G Compressor Service

Standards
 Startup
• Review compressor instruction manual
• Remove shipping bolts and brackets as indicated in instruction book
• Check electrical connections and grounding
• Check external starter to control panel interface (customer supplied starter)
• Check control panel transformer connections and jumper configuration
• Check and verify motor overload relay and fan circuit breaker settings
• Check all control panel electrical connections for tightness
• Check setting and operation of shutdown switches (electro-pneumatic)
• Ensure all safety shields are installed
• Check oil drain plugs for leaks and tightness
• Check oil level in receiver tank and top off if necessary (Do not mix oils)
• Pour compressor oil into inlet of element (Do not mix oils)
• Turn element by hand to displace oil
• Verify proper condensate drain line installation (open drains)
• Close aftercooler manual condensate drain valve
• Check cooling water connections (solenoid, strainer, inlet, outlet)
 Startup (continued)
• Check air system piping (receiver, condensate collection)
• Check room for proper ventilation (see Product Data)
• Turn on power to compressor
• Jog the unit and verify correct drive motor and cooling fan motor rotation
• Start unit and run unloaded for several minutes
• Stop unit and recheck oil level
• Repair air, oil, or water leaks as required
• Restart and load compressor
• Adjust pressure switch per customer’s requirements (electro-pneumatic)
• Set load and unload pressures on Elektronikon
• Adjust cooling water flow rates
• Measure and record all temperature, pressure, and SPM readings
• Instruct customer on proper operation of unit
• Instruct customer on preventative maintenance (Daily, 2,000 hr, etc..)
 Daily Checks
• Daily log book
– 1310 9050 77 - GA/GR
• Check gauge readings (electro-pneumatic)
• Check Elektronikon readings
• Check water circuit temperatures
• Check compressor oil level
• Check service indicators
• Check condensate drain operation
• Blow down manual condensate drain valve
 2,000 Hour Inspection
• Check inlet filter element
• Check control panel lamp operation (electro-pneumatic)
• Check instrumentation (electro-pneumatic)
• Check aftercooler condensate drain operation
• Blow down manual condensate drain valve
• Check operation of regulation system
• Check programmed settings of Elektronikon
• Check operation of Elektronikon LED’s
• Check oil level and top off with specified oil as required (Do not mix oils)
 2,000 Hour Inspection
(continued)
• Replace drive belts: GA5-10
• Inspect drive belts and retension: GA11-22
• Inspect drive coupling rubber element: GA30-315
• Check cooler performance
• Draw oil sample for oil analysis
• Change Oil if using mineral oil
• Replace oil filter(s)
• Repair air, oil, or water leaks as required
• Adjust cooling water flow rates
• Measure and record all temperature, pressure, and SPM readings
 4,000 Hour or Yearly Service
All 2,000 hour inspection items plus:
• Change compressor oil (Roto-Inject fluid)
• Clean scavenge line orifice
• Clean air cooled coolers externally
• Disassemble and inspect condensate drain
• Check all electrical connections for tightness
 8,000 Hour or 2 Year Service
All 4,000 hour service items plus:
• Check all flexible hoses for deterioration
• Test safety shutdown switch operation (electro-pneumatic)
• Change compressor oil (HD Roto Fluid)
• Check all bolt connections for tightness
• Replace oil separator element
• Replace drive coupling rubber insert (24,000 hours)
• Disassemble, inspect and rebuild inlet valve
• Disassemble, inspect and rebuild vent valve assembly
• Disassemble, inspect and rebuild discharge check valve
• Disassemble, inspect and rebuild oil stop valve
• Disassemble, inspect and rebuild minimum pressure valve
• Grease motor bearings. follow manufacturer recommendations
 Element replacement
All 8,000 hour service items plus:
• Rebuild compressor gearbox (new seals and
bearings)
• Replace drive coupling rubber element
• Clean air cooled coolers externally
• Clean water cooled coolers internally
• Replace compressor element with rebearinged
element (pre-charge element with compressor
oil before starting)
 Additional notes:
Follow lubricant manufacturers instructions
regarding oil change intervals and adjust the
expected oil lifetime for abnormal operating
conditions.