Gardner Denver APEX25-30B Service manual

13
-
25
-
6
33
Version: 00
September 21, 2018
APEX
SINGLE STAGE
VARIABLE AND FIXED SPEED
BASE- MOUNTED and TANK MOUNTED
COMPRESSORS
AirSmartäG2 Controller
MODELS
APEX25-30B, APEXVS18-22B
60HZ
OPERATING AND
SERVICE MANUAL

13-25-608 Page 1
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER® COMPRESSOR PARTS AND SUPPORT SERVICES
Gardner Denver®Compressor genuine parts, manufactured to design tolerances, are developed for optimum
dependability –specifically for Gardner Denver compressor systems. Design and material innovations are the result
of years of experience with hundreds of different compressor applications. Reliability in materials and quality
assurance is incorporated in our genuine replacement parts.
Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. An AirSmart™network of
authorized distributors provides the finest product support in the air compressor industry.
Your authorized distributor can support your Gardner Denver air compressor with these services:
1. Trained parts specialists to assist you in selecting the correct replacement parts.
2. Factory warranted new and remanufactured rotary screw air ends. Most popular model remanufactured
air ends are maintained in stock at the factory, for purchase on an exchange basis with liberal core credit
available for the replacement unit.
3. A full line of factory tested AEON™compressor lubricants specifically formulated for use in Gardner Denver
compressors.
4. Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.
Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They
are ready to respond and assist you by providing fast, expert maintenance and repair services.
To Contact Gardner Denver or locate your local distributor:
Visit: www.contactgd.com/compressors
Or
Call: [phone]
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL, Method of Cooling, HORSEPOWER and SERIAL NUMBER (see
nameplate on unit). The Air end Serial Number is also stamped on top of the discharge bearing carrier casting.
All orders for Parts should be placed with the nearest authorized distributor.
Where NOT specified, quantity of parts required per compressor or unit is one (1); where more than one is required
per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER OF PARTS REQUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right-Hand and Left-Hand side of a compressor, stand at the motor end and look toward the
compressor. Right-Hand and Left- Hand are indicated in parenthesis following the part name, i.e. (RH) and (LH),
when appropriate.

13-25-608 Page 2
WARNING –PROHIBITION –MANDATORY LABEL INFORMATION
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled
manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise
care in its operation and maintenance. This book is written to give the operator and maintenance
department essential information for day-to-day operation, maintenance and adjustment. Careful
adherence to these instructions will result in economical operation and minimum downtime.
Boxed text formats are used, within this manual, to alert users of the following
conditions:
Safety Labels are used, within this manual and affixed to the appropriate areas of
the compressor package, to alert users of the following conditions:
Indicates a hazard with a high level of risk, which if not avoided,
WILL
result in death or serious
injury.
Equipment Starts Automatically
Cutting of Finger or Hand Hazard –Rotating
Impeller Blade
Cutting of Finger or Hand Hazard –Rotating Fan
Blade
Health Hazard –Explosive Release of Pressure
High Voltage –Hazard of Shock, Burn, or Death
Present until Electrical Power is Removed
Entanglement of Fingers or Hand/Rotating Shaft

13-25-608 Page 3
Indicates a hazard with a medium level of risk which, if not avoided,
COULD
result in death or
serious injury.
Asphyxiation Hazard –Poisonous Fumes or Toxic Gases in Compressed Air
Indicates a hazard with a low level of risk which, if not avoided,
MAY
result in a minor or
moderate injury.
Burn Hazard –Hot surface
PROHIBITION/MANDATORY ACTION REQUIREMENTS
Do not Operate Compressor with Guard Removed
Do Not Lift Equipment with Hook –No Lift Point
Handle Package at Forklift Points Only
Lockout Electrical Equipment in De-Energized
State
Loud Noise Hazard –Wear Ear Protection
Read the Operator’s Manual Before Proceeding
with Task

13-25-608 Page 4
SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or
circumstances cannot always be predicted and covered by established rules. Therefore, use your past
experience, watch out for safety hazards and be cautious. Some general safety precautions are given
below:
Failure to observe these notices will result in injury to or death of personnel.
·Keep fingers and clothing away from rotating fan, drive coupling, etc.
·Disconnect the compressor unit from its power source, lockout and tagout before working on the
unit –this machine is automatically controlled and may start at any time.
·Do not loosen or remove the oil filler plug, drain plugs, covers, the thermostatic mixing valve or
break any connections, etc., in the compressor air or oil system until the unit is shut down and
the air pressure has been relieved.
·Electrical shock can and may be fatal.
·Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable
local electrical codes. Wiring and electrical service must be performed only by qualified
electricians.
Open main disconnect switch, lockout and tagout and check for voltage before working on the
control.
Failure to observe these notices could result in damage to equipment.
·Stop the unit if any repairs or adjustments on or around the compressor are required.
·Do not use the air discharge from this unit for breathing –not suitable for human consumption.
·An Excess Flow Valve should be on all compressed air supply hoses exceeding 1/2 inch
inside diameter (OSHA Regulation, Section 1926.302).
·Do not exceed the rated maximum pressure values shown on the nameplate.
·Do not operate unit if safety devices are not operating properly. Check periodically. Never
bypass safety devices.

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TABLE OF CONTENTS
Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And
Support Services.....................................................................................................................................1
Instructions For Ordering Repair Parts.....................................................................................................1
Warning –Prohibition –Mandatory Label Information..............................................................................2
Safety Precautions ..................................................................................................................................4
Index.......................................................................................................................................................6
SECTION 1, General Information.............................................................................................................8
SECTION 2, Installation.........................................................................................................................13
SECTION 3, Starting & Operating Procedures.......................................................................................19
SECTION 4, Controls & Instrumentation................................................................................................24
SECTION 5, Lubrication. Oil Cooler, Oil Filter & Separator.....................................................................53
SECTION 6, HEAT EXCHANGERS (OIL/AIR).......................................................................................60
SECTION 7, Air Filters...........................................................................................................................63
SECTION 8, Belt Drive System..............................................................................................................65
SECTION 9, Servicing Of Miscellaneous Devices..................................................................................68
SECTION 10, Tank Mounted Compressor - Total System......................................................................75
SECTION 11, Motor Lubricant...............................................................................................................77
SECTION 12, Maintenance Schedule....................................................................................................78
SECTION 13, Troubleshooting ..............................................................................................................80
This book covers the following models:
POWER PSIG Air Cooled Parts List Controller Manual
25, 30 HP 110, 125, 175 APEX25-30B 13-25-556 13-17-613
18, 22 KW 110, 125, 175 APEXVS18-22B 13-25-509 13-17-613

13-25-608 Page 6
INDEX
Air Cooled Unit...............................................13
Air Filters
Section 7.....................................................65
Air Flow in Compressor System....................... 9
Air Receiver
Auxiliary......................................................16
BELT DRIVE SYSTEM
SECTION 8.................................................67
Cold Weather
Installation ..................................................16
Compression Principle..................................... 8
Compressor..................................................... 8
Controls & Instrumentation
AirSmart G2 Controller Operation................24
General Description....................................24
Section 4.....................................................24
Cooling, Sealing and Lubrication...................... 9
Daily Check....................................................22
Discharge Service Line...................................16
ELECTRICAL WIRING...................................17
ELECTRICAL WIRING Sizing.........................17
Enclosure.......................................................15
Foundation.....................................................14
GENERAL INFORMATION
SECTION 1.................................................. 8
Grounding ......................................................18
HEAT EXCHANGERS (OIL/AIR)
Section 6.....................................................62
Inlet Line ........................................................16
Installation
Cold Weather..............................................16
General.......................................................13
Section 2.....................................................13
Lifting Unit......................................................13
Location .........................................................13
Lubrication, Cooling and Sealing...................... 9
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR
SECTION 5.................................................53
MAINTENANCE SCHEDULE
SECTION 10...............................................77
SECTION 12...............................................80
Miscellaneous Control Devices.......................49
Moisture Separator/Trap
Optional......................................................16
Motor Lubrication...........................................18
MOTOR LUBRICATION
SECTION 11..............................................79
Oil Reservoir
Drain..........................................................14
Piping
Control .......................................................16
Prestart-Up Instructions..................................19
Air Filter......................................................19
Compressor Oil ..........................................19
Electrical ....................................................19
Enclosure...................................................21
Grounding ..................................................19
Inlet Filter...................................................19
Operating Mode..........................................21
Piping.........................................................19
Rotation......................................................20
System Pressure........................................20
Target Pressure..........................................21
Unload Pressure.........................................20
Quick Start Guide...........................................23
SAFETY PRECAUTIONS ................................4
Sealing, Lubrication and Cleaning....................9
Service Check List.........................................80
Every 1000 Hours Operation.......................80
Every 125 Hours Operation ........................80
Every 4000 Hours Operation.......................80
Every 8 Hours Operation............................80
Every Year .................................................80
Motor Lubrication........................................80
SERVICING OF MISCELLANEOUS DEVICES
SECTION 9................................................70
STARTING & OPERATING PROCEDURES
SECTION 3................................................19
Starting the Unit.............................................22
Unit Cold....................................................22
Stopping the Unit ...........................................22
TROUBLE SHOOTING
SECTION 13..............................................82
TROUBLESHOOTING VOLTAGE PROBLEMS
...................................................................85
WARNING –PROHIBITION –MANDATORY
LABEL INFORMATION ................................2
Wiring
Electrical ....................................................17

13-25-608 Page 7
LIST OF ILLUSTRATIONS
Figure 1-1 - Compressor Cycle................................................................................................................8
Figure 1-2 –Compressor Illustration –Variable Speed...........................................................................10
Figure 1-3 –Compressor Illustration –Fixed Speed...............................................................................11
Figure 1-4 - Compressor Illustration - Total System............................................................................... 11
Figure 2-1 –Typical Compressor Room.................................................................................................14
Figure 2-2 –Air Flow Chart....................................................................................................................14
Figure 2-3 –Cold Weather Installation...................................................................................................15
Figure 2-4 –Electrical Wiring Sizing –FS Variants.................................................................................17
Figure 4-1 –Controller Layout And Main Screen....................................................................................24
Figure 4-2 –Wiring Diagram –VS (230 Volt) .........................................................................................26
Figure 4-3–Wiring Diagram –VS (575 Volt) ..........................................................................................30
Figure 4-4 –Wiring Diagram –VS (380-460 Volt) ..................................................................................34
Figure 4- 5 –Wiring Diagram –FS (208 –230, 460 Volt).......................................................................38
Figure 4- 6 –Wiring Diagram –FS (380-415, 460 Volt)..........................................................................41
Figure 4- 7 –Wiring Diagram –FS (575 Volt).........................................................................................44
Figure 4- 8 –Piping And Instrumentation Illustration ..............................................................................52
Figure 5-1 –Oil Level Sight Glass..........................................................................................................53
Figure 5-2 –Dew Point Chart °F............................................................................................................57
Figure 5-3 –Dew Point Chart °C............................................................................................................57
Figure 5-4 –Oil Change Interval............................................................................................................58
Figure 6-1 –Air Flow Chart....................................................................................................................62
Figure 6-2 –Cooler Access ...................................................................................................................64
Figure 7-1 –Compressor Air Filter, Package Pre-Filter And Vfd Filter Locations.....................................66
Figure 8 - 1 - Coupling Components ......................................................................................................67
Figure 8 - 2 –Coupling Element Spacing...............................................................................................68
Figure 8 –3 –Compressor-Motor Assembly Details...............................................................................69
Figure 8 –4 –Coupling Hub Removal Tool In Place..............................................................................69
Figure 9-1 –Inlet Valve Assembly..........................................................................................................70
Figure 9-2 –Inlet Valve Body Hex..........................................................................................................71
Figure 9-3 - Pressure Relief Valve.........................................................................................................72
Figure 9-4 - Minimum Pressure Valve And Seat.....................................................................................73
Figure 9-5 –Thermal Mixing Valve ........................................................................................................74
Figure 9-5 –Shaft Seal Illustration –Direct Drive Variant Shown............................................................75
Figure 9-6 –Compressor (Direct Drive Variant) Hardware Illustration.....................................................76

13-25-608 Page 8
SECTION 1
GENERAL INFORMATION
Figure 1-1 - COMPRESSOR CYCLE
COMPRESSOR - The rotary screw compressor is a single stage, positive displacement rotary machine
using meshing helical rotors to effect compression. Both rotors are supported between high capacity anti-
friction bearings located outside the compression chamber. Roller bearings are used at the inlet end of
the rotors to carry part of the radial loads. Angular contact ball and roller bearings at the discharge end
locate each rotor axially and carry all thrust loads and the remainder of the radial loads.
COMPRESSION PRINCIPLE (Figure 1-1)- Compression is accomplished by the main and secondary
rotors synchronously meshing in a one-piece cylinder. The main rotor has four (5) helical lobes 72°apart.
The secondary rotor has five (6) matching helical grooves 60°apart to allow meshing with main rotor
lobes.
The air inlet port is located on top of the compressor cylinder near the drive shaft end. The discharge port
is near the bottom at the opposite end of the compressor cylinder. Figure 1-1 is an inverted view to show
inlet and discharge ports. The compression cycle begins as the rotors unmesh at the inlet port and air is
drawn into the cavity between the main rotor lobes and the secondary rotor grooves (A). When the rotors
pass the inlet port cutoff, air is trapped in the interlobe cavity and flows axially with the meshing rotors (B).
As meshing continues, more of the main rotor lobe enters the secondary rotor grove, normal volume is
reduced and pressure increases.
Oil is injected into the cylinder to remove the heat of compression and seal internal clearances. Volume
reduction and pressure increase continues until the air/oil mixture trapped in the interlobe cavity by the
rotors passes the discharge port and is released to the oil reservoir (C). Each rotor cavity follows the
same “fill-compress-discharge”cycle in rapid succession to produce a discharge air flow that is
continuous, smooth and shock free.

13-25-608 Page 9
AIR FLOW IN THE COMPRESSOR SYSTEM
Figure 4- 8 page 52 - Air enters the air filter and passes through the inlet unloader valve and on into the
compression chamber where oil is injected into the air. After compression, the air/oil mixture passes into
the oil reservoir where most of the entrained oil is removed by velocity change and impingement and
drops back into the reservoir. The air and remaining oil then passes through the air/oil separator. The air
then passes through the minimum pressure/check valve, the after cooler and the moisture separator and
into the plant air lines.
LUBRICATION, COOLING AND SEALING - Oil is forced by air pressure from the oil reservoir through
the oil cooler, thermostatic mixing valve, and oil filter and discharge into the compressor main oil gallery.
A portion of the oil is directed through internal passages to the bearings and shaft oil seal. The balance
of the oil is injected directly into the compression chamber to remove heat of compression, seal internal
clearances and lubricate the rotors.

13-25-608 Page 10
Figure 1-2 –COMPRESSOR ILLUSTRATION –VARIABLE SPEED
304
USC797
-
01
(Ref. Drawing)

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Figure 1-3 –COMPRESSOR ILLUSTRATION –FIXED SPEED
30
5
USC797
-
01
(Ref. Drawing)

13-25-608 Page 12
Figure 1-4 –COMPRESSOR ILLUSTRATION - TOTAL SYSTEM
301USC804
-
A
(Ref. Drawing)
Page 1 of 1

13-25-608 Page 13
SECTION 2
INSTALLATION
GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit.
Report any damage or missing parts as soon as possible.
Do not electric weld on the compressor or base; bearings can be damaged by
passing of current.
LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Unit may
be moved into location by lift truck.
Lift compressor unit under base only. Do not use other places such as motor,
compressor or discharge manifold piping as lifting points.
The eyebolts or lugs provided on the motor are for lifting the motor only and
should not be used to lift any additional weight. All eyebolts must be securely
tightened. When lifting the motor the lifting angle must not exceed 15 degrees.
Failure to observe this warning may result in damage to equipment or personal
injury.
Compressor, air/oil reservoir, separator chamber and all piping and tubing may
be at high temperature during and after operation.
LOCATION (Figure 2-1, page 14) - The compressor must be installed where it is protected from rain,
snow and freezing temperatures, in a clean, well-lighted, well-ventilated area with ample space all around
for maintenance. Select a location that provides a cool, clean, dry source of air. In some cases it may be
necessary to install the air filter at some distance from the compressor to obtain proper air supply, see
“Inlet Line, page 15 and 16.
AIR-COOLED UNIT - A combination oil/air cooler is supplied as standard equipment on all air-cooled
units. An electric fan module supplies the ventilation needs for the oil/air cooler (Figure 1-2, page 10). Air
is drawn into the unit through the main intake grill and discharged through the cooler cores. Do not block
the air flow to and from the unit. Allow three and one half (3-1/2) feet to the nearest obstruction on the
control box end of the unit. Allow two (2) feet to the nearest obstruction above and on other sides of unit.

13-25-608 Page 14
For continuous efficiency, the cooler cores must be periodically cleaned with either vacuum or
compressed air. If wet cleaning is required, shield motor and spray on a mild soap solution and flush with
clean water.
NOTICE
Coolers are aluminum; do not use any cleaning solution that is not compatible
with aluminum. Use of improper solution may result in damage to the cooler.
Figure 2-1 –TYPICAL COMPRESSOR ROOM
Minimum Air Flow* For Compressor
And Cooling (cubic Feet/Minute)
Air Cooled
VS models 3022 CFM
FS models 2684 CFM
* 80°F Inlet Air
Figure 2-2 –AIR FLOW CHART
FOUNDATION - The rotary screw compressor requires no special foundation, but should be mounted on
a smooth, solid surface. Whenever possible install the unit near level. Mounting bolts are not normally
required. However, installation conditions such as piping rigidity, angle of tilt, or danger of shifting from
outside vibration or moving vehicles may require the use of mounting bolts and shims to provide uniform
support for the base. Belt alignment and tension should be checked after installation. (For information on
belt alignment and tension, Section 8 see page 67.
OIL RESERVOIR / OIL COOLER DRAIN - Both reservoir and core oil charge is drained from a single
connection and plug provided on the lower, left-hand side of the oil cooler core.

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ENCLOSURE - The compressor, electric motor, oil cooler and after cooler are mounted inside the
enclosure.
Service panels are provided for maintenance access. Be sure to allow enough space around the unit for
the panels to be removed. Any of the enclosure panels may be removed by opening the latch and lifting it
up slightly.
Do not operate the compressor with the fan and belt guard removed. Exposed
fan and belts may cause injury to personnel.
The enclosure doors and panels must be closed and latched while the
compressor is operating. Failure to close and latch the doors and panels will
cause high temperature shutdowns.
Figure 2-3 –COLD WEATHER INSTALLATION

13-25-608 Page 16
INSTALLATION FOR COLD WEATHER OPERATION (Figure 2-3, page 15) - It is recommended that
the unit be installed inside a shelter that will be heated to temperatures above freezing (32oF, 0oC). This
will eliminate many of the problems associated with operating units in cold climates, such as freezing in
control lines and downstream of the cooler.
Refer to Engineering Data Sheet 13-9-411 for the advantages of using the heat recovered from rotary
compressors. This heat recovery could easily pay for an adequate shelter for the unit.
When the unit must be installed in an outdoors installation and/or exposed to ambient temperatures below
freezing (32oF, 0oC), contact Gardner Denver for recommendations.
When using a Total System with a compressed air dryer option, refer to Section 10 for details.
Unsheltered (outdoors) installation shall be avoided. Installation next to a
heated building may be sufficient to keep the compressor package room above
freezing temperature and thus avoid operational complications.
AUXILIARY AIR RECEIVER - An auxiliary air receiver is not required if the piping system is large and
provides sufficient storage capacity to prevent rapid cycling. When used, an air receiver should be of
adequate size, provided with a relief valve of proper setting, a pressure gauge and a means of draining
condensate
OPTIONAL MOISTURE SEPARATOR/TRAP - The unit can be provided with an optional stand-alone
combination moisture separator and trap that is field-installed downstream of the after cooler.
CONTROL PIPING - Control piping is not necessary since the rotary screw unit is factory wired and piped
for the control system specified.
INLET LINE - The filter is close-coupled to the compressor intake flange, thus no inlet line is used or
recommended.
DISCHARGE SERVICE LINE - The discharge service line connection is provided at the outlet of the field
installed water separator, which in turn is located at the upper right hand side of the inlet air grill.
A hand operated valve, (air service valve) and a separate (swing-type) check valve must be installed
between the unit and the customer’s air system. If a fast operating valve such as a ball valve is used, it
must be closed slowly to give the intake valve time to shut and keep the discharge pressure from spiking.
When using a Total System, refer to Section 10 for details.
The controller has an automatic start/stop sequence built in. You do NOT need
to close the air service valve. Closing the air service valve on start-up or prior
to shutdown will cause rapid cycling, and could cause a high pressure
shutdown.

13-25-608 Page 17
When piping two or more rotary screw units on a common discharge line, each unit shall be isolated by
the check valve in the unit discharge line.
If a rotary screw and a reciprocating compressor are piped to a common discharge line, an air receiver
must be located between the two units.
Discharge air used for breathing will cause severe injury or death.
Consult filtration specialists for additional filtration and treatment equipment to
meet health and safety standards.
ELECTRICAL WIRING - Standard Units - The compressor package is factory wired for all connections
from the starter to the motor, for the horsepower and voltage specified on the order. The standard unit is
supplied with:
·UL Type 4 (NEMA 4) starter and controls enclosure and TEFC main motor on FS variants. Note that
the overload settings are to be selected based on motor nameplate full load amperage
·UL Type 1 (IP54 VFD and controls enclosure and TEAO main motor on VS variants.
See “Location”paragraph on page 13, for distance to the nearest obstruction on the control box side of
the package.
Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable local
electrical codes. Wiring must be performed only by qualified electricians.
Electrical shock can cause injury or death. Open main disconnect switch,
lockout and tag out before working on control box.
Electrical Wire Sizing - A certified electrician familiar with National Electric Codes and applicable local
codes shall size the electrical power wires serving the compressor package. Refer to Figure 2-4, 2-5 for a
summary of maximum package current draw values.
Power
Phase
-
Voltage
Max Current Draw
-
amps
25 / 30
HP
package
3
-
575
30.1 / 35.4
"
3
-
460
37.6 / 43.8
"
3
-
230
73.6 / 86.1
"
3
-
2
08
82.9 / 94.9
RNC 125 dryer
1
-
115
18.0
RNC 150 dryer
1
-
115
18.0
Figure 2-4 –Electrical Wiring Sizing –FS Variants

13-25-608 Page 18
Power
Phase
-
Voltage
Max Current Draw
-
amps
18 / 22 KW
package
3
-
575
41.0 / 41.0
"
3
-
460
61.0 / 61.0
"
3
-
230
91.0 / 91.0
RES 120 dryer
1
-
115
18.3
RES 140 dryer
1
-
115
18.3
Figure 2-5 –Electrical Wiring Sizing –VS Variants
Line Reactor (VS var) –A line reactor provides conditioning of the electrical power supply to the
compressor package by attenuating noise and fluctuations. It shall be required in your particular
application if any of the following conditions exist:
·Transformer KVA is greater that recommended –see Fig 2-5
·Line has switched Power Factor correction capacitors.
·Existing line reactor is not properly sized –see Fig 2.5
·Other large loads share the power feed to the compressor package.
GD Model
Voltage
VFD kW Rating
Max kVA
VS 18 / 22
575
18 / 22
Consult Factory
“
460
18 / 22
1000
“
380
18 / 22
1000
“
230
18 / 22
600
GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical
Code.
Failure to properly ground the compressor package could result in injury or
death. Install ground wiring in accordance with the National Electrical Code
and any applicable local codes.
MOTOR LUBRICATION –Long time satisfactory operation of an electric motor depends in large measure
on proper lubrication of the bearings. Refer to Section 11 of this manual for motor lubrication
specifications and details.

13-25-608 Page 19
SECTION 3
STARTING & OPERATING PROCEDURES
PRESTART-UP INSTRUCTIONS - A new unit as received from the factory has been prepared for
shipping only. Do not attempt to operate the unit until checked and serviced as follows:
1. Compressor Oil - The oil level must be checked before starting the unit and every 8 hours of
operation. For instructions on checking the oil and the proper oil level, refer to “Oil level gauge”,
SECTION 5 see page 53
Do not mix different type oils. Standard Unit is shipped filled with Gardner Denver AEON 4000
lubricant which is suitable for the first 4000 hours under normal operating conditions. Other AEON
lubricants are available. Check the decal on the reservoir to be sure which lubricant is in the
machine.
NOTICE
Regular maintenance and replacement at required intervals of the oil filter, air
filter and air/oil separator is necessary to achieve maximum service and
extended drain intervals of AEON 4000 lubricant. Use only genuine Gardner
Denver filters designed and specified for this compressor.
Always stop the unit and release air pressure before removing oil filler plug.
Failure to release pressure may result in personal injury or death.
Air Filter - Inspect the air filter to be sure it is clean and tightly assembled. Refer to SECTION 7, page 65
for complete servicing instructions. Be sure the inlet line, if used, is tight and clean.
2. Package Inlet Filter - Figure 1-2, page 10. Inspect the Pre-Filter to be sure it is clean. Refer to
Section 7, page 65 for complete servicing instructions
3. Piping –Refer to SECTION 2, page 13 “Discharge Service Line”and make sure all piping meets all
recommendations.
Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See
Figure 4-2 thru Figure 4-8 pages 26 thru page 46 for general wiring diagrams and SECTION 2, Page
13, for “Electrical Wiring”.
4. Grounding - Unit must be properly grounded according to Section 250 of the National Electrical
Code.
5. When using a Total System with a compressed air dryer option, refer to Section 10 for details.