Alkin W4 Series Manuale utente
W4
SERIES
BREATHING AIR COMPRESSORS
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
2
HIGH PRESSURE BREATHING AIR COMPRESSORS
(W4 SERIES)
Instruction Manual & Parts List
Instruction
Manual
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
ii
A L K I N C O M P R E S S O R S
© This manual or any parts thereof cannot be copied by any means, or used for any other purposes
other than servicing Alkin W4 series compressors, unless specific permission of Alkin®in writing is
received.
ALKIN KOMPRESOR San. ve Tic. Ltd. Sti
Cuneytbey Mh. Tabas Yolu Kume Evleri No.3, Menderes
35470 Izmir - TURKIYE
Tel: +90 232 78 222 90 • Fax: +90 232 78 222 89
www.alkin-compressors.com
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
ii
CONTENTS
1.0 SAFETY................................................................................................................................. 6
1.1 General .................................................................................................................................................... 6
1.1.1 General safety information...................................................................................................................6
1.1.2 Pressure release..................................................................................................................................6
1.1.3 Fire and Explosion ...............................................................................................................................6
1.1.4 Moving parts.........................................................................................................................................7
1.1.5 Hot Surfaces, Sharp Edges and Sharp Corners..................................................................................7
1.1.6 Toxic and Irritating Substances............................................................................................................7
1.1.7 Electrical Shock....................................................................................................................................8
1.1.8 Lifting....................................................................................................................................................8
2.0 General information on W4 series 4 Stage compressors....................... 10
2.1 General ..................................................................................................................................................10
2.2 P&I (Process & Instrument) Diagram......................................................................................12
2.3 Principles of Operation ..................................................................................................................13
2.4 Description of Major Components ............................................................................................14
2.4.1 Major Components - Compressor Unit ..............................................................................................14
2.4.2 Major Components –System.............................................................................................................15
2.5 Description of Controls ..................................................................................................................16
2.5.1 Compressor Controls.........................................................................................................................16
2.6 Owner records ...................................................................................................................................18
3.0 Installation..................................................................................................................... 20
3.1 Inspection.............................................................................................................................................20
3.2 Location.................................................................................................................................................20
3.3 Piping .....................................................................................................................................................20
3.4 Electrical check..................................................................................................................................21
3.5 Wiring ....................................................................................................................................................21
3.6 Sheaves and V-belt alignment check........................................................................................21
4.0 Operation ........................................................................................................................ 22
4.1 Initial start-up Procedure .............................................................................................................22
4.2 Oil recommendation........................................................................................................................22
4.3 Adjustment ..........................................................................................................................................23
4.3.1 Pressure Swtich Adjustment..............................................................................................................23
4.3.2 Sequential Drain Timer Adjustment...................................................................................................23
4.3.3 Safety Valve Adjustment....................................................................................................................24
5.0 Maintenance .................................................................................................................. 28
5.1 General ..................................................................................................................................................28
5.2 Daily........................................................................................................................................................28
5.3 Weekly...................................................................................................................................................28
5.4 Every 120 hours ................................................................................................................................28
5.5 300 hours maintenance .................................................................................................................28
5.6 500 hours maintenance .................................................................................................................29
5.7 1000 hours maintenance...............................................................................................................29
5.8 2000 hours maintenance...............................................................................................................29
5.9 As required ..........................................................................................................................................29
5.10 MAINTENANCE TABLE................................................................................................................30
5.11 Maintenance procedures ............................................................................................................31
5.11.1 General ............................................................................................................................................31
5.11.2 Torque values ..................................................................................................................................31
5.11.3 Servicing 1st stage valve..................................................................................................................31
5.11.4 Servicing 2nd stage valve .................................................................................................................31
5.11.5 Servicing 3rd &4th stage valve...........................................................................................................32
5.11.6 Piston ring replacement ...................................................................................................................33
5.11.7 Crankshaft bearing replacement......................................................................................................36
5.11.8 Oil seal replacement ........................................................................................................................37
5.11.9 Piston&piston pin removal and replacement ................................................................................37
5.11.10 Cylinder&piston removal and replacement....................................................................................37
5.11.11 Air head replacement.....................................................................................................................38
5.11.12 Precautions for storing...................................................................................................................38
5.11.13 Intercoolers and aftercooler...........................................................................................................39
5.11.14 Automatic drain valves...................................................................................................................39
5.11.15 Filtration equipment ....................................................................................................................39
6.0 Trouble shooting......................................................................................................... 41
7.0 Part List............................................................................................................................ 46
7.1 Crankcase Assy ..................................................................................................................................47
7.2 Connecting Rods................................................................................................................................49
7.3 1st&2nd Stage Assy..........................................................................................................................51
7.4 3rd Stage Assy....................................................................................................................................53
7.5 4th Stage Assy ....................................................................................................................................55
7.6 Pistons ...................................................................................................................................................57
7.7 Pipe Lines .............................................................................................................................................59
7.8 Intercoolers (1st&2nd Stage)......................................................................................................63
7.9 3rd Stage Intercooler & 4th Stage Aftercooler.....................................................................65
7.10 Water Separators ...........................................................................................................................67
7.11 Discharge Line.................................................................................................................................69
7.12 Filter Panel........................................................................................................................................73
7.13 Coelescer Filter Assy.....................................................................................................................77
7.14 Purifier Assy .....................................................................................................................................79
7.15 Pressure Gauge Lines ...................................................................................................................81
7.16 Drive Assy..........................................................................................................................................83
7.17 General Connectors.......................................................................................................................85
7.18 Filling Panel –Dual Pressure ....................................................................................................89
7.19 Filling Panel –330 Bar.................................................................................................................91
7.20 Filling Panel –225 Bar.................................................................................................................93
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
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Your new ALKIN air compressor will provide you with the solid and reliable performance that you should expect from a heavy-duty
industrial air compressor.
Please read this manual carefully before you operate your compressor. This will enable you to start-up your compressor in in the maintenance
section of this manual. This way the proper manner, as well as maintain it using the simple instructions your air compressor will always be in
top operating condition, giving you years long trouble free service.
LKIN air compressors are well known with their faultless design and unique features combined with the
best materials and workmanship. Some of the most important features are centrifugal unloading regulators,
overhung crankshaft design, solid end connecting rods, high efficiency valves, which all add to the superior
and lasting performance of the ALKIN compressors.
Your compressor is backed up with worldwide sales and service organization, ready to accommodate your everyday
needs for parts & service.
For any questions, please feel free to call our Menderes plant, in Izmir - Turkey.
Here are the contact details:
Address: ALKIN KOMPRESOR San. ve Tic. Ltd. Sti
Cuneytbey Mh. Tabas Yolu Kume Evleri No.3 , Menderes
35470 Izmir - TURKIYE
Tel: +90 232 78 222 90 •Fax: +90 232 78 222 89 •e-mail: alkin@alkin-compressors.com
Foreword
A
W 4 S E R I E S
H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R
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