Alkin W32 Series User manual

W32
SERIES

W32 SERIES
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
©ALKIN COMPRESSORS
2

InstructionsManual
and Parts List

A L K I N C O M P R E S S O R S
High Pressure Breathing Air Compressor
© This manual or any parts thereof cannot be copied by any means, or used for any other purposes
other than servicing ALKIN W32 Series compressors, unless specific written permission of ALKIN® is received.
©ALKIN KOMPRESOR San. ve Tic. Ltd. Sti.
Cuneytbey Mh. Tabas Yolu Kume Evleri No 3
Menderes,İzmir
Tel: [phone] • Fax: [phone]
www.alkin-compressors.com

W32 SERIES
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
©ALKIN COMPRESSORS
6

W32 SERIES
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
©ALKIN COMPRESSORS
7
Contents
1.0 GENERAL INFORMATION..........................................................................................................11
1.1 General......................................................................................................................11
1.1.1 General Safety ......................................................................................................................... 11
1.1.2 Safety Tags............................................................................................................................... 11
1.1.3 Pressure Release...................................................................................................................... 11
1.1.4 Fire and Explosion.................................................................................................................... 12
1.1.5 Moving Parts............................................................................................................................ 12
1.1.6 Hot Surfaces, Sharp Edges and Corners................................................................................... 12
1.1.7 Toxic and Irritating Substances................................................................................................ 13
1.1.8 Electrical Shock........................................................................................................................ 13
1.1.9 Lifting and Carrying.................................................................................................................. 13
1.1.10 Tags........................................................................................................................................ 14
1.2 Major Parts-Compressor............................................................................................14
1.2 Major Parts-Compressor Unit....................................................................................18
1.3 Major Parts-Compressor System ...............................................................................20
1.4 General Features .......................................................................................................22
1.5 Lubrication System ....................................................................................................24
1.6 P&I Process and Instrumentation Diagram ................................................................24
1.7 Operation Principle ...................................................................................................30
1.8 Descriptions of Controls ............................................................................................31
1.8.1 Start/Stop Controls.................................................................................................................. 31
I. Manual Start/Stop ......................................................................................................................... 31
II. Automatic Start/Stop.................................................................................................................... 31
1.8.2 Drain Controls.......................................................................................................................... 32
I. Manual Drain................................................................................................................................. 32
II. Automatic Drain............................................................................................................................ 32
1.9 Technical Specifications and User Records ................................................................32
1.9.1 W32 Mariner Electric Technical Datas..................................................................................... 33
1.9.2 W32 Mariner Petrol Technical Datas....................................................................................... 34
1.9.3 W32 Canopy Technical Datas .................................................................................................. 35
1.10 Installation ..............................................................................................................36
1.10.1 Inspection .............................................................................................................................. 36
1.10.2 Location ................................................................................................................................. 36
1.10.3 Piping..................................................................................................................................... 37
1.10.4 Electrical Controls.................................................................................................................. 38
1.10.5 Wiring .................................................................................................................................... 38
1.10.6 Sheave and V-Belt Alignment ................................................................................................ 38
1.11 Storage ....................................................................................................................39
1.12 Operation ................................................................................................................40
1.12.1 Initial Start-up Procedure ...................................................................................................... 40
1.12.2 Oil Recommendation............................................................................................................. 41
1.12.3 Extremely Cold Ambient Temperatures ................................................................................ 41
1.12.4 Motor Lubrication.................................................................................................................. 41
1.12.5 Adjustments .........................................................................................................41
1.12.6 Bottle Filling........................................................................................................................... 43
2.0 MAINTENANCE .............................................................................................................................47
2.1 General......................................................................................................................47
2.3 Maintenance Tables ..................................................................................................48
2.3.1 W32 Mariner Compressors Maintenance –Parts Control Table ............................................. 48
2.3.2 W32 Mariner Compressors Maintenance –Parts Replacement Table.................................... 49
2.3.4 W32 Canopy Compressors Maintenance –Parts Control Table .............................................. 51
2.3.5 W32 Mariner Compressors Maintenance –Parts Replacement Table.................................... 52
2.4 Torque values............................................................................................................53

W32 SERIES
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
©ALKIN COMPRESSORS
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2.5 Maintenance Instuctions ...........................................................................................53
2.5.1 General ....................................................................................................................................53
2.5.2 Servicing 1st stage valve ...........................................................................................................54
2.5.3 Servicing 2nd stage valve ..........................................................................................................54
2.5.4 Servicing 3rd stage valve...........................................................................................................54
2.5.5 Cylinder&piston removal and replacement.............................................................................55
2.5.6 Piston ring replacement...........................................................................................................56
2.5.7 Intake filter replacement .........................................................................................................57
2.5.8 Sintered filter element replacement........................................................................................57
2.5.9 Prufier cartridge replacement..................................................................................................57
2.5.10 Oil Filter replacement ............................................................................................................59
3.0 TROUBLE SHOOTING..................................................................................................................61
4.0 PARTS LIST ....................................................................................................................................67
4.1 Crankcase ..................................................................................................................68
4.2 First Stage..................................................................................................................70
4.3 Second Stage .............................................................................................................72
4.4 Third Stage ................................................................................................................74
4.5 Oil Pump....................................................................................................................76
4.6 Oil Filling Line ............................................................................................................78
4.7 Intake Filter ...............................................................................................................80
4.8 Water and Oil Separator & Purifier............................................................................82
4.9 Out Line (Standart) ....................................................................................................84
4.10 General Piping (Standart) ........................................................................................86
4.11 Out Line (Automatic Drain)......................................................................................90
4.12 General Piping (Automatic Drain) ............................................................................92
4.13 Lubrication ..............................................................................................................96
4.14 General Layout (Standart) .......................................................................................98
4.15 General Layout (Automatic Drain) .........................................................................102
4.16 General Layout (Petrol Engine) ..............................................................................104
4.17 General Layout (Petrol Engine - Automatic Drain) .................................................108
4.18 Electrical Panel (Standart) .....................................................................................110
4.19 Electrical Panel (Automatic Drain) .........................................................................112
4.20 Filling Line..............................................................................................................114
4.21 Out Line (Dual Pressure) ........................................................................................116
4.22 Filling Line (Dual Pressure).....................................................................................118

W32 SERIES
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
©ALKIN COMPRESSORS
9
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 the proper manner, as well as
maintain it using the simple instructions in the maintenance section of this manual. This way your air compressor will always be in top operating
condition, giving you years long trouble free service.
LKIN air compressors are well known for 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.
Service and parts supply anywhere in the world can be done by an ALKIN Dealer. For any questions, please feel
free to call our Menderes plant, in İzmir-Turkey. Here are the contact details:
Address: ALKIN Kompresor San. ve Tic. Ltd.Sti
Cuneytbey Mh. Tabas Yolu Kume Evleri N.3, Menderes
35470 Izmir, TURKEY
Telephone: [phone] (10 Lines)
Fax : [phone]
E-mail: [email protected]
In all correspondences, please provide serial number and a copy of invoice.
Additionally, replacement parts not manufactured or approved by ALKIN can damage your compressor, creating
risks of accidents and injuries.
ALKIN has the right to change information without any prior notice.
Users are expected to safely operate and maintain the compressor, observe the rules and instructions, as well as the
local safety codes, to minimize the risk of accidents and injuries.
FOREWORD
A

W32 SERIES
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
©ALKIN COMPRESSORS
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