. ft. CARTRIDGE NO.
O-RING 1328 Azalea Garden Road - Norfolk Virginia 23502-1944
BACK-UP RING Phone: (757) 855-6006 Fax: (757) 855-8224
LBL- LBL-
5.1.1 General
The C-D/DV/Navy compressor unit is available only with the P1 Purification System.
5.2 P1 Purification System
The P1 Purification System shown in Figure 5-2 approximates the physical location of the components
on a P1 Purification Panel. The P1 Purification System that is an integral part of your compressor unit
may have a different physical layout but will be functionally identical.

C-D/DV/Navy
Figure 5-2 P1 Purification System
IN
OU
6
3
1 2 3
4 5
1. Coalescing Oil/Water Separator 5. Vent valve

2. Condensate Drain Valve 6. Pressure Maintaining Valve
3. Check Valves 7. Final Pressure Safety Valve
4. Purifier Chamber
5.2.1 Component Description

5.2.1.1 Coalescing Oil/Water Separator.
The coalescing oil and water separator works by means of a sintered metal micro-filter element which
reliably separates liquid oil and water particles from the compressed air.
5.2.1.2 Condensate Drain Valve
A manually operated valve used before start-up and during operation to drain the condensed liquids from
the coalescing oil and water separator. It is recommended not to drain the condensate more than four
times per hour of operation.

MNL-0237
5.2.1.3 Moisture Indicator

Under normal conditions the element in the moisture indicator is blue and changes to pink with elevated
levels of moisture.
Figure 5-3 Moisture Indicator
5.2.1.4 Purification Chamber

The Purification Chamber is made of anodized aluminum alloy.
5.2.1.4.1 Purifier Cartridge
The casings of the purifier cartridge as well as the cover and bottom are aluminum. The purifier cartridge
is packed with a molecular sieve to absorb moisture, activated charcoal to absorb odor and a catalytic
agent to convert Carbon Monoxide to Carbon Dioxide.
NOTICE
The used purifier cartridge must be disposed of in accordance with local regulations.
5.2.1.5 Vent Valve

A manually operated valve used to release the pressure in the purifier chamber before maintenance.
5.2.1.6 Pressure Maintaining Valve
The pressure maintaining valve ensures that pressure is built up in the purification system from the start
of delivery, thus achieving constant optimum purification. It also assures proper working conditions for
the final stage of compression.
5.2.1.7 Safety Valve
The safety valve is located on the coalescing oil and water separator and acts as the safety valve for the
final stage of the compressor.

C-D/DV/Navy
5.2.2 Maintenance
5.2.2.1 Cartridge Operating Life
Every P1 purification system is designed to process a certain volume of air before the purification car-
tridges require replacement. By using special test equipment that measures the quality of air at the outlet
any quality reduction may be detected. However as most compressor owners do not have this test equip-
ment the recommended method of determining purification cartridge operating life is to maintain a record
of the volume of air processed by the purification system.
Each compressor block is rated to produce a standard volume of air per minute and by using this figure
and the air processing capability of the purification system it is possible to calculate the maximum operat-
ing hours before the purification cartridges need to be replaced. See Paragraph 5.2.2.2 for the method of
determining this figure.
Ambient temperature of the intake air supply also causes changes to the operating life of purification car-
tridges. The standard ambient temperature is 68° F (20° C). Operating at other temperatures changes the
time before purification cartridge replacement is required. See Paragraph 5.2.2.3 for the method of calcu-
lating this adjustment factor. A form, titled Air Purification Cartridge Operating Hours for recording the
ambient temperature, operating time and adjustment factor is found in Section I. It is suggested that it be
copied, placed in a protective folder and kept with the unit to record the adjusted operating hours. An
example of how this form is used is shown in Figure 5-5.
5.2.2.2 Calculating the Maximum Purification Cartridge Operating Hours
1. From the purification dataplate on the unit determine the Air Processed (cu. ft.)
2. From the compressor unit dataplate determine the Capacity (CFM).
3. Divide the Air Processed by the Capacity to obtain the Maximum Operating Time in minutes
4. Divide the Maximum Operating Time in minutes by 60 to obtain the Maximum Operating Hours.
5. Record the answer on the Air Purification Cartridge Operating Hours form.
5.2.2.3 Calculating the Adjusted Purification Cartridge Operating Hours

1. Using the Air Purification Cartridge Operating Hours form record the Date, Operating Hours and
Ambient Air Temperature.
2. Using either the graph or the chart in Figure 5-4 determine the Correction Factor.
3. Divide the Operating Hours by the Correction Factor and record it under the column labeled Today.
4. Add the hours recorded in Today to the previous Total and record it as the current Total.
5. When the Total approaches the Maximum Operating Hours replace the Purification Cartridges.
5.2.2.4 Adjusted Cartridge Operating Hours
When operating at temperatures other than 68oF, divide the number of hours operated at that temperature
by the correction factor as indicated in figure Figure 5-4.

MNL-0237
Figure 5-4 Correction Factor for Cartridge Operating Hours
3.5
3.0
2.5
Conversion Factor
2.0
1.5
1.0
0.5
0.0
0 10 20 30 40 50
Ambient Temperature in °C
°C °F Correction Factor
[(°F - 32) x 5/9] [°C x 9/5 +32]
50 122 0.21
40 104 0.34
30 86 0.58
20 68 1.00
10 50 1.81
0 32 3.44
Figure 5-5 Example Record of Adjusted Operating Hours
Operating Ambient Temp. Correction Adjusted Cartridge Hours

Date
Hours during Compression Factor Today Total
10/19/04 8 92°F (33 °C) 0.48 16.66 16.66
11/01/04 4 45°F (7.2 °C) 2.25 1.78 18.44

C-D/DV/Navy
5.2.2.5 Coalescing Oil/Water Separator
1. See Figure 5-6. Disconnect the power and shut off the inlet supply line if applicable.
2. Depressurize the system by means of the vent valve.
3. Remove the tubes connected to the side of the filter head (1).
4. Unscrew and remove the filter head.
5. Unscrew the sintered metal filter element (2) from the filter head.
6. Remove the center screw (3) to remove the sintered metal filter element.
7. Clean the sintered metal filter element using hot soapy water. Blow dry with compressed air.
8. After cleaning the element, record the number of operating hours to ensure exact attention to the
maintenance intervals.
9. Lubricate the threads and O-rings as well as the threaded part of the sintered metal filter element
with petroleum jelly. Apply sparingly.
10. Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the
micro-filter element.
11. In the event you discover corrosion, replace the corroded parts with new Bauer parts.
Figure 5-6 Oil and Water Separator
2
3
1. Filter Head 3. Sintered Metal Filter

2. Center Screw 4. O-rings

MNL-0237
5.2.2.6 Moisture Indicator

To install the indicator element see Figure 5-7 and proceed as follows:
2 1
1. Indicator Cap 3. Spring

2. Indicator Element 4. Indicator Base
1. Release the pressure from the system.

2. Unscrew the indicator cap (2) from the indicator base (5).
3. Remove the old element (3).
4. Place the new indicator element with the active side facing the indicator window (1).
5. Reinstall the indicator cap (2), ensuring the spring (4) is in place and holding the indicator element
against the window.
6. Tighten the indicator cap (2) hand tight.

C-D/DV/Navy
5.2.2.7 Purification Chamber
To change the cartridge, proceed as follows. See Figure 5-8
Disconnect the power and shut off the inlet supply line, if applicable.
1. Depressurize the system by means of the vent valve.
2. Unscrew the filter head using the special wrench supplied.
3. Pull out the cartridge using the lifting ring on top of the cartridge.
4. Dry the inside of the purification chamber with a clean cloth and check for corrosion.
5. Replace all corroded parts with new Bauer parts.
6. Remove the shipping covering and the protective cap from the bottom of the cartridge.
7. Lubricate the O-rings with white petroleum jelly. Apply sparingly.
8. Install the new cartridge. Be sure the cartridge snaps into place.
9. Reinstall the filter head.
10. Close the vent valve, restore the power and reconnect the inlet supply line, if applicable.
NOTICE
If air is detected bleeding out from the bottom of the purification chamber, the cartridge has not been
installed properly or is missing. Follow the instructions in Paragraph 5.2.2.8
Figure 5-8 Purifier Cartridge Replacement
Pull
Up
5.2.2.8 Cartridge Leaking after Installation

1. Remove the cartridge following steps to 3. in Paragraph 5.2.2.7.
2. Install cartridge if missing.
3. Remove cartridge and inspect O-rings
4. Replace O-rings if necessary.

MNL-0237
5. Ensure protective caps and devices have all been removed.
6. Replace cartridge following steps 7. to 10. in Paragraph 5.2.2.7.
Purification
Cartridge
Protective Cap

C-D/DV/Navy
5.2.3 Replacement Parts List
Figure 5-9 Oil/Water Separator
11
12
13
17
14
16 15
16
1 17
17 18
22 23
2 19
3 19
20
21 17
4
22
2
9
10
6 9
10
7

♦ 1 090058 Oil/Water Separator Assembly Items 1 through 6
1 † — Separator Head Available only with 090058
2 2 N04586 O-ring
3 1 N15133 O-ring
4 1 061860 Filter Element
5 † — Separator Housing Available only with 090058
6 † — Bottom Plug Available only with 090058
7 1 011430 Manual Drain Valve
8 1 058165 U-bolt
9 2 WAS-0021 Washer

MNL-0237
Figure 5-9 (cont.) Oil/Water Separator

10 2 N00084 Self Locking Hex Nut
11 1 065410-330 Safety Valve
12 1 N04499 Gasket
13 2 SCR-0136 Socket Head Cap Screw
14 1 064013 Flange Adapter
15 1 N04882 O-ring
16 2 N16875 Plug
17 4 N01316 Gasket
18 1 063999 Flange Elbow Items 19 through 22
19 2 N04178 O-ring
20 1 063998 Flange Adapter
21 1 063997 Flange Elbow
22 2 CON-0061SS Male Connector
23 4 SCR-0133 Socket Head Cap Screw

C-D/DV/Navy
Figure 5-10 P1 Purification Chamber
1
2
3
4
5
8
9
10
5
4

♦ 1 080143 Purification Chamber Assembly 6,500 psi, 10” Cartridge
1 2 012293 Tool Post Screw
2 1 061237 Cover Plate
3 † 080147 Filter Head Available only with 080143
4 2 N04736 Back-up Ring
5 2 N04735 O-ring
6 † 080146 Filter Housing Available only with 080143
7 † 080148 Filter Bottom Available only with 080143
8 1 058821A Purifier Cartridge 10” MS/AC/MS/HP
9 1 N04731 O-ring
10 1 N04566 O-ring
11 2 N04499 Gasket
12 2 ADP-0020SS Adapter
N.S. 2 CMP-0002 Clamp

MNL-0237

♦ 1 IND-0015 Moisture Indicator
1 † — Indicator Cap Available only with IND-0015
2 1 ELM-0056 Indicating Element
3 † — Spring Available only with IND-0015
4 † — Indicator Base Available only with IND-0015

C-D/DV/Navy
CHAPTER 6: COMPRESSOR DRIVE SYSTEM
6.1 Dive Units
The compressor is driven by the drive motor or engine through a V-belt. The direction of rotation, as seen
facing the flywheel, is counterclockwise. Observe the arrow on the compressor block.
Figure 6-1 Dive Unit Drive
Tensioning
Tensioning
1 Nut
Nut
5
3 4
1. Compressor Flywheel 4. Drive Mount (engine/motor)
2. V-belt 5. V-belt Sheave & Bushing
3. Compressor Mount 6. Tensioning Nut & Spring
Tightening of the V-belt is accomplished by screwing down the tensioning nut. By lowering the motor or
engine’s position the distance between the flywheel and sheave is increased, thus tightening the V-belt.
Figure 6-2 Tensioning
6.1.1 Maintenance of the V-belt and Sheave

6.1.1.1 Checking the Sheave.
Before a new drive belt is installed, the condition of the sheave should be checked. A dirty or rusty
sheave impairs the drive’s efficiency and abrades the cover of the belt, which results in premature failure.

MNL-0237
A worn sheave shortens belt life as much as 50%. If the groove is worn to the point where the belt bot-
toms, slippage may result and the belt may burn. If the side wall is “dished out,” the bottom shoulder
ruins the belt prematurely by wearing off the bottom corners.
6.1.1.2 Checking the V-belt
Inspect the V-belt regularly for damage and wear. Replace if necessary.

C-D/DV/Navy
6.2 Replacement Parts List
Figure 6-3 C-D/DV/Navy Drive
Tensioning
Tensioning
1 Nut
Nut
5
3 4
♦ C-D/DV/Navy; Diesel Engine Drive

1 1 KC-FH/P0 Compressor Block
2 1 BET-0013 V-belt
3 1 FRM-0267 Complete Dive Frame Includes Compressor Base
4 1 BAS-0079 Engine Base
5 1 SHE-0142 V-belt Sheave
— 1 BUS-0011 Sheave Bushing
6 1 NUT-0154 Tensioning Nut
— 1 SPG-0003 Spring
NS 1 ENG-0045 Diesel Engine Yanmar, 6.4 Hp

MNL-0237
CHAPTER 7: MISCELLANEOUS
7.1 Valves
7.1.1 Nonadjustable Valves
The condensate drain valve, vent valve and check valves are not adjustable. The condensate drain valve
and vent valve have seats and seals which should be replaced if the valve leaks. Check valves are not
adjustable or repairable and must be replaced if they malfunction.
Figure 7-1 Pressure Maintaining Valve
7.1.2 Pressure Maintaining Valve

The pressure maintaining valve is adjusted at the factory to the required pressure and does not normally
require maintenance or readjustment. The factory settings are:
Final Pressure Setting Minimum PMV Setting
2,000-5,000 psi (138-345 bar) 2,175 psi (150 bar)
If readjustment does become necessary proceed as follows.
1. Loosen the locking nut (1).
2. Set the adjusting screw (2) to the required pressure using an appropriate hex type wrench.
3. Turn clockwise to increase pressure, counterclockwise to decrease pressure.
4. Determine if the PMV is properly adjusted:
a. Depressurize the final separator and purifier chamber by slowly opening the vent valve.
b. Close the vent valve and start the compressor.
c. Observe the final pressure gauge and note the pressure at which the valve opens (delivers).
d. If the pressure is not at the specified pressure ± 200 psi, readjust the PMV.

C-D/DV/Navy
7.1.3 Safety Valves
Figure 7-2 Safety Valves
The safety valve must be checked periodically for proper functioning.

1. Operate the compressor with the shut-off valve closed until the safety valve vents.
2. Note the pressure registered on the pressure gauge.
7.1.3.1 Safety Valve Adjustment
The safety valve is adjusted at the factory to the required pressure and does not normally require mainte-
nance or readjustment. In case readjustment does become necessary, have the safety valve adjusted by a
Bauer qualified technician or contact the Bauer Product Support Department for instructions on returning
the valve to the factory for adjustment.
7.2 Calibration of Safety Valves and Pressure Gauges
Figure 7-3 Calibration Label, LBL-0300
Bauer sets all safety valves using a calibrated gauge traceable back to a U.S. National Institute Of Stan-
dards and Technology (NIST) Registry. Safety Valves set by Bauer have a LBL-0300 affixed to show set
date and pressure set. This is recorded on a Calibration report and kept by the QA Department.
GAG-0010W/CAL is also calibrated using a NIST standard, the gauge is checked to assure it is operating
within it accuracy range of 3% of full scale deflection. By doing this a one year time frame is established
before recertification of the gauge is required. Records are also kept on the calibration of each gauge and
shipped with the gauge in all applications

MNL-0237
7.3 Fill Hose Replacement Parts List.
Figure 7-4 Fill Hose Assembly
11
Hose Storage Assembly

9 8 10
12
13
14
6
5
7
4

♦ 1 C-D/DV/Navy/FHFill Hose Assembly Items 1 through 11
1 1 HOS-0080 High pressure hose
2 1 CON-0348 Male connector
3 1 VAL-0391 Needle valve
4 1 ADP-0325 Adapter
5 1 CON-0017SS Hex nipple connector
6 1 CON-0042SS Male Run Tee
7 1 VAL-0169 Safety valve 300 to 6000 psi
8 1 ADP-0113 Fill adapter CGA, 4500 psi SCBA
9 1 N04483 O-Ring
10 1 GAG-0010W/CALPressure gauge
11 1 CVR-0002 Protection cover Rubber
12 2 CON-133SS Bulkhead Fitting
13 2 WAS-0060 Flat Washer
14 2 ADP-0058 Adapter
Note: Two Fill Hose Assemblies are shipped with each C-D/DV/Navy unit.

C-D/DV/Navy
CHAPTER 8: APPENDIX
8.1 Maintenance Reference Data
8.1.1 Tightening Torque Values
1. Unless otherwise specified in text, the torque values in Table 1 apply.

2. The indicated torque values are valid for bolts in greased condition.
3. Self locking nuts must be replaced on reassembly
4. Pipe connections (swivel nuts) should be tightened just enough so that leakage is stopped. Not more
than finger tight plus up to an additional ½ turn.
Table 8-1: Torque Values
Bolt or Screw Thread Max. Torque

Hex and socket head ¼” (M 6) 7 ft. lbs. (10 Nm)
Hex and socket head 5/16” (M 8) 18 ft. lbs. (25 Nm)
Hex and socket head 3/8” (M 10) 32 ft. lbs. (45 Nm)
Hex and socket head ½” (M 12) 53 ft. lbs. (75 Nm)
Hex and socket head 9/16” (M 14 85 ft. lbs. (120 Nm)
Hex and socket head 5/8” (M 16) 141 ft-lbs (200 Nm)
8.1.1.1 Torque Sequence Diagrams
Figure 8-1 6 Bolt and 4 Bolt Torque Sequence

3
5 3
2 1 2 1
4 6
4

MNL-0237
8.1.2 Approved Lubricants Chart

Unless otherwise specified in text, use the lubricants in Table- 8-2.
Table 8-2: Lubricant Chart

Usage Lubricants
O-rings, rubber and plastic parts; filter housing threads,
Parker Super “O” Lube
sealing rings
Bolts, nuts, studs, valve parts, Copper gaskets and tube
connection parts (threads, cap nut and compression Never-Seez® NSWT, Pipe Dope or teflon tape
rings)
DOW Corning 732 or equivalent silicone com-
Paper gaskets
pound applied on both sides before assembly,
DOW Corning 732 or equivalent temperature
High temperature connections
resistant compound,
Tube connection ferrules, Never-Seez® NSWT
8.1.3 Glossary of Abbreviations and Acronyms

ACD automatic condensate drain
ASME American Society of Mechanical Engineers
CW clockwise
CCW counterclockwise
CGA Compressed Gas Association
DIN Deutsches Institut für Normung
E1 single phase electrical supply
E3 three phase electrical supply
NEC National Electrical Code
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
NHA Next Higher Assembly
OSHA Occupational Safety & Health Administration
ODP open drip-proof (motor)
DOT Department of Transportation
Para. Paragraph
PMV pressure maintaining valve

C-D/DV/Navy
8.2 Safety Precautions
8.2.1 General
• Read the operating manual before installing or operating this compressor unit. Follow appropriate
handling, operation and maintenance procedures from the very beginning. The maintenance plan
contains measures required to keep this compressor unit in good condition. Maintenance is simple,
but must be executed regularly to achieve safe operation, maximum efficiency and long service life.
• We recommend that all maintenance work be recorded in a service book, showing the date and details
of the work carried out. This will help to avoid expensive repairs caused by missed maintenance
work. If it is necessary to make a claim against the warranty, it will help to have proof that regular
maintenance has been carried out and that the damage has not been caused by insufficient mainte-
nance.
• This compressor unit must be installed, operated, maintained and repaired only by authorized, trained
and qualified personnel.
• Consult and follow all OSHA, NEMA, ASME and local regulations, laws and codes covering the
installation and operation of this compressor and accessories before operating the unit.
• Do not operate this unit in excess of its rated capacity, speed, pressure, temperature, or otherwise than
in accordance with the instructions contained in this manual. Operation of this unit in excess of the
conditions set forth in this manual will subject the unit to limits which it may not be designed to with-
stand.
• Keep safety guards in place.
• Do not modify the compressor or its systems.
• Do not wear loose clothing around machinery. Loose clothing, neckties, rings, wrists watches, brace-
lets, hand rags, etc. are potential hazards.
• Provide adequate fire protection. Make sure fire extinguishers are accessible. Select alternate routes
of escape and post such routes.
• Make sure you are equipped with all required safety equipment; hearing protection, safety glasses,
hard hats, safety shoes and fire extinguisher.
• Visually inspect the unit before starting. Remove and/or replace any loose or broken components,
tools, valves, missing equipment, etc.
• Do not tamper with, modify, or bypass safety and shutdown equipment.
• Do not tighten or adjust fitting or connections under pressure.
• The use of plastic pipe or rubber hose in place of steel tube or iron pipe, soldered joints or failure to
ensure system compatibility of flex joints and flexible hose can result in mechanical failure, property
damage, and serious injury or death.
• The use of plastic or nonmetallic bowls on line filters without metal guards can be dangerous.
• Replace damaged fan blades promptly. Fan assemblies must remain in proper balance. An unbalanced
fan can fly apart and create an extremely dangerous condition.

MNL-0237
• Allow the compressor to cool before servicing. Whenever the compressor is shut down and over-
heating is suspected, a minimum period of 15 minutes must elapse before opening the crankcase.
Premature opening of the crankcase of an overheated unit can result in an explosion.
• Incorrect placement of the inlet and discharge valves in a compressor cylinder head can cause an
extremely dangerous condition. Refer to the appropriate section of this instruction manual before
installing or replacing valves.
• Before doing any work involving maintenance or adjustment, be sure the electrical supply has been
disconnected, and the complete compressor system has been vented of all internal pressure. Failure to
follow these warnings may result in an accident causing personal injury and/or property damage.
• Before working on the electrical system, be sure to disconnect the electrical supply from the system at
the circuit breaker or other manual disconnect. Do not rely on the ON/OFF switch to disconnect the
electrical supply.
• Installer must provide an earth ground and maintain proper clearance for all electrical components.
• All electrical installation must be in accordance with recognized national, state, and local electrical
codes.
• A compressor which has been used for gas service is unsuitable for air applications. Should the
purchaser and/or user proceed to use the compressor for air service after it has been used for gas, the
purchaser and/or user assumes all liability resulting therefrom without any responsibility being
assumed by Bauer Compressors, Inc. The purchaser is urged to include the above provision in any
agreement for resale of this compressor.
• The use of repair parts other than those included in the Replacement Parts List may create unsafe
conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be
life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore,
Bauer Compressors, Inc. can bear no responsibility for equipment in which non-approved repair parts
are installed

C-D/DV/Navy
8.2.2 Safety Warning Labels

Notes, labels and warning signs are displayed on the compressor unit according to model, application or
equipment and may include any of the following.
HOT SURFACES DO NOT TOUCH!

Danger of burning if cylinders, cylinder heads, or pressure lines of individual
compressor stages are touched.
HIGH VOLTAGE!
Life threatening danger of electrical shock. Maintenance work on electric units
or operating equipment should be carried out by a qualified electrician or by a
person supervised by a qualified electrician according to electrical regulations.
AUTOMATIC COMPRESSOR CONTROL
UNIT MAY START WITHOUT WARNING!
Before carrying out maintenance and repair work, switch off at the main switch
and ensure the unit will not restart.
THE INSTRUCTIONS MUST BE READ BEFORE OPERATING UNIT!
The instruction manual and all other applicable instructions, regulations, etc.
must be read and understood by the operating personnel before using the
machine.
HEARING PROTECTION MUST BE WORN!
Hearing protectors must be worn when working on a machine which is running.
DIRECTION OF ROTATION!
When switching on the machine, check the arrow to ensure correct direction of
rotation by the drive motor.
8.3 Long Term Storage and Preservation

8.3.1 General
If the compressor unit will be out of service for more than six months, it should be preserved in accor-
dance with the following instructions:
5. Make sure that the compressor is kept indoors in a dry, dust-free room.
6. Cover the compressor with plastic sheets only if no condensation will form under the sheet.
7. Remove the sheet from time to time and clean the outside of the unit.
8. If this procedure cannot be followed, or if the compressor will be out of service for more than 24
months, please contact the Bauer Service Department for special instructions.
8.3.2 Preparations
Prior to preserving the compressor unit, it must be run until warm, i.e., up to the specified service pres-
sure. Operate the unit for approximately 10 minutes, then carry out the following checks.
1. Check all pipes, filters and valves (including safety valves) for leakage.
2. Tighten all couplings, as required.

MNL-0237
3. After 10 minutes, open the outlet valve and operate the compressor at adjusted minimum pressure
using the pressure maintaining valve for approximately 5 minutes.
4. After the 5 minutes, shut the compressor unit down and completely drain all separators and filters.
Close all valves.
5. Remove filter heads and lubricate the threads with white petroleum jelly.
8.3.2.1 Units Equipped with a Filter System

1. Ensure that filter elements remain in the filters! This will prevent oil from entering the outlet lines
as a result of preservation procedures.
2. Remove the intake filter/intake pipe completely.
8.3.3 Preserving the Compressor

1. Operate the compressor again and slowly spray approximately 0.35 oz. (10 cc) of oil into the inlet
port while the compressor is running. Keep the shut-off valve open and the condensate drain valves
closed.
2. After spraying the oil into the inlet port, run the compressor unit for an additional 5 minutes before
shutting the compressor unit down.
3. Close the shut-off valve.
4. Close the inlet port with a dust cap and/or tape.
8.3.4 Preventive Maintenance During Storage

Operate the compressor once every six months as follows:
1. Remove the dust cap from the inlet port and install the inlet filter.
2. Open the outlet valve and allow the system to run approximately 5 minutes until there is outflow
from the valve and oil is visible in the sight glass of the oil regulating valve.
3. Shut down the compressor.
4. Open the condensate drain valves, depressurize the unit, then close the drain valves again.
5. Remove the intake filter and replace the dust cap on the inlet port.
8.3.5 Lubrication Oils for Preservation

1. After prolonged storage periods, the oil will age in the compressor crankcase. The oil must be
drained at least every 24 months and replaced with fresh oil.
2. The stated period can only be attained when the crankcase is sealed during the preservation period
in accordance with the preservation requirements.
3. After changing the oil, the compressor must be operated according to the instructions above.
4. Check the lubrication of the compressor during the every-six-month brief operation or when turning
the compressor.

C-D/DV/Navy
5. The oil pump is functioning properly when oil can be seen flowing through the sight glass of the oil
pressure regulator or if the oil pressure gauge indicates the prescribed pressure.
8.3.6 Reactivating the Compressor Unit

1. Remove the dust cap from the inlet port and install the intake filter.
2. Check the oil level of the compressor. If necessary, change the oil.
3. The motor must be thoroughly dry before applying power.
4. For units with a filter system, change all filter cartridges.
5. Run the compressor with open outlet valve for approximately 10 minutes. Check for proper opera-
tion of the lubricating system.
6. After 10 minutes, close the shut-off valve and run the system up to final pressure until the final
pressure safety valve vents. On compressor units with a compressor control system, raise the pres-
sure switch setting the switch above normal limits to override the pressure switch. Be sure to reset
the switch after checking.
7. Check the interstage safety valves for leakage.
8. Establish the cause of any faults and remedy.
9. Stop the unit when it is running properly. The compressor is then ready for operation.
8.4 Installation
8.4.1 Unpacking and Handling
This compressor unit is packaged according to the requirements for shipping via the requested type of
carrier service. It is possible that the compressor unit could have been damaged during shipping. For this
reason, we urge you to thoroughly examine the unit for possible damage and report any such damage to
the shipping company immediately.
Care must be taken in unpacking the compressor unit. Serious damage could result by not checking for
clearance between the item to be unpacked and the packaging to be removed.
This compressor unit may be furnished with one or more shipping braces for shipping and handling only.
After installation and before operation, these braces must be removed entirely. Under no circumstances
should the braces remain installed during operation or the manufacturer’s warranty for the compressor
unit will be voided. The braces are all tagged and labelled.
The floor at the site must be capable of supporting the weight of the unit. Position the unit so that it is
level. Permissible inclination of the compressor unit is 10° forward or backward, 10° right or left.
^ CAUTION
These values are valid only if the oil level of the compressor in normal position is level with
but does not exceed the upper mark of the oil dipstick or oil level sight glass.

MNL-0237
8.4.2 Ventilation
During normal compression, heat is generated by the compressor and by the drive motor or engine. For
air-cooled compressor units, this heat needs to be vented away by sufficient ventilation.
8.4.2.1 Outdoor Installation
It is recommended that all gasoline and diesel engine driven compressor units be installed outdoors.
Additionally, electrically driven compressor units may be installed outdoors only if enclosed with weath-
erproof enclosure panels.
8.4.2.2 Indoor Installation
The best location to install the compressor unit indoors is against an outside wall with a suitably large air
vent in front of the cooling fan. Additionally, it is necessary to position an exhaust opening in the oppo-
site wall, close to the ceiling or in the ceiling.
As a basic rule of thumb, the room should be ventilated sufficiently so as to prevent the ambient room
temperature from exceeding 105° F. Additional heat generating equipment or piping should be avoided or
must be well insulated.
8.4.2.3 Natural Ventilation
Natural ventilation should only be used up to a maximum drive power of 20 hp. To determine the size of
the required intake and exhaust openings, consider the following table:
Intake and Exhaust Openings Dependent on Room Volume (V) and Height (h)
Drive hp V = 1750 ft³ h = 6.5 ft V = 3500 ft³ h = 10 ft V = 7000 ft³ h = 13 ft
Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²)
3 1.3 1.1 --- --- --- ---
5 3.2 2.7 1.3 1.1 --- ---
7.5 4.5 3.8 2.6 2.2 1.3 1.1
10 9.7 8.1 6.5 5.4 2.6 2.2
15 14.5 12.4 9.7 8.1 5.8 4.8
20 20.6 17.2 15.6 12.9 9.7 8.1

C-D/DV/Navy
8.5 Reproducible Maintenance Record Forms
8.5.1 Scheduled Maintenance Form
Daily Para. Date Signature

MNL-0237
Weekly or as required. Para. Date Signature
500 Operating Hours. Para. Date Signature
1,000 Operating Hours. Para. Date Signature

C-D/DV/Navy
Annually. Para. Date Signature
Annually, or as required. Para. Date Signature
Biennially. (Every two years) Para. Date Signature

MNL-0237
8.5.2 Record of Operating Hours
Date Minutes Total Date Minutes Total

Subtotal: Subtotal:

C-D/DV/Navy
8.6 Additional Data
• Any included drawings, wiring diagrams, pneumatic flow diagrams, etc., will be bound in this manual
next to the back cover.
• OEM Manuals and other Bauer manuals may be included in the documentation shipping package.
8.7 Drive Motor Supplement
Bauer Part Number ENG-0045 is a 6 hp diesel engine manufactured by Yanmar Diesel Engine Company.
The Yanmar model number is L60AED.

Unlok

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Unlok

Uploaded by

Copyright:

Available Formats

Instruction Manual and Replacement Parts List

June 1, 2010 2nd Edition, Rev. 2 Chg. 4 MNL-0237

Editions, Revisions and Changes

Page i 2nd Edition, Rev. 2 Chg. 4

1st Edition: April 1997

Rev Chg Date Notes Auth

2nd Edition: January 2002

Rev Chg Date Notes Auth

Addition of Moisture Indicator, Frame & Supplemental Man-

2 0 Oct. 6, 2008 Updated to Standard Manual Format CLA

June 1, 2010 Page ii

EFFECTED PAGES of CHANGES

Edit./Rev. / Chg. Effected Pages Edit. / Rev. / Chg. Effected Pages

Revision 2 All Rev. 2, Chg. 3 35, 39

Page iii 2nd Edition, Rev. 2 Chg. 4

CHAPTER 3: - - - - - - COMPRESSOR BLOCK - KC-FH CAPITANO

June 1, 2010 Page iv

CHAPTER 4:- - - - - - - - - - - - - - MAINTENANCE SCHEDULE

CHAPTER 5:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

Page v 2nd Edition, Rev. 2 Chg. 4

CHAPTER 6: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

June 1, 2010 Page vi

CHAPTER 2:- - - - - - - - - - - - - - - - - - - - - - - OPERATION

CHAPTER 3:- - - - - - COMPRESSOR BLOCK - KC-FH CAPITANO

CHAPTER 4:- - - - - - - - - - - - - - MAINTENANCE SCHEDULE

Page vii 2nd Edition, Rev. 2 Chg. 4

CHAPTER 5: - - - - - - - - - - - - - - - - PURIFICATION SYSTEM

CHAPTER 6: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

June 1, 2010 Page viii

Page 1 2nd Edition, Rev. 2 Chg. 4

Figure 1-1 Compressor Identification Plate

BAUER COMPRESSORS, INC. BAUER

MODEL NO. BLOCK NO.

June 1, 2010 Page 2

1.3 How to Use the Appendix

Page 3 2nd Edition, Rev. 2 Chg. 4

Figure 1-2 C-D/DV/NAVY Air Compressor

1. Belt guard 5. Purification Cartridge

June 1, 2010 Page 4

Figure 1-3 Air Flow Diagram

1. Intake Manifold 7. Aftercooler 12. Oil and Water Separator

Page 5 2nd Edition, Rev. 2 Chg. 4

1.6 C-D/DV/NAVY Specifications

Compressor block KC-FH (Capitano)

Compressor Drive Diesel Engine

Bauer Part # Fuel Cap. Oil Cap. Power Speed Cylinders

1. Based on recharging an 80 cubic foot tank from 500 to 3000 PSIG

June 1, 2010 Page 6

Figure 2-1 Compressor Oil Dipstick

Page 7 2nd Edition, Rev. 2 Chg. 4

Figure 2-2 Purification Cartridge Installation

Figure 2-3 Fill Hose

June 1, 2010 Page 8

Figure 2-4 Hose Connection Figure 2-5 Air Intake Hose

Page 9 2nd Edition, Rev. 2 Chg. 4

2.2 Routine Use

2.2.2 Diesel Engine Start-up Procedure

June 1, 2010 Page 10

Figure 2-8 Fuel Valve Figure 2-9 START/STOP Control

Figure 2-10 Recoil Starter Figure 2-11 Decompression Lever

2.2.3 Post Start Procedures

Page 11 2nd Edition, Rev. 2 Chg. 4

Figure 2-12 Final Relief Valve