WARNING. CURTIS-TOLEDO, INC Kienlen Avenue St. Louis, MO 63133

Transcription

1 X MAY, 2005 WARNING Before installing and operating this compressor, read and understand the safety precautions contained in LV-474 supplement to and part of IMPORTANT Make a permanent record of the Model and Serial number of your machine here. You ll save time and expense by including this reference identification on replacement part orders. CURTIS-TOLEDO, INC. 905 Kienlen Avenue St. Louis, MO 6333 REFER TO MODEL & SERIAL NUMBER. READ INSTAL. & OPERATION INSTR. DO NOT OPERATE LOWER THAN 500 R.P.M. OR ABOVE MAX. AS STIPULATED BY PERFORMANCE DATA SHEET. MODEL NO. SERIAL NO. *CONSULT FACTORY FOR SPECIAL APPLICATIONS CURTIS-TOLEDO, INC. 905 Kienlen Avenue, St. Louis, Missouri 6333 phone: fax: Sales representatives in principal cities info@curtistoledo.com

2 INSTALLATION CONGRATULATIONS on your new Curtis Challenge Air Compressor. Please examine the compressor for shipping damage(s) and if any are found report it immediately to the carrier. Select a clean dry location with a rigid floor strong enough to support the compressor. If the compressor is to be located in an area where vibration is critical, properly engineered vibration mounts and flexible piping should be used. Remove the skid. NOTE: The compressor should never be operated on the shipping skid. Level the compressor so it can be bolted down securely. Before tightening the bolts, check to see that all four feet are resting on the foundation. Shim as necessary to eliminate stress on the receiver or base when the bolts are tightened. We suggest using a level for proper alignment. Maximum ambient temperature in which the compressor and motor should be operated is 04 F. Therefore, adequate ventilation must be provided. The suction openings of the compressor are equipped with a combination air filter-muffler to protect the compressor from normal dust and other harmful substances. If the air around the compressor is excessively hot, dusty, humid or contaminated with foreign gases (such as ammonia or acid fumes) move the filter-muffler to a remote point where the air is clean, cool and dry. Run a pipe to the compressor suction opening. If the run is over 50 feet in length, use a larger pipe to avoid excessive pressure drop. In order to fit the filter to the compressor, bush down the connections. Be sure piping and fittings are clean and free from dirt and chips. If the filter is installed outside, check to insure that it is located above the normal outside dust level, and that rain cannot enter the filter element. Where the relocation of the filter-muffler is not possible or feasible, an oil bath filter is recommended and is available from Curtis. On basic or base mounted compressors run a discharge pipe to the receiver or optional aftercooler and bush up or down as necessary. The pipe should enter near the top of the receiver. Keep in mind that condensate may form in the discharge line; therefore, the lines should always be pitched to drain condensate away from the compressor. Always provide a safety relief valve in the discharge line between the compressor and inline shutoff valves. If more than one compressor pumps into a common system, a check valve in the discharge line of each compressor is recommended to prevent moisture from entering the cylinder head when one compressor is idle. A globe or gate valve installed in the discharge line will allow compressor isolation from plant air system for compressor maintenance. (Note: A safety relief valve should be located between the compressor and the globe/gate valve.) Check the electrical supply for voltage, phase, and frequency to see that they match the nameplate stampings on the motor, magnetic starter, solenoids, and other controls. Use electrical wires of adequate size to carry the full load current of the motor without excessive voltage drop. Charts are available from Curtis (upon request) to provide information on this. The motor must always be protected by a starter with properly sized thermal overload(s). The starter should protect the motor from overheating and burnout due to an overload, low voltage or single phasing of a 3-phase circuit. Failure to install the proper starter and overloads will void the motor manufacturers warranty. Follow the National Electric Code or local electric code in providing wiring, fusing and disconnect switches. NOTE: Do not close the disconnect switch to start the compressor until the procedures outlined under "Startup Procedures" have been completed. LIMITED SAFETY PRECAUTIONS (Also see supplement LV-474) The following safety precautions are recommended in the use of this compressor:. Use a totally enclosed OSHA-approved belt guard to cover the drive assembly. Where possible, place the flywheel toward the wall, and mount the unit a minimum distance of 2 feet from the wall for maintenance convenience. 2. Turn off & lock out the electrical disconnect switch before working on the unit to prevent the unit from starting unexpectedly 3. Release all air pressure from the system before working on the unit and red tag all electrical control switches, for safety precaution. 4. Do not by-pass motor over-current protection. 5. Do not change the setting or in any way affect the operation of the safety valve. 6. Keep unit securely anchored so that movement will not put a strain on piping, wiring, or air receiver. WARNING: Read and understand supplement LV-474 before installing and operating the compressor. 2

3 OIL RECOMMENDATION Use a good grade of industrial compressor oil (nondetergent) with foam, rust and oxidation inhibitors and a minimum life of 500 hours in the ASTM D 943 test for oxidation stability. Ambient Temperatures: 0-32º F - Viscosity 80 to 240 SUS at 00º F. Minimum pour point of - 20º F. Grade ISO 4 Approved listing: Chevron-Turban GST Oil 46. Amoco-Amokon Oil 46. Conoco-Turban Oil 46. Shell-Turbo Oil T-46. Texaco-Regal R & O Oil 46. Exxon- Teresstic Oil º F - Viscosity 300 to 350 SUS at 00º F. Grade ISO Approved listing: Chevron-Turban GST Oil 68. Amoco-Amokon Oil 68. Conoco-Turban Oil 68. Shell-Turbo Oil T-68. Texaco-Regal R & O Oil 68. Exxon- Teresstic Oil º F - Viscosity 450 to 550 SUS at 00º F. Grade ISO 00. Approved listing: Chevron-Turban GST Oil 00. Amoco-Amokon Oil 00. Conoco-Turban Oil 00. Shell-Turbo Oil T-00. Texaco-Regal R & O Oil 00. Exxon- Teresstic Oil 00 A good maintenance program will add years of service to your air compressor. The following is recommended as a minimum maintenance program. (TURN OFF POWER BEFORE SERVICING.) LUBRICATION. For proper lubrication the compressor shall not be operated below the minimum or above the maximum R. P.M. recommended for the various models. 2. Maintain oil level mid-way between the upper and lower lines of the crankcase sight gage. NOTE ILLUSTRATION: 3. Stop compressor to add and gauge oil. 4. Do not fill above the upper line and do not operate compressor with oil level below the lower line. DO NOT OVER FILL 5. Change oil at the first 00 hours of operation and 000 hours thereafter, or as required. It may be necessary to change oil more frequent due to abnormal humid and contaminated conditions. DAILY MAINTENANCE. Check and maintain oil level at centerline of sight glass and add oil as necessary. 2. Drain condensate from receiver unless it is equipped with an automatic tank drain, in which case the drain should be checked weekly to see that it is operating. See automatic tank drain instructions. START-UP PROCEDURES If the compressor is equipped with an automatic start-stop control (with pressure switch unloading), it is automatically unloaded upon starting, and will automatically load after attaining running speed. If the compressor is equipped with a constant speed control (pilot valve unloading), it is necessary to manually unload the compressor, if there is pressure in the discharge line, in order to achieve an unloaded start. The compressor must be manually loaded after the compressor has attained full running speed, thereafter, it functions automatically to maintain operating pressure until the unit is shut off. Close the disconnect switch and start the compressor. Observe the direction of rotation, which should be counterclockwise when viewed from the flywheel side of the compressor on all models. For single-phase units, the direction of rotation is determined by the motor nameplate instructions, and is adjusted at the factory. For three-phase units, if the rotation is incorrect, stop the unit and interchange any two of the three wires to the motor at the disconnect switch. This will reverse the direction of rotation of the motor and compressor. PREVENTIVE MAINTENANCE 3. Check for unusual noise or vibration (See "Trouble Shooting".) WEEKLY MAINTENANCE. Clean the air filters. A clogged air filter can seriously affect the efficiency of the compressor and cause overheating and oil usage. 2. Clean all external parts of the compressor and driver. Be sure to clean the intercooler-finned surface on two-stage compressors. A dirty compressor will cause abnormally high discharge temperature and resulting oil carbonization on internal valve components 3. Check the safety valve manually (by pulling ring or lever) to see that it is not stuck. MONTHLY MAINTENANCE. Inspect the entire air system for leaks. 2. lnspect condition of oil and change if necessary. 3. Check drive belt tension and tighten if needed. EVERY 3 MOS. OR,000 HRS. OF OPERATION. Change oil. 2. lnspect valves. Clean the carbon from valves and head if necessary. 3. Check and tighten if necessary all bolts, nuts, etc. 4. Check unloader operation. *CHECKING BELT TENSION The v-belt(s) should be adjusted so that a declination of about 3/8 /2 inch will be obtained when it is pushed by a finger at the middle point as shown in Figure. CAUTION: Over tightening the v-belt(s) will result in overloading of the motor and belt failure, while a loose belt will be slipping and resulting in an unstable speed, overheating the belt and high amp draw. WARNING: Read and understand supplement LV-474 before installing and operating the compressor. 3

4 To change tension, loosen the motor hold-down bolts and slide the motor on the base, using a lever if necessary, or by turning the adjusting bolt at the end of the base. Retighten motor hold-down bolts. NOTE: Do not over tighten belts. Figure ELECTRIC MOTOR Grease once a year with a good grade of lithium ball bearing grease, or as directed by the motor manufacturer. Valves should be inspected at regular intervals as recommended under "Maintenance" and cleaned or replaced when necessary. The valve can be serviced without disconnecting air piping or removing the head. (Be sure the power to the motor is disconnected and all pressure released before starting to work on the compressor.) On constant run models, it is necessary to remove the unloader piping before the valve plugs can be removed. MODELS E- AND E-23 (Figures 2 and 3) A. Disassembly:. Unbolt the outlet valve push cover ( ). 2. Remove the outlet valve push cover packing ( ), spring ( ) and valve plate ( ). CAUTION: Steps and 2 are for outlet valve. 3. Remove the unloading connecting tube for Models E- and E Untighten four cylinder head fixed bolts. 5. Remove cylinder head carefully and turn it over. 6. Unbolt inlet valve receiver ( ). 7. Remove valve spring ( ) and valve plate ( ). VALVE INSPECTION AND MAINTENANCE Valves should be inspected approximately every,000 hours of operation. Inspect the valve seats on cylinder head for dents, cracks or wear. Replace all defective parts. Remove carbon deposits and wash all valve components in a suitable non-flammable cleaning fluid. B. Assembly:. Place outlet valve plate ( ) in position. 2. Place the outlet valve push cover packing ( ) in position. 3. Insert the spring ( ) into outlet valve push cover ( ). 4. Turn outlet valve push cover ( ) in position carefully. 5. Check the valves to see if they can move freely in their guides. 6. Turn over the cylinder head (702-00). 7. Place the inlet valve plate ( ) in position. 8. Insert the small end of inlet valve spring ( ) into position of valve receiver ( ). 9. Screw inlet valve receiver in position. 0. Check the valves to see if they can move freely in their guides and do not pinch or bind between the seat and guard legs. Figure 2 Figure 3 WARNING: Read and understand supplement LV-474 before installing and operating the compressor. 4

5 MODELS E-50, E-7 AND E-5 (Figures 4 and 5) A. Disassembly of Inlet Valve Assembly (Figure 4).. Untighten the hex nut. 2. Remove unloading fork ( ), unloading fork guide ( ), unloading spring ( ) and valve seat ( ). CAUTION:. If a vise is used to hold the valve assembly, be careful not to clamp the assembly too tight. 2. Valve assembly should be inspected approximately every,000 hours of operation. 3. Inspect the valve seat for dents, cracks or wear. 4. Replace all defective parts. 5. Valve seats that might be worn after years of operation can be re-lapped or re-ground, in this case the recess in which the valve guard legs fit must also be cut down accordingly to ensure a same valve lift. 6. Remove carbon deposits and wash all valve components in a suitable non-flammable cleaning fluid. D. Reassembly of Outlet Valve Assembly. Place valve spring ( ) in valve receiver ). 2. Place valve plate ( ) in valve receiver. ( ). 3. Insert the sub-assembled part (assembled in step I and 2) into valve seat ( ). 4. Tighten the hex nuts. 5. Check the valves to see if they can move freely in their guides and do not pinch or bind between the seat and guard legs. B. Reassembly of Inlet Valve Assembly. Place valve spring ( ) and valve plate ( ) on valve receiver ( ). 2. Place valve seat ( ), unloading fork guide ), unloading spring ( ) and unloading fork ( ) respectively. 3. Tighten the valve assembly by tightening the hex nut. 4. Check the valves to see if they can move freely in their guides and do not pinch or bind between the seat and guard legs. C. Disassembly of Outlet Valve Assembly (Figure 5). Untighten the hex nuts. 2. Remove valve receiver ( ), valve spring ( ) and valve plate ( ). FIGURE 4 (EXAMPLE SHOWN E-50) CAUTION: Refer to disassembly of inlet valve assembly (paragraph B). FIGURE 5 (EXAMPLE SHOWN E-50) WARNING: Read and understand supplement LV-474 before installing and operating the compressor. 5

6 VALVE ASSEMBLY INSTALLATION - E-50 MODEL (Figures 6 and 7). Install valve assembly gasket (7023-0) 2. Install valve assembly ( ). 3. Install valve push cover ( ). 4. Install head bolt and tighten evenly and securely. It is strongly recommended that a Preventative Maintenance Kit & Valve/Gasket Maintenance Kit be kept on hand. In this manner, the valves can be used in turn to keep the compressor always in good condition and a minimum downtime. PISTON RINGS (Rebuild Kit) To inspect or replace piston rings as follows:. Remove cylinder head. 2. Remove cylinder. 3. Loosen the connecting rod bolts. 4. Push out the piston with piston rings and connecting rod. 5. To remove the old rings, pry them out of their grooves and slide them over the piston. Care should be taken not to damage the piston. 6. Inspect the ring grooves for nicks and carbon deposits. Clean the ring grooves and remove the obstructions, which might prevent the rings from moving freely. To install new rings on the piston as follows: (Be careful not to damage the piston and rings). FIGURE 6. Install the oil control ring ( ) first. Rotate ring in groove to make sure it is free. 2. Install the Compression ring ( ). Make sure the "top" or "R" mark is exactly on top. If not, it might cause excessive oil consumption. 3. Repeat the process with other rings, if any. 4. Assemble connecting rod into the crankshaft. Be sure that the connecting rod and its cap are in original pair and position, since the connecting rod cap and crankshaft pin bushing are selected fitted and are not interchangeable. 5. Check if the ring gaps are in proper positions (Figure 8). FIGURE 8 WARNING: Read and understand supplement LV-474 before installing and operating the compressor. 6

7 REBUILD KITS AIR COOLED SINGLE STAGE MODELS PART NO. CF299 ES03 ES05 CONSISTS OF: PART NO. CONSISTS OF: Filter Element Filter Element Valve Disc CF Valve Disc Spring Spring Spring Spring Gasket Comp. Ring Head Gasket Oil Ring Comp. Ring Head Gasket Oil Ring Crankcase Gasket Bottom Cover Gasket Front Cover Gasket Front bearing cover gasket Rear Cover Gasket Front Oil Seal Oil Seal Rear Cover Gasket Copper Washer Copper Washer Copper Gasket ES06 ES0, ES0P ES20 PART PART PART CONSISTS OF: CONSISTS OF: NO. NO. NO. CONSISTS OF: Filter Element Filter Element Filter Element CF Valve Disc CF Disc CF Disc Spring Spring Spring Spring Spring Spring Gasket Compression Ring Compression Ring Head Gasket Oil Ring Oil Ring Crankcase Gasket Head Gasket Head Gasket Comp. Ring Crankcase Gasket Crankcase Gasket Oil Ring Front Cover Gasket Front Cover Gasket Front Cover Gasket Rear Cover Gasket Rear Cover Gasket Rear Cover Gasket Front Oil Seal Front Oil Seal Bottom Cover Gasket Copper Washer Copper Washer Copper Washer Copper Gasket Copper Gasket ES-30 ES-50 ES-00 ES-50 ES-50A PART PART PART PART PART CONSISTS OF: CONSISTS OF: CONSISTS OF: CONSISTS OF: NO. NO. NO. NO. NO. CONSISTS OF: CF246 REBUILD KIT INCLUDES: CF252 PREVENTATIVE MAINTENANCE PREVENTATIVE MAINTENANCE PREVENTATIVE MAINTENANCE PREVENTATIVE MAINTENANCE CF252 CF252 CF252 KIT INCLUDES KIT INCLUDES KIT INCLUDES KIT INCLUDES Filter Kit Disc Filter Element Filter Element Filter Element Filter Element Spring Spring CF245 VALVE / GASKET MAINT. KIT INCLUDES CF243 VALVE / GASKET MAINT. KIT INCLUDES: CF24 VALVE / GASKET MAINT. KIT INCLUDES: CF320 VALVE / GASKET MAINT. KIT INCLUDES: Compression Ring Oil Ring Disc Disc Disc Disc I / V Seat Gasket Spring Spring Spring Spring Head Gasket Spring Spring Spring A-4075 Spring Crankcase Gasket Seat Gasket Seat Gasket Seat Gasket Seat Gasket Front Cover Gasket Head Gasket Head Gasket Manifold Gasket Disc O / V Rear Cover Gasket Head Gasket Head Gasket Front Oil Seal ** Head Gasket * Bushing Set, Rod Bearing CF244 REBUILD KIT INCLUDES: CF242 REBUILD KIT INCLUDES: CF244 REBUILD KIT INCLUDES: CF244 REBUILD KIT INCLUDES: Copper Washer Front Oil Seal Frt. Brg. Cvr. Gasket Front Oil Seal Front Oil Seal Compr.Ring Compr.Ring Compression Ring Compression Ring Oil Ring Oil Ring Oil Ring Oil Ring * Bushing Bushing * Bushing * Bushing Set, Rod Bearing Set, Rod Bearing Set, Bearing Set, Bearing Crankcase Gasket Crankcase Gasket * Crankcase Gasket * Crankcase Gasket Frt. Brg. Cvr. Gasket Front Oil Seal Frt. Brg.Cvr Gasket Frt. Brg.Cvr Gasket Rear Brg. Cvr. Gasket Rear Brg. Cvr. Gasket Rear Brg.Cvr Gasket Rear Brg.Cvr Gasket Copper Washer Copper Washer Copper Washer Copper Washer * WARNING THESE ITEMS INTERCHANGE WITH PARTS ON SERIAL # & HIGHER ONLY. CONTACT FACTORY FOR EARLIER SERIES. ** USE WITH SERIAL #A3XXXX AND LATER REPLACES

8 REBUILD KITS AIR COOLED TWO STAGE MODELS PART NO. CF306 E-35 CONSISTS OF: PREVENTATIVE MAINTENANCE KIT INCLUDES: PART NO. E- E-23 CONSISTS OF: PART NO. CONSISTS OF: Element CF307 VALVE/GASKET MAINT KIT INCLUDES: CF Filter Element CF Filter Element Disc Disc Disc Disc Spring Spring Spring Spring Spring Spring Spring Spring Compression Ring Compression Ring Oil Ring Oil Ring Compression Ring Compression Ring Oil Ring Oil Ring Head Gasket ( st ) Head Gasket ( st ) Head Gasket (2 nd ) Head Gasket (2 nd ) Crankcase Gasket Crankcase Gasket Front Cover Gasket Front Cover Gasket Rear Cover Gasket Rear Cover Gasket Front Oil Seal Front Oil Seal Copper Washer Copper Washer Copper Gasket Copper Gasket Copper Gasket Disc Disc Spring Spring Head Gasket Seat Gasket Seat Gasket CF308 REBUILD KIT INCLUDES: Case Gasket Rear Cover Gasket Comp. Ring Oil Ring Bushing (L.P.) Bushing (H.P.) Rod Bearing Set Compression Ring Oil Ring Front Cover Gasket Front Oil Seal Copper Washer PART NO. CF29 E-57 E-50 E-7 E-5 CONSISTS OF: PREVENTATIVE MAINTENANCE KIT INCLUDES PART NO. CF35 CONSISTS OF: PREVENTATIVE MAINTENANCE KIT INCLUDES: PART NO. CF35 CONSISTS OF: PREVENTATIVE MAINTENANCE KIT INCLUDES: PART NO. CF35 CONSISTS OF: PREVENTATIVE MAINTENANCE KIT INCLUDES: Element Element Element Element CF292 VALVE/GASKET MAINT KIT INCLUDES: CF253 VALVE/GASKET MAINT KIT INCLUDES: CF255 VALVE/GASKET MAINT KIT INCLUDES: CF257 VALVE/GASKET MAINT KIT INCLUDES: Disc Disc Disc Disc Disc Spring Disc Disc Spring Spring Spring Spring Spring Seat Gasket Spring Spring Head Gasket Head Gasket Spring Spring Seat Gasket Spring Spring Seat Gasket Seat Gasket Seat Gasket Seat Gasket Seat Gasket Head Gasket Manifold Gasket Head Gasket Head Gasket Head Gasket ** Head Gasket CF293 REBUILD KIT INCLUDES: CF254 REBUILD KIT INCLUDES: CF256 REBUILD KIT INCLUDES: CF258 REBUILD KIT INCLUDES: Front Bearing Gasket Front Bearing Gasket Front Bearing Gasket Compression Ring Compression Ring Compression Ring Compression Ring Oil Ring Oil Ring Oil Rings Oil Ring Compression Ring Compression Ring Compression Ring Compression Ring Oil Ring Oil Ring Oil Ring Oil Ring Bushing Bushing (L.P.) Bushing Bushing Rod Bearing (2 Halves) Bushing (H.P.) 93503TA725 Needle Bearing Bushing Gasket Rod Bearing (Halves) Rod Bearing (Halves) Gasket Oil Seal Case Gasket Crankcase Gasket Oil Seal Front Bearing Gasket Oil Seat Oil Seal Bearing (Halves) Rear Bearing Gasket Rear Bearing Gasket Rear Bearing Gasket Rear Bearing Gasket Copper Washer Copper Washer Copper Washer Copper Washer NK28/30 Needle Bearing *** Bushing Bushing **** * WARNING THESE ITEMS INTERCHANGE WITH PARTS ON SERIAL # & HIGHER ONLY. CONTACT FACTORY FOR EARLIER SERIES. ** USE WITH SERIAL #A3XXXX AND LATER REPLACES *** USE WITH SERIAL #A409XXXX AND LATER **** USE FOR UNITS PRIOR TO SERIAL #A409XXXX 8

9 RING SETS & GASKET SETS SINGLE STAGE MODEL PART NO. DESCRIPTION CF297 Ring set ES03 CF298 Gasket set ES05 ES06 ES0 ES20 ES30 ES50 ES00 ES50 & ES50A CF259 CF276 CF300 CF30 CF260 CF277 CF26 CF278 CF262 CF279 CF263 CF280 CF264 CF28 CF265 CF282 *CF3 Ring set Gasket set Ring set Gasket set Ring set Gasket set Ring set Gasket set Ring set Gasket set Ring set Gasket set Ring set Gasket set Ring set Gasket set *Gasket set QUANTITY REQ D TWO-STAGE MODEL PART NO. DESCRIPTION CF266 Ring set (LP) E CF267 Ring set (HP) CF283 Gasket set E23 E35 E50 E57 E7 E5 CF268 CF269 CF284 CF303 CF304 CF305 CF270 CF27 CF285 CF288 CF289 CF290 CF272 CF273 CF286 CF274 CF275 CF287 *CF33 Ring set (LP) Ring set (HP) Gasket set Ring set(lp) Ring set(hp) Gasket set Ring set(lp) Ring set(hp) Gasket set Ring set(lp) Ring set(hp) Gasket set Ring set(lp) Ring set(hp) Gasket set Ring set(lp) Ring set(hp) Gasket set *Gasket set QUANTITY REQ D * USE WITH SERIAL #A3XXXX AND LATER 9

10 MODEL ES-03 AIR COOLED, SINGLE STAGE, SINGLE CYLINDER Description QTY PART NO. VALVES. Inlet & Outlet Valve Plate Inlet Valve Spring Inlet Valve Receiver Inlet Valve Snap Ring Outlet Valve Spring Outlet Valve Push Cover Gasket Outlet Valve Push Cover Manual Unloader Assembly CYLINDERS 9A. Cylinder Head Assembly (Includes Valves) B. Cylinder Head (Bare Casting) Cylinder Head Bolt (Not Shown) 4 (Hardware Item). Cylinder Head Gasket Cylinder & Crankcase Compression Ring Oil Control Ring Piston Piston Pin Piston Pin Snap Ring Connecting Rod Assembly Connecting Rod Bolt 2 (furnished on conn. Rod only) 20. Oil Splash Dipper Oil Splash Dipper Bolt Oil Splash Dipper Bolt Washer (Not Shown) CRANKCASE AND CRANK ASSEMBLY Description QTY PART NO. CRANKCASE AND CRANK ASSEMBLY 23. Crankshaft Front Bearing Cover Front Bearing Cover Gasket Front Cover Bolts (Not Shown) Front Bearing # Rear Bearing Cover Rear Bearing Cover Gasket Rear Bearing # Rear Bearing Cover Bolts (Not Shown) Front Oil Seal Compressor Pulley Compressor Pulley Thrust Washer Compressor Pulley Thrust Bolt Crankcase Bottom Cover (Not Shown) Crankcase Bottom Cover Gasket (Not Shown) Compressor Pulley Pin NA (Not Required) 39. Oil Level Gauge And Cover Gauge Cover Seal Crankcase Oil Plug (/4 PT) Breather Assembly AIR STRAINER ELEMENT 43. Air Strainer Assembly Air Strainer Element (Not Shown)

11 MODEL ES-06 AIR COOLED, SINGLE STAGE, SINGLE CYLINDER DESCRIPTION QTY PART NO. DESCRIPTION QTY PART NO. VALVES 28 Front Bearing Cover Gasket Inlet And Outlet Valve Plate Front Bearing Cover Bolt Inlet Valve Spring Front Bearing # Inlet Valve Receiver Rear Bearing Cover Inlet Valve Snap Ring Rear Bearing Cover Gasket Outlet Valve Spring Rear Bearing Cover Bolt (Not Shown) Outlet Valve Push Cover Gasket Rear Bearing # Outlet Valve Push Cover Crankcase Bottom Cover (Not Shown) Crankcase Bottom Cover Bolt (Not Shown) CYLINDERS, CRANKCASE AND CRANK ASSEMBLY 38 Crankcase Bottom Cover Washer (Not Shown) 4 (Hardware Item) 8a. Cylinder Head Assy. (Includes Valves) Front & Rear Cover Bolt Washer (Not Shown) b. Cylinder Head (Bare Casting) Compressor Pulley Pin Cylinder Head Gasket Compressor Pulley Cylinder Head Bolt Compressor Pulley Thrust Washer Cylinder Compressor Pulley Thrust Bolt Cylinder To Case Gasket Oil Level Gauge & Gauge Cover Cylinder To Case Bolt (Not Shown) *44A Oil Level Gauge Assy Cylinder To Case Bolt Washer (Not Shown) Oil Level Gauge Cover Seal Compression Ring *45A Oil Level Gauge O Ring Oil Control Ring Crankcase Oil Plug (/4 NPT) Piston Breather Assembly CCC357 8 Piston Pin UNLOADERS(* Indicates Not Included On Basic Units) 9 Piston Pin Snap Ring Auto Unloader Assembly Connecting Rod Assembly Unloading Elbow* (Includes Nut & Sleeve) VA786 2 Connecting Rod Bolt 4 (Furnished On Conn, Rod Only) 50 Unloading Tee* (Includes Nut & Sleeve) VA Oil Splash Dipper AIR STRAINER ASSEMBLY & DISCHARGE PIPING 23 Oil Splash Dipper Bolt Air Strainer Assembly Oil Splash Dipper Lockwasher (Not Shown) Air Strainer Element (Not Shown) Crankshaft Compressor Body Discharge Pipe Assembly Crankcase Outlet Pipe Elbow Front Bearing Cover Outlet Pipe Tee Outlet Pipe Tee Nut * START S/N AS

12 AIR COOLED, SINGLE STAGE MODELS ES-05, ES-0 & ES-20 2

13 MAIN PARTS LISTING FOR SINGLE STAGE MODELS ES-05, ES-0 & ES-20 QTY VALVES MODEL ES05 REQ D QTY MODEL ES0 REQ D QTY REQ D MODEL ES20. Inlet And Outlet Valve Plate Inlet Valve Spring Inlet Valve Receiver Inlet Valve Snap Ring Outlet Valve Spring Outlet Valve Push Cover Gasket Outlet Valve Push Cover CYLINDER AND CYLINDER HEADS 6A. Cylinder Head Assembly B. Cylinder Head Cylinder & Head Gasket Cylinder Cylinder And Case Gasket Compression Ring Oil Control Ring Piston Piston Pin Piston Pin Snap Ring Connecting Rod Assembly Connecting Rod Bolt Oil Splash Dipper A. Oil Splash Dipper Oil Splash Dipper Bolts Cylinder Head Bolt 4 (Hardware Item) 8 (Hardware Item) 2 (Hardware Item) CRANK ASSEMBLY 39. Crankcase Crankshaft Front Bearing Cover Front Bearing Cover Gasket Rear Bearing Cover Rear Bearing Cover Gasket A. Bearing Front B. Bearing Rear Front Oil Seal V-Pulley Pin Compressor Pulley Compressor Pulley Thrust Washer Compressor Pulley Thrust Bolt Breather Assembly CCC375 CCC375 CCC Oil Gauge & Gauge Cover A Oil Level Gauge Assembly Gauge Cover Seal A Oil Level Gauge O Ring Crankcase Oil Plug A. Oil fill cap B. O Ring UNLOADERS 55. Auto Unloader Assembly Auto Unloader Spring Auto Unloader Piston O-Ring (Unloader) AIR STRAINER 6. Air Strainer Element Air Strainer Assembly Discharge Piping Assembly (Not Required) Outlet Pipe Joint A Outlet Pipe Joint B Outlet Pipe Joint C ES0, START S/N AS ES20, START S/N AS

14 AIR COOLED SINGLE STAGE MODELS ES-30, ES-50, ES-00 VALVE ASSEMBLIES VALVE & UNLOADERS Description Qty. MODEL Qty. MODEL Qty. MODEL Req. ES30 Req. ES50 Req. ES00 Inlet Valve Assembly, st Stage Outlet Valve Assembly, st Stage Air Strainer Assembly Breather Assembly MAIN PARTS LISTING FOR MODELS ES-30, ES-50, ES-00 Item No. Description Qty. MODEL Qty. MODEL Qty. MODEL Req. ES30 Req. ES50 Req. ES00. Inlet Valve Seat Inlet Valve Receiver Inlet & Outlet Valve Plate Inlet Valve Spring Inlet Valve Unloading Fork Guide Unloading Spring A. Valve Gasket

15 AIR COOLED SINGLE STAGE MODELS ES-30, ES-50, ES-00 VALVE ASSEMBLIES VALVE & UNLOADERS Description Qty. MODEL Qty. MODEL MODEL Qty. Req. Req. ES30A Req. ES50A ES00A Inlet Valve Assembly, st Stage A A A-3000 Outlet Valve Assembly, st Stage A A A-4000 Air Strainer Assembly A A A Breather Assembly 7005A A A-5760 MAIN PARTS LISTING FOR MODELS ES-30A, ES-50A, ES-00A Item No. Description Qty. MODEL Qty. MODEL MODEL Qty. Req. Req. ES30A Req. ES50A ES00A. Inlet Valve Seat A A A Inlet Valve Receiver A A A Inlet & Outlet Valve Plate A A A Inlet Valve Spring A A A Inlet Valve Unloading Fork Guide A A A Unloading Spring A A A-230 7A. Valve Gasket A A A-0 4A

16 VALVES & UNLOADERS (Cont d) CYLINDERS CRANKCASE & CRANK ASSEMBLY MAIN PARTS LISTING FOR MODELS ES-30, ES-30A, ES-50 & ES-00 (Continued) Qty. Req. MODEL ES30 Qty. Req. MODEL ES50 Qty. Req. MODEL ES00 7B Inlet Valve Unloading Fork Locknut Outlet Valve Seat Outlet Valve Receiver Outlet Valve Spring Outlet Valve Bolt Nut (Outlet Valve) Inlet Valve Push Cover, st Stage O Ring G Viton O Ring G 40 (Outlet Valve) Unloading Piston, st Stage O Ring P Outlet Valve Push Cover, st Stage A. Cylinder Head Assembly Cylinder Head ( st ) Cylinder & Head Gasket, st Stage Cylinder ( st ) A. S/N THRU A3XXXX Cylinder & Case Gasket Compression Ring ( st ) Oil Control Ring ( st ) Piston ( st ) A. S/N & later use Piston Pin Snap Ring Piston Pin ( st ) Connecting Rod Piston Pin Bushing ( st ) Connecting Rod Assembly, st Stage A. S/N & later use Connecting Rod Crank Pin Metal Connecting Rod Bolt A. Oil Splash Dipper H.P Oil Splash Dipper Oil Splash Dipper Bolt Crankshaft Counterweight Lockwasher Bolt Crankcase Front Bearing Cover Front Bearing Cover Gasket Rear Bearing Cover A. S/N & later use Rear Bearing Cover Gasket Front Bearing Rear Bearing Front Oil Seal V Pulley Pin A. Compressor Fan (Not Required) (Not Required) B. Compressor Pulley Compressor Pulley Washer Compressor Pulley Set Bolt Gauge Cover A. Oil Level Gauge Assy Gauge Cover Seal A. Oil Level Gauge O Ring Crankcase Oil Cap CCC257 CCC257 CCC Crankcase Oil Plug Air Strainer Filter Outlet Pipe Joint B Compressor Body Discharge Piping Assy A. S/N & Later Use Outlet Pipe Joint A Outlet Pipe Joint C Gasket (Manifold) Breather Assembly CCC375 CCC375 CCC375 * ES30, START S/N AS * ES50, START S/N AS

17 VALVES & UNLOADERS (Cont d) CYLINDERS CRANKCASE & CRANK ASSEMBLY MAIN PARTS LISTING FOR MODELS ES-30A, ES-50A & ES-00A (Continued) Qty. Req. MODEL ES30A Qty. Req. MODEL ES50A Qty. Req. MODEL ES00A 7B Inlet Valve Unloading Fork A A A Locknut Outlet Valve Seat A A A-40. Outlet Valve Receiver A A A Outlet Valve Spring A A A Outlet Valve Bolt A A Nut (Outlet Valve) Inlet Valve Push Cover, st Stage A A A O Ring G 40 (G55 ES00) Viton O Ring G 40 (Outlet Valve) Unloading Piston, st Stage A A A O Ring P 20 (P2 ES00) Outlet Valve Push Cover, st Stage A A A-450 2A. Cylinder Head Assembly Cylinder Head ( st ) A A A Cylinder & Head Gasket, st Stage A A A Cylinder ( st ) A A A A. S/N THRU A3XXXX A A A Cylinder & Case Gasket A A A Compression Ring ( st ) A A A Oil Control Ring ( st ) A A A Piston ( st ) A A A-60 27A. S/N & later use A Piston Pin Snap Ring A A A Piston Pin ( st ) A A A Connecting Rod Piston Pin Bushing ( st ) Connecting Rod Assembly, st Stage A A A-620 3A. S/N & later use A A A Connecting Rod Crank Pin Metal Connecting Rod Bolt A. Oil Splash Dipper H.P FA A Oil Splash Dipper FA FA A Oil Splash Dipper Bolt Crankshaft 70208A A A Counterweight A Lockwasher A Bolt A Crankcase 70208A A A Front Bearing Cover 70208A A A Front Bearing Cover Gasket 70208A A A Rear Bearing Cover 70208A A A A. S/N & later use 70208A A A Rear Bearing Cover Gasket 70208A A A Front Bearing Rear Bearing Front Oil Seal 70208A A A V Pulley Pin 70208A A A A. Compressor Fan (Not Required) (Not Required) B. Compressor Pulley 70208A A A Compressor Pulley Washer 70208A A Compressor Pulley Set Bolt Gauge Cover A A. Oil Level Gauge Assy. 70A09B A09B A Gauge Cover Seal A A. Oil Level Gauge O Ring Crankcase Oil Cap CCC257 CCC257 CCC Crankcase Oil Plug Air Strainer Filter A A A Outlet Pipe Joint B Compressor Body Discharge Piping Assy A A. S/N & Later Use 70208A A A Outlet Pipe Joint A 70208A Outlet Pipe Joint C Gasket (Manifold) Breather Assembly CCC375 CCC375 CCC375 * ES30, START S/N AS * ES50, START S/N AS A

18 AIR COOLED, SINGLE STAGE MODEL ES-50 VALVE ASSEMBLIES DESCRIPTION Qty. MODEL Req. ES50 Inlet Valve Assembly, st Stage Outlet Valve Assembly, st Stage Air Strainer Assembly Breather Assembly MAIN PARTS LISTING FOR MODEL ES-50 VALVE & UNLOADERS DESCRIPTION Qty. MODEL Req. ES50. Inlet Valve Seat Inlet Valve Receiver Inlet & Outlet Valve Plate Inlet Valve Spring Inlet Valve Unloading Fork Guide Unloading Spring A. Valve Gasket

19 VALVES & UNLOADERS (Cont d) CYLINDERS CRANKCASE & CRANK ASSEMBLY MAIN PARTS LISTING FOR MODEL ES-50 (Continued) DESCRIPTION Qty. Req. MODEL ES50 7B Inlet Valve Unloading Fork Locknut Outlet Valve Seat Outlet Valve Receiver Outlet Valve Spring Outlet Valve Bolt Nut (Outlet Valve) Inlet Valve Push Cover, st Stage O Ring G Viton O Ring G 65 (Outlet Valve) Unloading Piston, st Stage O Ring P 22A A 20. Outlet Valve Push Cover, st Stage A. Cylinder Head Assembly A 2. Cylinder Head ( st ) B. S/N A3XXXX AND LATER Cylinder & Head Gasket, st Stage A. S/N A3XXXX AND LATER Cylinder ( st ) A. S/N THRU A3XXXX B. S/N A3XXXX AND LATER Cylinder & Case Gasket Compression Ring ( st ) Oil Control Ring ( st ) Piston ( st ) A. S/N & later use Piston Pin Snap Ring Piston Pin ( st ) Connecting Rod Piston Pin Bushing ( st ) Connecting Rod Assembly, st Stage A. S/N & later use Connecting Rod Crank Pin Metal Connecting Rod Bolt A. Oil Splash Dipper H.P Oil Splash Dipper Oil Splash Dipper Bolt Crankshaft Counterweight Lockwasher Bolt Crankcase Front Bearing Cover Front Bearing Cover Gasket Rear Bearing Cover A. S/N & later use Rear Bearing Cover Gasket Front Bearing Rear Bearing Front Oil Seal V Pulley Pin A. Compressor Fan B. Compressor Pulley Compressor Pulley Washer Compressor Pulley Set Bolt Gauge Cover Gauge Cover Seal Crankcase Oil Cap CCC Crankcase Oil Plug Air Strainer Filter Outlet Pipe Joint B Compressor Body Discharge Piping Assy (Long) 70A. S/N & Later Use (Short) 7. Outlet Pipe Joint A Outlet Pipe Joint C Gasket (Manifold) Discharge Piping Assembly Discharge Piping Assembly Discharge Piping Assembly Copper Connector - Copper Connector - Copper Connector Breather Assembly CCC258 7

20 AIR COOLED SINGLE STAGE MODEL ES-50A 8

21 AIR COOLED SINGLE STAGE MODEL ES-50B 8A

22 MAIN PARTS LISTING FOR MODEL ES50A ITEM PART NO. NO. DESCRIPTION QTY BOLT, M0 X COPPER WASHER REAR BEARING COVER 4 703B TUBE & BRTHR. ASSY. 4a 703BA TUBE, BREATHER 4b CCC697 BREATHER, ASSY REAR COVER OIL BAFFLE REAR BRG CVR PACKING CRANKCASE OIL CAP GAUGE SET BOLT OIL GLASS & COVER 9a OIL COVER OIL COVER GLASS GAUGE COVER SEAL CRANKCASE OIL PLUG CRANKCASE BEARING # CRANKSHAFT A CRANKSHAFT CTR. WGT CTR WGT LK WASHER CTR WGT MGT BOLT V-PULLEY KEY BEARING # FRONT BEARING GASKET FRONT OIL SEAL FRONT BEARING COVER COMPRESSOR PULLEY COMP PULLEY FAN WASHER BOLT PULLEY THRUST WASHER SPRING WASHER BOLT CYL & CASE PACKING CYL & CASE BOLT OIL SPLASH DIPPER NUT CONN.ROD CRANK PIN METL CONN.ROD ASS Y CONN.ROD ASS Y BOLT CONN.ROD CRANK PIN METL PISTON PIN SNAP RING PISTON PIN PISTON OIL CONTROL RING COMPRESSION RING CYLINDER NUT CYL & HEAD PACKING BOLT CYLINDER HEAD I/O VALVE SEAT GASKET INLET VALVE RECEIVER 3 ITEM PART NO. NO. DESCRIPTION QTY INLET VALVE SPRING PLATE, INLET VALVE INTER VALVE SEAT I. VALVE UNLOAD FORK GUIDE UNLOADING SPRING I.VALVE UNLOAD FORK SLOTTED NUT A O-RING P#22A UNLOADING PISTON O-RING G# I. VALVE PUSH COVER BOLT SCREW PLUG BOLT OUTLET VALVE SEAT A-4075 OUTLET VALVE SPRING OUTLET VALVE RECEIVR NUT VITON O-RING G# O. VALVE PUSH COVER A DIST. MANIFOLD #C COMP.BODY DIS. PIPING ASSEMBLY A DIST. MANIFOLD #B COMP.BODY DIS. PIPING ASSEMBLY A2-870 DIST. MANIFOLD #A PLATE, OUTLET VALVE OUTLET, VALVE ASSY INLET, VALVE ASSY AIR STRAINER ASSY AIR STRAINER FILTER 3 9

23 MAIN PARTS LISTING FOR MODEL ES50B ITEM PART NO. NO. DESCRIPTION QTY BOLT, M0 X COPPER WASHER A-5706 REAR BEARING COVER 4 703B TUBE & BRTHR. ASSY. 4a 703BA TUBE, BREATHER 4b CCC697 BREATHER, ASSY A REAR COVER OIL BAFFLE A REAR BRG CVR GASKET CRANKCASE OIL CAP GAUGE SET BOLT A OIL GLASS & COVER 9a 7020A OIL COVER ASSY OIL COVER GLASS 7020A GAUGE COVER SEAL CRANKCASE OIL PLUG A CRANKCASE BEARING # A-560 CRANKSHAFT A CRANKSHAFT CTR. WGT A CTR WGT LK WASHER A-568 CTR WGT MGT BOLT A V-PULLEY KEY BEARING # FRONT BEARING GASKET A FRONT OIL SEAL A FRONT BEARING COVER A-760 COMPRESSOR PULLEY COMP PULLEY FAN WASHER BOLT A-7620 PULLEY THRUST WASHER SPRING WASHER BOLT A-5030 CYL & CASE PACKING A-580 CYL & CASE BOLT A-628 OIL SPLASH DIPPER NUT A-6090 CONN.ROD CRANK PIN METL A-6200 CONN.ROD ASS Y CONN.ROD ASS Y BOLT A-608 CONN.ROD CRANK PIN METL A-6070 PISTON PIN SNAP RING A-620 PISTON PIN A-600 PISTON A-6050 OIL CONTROL RING A-6030 COMPRESSION RING A3-500 CYLINDER NUT A3-020 CYL & HEAD GASKET BOLT A3-00 CYLINDER HEAD A-0 I/O VALVE SEAT GASKET 6 ITEM PART NO. NO. DESCRIPTION QTY A-3023 INLET VALVE RECEIVER A-3070 INLET VALVE SPRING A-3030 PLATE, INLET VALVE A-300 INTER VALVE SEAT A-3090 I. VALVE UNLOAD FORK GUIDE A-230 UNLOADING SPRING A-3080 I.VALVE UNLOAD FORK SLOTTED NUT O-RING P#22A A-220 UNLOADING PISTON O-RING G# A-5 I. VALVE PUSH COVER BOLT SCREW PLUG BOLT A-402 OUTLET VALVE SEAT A-4075 OUTLET VALVE SPRING A-4025 OUTLET VALVE RECEIVR NUT VITON O-RING G# A-45 O. VALVE PUSH COVER A DIST. MANIFOLD #C 3 COMP.BODY DIS. PIPING ASSEMBLY A DIST. MANIFOLD #B COMP.BODY DIS. PIPING A ASSEMBLY A2-870 DIST. MANIFOLD #A PLATE, OUTLET VALVE A-400 OUTLET, VALVE ASSY A-3000 INLET, VALVE ASSY A AIR STRAINER ASSY A-660 AIR STRAINER FILTER 3 3 9A