Gardner Denver HGR7-3K User manual

OPERATION/MAINTENANCE
MANUAL & PARTS LIST
Gasoline And Diesel Powered Two Stage Air
Compressor Featuring the R10DHU & R15BHU Compressors
WARNING
THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND SHOULD ALWAYS BE
AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT.
READ, UNDERSTAND AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS
EQUIPMENT TO PREVENT INJURY OR EQUIPMENT DAMAGE.
MODEL HGR7-3K UNIT
Form No. GF3122 VER: 19 07/19/2011
303CAE797-
A
(Ref. Drawing)

2
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 are incorporated in our genuine replacement parts.
Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. A worldwide
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. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner
Denver compressors.3
3. 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.
For the location of your local authorized Gardner Denver Air Compressor distributor, refer to the
yellow pages of your phone directory or contact:
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL, HORSEPOWER and SERIAL NUMBER (see
nameplate on unit). All orders for Parts should be placed with the nearest authorized distributor.
Order by part number and description. Reference numbers are for your convenience only.
Factory:
Gardner Denver
1301 North Euclid Avenue
Princeton, IL 61356
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]

3
TABLE OF CONTENTS
_______________________________________________________
Subject Page
Maintain Compressor Reliability And Performance .............................................................................. 2
Safety And Operation Precautions ....................................................................................................... 4
Explanation Of Safety Instruction Symbols And Decals ....................................................................... 5
Introduction ........................................................................................................................................... 6
Warranty ............................................................................................................................................... 6
Dimensions And Specifications ............................................................................................................ 7
Installation.......................................................................................................................................8 & 9
Operation .............................................................................................................................................. 9
Maintenance .........................................................................................................................10, 11 & 12
Compressor Pilot Valve Differential Pressure Adjustment ................................................................. 12
Compressor Oil Specifications............................................................................................................ 13
Lubricant ............................................................................................................................................. 13
Torque Valves..................................................................................................................................... 13
Trouble Shooting Guide...................................................................................................................... 14
Unit Repair Parts List ..............................................................................................................15 thru 21
Compressor Repair Parts List.................................................................................................23 thru 26
Hazard Decal Listing........................................................................................................................... 27
Unit Hazard Decals ............................................................................................................................. 28
Pump Hazard Decals.......................................................................................................................... 29
Record Of Maintenance Service............................................................................................. 30 thru 31

4
SAFETY AND OPERATION PRECAUTIONS
_______________________________________________________________________________________
Because an air compressor is a piece of machinery with moving and rotating parts, the same precautions should be
observed as with any piece of machinery of this type where carelessness in operation or maintenance is hazardous
to personnel. In addition to the many obvious safety rules that should be followed with this type of machinery, the
additional safety precautions as listed below must be observed:
1. Read all instructions completely before operating air compressor or unit.
2. For installation, follow all local safety codes, as well as the Occupational Safety and Health Act (OSHA).
3. Do not attempt to remove any compressor parts without first relieving the entire system of pressure.
4. Do not attempt to service any part while machine is in an operational mode.
5. Do not operate the compressor at pressures in excess of its rating.
6. Do not operate compressor at speeds in excess of its rating.
7. Periodically check all safety devices for proper operation. Do not change pressure setting or restrict
operation in any way.
8. Be sure no tools, or rags or loose parts are left on the compressor or drive parts.
9. Do not use flammable solvents for cleaning the air inlet filter or element and other parts.
10. Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts by covering
parts and exposed openings with clean cloth or Kraft paper.
11. Do not operate the compressor without guards, shields and screens in place.
12. Do not install a shut-off valve in the discharge line, unless a pressure relief valve, of proper design
and size, is installed in the line between the compressor unit and shut-off valve.
13. Do not operate compressor in areas where there is a possibility of ingesting flammable or toxic fumes.
14. Be careful when touching the exterior of a recently run engine - it may be hot enough to be painful or cause
injury.
15. Inspect unit daily to observe and correct any unsafe operating conditions found.
16. Do not "play around" with compressed air or direct air stream at body, because this can cause injuries.
17. Compressed air from this machine absolutely must not be used for food processing or breathing air without
adequate downstream filters, purifiers and controls.
18. Always use an air pressure regulating device at the point of use, and do not use air pressure greater than
marked maximum pressure of attachment.
19. Check hoses for weak or worn condition before each use and make certain that all connections are secure.
20. Always wear safety glasses when using a compressed air blow gun.
The user of any air compressor package manufactured by Gardner Denver is hereby warned that failure to follow
the preceding Safety and Operation Precautions can result in injuries or equipment damage. However, Gardner
Denver does not state as fact or does not mean to imply that the preceding list of Safety and Operating Precautions
is all inclusive, and further that the observance of this list will prevent all injuries or equipment damage.

5
EXPLANATION OF SAFETY INSTRUCTION SYMBOLS AND DECALS
DANGER
Indicates immediate hazards which will result in severe injury or death.
WARNING
Indicates hazards or unsafe practice which could result in severe injury or death.
CAUTION
Indicates hazards or unsafe practice which could result in damage to the Gardner Denver
compressor or minor injury.
NOTICE
Notice is used to notify people of installation, operation or maintenance information which is
important but not hazard-related.
SAFETY AND OPERATION PRECAUTIONS
OBSERVE, UNDERSTAND AND RETAIN THE INFORMATION GIVEN IN THE SAFETY PRECAUTION
DECALS AS SHOWN IN THE PARTS LIST SECTION
DANGER
This reciprocating compressor must not be used for breathing air. To do so will cause serious injury
whether air is supplied direct from the compressor source or to breathing tanks for later use. Any and all
liabilities for damage or loss due to injury, death and/or property damage including consequential
damages stemming from the use of this compressor to supply breathing air, will be disclaimed by the
manufacturer.
WARNING
The use of this compressor as a booster pump and/or to compress a medium other than atmospheric air is
strictly non-approved and can result in equipment damage and/or injury.
CAUTION
This unit may be equipped with special options which may not be included in this manual. User must
read, understand and retain all information sent with special options.

6
INTRODUCTION
______________________________________________________________________
Gardner Denver R Series 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.
Gardner Denver Five Year Warranty
"R" Series Compressors
Gardner Denver, Inc. (“the Company”) warrants each new compressor pump manufactured by the
Company, mounted on a factory assembled unit, to be free from defects in material and workmanship under
normal use and service for a period of sixty (60) months from date of installation or sixty-six (66) months from
date of shipment by the Company or the Company distributor, whichever may occur first. Applies to the
compressor pump only, excluding head valves. Valves, controls and accessories are warranted for
the first year only. Compressor pumps purchased separately would carry a one year warranty.
This five year extended warranty will be prorated over the 5 years as follows:
First Year - 100% Allowance, Parts and Labor
Second Year - 90% Allowance, Parts and Labor
Third Year - 80% Allowance, Parts and Labor
Fourth Year - 70% Allowance, Parts and Labor
Fifth Year - 60% Allowance, Parts and Labor
Applies to the Company logo, tank or base mounted complete compressors only.
Express Limited Warranty
The Company warrants each new air compressor unit manufactured by the Company to be free from defects
in material and workmanship under normal use and service for a period of twelve (12) months from date of
installation or eighteen (18) months from date of shipment by the Company or the Company distributor,
whichever may occur first.
The Company makes no warranty in respect to components and accessories furnished to the Company by
third parties, such as ELECTRIC MOTORS, GASOLINE ENGINES and CONTROLS, which are warranted
only to the extent of the original manufacturer's warranty to the Company. To have warranty consideration,
electric motors must be equipped with thermal overload protection.
The extended five year warranty will apply to ASME air receivers provided they are installed on rubber vibro
isolator pads or approved equivalent.
When a compressor pump, or component is changed or replaced during the warranty period, the
new/replaced item is warranted for only the remainder of the original warranty period.
Repair, replacement or refund in the manner and within the time provided shall constitute the Company 's sole
liability and your exclusive remedy resulting from any nonconformity or defect. THE COMPANY SHALL NOT
IN ANY EVENT BE LIABLE FOR ANY DAMAGES, WHETHER BASED ON CONTRACT, WARRANTY,
NEGLIGENCE, STRICT LIABILITY OR OTHERWISE, INCLUDING WITHOUT LIMITATION ANY
CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES, ARISING WITH RESPECT TO THE
EQUIPMENT OR ITS FAILURE TO OPERATE, EVEN IF THE COMPANY HAS BEEN ADVISED OF THE
POSSIBILITY THEREOF.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND, EXCEPT THAT
OF TITLE, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OR
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY EXPRESSLY
DISCLAIMED. NO SALESMAN OR OTHER REPRESENTATIVE OF THE COMPANY HAS AUTHORITY TO
MAKE ANY WARRANTIES.

7
TWO STAGE AIR COMPRESSORS - MODEL R10DHU & R15BHU
DIMENSIONS
ITEM R10DHU &
R15BHU
A
B
C
D
E
F
I
J
K
L
M
N
O
P
Q
R
Base-Width
Bolt Down-Width
Bolt Down to Edge
Base to Crank Ctr
Overall Width
Overall Height
Bolt Down Hole Dia.
Base-Depth
Bolt Down Depth
Bolt Down to Edge
Bolt Hole to Wheel (Max.)
Flywheel Width
Crank Diameter
Flywheel Diameter
Flywheel Grooves
Overall Depth
10”
4-3/8”
5/8”
5-1/2”
18”
23-1/4”
15/32”
7-1/2”
5-3/4”
7/8”
3-5/8”
2-1/2”
1-5/16”
16-1/2”
2VB
20”
NOTE: H.P. Exhaust Opening 3/4" Tubing.
Flywheel Rotation – Clockwise when viewed
from front, flywheel to rear.
SPECIFICATIONS
MODEL BORE & STROKE
(INCH)
NO. of
CYLINDERS
OIL
CAPACITY
(QTS)
WEIGHT
(LBS)
MAXIMUM
PRESSURE
(PSIG)
CU
FT./REV.
MIN./MAX.
RPM.
R10DHU 4-5/8" & 2-1/2" x 2" 2 2 107 175 .01942* 400/1050
R15BHU 4-5/8" & 2-1/2" x 3" 2 2 109 175 .02914 400/1050
*Clearance volume modified to effective .014 cu. ft/rev.
PERFORMANCE
PUMP
OUTPUT
PRESS.
PSIG
ENGINE
H.P.
PUMP
RPM
DISPL.
CFM
R10DHU 175 5 542 10.5
R15BHU 175 8 600 17.5
R15BHU 175 9 870 20.7
R15BHU 175 11 895 26.1
R15BHU 175 13 1025 29.9
Pulley Dia. (approx.) = Compressor RPM x Flywheel Dia.
Motor or Engine RPM
C-593-B
(Ref. Drawing)

8
INSTALLATION
WARNING
Do not operate unit if damaged during shipping, handling or use. Operating unit if damaged
may result in injury.
1. Permanently installed compressors must be located in a clean, well ventilated dry room so
compressor receives adequate supply of fresh, clean, cool and dry air. It is recommended that a
compressor, used for painting, be located in a separate room from that area wherein body sanding
and painting is done. Abrasive particles or paint, found to have clogged the air intake filters and
intake valves, shall automatically void warranty.
2. Compressors should never be located so close to a wall or other obstruction that flow of air
through the fan blade flywheel, which cools the compressor, is impeded. Permanently mounted
units should have flywheel at least 12" from wall.
3. Place stationary compressors on firm level ground or flooring. Permanent installations require
bolting to floor or truck bed. Bolt holes in tank or base feet are provided. Before bolting or lagging
down, shim compressor level. Avoid putting a stress on a tank foot by pulling it down to floor. This
will only result in abnormal vibration, and possible cracking of air receiver. It is recommended that
unit be set on optional vibro-isolator pads. Tanks bolted directly to a concrete floor without
isolators will not be warranted against cracking. Champion vibro-isolators or approved equivalent
must be installed for extended warranty to apply to ASME receivers.
4. If installing base mounted unit, make certain the pressure limiting controls are properly installed
and operational. The unloading system requires a control air pressure line from the air receiver to
be connected to the pilot valve fitting on the pump.
5. Gas or diesel engine powered units installed indoors must have proper engine exhausting out of
building.
6. 13 HP KOHLER ENGINE ONLY: Attach exhaust deflector (shipped loose) to muffler by sliding
deflector over muffler outlet. Outlet of deflector should be positioned to face fuel tank side of
engine. Tighten screw on exhaust deflector.
DANGER
Do not install isolating valves between compressor outlet and air receiver. This will cause excessive
pressure if valve is closed and cause injury and equipment damage.
WARNING
Always use an air pressure regulating device at the point of use. Failure to do so can result in injury or
equipment damage.
CAUTION
• Do not install in an area where ambient temperature is below 32 degrees F or above
100 degrees F.
• Do not install unit in an area where air is dirty and/or chemical laden.
• Unit is not to be installed outdoors.

9
AIR LINE PIPING
Connection to air system should be of the same size, or larger, than discharge pipe out of unit.
The table gives recommended minimum pipe sizes. A union connection to the unit and water
drop leg is recommended. Install a flexible connector between the discharge of the unit and the
plant air piping. Plant air piping should be periodically inspected for leaks using a soap and water
solution for detection on all pipe joints. Air leaks waste energy and are expensive.
Minimum Pipe Sizes For Compressor Air Lines
(Based on clean Smooth Schedule 40 Pipe)
MODEL 25’ 50’ 100’ 200’ 300’
R10DHU & R15BHU 3/4” 3/4” 3/4” 1” 1”
WARNING
Never use plastic pipe or improperly rated metal pipe. Improper piping material can burst and
cause injury or property damage.
OPERATION
This compressor has been inspected, thoroughly tested and approved at the factory. For this unit to give
long satisfactory service it must be installed and operated properly. This compressor has been designed
for a 80%/ON – 20%/OFF duty cycle.
R10D & R15B models are equipped with a pilot valve and head unloaders to provide continuous run
capabilities. The pilot valve acts as an automatic air switch allowing air to flow from the receiver to the
head unloader mechanism, thus actuating it. The pilot valve senses receiver pressure. When the
receiver pressure reaches the cut-out pressure setting of the pilot valve, the pilot valve opens and air is
released to the unloader mechanism. The compressor stops compressing air and runs unloaded until the
cut-in pressure setting of the pilot valve has been reached. At this time air is released from the unloader
mechanism and the compressor starts compressing again.
Initial Start Up
1. Inspect unit for any visible signs of damage that would have occurred in shipment or during
installation.
2. Check compressor oil level. Add oil as required. See “Compressor Oil Specifications” Section.
NOTE: Do not mix oil type, weights or brands.
3. Check engine oil level. Add oil as required. Consult engine manual for oil specifications.
4. Close receiver outlet hand valve.
5. With receiver hand valve closed, let machine pump up to operating pressure. At this stage the
automatic controls will take over. Check for proper cycling operation.
6. When the initial run period has shown no operating problems, shut unit down and recheck oil
level.
7. Open receiver hand valve. The air compressor unit is now ready for use.
NOTICE
For starting unit, make sure receiver pressure is below 130 psig.

10
GUIDE TO MAINTENANCE
For Service contact an authorized Gardner Denver distributor. All requests should include model
number and serial number. To obtain reliable and satisfactory service, this unit requires a consistent
preventive maintenance schedule. Maintenance schedule form is included to aid in keeping the
proper records, see pages 30 and 31.
WARNING
Before performing any maintenance function, be sure all air pressure in unit is relieved.
Failure to do this may result in injury or equipment damage.
WARNING
Never add fuel to the fuel tank of a hot engine. Spilled fuel may ignite and cause injury or
equipment damage.
DAILY MAINTENANCE
1. Check oil level of compressor. Add AEON recip lubricant as required. See “Compressor Oil
Specifications” Section. NOTE: Do not mix oil type, weight, or brands.
2. Check oil level of engine. Consult engine manual for manufacturer’s recommended oil.
3. Drain moisture from tank by opening tank drain cock located in bottom of tank. Do not open drain
valve if tank pressure exceeds 25 PSIG.
WEEKLY MAINTENANCE
1. Clean dust and foreign matter from cylinder head, engine, fan blade, air lines, intercooler and tank.
2. Remove and clean intake air filters.
WARNING
Do not exceed 15 PSIG nozzle pressure when cleaning element parts with compressed air. Do
not direct compressed air against human skin. Serious injury could result. Never wash
elements in fuel oil, gasoline or flammable solvent.
3. Check V-belts for tightness. The V-belts must be tight enough to transmit the necessary power to
the compressor. Adjust the V-belts as follows:
a. Remove bolts and guard to access compressor drive.
b. Loosen mounting hardware which secures engine to base. Slide engine within slots of baseplate
to desired position.
c. Apply pressure with finger to one belt at midpoint span. Tension is correct if top of belt aligns with
bottom of adjacent belt. Make further adjustments if necessary.
d. Check the alignment of pulleys. Adjust if necessary.
e. Tighten mounting hardware to secure motor on base.
f. Re-install guard and secure bolts.
WARNING
Never operate unit without belt guard in place. Removal will expose rotating parts which can
cause injury or equipment damage.

11
EVERY 90 DAYS OR 500 HOURS MAINTENANCE
1. Change compressor crankcase oil and oil filter. Use only AEON recip lubricant.
2. Check entire system for air leakage around fittings, connections, and gaskets, using soap solution
and brush.
3. Tighten nuts and cap screws as required.
4. Check and clean compressor valves as required. Replace when worn or damaged parts.
CAUTION
Valves must be replaced in original position. Valve gaskets should be replaced each time valves
are serviced.
5. Pull ring on all pressure relief valves to assure proper operation.
GENERAL MAINTENANCE NOTES
PRESSURE RELIEF VALVE: The pressure relief valve is an automatic pop valve. Each valve is properly
adjusted for the maximum pressure of the unit on which it is installed. If it should pop, it will be
necessary to drain all the air out of the tank in order to reseat properly, or drop pressure in line. Do
not readjust.
BELTS: Drive belts must be kept tight enough to prevent slipping. If belts slip or squeak, see V-belt
maintenance in preceding section.
CAUTION
If belts are too tight, overload will be put on motor and motor bearings.
COMPRESSOR VALVES: If compressor fails to pump air or seems slow in filling up tank, disconnect
unit from power source and remove valves and clean thoroughly, using compressed air and a soft
wire brush. After cleaning exceptional care must be taken that all parts are replaced in exactly the
same position and all joints must be tight or the compressor will not function properly. When all
valves are replaced and connections tight, close hand valve at tank outlet for final test. Valve
gaskets should be replaced each time valves are removed from pump.
CENTRIFUGAL UNLOADER AND PRESSURE RELEASE VALVE: The centrifugal unloader is
operated by two governor weights. It is totally enclosed and lubricated from the crankcase of the
compressor. When compressor starts the governor weights automatically open compressing the
main spring, allowing the unloader pressure release valve to close. When the compressor stops,
the main spring returns the governor weights to normal position opening the unloader pressure
release valve and unloading the compressor. This prevents overloading the engine when starting.
If air continues to escape through the governor or unloader pressure release valve while operating,
this is an indication that the unloader pressure release valve is not closing tightly and may be held
open by foreign substance which has lodged on the seat. In order to correct this, remove the
governor release valve cap, giving access to release valve spring and ball. Clean thoroughly and
return parts in the same order in which they were removed. Loose drive belts can also cause
unloader to leak by preventing the compressor from reaching proper speed. (See “BELTS” above).
CHECK VALVE: The check valve closes when the compressor stops operating, preventing air from
flowing out of the tank through the pressure release. After the compressor stops operating, if air
continues to escape through the release valve, it is an indication that the check valve is leaking.
This can be corrected by removing check valve and cleaning disc and seat. If check valve is worn
badly, replace same.
WARNING
Before removing check valve be sure all air is drained out of tank and power is disconnected.
Failure to do so may result in injury or equipment damage.

12
GENERAL MAINTENANCE (Cont'd.)
THE INTERSTAGE PRESSURE RELIEF VALVE is provided to protect against interstage over pressure
and is factory set for maximum pressure of 75 PSIG. DO NOT RESET
If the pressure relief valve pops, it indicates trouble. Shut down the unit immediately and determine
and correct the malfunction. Inspect the head valves. Serious damage can result if not corrected
and can lead to complete destruction of the unit. Tampering with the interstage pressure relief
valve, or plugging the opening destroys the protection provided and voids all warranty.
COMPRESSOR LUBRICATION: Fill crankcase to proper level as indicated by oil sight gauge. Keep
crankcase filled as required by usage. It is recommended that only Champlub recip lubricant be
used. This is a 30-weight, non-detergent industrial oil with rust and oxidation inhibitors specially
formulated for reciprocating compressors. Do not mix oil types, weights or brands.
PILOT VALVE: The pilot valve actuates the head unloader mechanism to provide a means of stopping
or starting the compression of air by the compressor without stopping or starting the electric motor.
DIESEL OR GAS ENGINE: For service refer to separate engine manual.
COMPRESSOR PILOT VALVE PRESSURE ADJUSTMENT
Proceed with the following instructions while compressor is running:
1. Loosen locknut (4) and back off several turns. Do not turn differential pressure adjustment nut (3).
2. Check reading on the tank pressure gauge. Set the compressor maximum pressure by turning the
threaded cap (1) clockwise to increase pressure or counter clockwise to decrease pressure.
3. After pressure is set, tighten locknut (4). Be careful not to move threaded cap (1).
COMPRESSOR PILOT VALVE DIFFERENTIAL PRESSURE ADJUSTMENT
Proceed with the following instructions while compressor is running:
1. Loosen locknut (2) and back off several turns.
2. Check reading on the tank pressure gauge. Set the pressure to 30 psig differential (unload at 170
psig, reload at 140 psig). Turn nut (3) clockwise to increase differential pressure or
counterclockwise to decrease differential pressure.
3. After pressure is set, tighten locknut (2). Be careful not to move nut (3).
B980-B
(Ref. Drawing)

13
COMPRESSOR OIL SPECIFICATIONS
Compressors are factory filled with AEON hydrocarbon based recip lubricant. This is an ISO 100 non-
detergent industrial lubricant with rust and oxidation inhibitors specially formulated for reciprocating
compressors. It is recommended this compressor be maintained using this oil for ambient temperatures
above 32°F.
AEON synthetic is a premium grade diester based synthetic lubricant providing excellent performance in
high temperature applications.
CAUTION
Do not mix oil types, weights or brands.
CAUTION
“Emulsification of oil (white milky substance) indicates unsafe accumulation of moisture and
may be evidence compressor is oversized for application. Failure to promptly consult your
local distributor, or Gardner Denver Customer Service, can be grounds to deny warranty.”
NOTES:
1. Normal break-in period of Gardner Denver air compressors is 25 hours.
2. For the first 100 hours of compressor operation, a careful and regular check of the oil level should be
made. Maintain oil level at the full line.
CHANGING TO SYNTHETIC LUBRICANT
(Applies to diester based synthetic lubricant only)
1. Compressor must run for a 25 hour break-in period using AEON ISO 100 oil.
2. Thoroughly drain existing oil from crankcase.
3. Fill crankcase with a full charge of synthetic lubricant.
4. Run compressor for 200 hours.
5. Stop compressor and thoroughly drain the synthetic lubricant.
6. Add a full charge of synthetic lubricant.
7. Compressor now ready to run for extended period before next lubricant change.
LUBRICANT
AEON
DESCRIPTION PART NUMBER
1 – Quart Case (12/case) 28H213
1 – Gallon Case (4/case) 28H212
5 – Gallon Pail 28H211
55 – Gallon Drum 28H210
AEON SYNTHETIC
DESCRIPTION PART NUMBER
1 – Quart Case (12/case) 28H216
1 – Gallon Case (4/case) 28H215
5 – Gallon Pail 28H214
TORQUE VALVES
SPECIFIC APPLICATION FASTENER SIZE & THREAD TORQUE INCH-POUNDS
BEARING HOUSING BOLT 7/16 – 20 540
CYLINDER FLANGE BOLT 1/2 – 13 900
CONNECTING ROD BOLT 7/16 – 20 400
MANIFOLD BOLT 7/14 – 14 230
FLYWHEEL BOLT 7/16 – 20 600

14
TROUBLE SHOOTING CHART FOR COMPRESSOR
WARNING
Always shut off unit and relieve all pressure from air tank before performing any maintenance.
Failure to do so may result in equipment damage or injury.
Never operate unit without belt guard in place.
Troubleshooting Chart
Symptom Possible Cause(s) Corrective Action
Engine will not start. 1. No fuel in fuel tank.
2. High tank pressure.
3. Refer to separate engine manual for
other causes.
1. Add fuel
2. Reduce tank pressure to 130 PSIG or
less.
Tank pressure builds up slowly. 1. Air leaks.
2. Dirty air filter.
3. Defective compressor valves
1. Tighten fittings.
2. Clean or replace.
3. Install new valve plate assembly.
Tank pressure builds up quickly. 1. Excessive water in tank. 1. Drain tank.
Discharge pressure relief valve pops
off while compressor is running.
1. Wrong pressure switch setting.
2. Defective ASME relief valve.
1. Adjust to correct setting.
2. Replace valve.
Warning – Relieve tank pressure
before servicing.
Compressor will not unload 1. Wrong pilot valve setting.
2. Defective pilot valve.
3. Lack of air to pilot valve..
1. Adjust to correct sitting
2. Replace pilot valve.
3. Check piping from tank to pilot valve
for leaks.
Excessive belt wear. 1. Pulley out of alignment.
2. Belts too tight or too loose.
1. Realign engine pulley.
2. Adjust belt tension.
Compressor runs hot. 1. Improper flywheel rotation
2. Defective compressor valves.
3. Dirty air filter.
4. Dirty cylinder and/or intercooler.
1. Check for correct rotation.
(Counter clockwise when viewed
from drive side.
2. Install new valve plate assembly.
3. Clean or replace.
4. Clean cylinder fins and/or intercooler.
Interstage pressure relief valve pops off. 1. Defective compressor valves. 1. Install new valves.
Excessive oil consumption. 1. Dirty air filter.
2. Wrong oil viscosity.
3. Oil leaks.
4. Worn piston rings.
5. Scored cylinder
1. Clean or replace.
2. Refill with proper viscosity oil.
3. Tighten bolts. Replace gaskets.
4. Replace rings.
5. Replace cylinder.
Air escapes from centrifugal unloader
when unit is running.
1. Centrifugal unloader release valve
dirty or defective
1. Clean or replace valve.
Air escapes from centrifugal unloader
when unit is stopped.
1. Check valve stuck in open position. 1. Replace check valve.
Warning – Relieve tank pressure
before servicing.

15
UNIT REPAIR PARTS ILLUSTRATION
MODELS: HGR3-3B, HGR5-3H, HDR5-3L & HDR5-3Y
REPAIR PARTS LIST
MODEL
HGR3-3B HGR5-3H HDR5-3L HDR5-3Y
1 Pump R15BHU R15BHU R15BHU R15BHU
2 Pressure Gauge M519C M519C M519C M519C
3 Belt Guard CQZ13160 Z5280 Z5280 Z5280
4 Drain Valve VP1022988 VP1022988 VP1022988 VP1022988
5 Check Valve P05822A P05822A P05822A P05822A
7 Pressure Relief Valve M2843 M2843 M2843 M2843
* 8 Vibration Isolators Z5123 Z5123 Z5123 Z5123
9 Engine 8 HP 11 HP 10 HP 10 HP
10 Tank P13706D P05182D CC1007178 P05182D
11 Isolation Valve M3590 M3590 M3590 M3590
12 Pilot valve M2853 M2853 M2853 M2853
VP1041597 P13197A P13197A
Pulley Pulley Pulley
P09799A P09799A P09799A
13 Pulley
Bushing
P07783A
Pulley
P09799A
Bushing Bushing Bushing
14 Belts B73 (2) 5L740 (2) 5L730 (2) 5L700 (2)
* Heavy Duty Vibration Isolators available as option. Part Number Z2808.
NOT SHOWN: ENGINE SLOWDOWN CONTROL P09795A (11 HP HONDA)
Z266 (10 HP DIESEL)
304CAE800-A
(Ref. Drawing)

16
UNIT REPAIR PARTS ILLUSTRATION
MODEL: HGR7-3K.
304CAE810-A (Ref. Drawing)

17
REPAIR PARTS LIST
MODEL: HGR7-3K
REF NO DESCRIPTION PART # QTY
1 R15BHU Z2409 1
2 Hex head cap screw M3460 4
3 Serrated flange hex nut M3483 4
4 Hex head cap screw M3465 1
5 Flat washer M3056 1
6 Compression fittin
g
86A40 1
7 Pilot valve M2853 1
8 Compression fitting, tee M2879 1
9 Polypropylene tubing P10117A 5.625 ft
10 Insert tube P10118A 6
11 Pipe nipple M1035B 1
12 Compression fitting M2398 1
13 Check valve P05822A 1
14 Discharge tube P10374B 1
15 Compression ferrule SE542 1
16 Compression hex nut SE541 1
- Belt Guard Kit (Includes Items 17 thru 22) Z5280 1
17 Thread rolling screw M1454 2
18 Serrated flange hex nut M3485 3
19 Belt guard bracket M855 1
20 Belt
g
uard bracket P05517A 1
21 Belt guard P09473D 1
22 Belt guard bracket P02525A 1
23 Hex head cap screw VP1071821 4
24 Assembly, 14hp Kohler engine (Includes Items 42 thru 54) CC1071049 1
25 Flat washe
r
M3055 8
27 Bushing-sheave 22F16SDS 1
28 Pulley P05008A 1
29 V belt 5L740 2
30 Ball Valve M3590 1
31 Air receive
r
P05182D 1
32 Close pipe nipple P08798A 2
33 Street elbow M980B 1
34 Ball Valve VP1022988 1
35 Serrated flange hex nut M3483 12
36 Mountin
g
foot P09179B 4
37 Vibration isolator P09180A 4
38 Pipe cross 64K1 1
39 Compression fitting 86A40 1
40 Safety valve M2843 1
41 Pressure
g
au
g
e M519C 1
42 Adaptor P11406A 1
43 Nipple M933B 1
44 Cap M473 1
45 Compression Fitting M3199 1
46 Nipple M3137 1
47 Locknut M2372 2
48 Throttle Bracket VP1070557 1
49 Washer M1740 1
50 Screw VP1071820 1
51 O-Rin
g
OR11 1
52 Piston P11392A 1
53 Cylinder M708 1
54 Spring M710 1
- Engine Slowdown Control (Includes Ref. No. 45-47, 51 – 54) CC1071047 1
Heavy Duty Vibration Isolators available as option. Part Number Z2808.

18
UNIT REPAIR PARTS ILLUSTRATION
MODELS: HGR5-6H, HGR5-8H, HDR5-8L, HDR5-8Y, HGR7-6K, & HGR7-8K.
305CAE800-A
(Ref. Drawing)

19
REPAIR PARTS LIST
MODELS: HGR5-6H, HGR5-8H, HDR5-8L, HDR5-8Y, HGR7-6K, & HGR7-8K.
MODEL
HGR5-6H HGR5-8H HDR5-8L HDR5-8Y HGR7-6K HGR7-8K
1 Pump R15BHU R15BHU R15BHU R15BHU R15BHU R15BHU
2 Pressure Gauge M519C M519C M519C M519C M519C M519C
3 Belt Guard Z5280 Z5280 Z5280 Z5280 Z5280 Z5280
4 Drain Valve VP1022988 VP1022988 VP1022988 VP1022988 VP1022988 VP1022988
5 Check Valve P05822A P05822A P05822A P05822A P05822A P05822A
7 Pressure Relief Valve M2843 M2843 M2843 M2843 M2843 M2843
8 Engine 11 HP 11 HP 10 HP 10 HP 14 HP 14 HP
9 Tank P01136D P01400D CC1007177 P01400D P01136D P01400D
10 Isolation Valve M3590 CQM3756 CQM3756 CQM3756 M3590 CQM3756
11 Pilot Valve M2853 M2853 M2853 M2853 M2853 M2853
P07783A P07783A P13197A P13197A P05008A P05008A
PULLEY PULLEY PULLEY PULLEY PULLEY PULLEY
P09799A P09799A P09799A P09799A 22F16SDS 22F16SDS
12 Pulley
BUSHING BUSHING BUSHING BUSHING BUSHING BUSHING
13 Belts 5L740 (2) 5L740 (2) 5L730 (2) 5L700 (2) 5L740 (2) 5L740 (2)
NOT SHOWN: ENGINE SLOWDOWN CONTROL CC1071047 (14 HP KOHLER)
P09795A (11 HP HONDA)
Z266 (10 HP DIESEL)

20
UNIT REPAIR PARTS ILLUSTRATION
MODELS: BGR5H, BDR5L, BDR5Y & BGR7K
REPAIR PARTS LIST
MODEL
BGR-5H BDR-5L BDR-5Y BGR-7K
1 Pump R15BHU R15BHU R15BHU R15BHU
2 Belt Guard Z5280 Z5280 Z5280 Z5280
3 Base Plate P13543C CC1007176 P13543C P13543C
4 Engine 11 HP 10 HP 10 HP 14 HP
5 Pilot Valve M2853 M2853 M2853 M2853
P07783A P13197A P13197A P05008A
Pulley Pulley Pulley Pulley
P09799A P09799A P09799A 22F16SDS
6 Pulley
Bushing Bushing Bushing Bushing
7 Belts 5L740 (2) 5L730 (2) 5L730 (2) 5L740 (2)
NOT SHOWN: ENGINE SLOWDOWN CONTROL CC1071047 (14 HP KOHLER)
P09795A (11 HP HONDA)
Z266 (10 HP DIESEL)
306CAE800-A
(Ref. Drawing)