Check Compressor Oil Level

Precondition

• The machine is parked on a flat and level surface.

1. •
   1.
   Stop the machine and allow the oil level to settle for at least 5 minutes.
2. •
   2.
   Check that the indicator on the gauge (A) is in the green zone.
3. •
   3.
   Fill with oil through inlet (B), if necessary. Use the correct amount and oil grade.

Oil Change and Oil Filter Replacement

Oil grade and operating temperature determines the intervals for oil change. The prescribed interval is based on an oil temperature of up to 120 ºC (248 ºF) and normal operating conditions. Oil must be changed more frequently when working in high ambient temperatures or dusty or damp conditions.

• The system must be flushed clean before new oil is filled if the oil is

• Contaminated by incorrect oil.

• Broken down due to excessive temperature.

• Used beyond the operating interval.

Filling Compressor Oil

WARNING

Burning Hazard

High oil temperature can cause serious personal injury.

1. Shut off the engine.

2. Use working gloves, face shield, and cover your arms with long sleeves.

Precondition

• The machine must have been off for at least 8 h before checking the oil level.

• The machine stands horizontally before the check.

1. •
   1.
   Depressurize the system by opening the extra air outlet (B).
2. •
   2.
   Open the plug and check that the oil is visible in the pipe (A).
3. •
   3.
   Top up (A) if necessary. See the chapter "Recommended oils and lubricants".

Draining Compressor Oil

WARNING

Burning Hazard

High oil temperature can cause serious personal injury.

1. Shut off the engine.

2. Use working gloves, face shield, and cover your arms with long sleeves.

1. •
   1.
   Depressurize the system by opening the extra air outlet (B).
2. •
   2.
   Place a container under the drain point (C) on the left-hand side of the rig.
3. •
   3.
   Remove the plug and drain the tank.
4. •
   4.
   Position a container under the drain points (D) of the compressor and (E) of the radiator. Drain the system of the last oil.
5. •
   5.
   Close the drain points.
6. •
   6.
   Fill with new oil in the pipe (A).

Replace Air Compressor Oil and Oil Filter

WARNING

Risk of Fire and Explosion

Using incorrect or old oil increases the risk of fire or explosion in the compressor system.

1. Use correct, new oil according to the Fluids and greases manual.

1. •
   1.
   Run the compressor to operating temperature and confirm that the pressure is zero.
2. •
   2.
   Place the vessels under the drain plugs to collect the oil.
3. •
   3.
   Loosen the oil filler plug (B) one turn to release pressure from the system.
4. •
   4.
   Drain the oil through the drain plugs for compressor tank, compressor cooler, and compressor element.
5. •
   5.
   Tighten the plugs after draining.
6. •
   6.
   Place the vessel below the filter (C) to collect the oil.
7. •
   7.
   Remove the compressor oil filter (C).
8. •
   8.
   Clean the filter seat on the manifold using new oil, and make sure that no dirt enters into the system.
9. •
   9.
   Lubricate the gasket on the new filter.
10. •
    10.
    Replace with new filter.
11. •
    11.
    Remove the filler plug (B) and fill oil into the compressor tank until the oil level reaches the filler pipe.

    The indicator on the gauge (A) must be in the upper section of the green zone.

12. •
    12.
    Insert and tighten the filler plug.
13. •
    13.
    Operate the compressor without any load for several minutes to circulate the oil and force out any air in the oil system.
14. •
    14.
    Stop the compressor, let the oil to settle for several minutes.
15. •
    15.
    Repeat steps 10 and 11.

Check Safety Valve on Compressor System

1. •
   1.
   Perform a 15 bar (217 psi) pressure test on the safety valve (A).

Replace Separator Filter

1. •
   1.
   Replace the separator filter (A) in the pressure tank.

   NOTE

   Check that the washer (B) under the filter remains in place. Do not throw it away with the old filter during replacement.

Recommendations for Replacing to New Type of Compressor Oil

To avoid problems when changing to a new type of oil, a special procedure for compressor oil flushing must be followed. The table is only applicable if the replaced oil has not passed its expiration date. Old oil is best detected by using an analysis program for oil samples, SOS (Scheduled Oil Sampling). There are three indications that the oil is old. The oil can be contaminated such as sediments inside the oil reservoir and the stop valve, the oil has a brownish color or has a strong odor.

* When changing to the same oil within the interval between changes, drainage is sufficient

** Changing not recommended

Flushing Air Compressor

WARNING

Risk of Fire and Explosion

Using incorrect or old oil increases the risk of fire or explosion in the compressor system.

1. Use correct, new oil according to the Fluids and greases manual.

Precondition

• Run the compressor to operating temperature and confirm that the pressure is zero.

1. •
   1.
   Place vessels under the drain plugs.
2. •
   2.
   Remove drain plugs for compressor tank, compressor cooler, and compressor element and drain the oil.
3. •
   3.
   Refit and tighten the plugs.
4. •
   4.
   Remove the oil filters (E).
5. •
   5.
   Open the cover plate (A) on the air reservoir and remove the oil separator element.
6. •
   6.
   Check the inside of the oil reservoir (B).

   Step result

   If sediments are detected, the parts (A-D) must be thoroughly cleaned before the procedure is completed.

7. •
   7.
   Insert a new oil separator element and refit the cover plate (A).
8. •
   8.
   Clean the filter seat on the manifold using new oil, and make sure that no dirt falls down into the system.
9. •
   9.
   Lubricate the gasket on the new filters with new oil.
10. •
    10.
    Replace the filters (E) and close the valve (C).
11. •
    11.
    Fill the oil reservoir with the minimum amount of oil permissible through the oil inlet (F).
12. •
    12.
    Run the compressor unloaded in light mode for 30 minutes.
13. •
    13.
    Drain the oil.
14. •
    14.
    Fill the system with new oil.

    The indicator on the gauge (G) must be in the upper section of the green zone.

15. •
    15.
    Run the compressor without load in light mode for 15 minutes and check for leaks.
16. •
    16.
    Check that the oil level on the gauge is in green zone. Top up if necessary.

Check Compressor Components

1. •
   1.
   Check for signs of oil or water or air leakage on the compressor (A).
2. •
   2.
   Check connections and couplings on intake manifolds (B) on the air filters for compressor and diesel engine.

Drain Condensate from Compressor Tank

Precondition

• The machine has been shut down for eight hours.

1. •
   1.
   Open the drain plug under the compressor tank (A) and drain off the water.

Lubricate Compressor Coupling

1. •
   1.
   Lubricate with 1/4 to 1/3 pump pressure in accordance with quality Isoflex Topas L 152 (Klüber) or Q8 Rubens W8 and then annually.