Gardner Denver INTEGRA AIRSMART EFC99J Service manual

13-20-600
Version: 04
August 11, 2009
INTEGRA™
BASE-MOUNTED
COMPRESSORS
AIRSMART™ CONTROL
MODELS – EFC99J
20, 25, 30 HP
60 HZ
OPERATING AND
SERVICE MANUAL

13-20-600 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 airends. Most popular model remanufactured airends are
maintained in stock at the Remanufacturing Center in Indianapolis, IN., 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.
For the location of your local authorized Gardner Denver Air Compressor distributor, refer to the yellow pages of your
phone directory, check the Gardner Denver Web Site at www.gardnerdenver.com or contact:
Gardner Denver
1800 Gardner Expressway
Quincy, IL 62305
Phone: [phone]
Fax: [phone]
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL, Method of Cooling, HORSEPOWER and SERIAL NUMBER (see
nameplate on unit). The Airend 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.

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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

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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

13-18-601 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 could 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 before working on the control, wait 10 minutes
and check for voltage.
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.

13-18-601 Page 5
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
List Of Illustrations.........................................................................................................................................8
Section 1, General Information .....................................................................................................................9
Section 2, Installation..................................................................................................................................11
Section 3, Starting & Operating Procedures...............................................................................................18
Section 4, Controls & Instrumentation ........................................................................................................24
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator............................................................................51
Section 6, Air Filter......................................................................................................................................62
Section 7, Belt Drive....................................................................................................................................64
Section 8, Maintenance Schedule ..............................................................................................................67
Section 9, Troubleshooting .........................................................................................................................69
This book covers the following models:
HP PSI Air Cooled Parts List Controller Manual Communication
Module
20, 25 & 30 100, 125, 150, 175 EFC99J 13-20-500 13-17-600 13-17-604

13-18-601 Page 6
INDEX
Air Cooled Unit.................................................11
Air Filter
Element.........................................................62
Element Life..................................................63
Section 6.......................................................62
Standard Duty...............................................62
Air Flow In Compressor System ........................9
Air Receiver
Auxiliary........................................................14
Air/Oil Separators.............................................59
Belt Drive
Checking Belt Tension..................................65
Replacing Belts.............................................64
Replacing Compressor Sheave....................65
Section 7.......................................................64
Cold Ambient Operation...................................52
Cold Weather
Installation ....................................................14
Compression Principle.......................................9
Compressor........................................................9
Controls & Instrumentation
Airsmart Operation .......................................24
Control Devices............................................25
General Description......................................24
Section 4.......................................................24
Cooler
Compressor Oil.............................................59
Cooling, Sealing And Lubrication.......................9
Daily Check......................................................21
Discharge Service Line....................................15
Electrical Wiring ...............................................15
Enclosure .........................................................13
Foundation .......................................................12
General Information
Section 1.........................................................9
Grounding.........................................................16
High Temperature Operation ...........................52
Inlet Line...........................................................14
Installation
Cold Weather................................................14
General.........................................................11
Section 2.......................................................11
Lifting Unit ........................................................11
Location............................................................11
Lubricant
Recommended.............................................51
Upgrade Procedure......................................55
Lubrication
Motor............................................................16
Lubrication, Cooling And Sealing.......................9
Lubrication, Oil Cooler, Oil Filter & Separator
Section 5 ......................................................51
Maintenance Schedule
Section 8 ......................................................67
Moisture Separator/Trap
Optional........................................................14
Motor Lubrication.............................................16
Oil Cooler
Compressor..................................................59
Oil Filter............................................................57
Oil Level
Gauge...........................................................57
Procedure For Checking..............................52
Oil Reservoir....................................................59
Drain.............................................................12
Filling............................................................54
Oil Separator
Inspection.....................................................60
Removal For Inspection Or Replacement....60
Oil Specifications .............................................51
Oil System
Addition Of Oil Between Changes................52
Compressor..................................................51
Draining And Cleaning.................................54
Moisture........................................................57
Oil Change Interval ......................................53
Oil System Check ............................................61
Air And Oil Discharge Temperature.............61
Compressor Oil Inlet Temperature...............61
Oil Cooler Oil Pressure Differential..............61
Oil Cooler Temperature Differential.............61
Oil Inlet Pressure..........................................61
Piping
Control..........................................................14
Pressure Differential Gauging..........................59
Prestart-Up Instructions...................................18
Air Filter........................................................18
Compressor Oil ............................................18
Electrical.......................................................18
Enclosure .....................................................20
Grounding.....................................................18
Operating Mode............................................19
Piping ...........................................................18
Rotation........................................................19
System Pressure..........................................19
Quick Start Guide.............................................22

13-18-601 Page 7
Safety Precautions.............................................4
Sealing, Lubrication And Cleaning.....................9
Separators
Air/Oil............................................................59
Service Check List ...........................................67
Air Filter ........................................................67
Every 1000 Hours Operation........................67
Every 125 Hours Operation..........................67
Every 4000 Hours Operation........................67
Every 8 Hours Operation..............................67
Every Year....................................................67
Motor Lubrication..........................................67
Sheave Alignment............................................64
Starting & Operating Procedures
Section 3.......................................................18
Starting The Unit..............................................20
Unit Cold.......................................................20
Unit Hot ........................................................21
Stopping The Unit............................................21
Trouble Shooting
Section 9 ......................................................69
Troubleshooting Voltage Problems..................72
Valve
Thermal Control (Thermostatic Mixing)........59
Warning – Prohibition – Mandatory Label
Information .....................................................2
Wiring
Electrical.......................................................15

13-18-601 Page 8
LIST OF ILLUSTRATIONS
Figure 1-1 – Compressor Cycle....................................................................................................................9
Figure 1-2 – Compressor Illustration...........................................................................................................10
Figure 2-1 – Typical Compressor Room.....................................................................................................12
Figure 2-2 – Air Flow Chart.........................................................................................................................12
Figure 2-3 – Cold Weather Installation .......................................................................................................13
Figure 4-1 – Control Schematic ..................................................................................................................24
Figure 4-2 – Key Pad..................................................................................................................................25
Figure 4-3 – Wiring Diagram – Wye Delta 20, 25 & 30 HP (200 & 460 Volt) .............................................29
Figure 4-4 – Wiring Diagram – Wye Delta 20, 25 & 30 HP (230 Volt)........................................................31
Figure 4-5 – Wiring Diagram – Full Voltage 20, 25 & 30 HP (460 Volt) .....................................................33
Figure 4-6 – Wiring Diagram – Full Voltage 20, 25 & 30 HP (200 Volt) .....................................................35
Figure 4-7 – Wiring Diagram – Full Volt - 20 HP (230 Volt)........................................................................37
Figure 4-8 – Wiring Diagram - Full Voltage 25 & 30 HP (230 Volt) ............................................................39
Figure 4-9 – Wiring Diagram – Less Starter (200 & 460 Volt)....................................................................41
Figure 4-10 – Wiring Diagram – Less Starter (230 Volt).............................................................................43
Figure 4-11 – Wiring Diagram – Wye Delta (575 Volt) ...............................................................................45
Figure 4-12 – Wiring Diagram – Full Voltage (575 Volt).............................................................................47
Figure 4-13 – Wiring Diagram – Less Starter (575 Volt).............................................................................49
Figure 5-1 – Flow Diagram..........................................................................................................................51
Figure 5-2 – Approximate Oil System Capacities.......................................................................................53
Figure 5-3 – Oil Change Interval.................................................................................................................53
Figure 5-4 – Oil Level Gauge, Oil Fill And Oil Drain...................................................................................57
Figure 5-5 – Oil Filter ..................................................................................................................................58
Figure 5 6 – Oil Separator...........................................................................................................................61
Figure 6-1 – Air Filter ..................................................................................................................................62
Figure 7-1 – Belt Tension – J Section Micro-V Belts ..................................................................................66

13-20-600 Page 9
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
roller bearings located outside the compression chamber. Single width cylindrical roller bearings are
used at the inlet end of the rotors to carry part of the radial loads. 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 (4) helical lobes 90°apart.
The secondary rotor has five (5) matching helical grooves 72°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.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 5-1, page 51) - 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 aftercooler 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.

13-20-600 Page 10
Figure 1-2 – COMPRESSOR ILLUSTRATION
302EFC797-B
(Ref. Drawing)

13-20-600 Page 11
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 12) - The compressor should 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.
AIR-COOLED UNIT - A combination oil/aftercooler is supplied as standard equipment on all air-cooled
units. The air-cooled unit with the standard enclosure requires sufficient flow for the compressor
oil/aftercooling system and electric motor cooling (Figure 1-2, page 10). Air is drawn into the unit above
the motor and discharged through the cooler. 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.

13-20-600 Page 12
For continuous efficiency, oil 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. N
N
NO
O
OT
T
TI
I
IC
C
CE
E
E
For aluminum oil coolers, 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
All Models 3000 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. Temporary installation may be
made at a maximum 5°angle lengthwise or 5°sidewise. 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, see SECTION 7, page 64.
OIL RESERVOIR DRAIN - The oil drain is piped from the bottom of the reservoir to the side of the frame.
This drain is approximately 20 inches above the floor level.

13-20-600 Page 13
If the compressor unit base is raised above floor level, the space between the
floor and the base bottom must be closed with solid material all around to
prevent recirculation of hot air from the oil cooler end and over temperature
operation.
ENCLOSURE - The compressor, electric motor, oil cooler and aftercooler 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

13-20-600 Page 14
INSTALLATION FOR COLD WEATHER OPERATION (Figure 2-3, page 13) - 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 an outside installation must be made, the precautions required will depend on the severity of the
environment. The following are general guidelines for outside installations:
Cold Weather (Down To +10oF)
1. Be sure all drains, traps, and control lines, including pressure transducer lines are heated to avoid
freezing of condensate. Heat tape with thermostat control is generally satisfactory for this purpose
and can be obtained at various local plumbing or hardware outlets at nominal cost.
2. Provisions to bypass the aftercooler must be made. Since cold air contains very little moisture,
successful operation can be achieved without the aftercooler.
3. Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow.
4. Use only Gardner Denver AEON 9000SP lubricant.
5. Monitor unit carefully during start-up and operation to be sure it is functioning normally.
Remember unsheltered (outside) installations should be avoided where possible. Installation next to a
heated building where enough heat can be used to keep the compressor room above freezing will save
many complications in the operation and installation of the unit.
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
STANDARD MOISTURE SEPARATOR/TRAP - The unit is equipped with a built-in aftercooler, a
combination moisture separator and trap piped into the system down stream of the aftercooler.
CONTROL PIPING - Control piping is not necessary since the rotary screw unit is factory wired and piped
for the control system specified.
INLET LINE - Where an inlet line is used between the air filter and the compressor, it must be thoroughly
cleaned on the inside to prevent dirt or scale from entering the compressor. If welded construction is
used, the line must be shot blasted and cleaned to remove welding scale. In either case, the inlet
line must be coated internally by galvanizing or painting with a moisture and oil-proof sealing lacquer. Up
to ten (10) feet in length, the inlet line should be the full size of the inlet opening on the compressor. If an
extra-long line is necessary, the pipe size should be increased according to “Inlet Line Length Chart”,
page 15.
Accessibility for inlet air filter servicing must be considered when relocating the filters from the unit to a
remote location.

13-20-600 Page 15
INLET LINE LENGTHS
Length of Inlet Line Diameter of Pipe Size
0 to 10 Feet............................................. Same as Compressor Inlet Opening
10 to 17 Feet........................................... One Size Larger Than Inlet Opening
17 to 38 Feet........................................... Two Sizes Larger Than Inlet Opening
DISCHARGE SERVICE LINE - The discharge service line connection is made at the left hand corner of
the package when viewed from the control box end. A hand operated valve, (air service 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.
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.
When manifolding two or more rotary screw units on the same line, each unit is isolated by the check
valve in the unit discharge line.
If a rotary screw unit is manifolded to another compressor, be sure the other compressor has a check
valve in the line between the machine and the manifold.
If a rotary screw and a reciprocating compressor are manifolded together, 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 open drip proof motors and a UL/NEMA Type 4 starter and controls enclosure. Totally
enclosed motors are available as factory options. See “Location” paragraph on page 11, for distance to
the nearest obstruction on the control box side of the package.
The overload settings are to be selected based on motor nameplate full load amperage.
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.

13-20-600 Page 16
Electrical shock can cause injury or death. Open main disconnect switch,
lockout and tagout before working on control box.
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. The following charts show recommended grease qualities and
regreasing intervals for ball bearing motors. For additional information, refer to the motor manufacturer’s
instructions.
The following procedure should be used in regreasing:
1. Stop the unit.
2. Disconnect, lockout and tagout the unit from the power supply.
3. Remove the relief plug and free hole of hardened grease.
4. Wipe lubrication fitting clean and add grease with a hand-operated grease gun.
5. Leave the relief plug temporarily off. Reconnect unit and run for about 20 minutes to expel the
excess grease.
6. Stop the unit. Replace the relief plug.
7. Restart the unit.
Rotating machinery can cause injury or death. Open main disconnect, lockout
and tagout power supply to starter before working on the electric motor.

13-20-600 Page 17
ELECTRIC MOTOR GREASE RECOMMENDATIONS (-30°TO 50°C)
MANUFACTURER TRADE NAME
CHEVRON SRI #2
SHELL DOLIUM R
EXXON UNIREX #2
EXXON POLYREX
ELECTRIC MOTOR REGREASING INTERVAL
Type of
Service Typical Rating Relubrication Interval
Up to 150 HP (112 KW) 18 Months
Standard One or Two Shift Operation Above 150 HP (112 KW) 12 Months
Up to 150 HP (112 KW) 9 Months
Severe Continuous Operation Above 150 HP (112 KW) 6 Months
Up to 150 HP (112 KW) 4 Months
Very Severe Dirty Locations, High Ambient
Temperature Above 150 HP (112 KW) 2 Months

13-20-600 Page 18
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 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 “Compressor Oil Filter”,
SECTION 5, page 51.
Do not mix different type oils. Unit is shipped filled with Gardner Denver AEON 4000 Lubricating
Coolant which is suitable for the first 4000 hours under normal operating conditions. AEON 9000SP
is also available. Check the decal on the reservoir to be sure which lubricant is in the machine.
REPLACE OIL FILTER EVERY 1000 HOURS.
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.
2. Air Filter - Inspect the air filter to be sure it is clean and tightly assembled. Refer to SECTION 6,
page 62 for complete servicing instructions. Be sure the inlet line, if used, is tight and clean.
3. Piping – Refer SECTION 2, page 15 “Discharge Service Line” and make sure all piping meets all
recommendations.
4. Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See
Figure 4-3 thru Figure 4-13, pages 29 thru 49, for general wiring diagrams and SECTION 2, page 15,
for “Electrical Wiring”.
5. Grounding - Unit must be properly grounded according to Section 250 of the National Electrical
Code.

13-20-600 Page 19
Failure to properly ground the compressor package could result in controller
malfunction.
Failure to properly ground the compressor package could result in controller
malfunction.
6. Rotation - Check for correct motor rotation by jogging the motor. See “Unit Setup Adjust Menu” in
Controller Operating and Service Manual. Compressor drive shaft rotation must be
counterclockwise, standing facing the compressor sheave.
Operation with incorrect motor rotation can damage equipment and cause oil
eruption from the compressor inlet. When checking motor rotation, induce
minimum rotation (less than one revolution if possible). Never allow motor to
reach full speed.
The compressor unit’s direction of rotation must be check every time the
compressor is reconnected to the power supply.
7. System Pressure - The discharge pressure of the unit is set at the factory. To change the
discharge pressure, set the controls to the desired load pressure. DO NOT EXCEED THE
MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE. See "Operation
Adjustments Menu" in Controller Operating and Service Manual.
Operation at excessive discharge air pressure can cause personal injury or
damage to equipment. Do not adjust the full discharge air pressure above the
maximum stamped on the unit nameplate.
8. Operating Mode - Refer to SECTION 4, page 24 for detailed information on the control system.