Honeywell WP241 Series Mounting instructions

WP241 DUAL
AIR COMPRESSORS
Subject TABLE OF CONTENTS
Page
GENERAL ..................................................................... 2
SPECIFICATIONS ............................................................... 2
APPLICATION .................................................................. 2
OPERATION ................................................................... 2
MAINTENANCE..............................................................
.......... 3
Maintenance Schedule ....................................................... 3
Lubrication .................................................................. 3
DrainingTank ................................................................. 4
Air Intake Filter ............................................................... 4
Filter Cartridge (at PRV) ......................................................... 4
Safety Relief Valves. ............................................................ 4
Belts (SeeFig.2). .. .......................................................... 4
Pressures .................................................................. 5
Wiring Options ............................................................... 5
Operational Check. 6
.........................................
TROUBLESHOOTING ............................................................ 7
Wrong Oil Pressure, ......................................................... 7
Oil Pressure Adjustment (See Fig. 6).
.................................................
Oil Leaks ....................................................................
7
7
Excessive Oil Consumption ....................................................... 8
Noisy Pump ................................................................. 8
Noisy Motor .................................................................. 8
Noise Not Locatable ............................................................ 8
Chart 1-Motor Won’t Start. ....................................................... 9
Chart 2-Circuit Breaker Trips (Fuse Opens), ............................................ 10
Chart 3-Won’t Pump Air-Runs, but Tank Shows No Pressure Build-Up .......................... 11
Chart 4 -Won’t Pump Air-Builds Up Slowly, or Not Complete ................................
12
Chart S-Won’t Pump Air-Pump Slows, Stalls, or Trips Circuit Breaker (Fuse Opens) ................... 13
Excessive Vibration ............................................................. 13
REPAIR ...................................................................... 14
Pump Removal and Replacement ..........
Oil Pump Replacement. ................
Belt Replacement ...
.
................
Motor Replacement. ..................
Intake and Exhaust Valves, Unloader .......
Pressure Regulating Valve (PRV) Station .....
......
......
. . . . . . . . . . . . . . . . . . . . . . . . . 14
.................................. 14
..................................
15
..................................
16
.................................. 15
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16
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......
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......... .........
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17
. . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . 17
......................
18
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19
Rev. 4-80

GENERAL
This sheet contains maintenance and repair informa-
tion for the WP241 series air compressors. The WP241
Dual Air Compressor has two electric motor-driven pumps
mounted on a common storage tank, allowing automatic
alternating operation with standby capability.
SPECIFB IONS
PRESSURE RANGE: Cut-in pressure-70 lb/in2(483
kPa), Cut-out pressure -90
lb/in2 (621 kPa). MAXIMUM AMBIENT TEMPERATURE: 104
F (57 C).
TANK CAPACITY: 30, 80, or 200 gallons (114,303, or
757 R).
Table 1. WP241 Dual Air Compressor Specifications.
-~
Compressor WP241YWP241B WP241C WP241D WP241E WP241F WP241G WP241H WP241J
No. of Cylinders 11 11222222
RPM Compressor 500 410 460 480 460 400 570 550
610
~-
Displacementft3/min (l/min) 11.6 (45) 2.9 0(82) 4.7 (13.3) 5.4 (153) 5.9 (269) 13.3 (377) 16.0 (453) 24.3 (688) 40.0 (1l33)
Delivery ft3/min. (l/min)
at 70 to 90 lb/in2 1.1 (31)
1.9 (54) 3.3 (93) 3.8 (108) 5.9 (167) 8.6 (144 12.6 (357) 19.3 (547) 30.0 (849)
(483 to 621kPa) One unit only
Tank Size Gal (l)30 (114) 80 (303) 80 (303) 80 (303) 80 (303) 80 (303) 80 (303) 700 (757) 200 (757)
Intake Size NPT-Compressor 1/4 3/4 3/4 1/2 3/4 1-1/4 11-1/2 2
Outlet Size-NPT-Compressor 1/4 3/4 3/4 1/2 3/4 1-1/4 3/4 1-1/4 1-1/4
___-
Flywheel O.D. (in.) 10 14 14 12 14 16 16 19.5 19.5
-
Motor Pulley Pitch Dia. (in.) 2.8 3.2 3.6 3.2 3.6 3.6 5.1 6.0 6.6
Safety Valve-Receiver-NPT 11/4 1/4 1/4 1/4 1/4 1/2 1/2 1/2 1/2
Crankcase Oil Capacity 4 oz (118 ml) 28 oz. (828 ml) 28 oz (828 ml) 22 oz (651 ml) 48 oz (1.4l) 2 qt (1.4l) 2 qt (1.9l)6 qt (5.7l)6 qt (5.7l)
Lubrication System Splash Pressure Pump
WP241Y
1/3 (0.25)
115/60/1
-48
WP241B
1/2 (0.37)
208/60/3/60/3
-56
WP241C
3/4 (0.56)
230/60/3
-56
WP241D
1(0.75)
460/60/3
-143T
WP241E WP241F WP241G WP241H WP241J
1-1/4 (1.12) 2 (1.49) 3 (2.24) 5 (3.73) 7-1/2 (5.60)
208/60/3 230/60/3 460/60/3 460/60/3 460/60/3
-145T -145T -182P -184T t-213T
APPLICATION
The WP241 Dual Air Compressors are used where
continual operation is a necessity. The motors are inter- maintenance, or be unable to maintain minimum storage
connected to operate on alternate cycles with standby tank pressure, the other motor provides backup by
start-
capability. Should one motor fail, be shut down for ing automatically.
OPERATION
Air is drawn through the intake filter of the operating
motor-pump unit(s), compressed, and stored in the tank.
As the control system consumes air, the tank pressure
drops. When tank pressure drops to 70
lb/in2 (480 kPa),
the motor energizes operating the compressor pump,
which restores tank pressure to 90 lb/in2(620 kPa). When
tank pressure increases to 90 lb/in2 (620 kPa), a pressure
switch stops the motor.
75-7268
2

MAINTENANCE SCHEDULE
WEEKLY
1. Check oil level and pressure on 1 hp (0.75
kW) and
larger compressors. See LUBRICATION paragraph.
2. Drain water from tank or check automatic drain
operation. See DRAINING TANK paragraph.
3. Check tank and pressure relief valve (prv) pressure.
See PRESSURES paragraph.
4. Observe operation to confirm that pumps build up to
cut-off pressure and shut off. See OPERATIONAL
CHECK paragraph.
EVERY THREE MONTHS
1. Change oil. See LUBRICATION paragraph.
2. Check intake filters. See AIR INTAKE FILTER para-
graph.
3. Drain water from tank and filter bowls. See DRAIN-
ING TANK paragraph.
4. Check tension and condition of belts. See BELTS
paragraph.
5.
Check sequential operation. See OPERATIONAL
CHECK paragraph.
6. Check safety relief valves. See SAFETY RELIEF
VALVES paragraph.
7. Check filter cartridge on 7-l/2
hp (5.6 kW) only. See
FILTER CARTRIDGE paragraph.
EVERY YEAR
1.
*Change intake filters. See AIR INTAKE FILTER
paragraph.
2. *Change
prv filter on 7-l/2 hp (5.6 kW) only. See
FILTER CARTRIDGE paragraph,
3. Service motors. See LUBRICATION paragraph.
*Dirty operating environment may require changing these
items more often. The three-month checks will uncover
any need for more frequent replacement.
LUBRICATION
Quincy units use splash lubrication on the 1/3 to 3/4
hp (0.25 to 0.56
kW) units and pressurized lubrication
on 1 hp to 7-l/2 hp (0.75 to 5.6
kW) units, Stop both
pumps, remove and wipe off dipsticks; reinsert dipsticks;
remove again and read. If necessary, add oil through dip-
stick port. Use oil in accordance with Table 1. A high
quality, nondetergent automotive oil is satisfactory
(Table 2).
On
1-hp (0.75 kW) units and larger, in addition to
checking oil level, check the oil pressure gage. Gage read-
ing should be in the 10 to 20 lb/in2 (70 to 140 kPa)
range.
Recommended operating pressure is 15 lb/in2
(100 kPa).
To change oil, stop both units.
WARNING
Personal injury could result from starting a unit
not containing oil.
Remove the drain plug and dipstick and allow oil to
drain completely. Ordinarily, a crankcase need not be
flushed. If flushing seems necessary, use a nonflammable
solvent (available at most auto parts stores). Replace
plug and refill according to Table 2. DO NOT OVER-
FILL! Overfilling causes excessive oil consumption and
contamination of the compressed air.
Lubricate the motor annually in accordance with
instruction on nameplate.
Table 2. Compressor Oil Requirements.
3
75-7268

To drain tank, open drain cock, located in the middle
of the tank at one end. Allow a few seconds to purge the
tank
of water. Weekly draining is usually the minimum
requirement.
NOTE. The frequency of draining depends on climatic
conditions. In humid climates, daily draining
may be necessary.
Consider adding the Honeywell AK3485 automatic
drain kit.
Visually check the air intake filter on l/3- to 2-hp
(0.25 to 1.49 kW) compressors for build-up of foreign
material on a routine basis. A dirty filter causes excessive
oil consumption, replace it.
The
3-hp (2.24 kW) and larger units use the Quincy
Air Maze
filter silencer, which is checked for dirt by
removing it from the unit and holding a strong light
against the intake openings. Light should be visible when
observing from the inside of the filter. ash the filter
in
nonflammable solvent or in warm, soapy water.
Check filter element condition by comparing tank
pressure to line pressure downstream from filter. If one
doesn’t exist, a gage tap may have to be installed in the
line to read the pressure. The pressure difference should
not exceed 15
lb/in2 (100 kPa) at any time. Filter ele-
ment should be replaced if the difference in pressure is
approaching this limit. Subtract the line pressure reading
from the tank pressure. The difference should not exceed
15
lb/in2 (100 kPa).
Allowing system pressure to drop to zero during
replacement of element or gage tap installation
will
cause all actuators in the system to assume
stem drawings for
To change a filter in the 7-l/2 hp (5.6 k
to Fig.
1. Shut off air to filter at point (A) and bleed
down housing by manually operating drain trap (B).
Remove wing nut and clamp ring (C) from housing and
remove housing and automatic drain. Remove knurled
nut at bottom of filter and replace filter. Reassemble,
taking care that O-ring seal on bottom side of cover has
not been disturbed. Turn on air slowly, checking for
leaks.
6275
-1/2 HP (5.60 kW) Fig. 1. Changing Filter Cartridge on 7
Units.
Safety relief valves are factory set to approximately
15 lb/in2(100
kPa) higher than the rated pressure of the
compressor. Check each safety relief valve by pulling on
the ring to unseat it. Replace
or repair malfunctioning
valves immediately. Safety relief’ valves are located next
to the pressure switch or on the tank.
.
Hand pressure should depress the belt about 1/2 inch
(13 mm). Tighten the belt just enough to prevent slippage.
Adjust tension by loosening the motor hold-down bolts,
moving the motor until tension is correct, then retighten
the bolts. Insure that belt and pulleys are aligned. Replace
worn or frayed belts.
HAND PRESSUR
PUMP 1/2” (13mm) APPROXIMATE
FLYWHEEL
Fig. 2. Checking Belt Tension.
4
7.5-7268

II5VAC 60HZ
PRESSURES
During weekly checks, verify that the tank pressure is
in the 70 to 90 lb/in2 (480 to 620 kPa) range and each
prv pressure is at the proper setting.
WIRING OPTiONS
Dual Compressors usually have automatic alternation
between pumps after each pump cycle, and with auto-
matic backup. See wiring options shown in Fig. 3,4 and
* SET PS-2 5-10 lb/in*
(35-70 kPd
BELOW
CUT-IN PRESSURE
6278- 1
Fig. 4. Automatic Alternation with Automatic Backup.
For Single-Phase Internally Protected Motors
Ody .
FUSES. FUSED DISCONNECT, OR CIRCUIT BREAKER
I+ IF SPiClFlED
----a
-----
---0 -----
__----
r-
PRESSURE SWITCHES
7
: ji
III
i
---
r-- M2
1
I*I Qs /
3
COMP
#I
L-4 ITI ’
--I*
IL2
IL----&’
L-------i
COMP
MOTOR
*2
STARTER
6277-l
Fig. 3. Automatic Alternation with Automatic Backup. Three-Phase Motor with Low Voltage Control.
75-7268
5

j+.- 115VAC 60HZ -1
r----7
PRESSURE
SWITCH I
ALTERNATOR I
COMP+rl
1SWITCH If------- _-i-
--L--L-.
PRESSURE
SWITCH STARTER
COMP*2
*SET PS-2 AND PS-3 TO OPERATE IN SEQUENCE, ABOUT 5-10
LB/IN2 (35-70 kPa)
BELOW CUT-IN PRESSURE POINT OF PSl.
6279-l
Fig. 5. Automatic Alternation with Backup and 11 SV Isolated Control of Three-Phase Motors.
OPERATIONAL CHECK
It is sufficient to confirm that both compressor pumps
have an off cycle and are not running continuously.
Switch over the manual alternation system or bleed air
from tank on automatic alternation system to confirm
startup and off cycle of both pumps.
Measure the cut-in pressure, pump-up time, cut-out
pressure, and off time under normal operating conditions.
Pump-up time should be below 50 percent operation
(less on time than off time) and operate between 70 to
90 lb/in2 (480 to 620 kPa) pressure. Check operation of
each pump using manual switch over if necessary.
Record these figures for reference (a card attached to
the unit is handy). Decreasing off periods (with no change
in pressure range) indicate an increase in air consumption
with an increasing pump-up time. This could be due to
75-7268
6
added devices or leaks. Increasing pump-up time with no
change in pressure range or off time indicates wear in the
compressor pump and may warrant closer observation as
it is usually followed by an increase in oil consumption.
Check backup operation by operating the safety relief
valve (see SAFETY RELIEF VALVE paragraph). The
second pump should cut in after the tank pressure has
dropped 5 to 10 lb/in2 (35 to 70 kPa) below cut-in
pressure for the first unit.
If wear is suspected, check the dead-ended pump-up
time (pumping up tank with the system off) against the
value given in Table 3. If this time differs from the table
by more than 10 percent, troubleshoot according to
instructions given under WON’T PUMP AIR paragraph,
and take proper action.

TROUBLESHOOTING
This section aids isolation of most common problems
and pinpoints causes. Notify Honeywell Applications
Engineering (Arlington Heights) of any other problems
frequently encountered.
WRONG OIL PRESSURE
IHP (0.75 kw) AND UP
Oil pressure in the 10 to 20 lb/in2 (70 to 140 kPa)
range is normal. The recommended operating pressure is
15 lb/in2 (100 kPa). There should be no pressure during
the off cycle.
OIL PRESSURE ADJUSTMENT
(See Fig. 6)
Check oil level before adjusting pressure The oil
pressure is regulated by a spring-loaded ball mounted in
the bearing carrier on the same side as the dipstick,
Loosen the adjustment lock nut before making any
adjustment. Turn the pressure adjusting screw slowly
clockwise (pressure increases) until the oil gage registers
approximately 15 lb/in2 (100 kPa). After adjustment,
tighten adjustment screw lock nut.
DIPSTICK 01 L PRESSURE ROTATION OF FLYWHEEL
xE -) ~~~~i%JR:fii’%TS
/
I
DRAIN PLUG
OIL INTAKE FILTER (I TO 3 HP ONLY)
MAY BE REMOVED FOR CLEANING
AND INSPECTION OF CRANKCASE
ACCUMULATION
6280
Fig. 6. Crankcase End View of l-HP (0.75 kW) Model.
If oil pressure is low, check oil pump(s) and pressure
gage(s) by unscrewing the pressure gage(s) slowly until
oil seeps out around the threads during compressor(s)
operation. This indicates that oil pressure is reaching the
system and the pressure gage(s). The pumps require oil
pressure to operate intake valve unloaders and for lubri-
cation. Lack of pumping ability indicates possible loss of
oil pressure. If oil appears at the threads of the gage and
the oil pressure gage indicates no pressure, replace the oil
pressure gage. No oil appearing at the threads of the oil
gage indicates possible oil pump failure (see OIL PUMP
REPLACEMENT paragraph in the REPAIR section),
NOTE: A clogged oil intake filter will cause restricted
oil flow in the loop system and no air pressure
in the system. Clean or replace filter as neces-
sary.
In cases of low (not zero) pressure, the cause may be
excessive wear in the pumping unit or a gage not in calibra-
tion. Check the pump-up time against Table 3 and listen
for unusual knocks indicating worn bearings. If pump up
time is normal and no unusual noises are detected, recali-
brate or replace the gage.
Table 3. Pump Up Time in Min:Sec.
WP241H 8:45 2:lS
WP241J 5:45 1:30
OIL LEAKS
Oil leaks usually occur around screws and gaskets.
These are normally corrected by tightening screws or
replacing gaskets.
If unable to locate the source of the leak, clean the
unit as much as possible and sprinkle the suspected area
with talcum powder (avoid getting powder into intake).
After several hours, check powder to locate leak.
75-7268

Excessive oil on the after cooler pipe or compressor
head usually indicates air leakage. Locate air leaks with
soap solution while the compressor is operating. While
the compressor is in the off cycle, check the unloaders
under pressure.
XCESSSV NSUAA
Excessive oil consumption is a difficult problem.
Before repair, take the following steps:
a. Confirm the Complaint-Oil at the tank drain does
not necessarily indicate high oil consumption.
Table 4 shows acceptable oil consumption in terms
of fill amount and time between refills.
Oil capacity in crankcase between high and low
Days running time between high and low dipstick
levels, based on three oz oil per 100,00C1 ft3 air used
(31 ml oil per Ml air used) and 50 percent maxi-
mum duty cycle. Does not allow for spillage or
leakage.
b. Make certain proper grade of nondetergent oil is
being used (see Table 2) and compressors are not
being overfilled. Overfilling always causes high oil
consumption. Oil level should never be above the
high mark on the dipstick.
c. Check for leaks.
d. Check intake filter/piping and crankcase breather
valve(s) for cleanliness and obstruction.
e. Check for excessive oil pressure or high percent
operation (see LUBRICATION and PRESSURE
paragraphs in MAINTENANCE section). If, after
performing the above, a unit is still considered an
oil consumer with no apparent external cause, then:
f. Check pump-up and cycle pressures against the
values in Table 3. Differences greater than 10 per-
cent indicate worn parts (see WON’T PUMP AIR
paragraph).
g. Remove valves and examine piston top for oil. Oil
wetting is acceptable, but an accumulation of oil
indicates a defective pump.
The most common reason for a noisy pump is a loose
flywheel or motor pulley. Check for these first, then
check:
Oil pressure-If low, check pump as described in
WRONG OIL PRESSURE paragraph. Lack of oil
pressure may have caused bearing damage.
Valve assemblies -Make certain they are tight.
Wrist pin OY connecting rod bearings-Stop pump
and remove belts. Using the flywheel, rotate pump
back and forth about two inches (5 1 mm). If knock
is heard, a bad wrist pin or connecting rod bushing
probably exists. Inspect the rod bushings by
removing side plate and rod caps or remove head
and observe piston while rocking flywheel. Piston
should follow movement without play (except at
top and bottom dead center where piston appears
to hesitate). Inspect cylinder and head for carbon
build-up.
Bad main bearings-Check for end play by attempt-
ing to move flywheel in different directions. Listen
and feel for any play. End play on the crankshaft
is usually eliminated by removing one of the shims
beneath the bearing housing adjustment plate. A
slight drag, when turned by hand, is proper,
Check for a loose motor pulley. A low-pitch growl is
an indication of low voltage.
If noise is slight, lubricate motor in accordance with
instructions on nameplate. Noise should disappear so
motor runs properly. Watch for dry bearings, as these
shorten motor life. To check bearings, stop motor,
remove belt and check for side play in motor shaft. Turn
motor by hand. Any side play or noise is an indication
of bad bearings. If bearings are bad, replace motor. End
play (movement or motor shaft in and out) is common
in this type of motor and is not an indication of wear.
Use a large screwdriver or similar implement. Place
the point end against suspected areas and the other against
the ear. Listen for abnormalities.
75-7268
8

r‘--p WARNING ~1
valve. (Larger units do not have a check valve.) Dis-
Before using listening rod near spinning flywheel, assemble the check valve and inspect. If cleaning does
belts, etc, determine if it is long enough to avoid
not stop the noise, replace check valve.
moving parts.
I
Another noise which is not easily traceable is a
In the l/2 and l/3 hp (0.37 and 0.25 kW) a noise vibrating guard. Check the belt guard by applying hand
which cannot be traced to the pump is usually the check pressure to outside surfaces at different points.
CHART l-MOTOR WON’T START
CHECK CIRCUIT
BREAKER OR FUSE
CHECK PRESSURE
SWITCH,
TRACE WIRING
TO FIND FAULT
DISCONNECT POWER,
COOL MOTOR
RECONNECT POWER
NO
*
+ REPLACE
MOTOR
c
A
REPLACE CAPACITOR,
STARTING SWITCH,
OR MOTOR
I
*ON l-HP (0.75 kW) OR SMALLER MOTORS, THERMAL OVERLOAD PROTECTORS MAY SHUT
MOTOR OFF AFTER A SHORT PERIOD OF TIME. I1033
9
75-7268

CHART 2-CIRCUIT BREAKER TRIPS (FUSE OPENS)
START
0
1YES
SEE
TROUBLESHOOTING
CHART 5
YES
,
-\
SEE
TROUBLESHOOTING 4
NO
PROPERLY
CHART 1
4 .
DISCONNECT POWER,
REINSTALL BELTS,
PLUG INTAKE (BY HAND),
RECONNECT POWER
SEE
TROUBLESHOOTING
t CHART 5 A
YES
*GROWL IS LOW VOLTAGE CLUE. I
I034
75-7268
10

CHART 3-WON’T PUMP AIR
- RUNS, BUT TANK SHOWS NO PRESSURE BUILD-UP
START
9
ISOLATE BUILDING
Al R SUPPLY
NO
TURN UNIT ON REPLACE
+ LOOK FOR AIR LEAK
BETWEEN PUMP AND
OUTLET VALVE*
jYES YES
4
DISASSEMBLE
AND INSPECT
VALVES
c
,
REPAIR AS NEEDED,
SEE “PARTS LIST”
*CRACKED DISCHARGE TUBE, TANK, OPEN VALVE, ETC.
11035
11 7.5-7268

CHART4-BUILDS UP SLOWLY, OR NOT COMPLETE
,
ISOLATE
BUILDING AIR
SUPPLY
.*
1
UP IIM
1/3 & l/2 HP
(0.25 /0.37 kW)
REMOVE DlSCtHARGE
TUBE, HAND BLOCK
n I- CI _I.
REPAIR 1
3/4 HP (0.56 kW) &UP
1
LOOK FOR AIR
LEAK BETWEEN
PUMP AND
OUTLET VALVE*
*CRACKED DISCHARGE TUBE, TANK, OPEN VALVE, E
TC.
ZIPPER LINE
I\ IHM~ VALVES
I
SHUT OFF UNIT,
DISCONNECT COPPER LINE
LREMOVE COVER BOLTS &
COVER (TAP WITH BLUNT
INSTRUMENT TO LOOSEN)
1
SLOWLY DEPRESS PISTON
TO FEEL RESISTANCE OF
LRETURN SPRING AND
PISTON CONTACTING VALVE
REMOVE PISTON
CUP AND CLEAN
L
UNDERNEATH
NO
NORMAL
OPERATION
*
NO
IN INTAKE
VALVES, INSPECT
PISTON TOP AND
REPAI R AS NEEDED,
SEE “PARTS LIST”
11036
75-7268 12

CHART 5-WON’T PUMP AIR
- PUMP SLOWS, STALLS, OR TRIPS CIRCUIT BREAKER (FUSE OPENS)
CHECK FOR PLUGGED
DISCHARGE TUBE
DISCONNECT TUBE AT
COMPRESSOR PUMP
MOTOR DEt=ECTIVE,
REPLACE
CLEAN OR
REPLACE
AND TEST
v 1CHECK VALVE ]
NO
REPLACE OR REPAIR
PUMP, SEE “PUMP
REMOVAL &REPLACEMENT”
I
I
J
I1037
EXCESSIVE VIBRATION normal operating conditions. Readjust to eliminate or
reduce vibration noise.
This problem is usually due to omission of vibration
pads or an uneven weight distribution on the pads. Shut
unit off and apply weight to different corners of the unit.
Shim out excessive rocking. Use adjustable levelers for
uneven floors.
Belt guards often produce a vibrating noise even under
Sometimes, even normal operation of the compressor
is considered excessive in noise or vibration. In such cases,
a remote air intake, adjustable pads, and air-line vibration
isolators may be required. Isolators are stocked by
Honeywell.
13
75-7268

REPAIR
PUMP REMOVAL
AND REPLACEMENT
If major repair is needed, order a Parts List for the
specific pump. See ORDERING INFORMATION para-
graph in PARTS LIST section.
Remove pump hold-down bolts, and pump. Remove fly-
wheel if not done previously.
Shut off power to both units. Drain oil from faulty When installing new pump, be sure flywheel is in line
unit, and bleed down tank. Remove belt guard, loosen with motor pulley before removing wedge and tighten-
motor mounts and remove belt(s).
ing hub bolts.
Remove discharge tube at pump end. If tube wraps
around crankshaft, remove both ends and any hold-down
straps.
If accessible, remove flywheel at this time. The l/2-hp
(0.27 kW) unit is held on with a keyed shaft and setscrew
and a puller will probably be necessary. All others use a
split hub and key. Remove flywheel by removing hub
bolts and nuts and driving a wedge into split.
NOTE: When removing discharge tube connector from
old pump, loosely install the male coupling on
the discharge tube in the connection to prevent
collapse during removal.
OIL PUMP REPLACEMENT
Remove pump intake filter and the unloader air supply
line of 3/4 hp (0.56 kW) and up.
If flywheel has not been removed, its weight may
topple pump when the hold-down bolts are
The oil pump is factory machined as an assembly, and
partial replacement is not possible. In the event the pump
(or crank bearing which is part of the pump) is faulty,
replace whole assembly. The assembly is held by four
bolts (see Fig. 7). Order the replacement oil gage sep-
arately if needed. After installation, adjust oil pressure
on replacement pump (see WRONG OIL PRESSURE
paragraph in TROUBLESHOOTING section).
OIL PUMP
X1082-l
75-7268
Fig. 7. Crankcase Group.
14

BELT REPLACEMENT
(Refer to Fig. 2)
Disconnect electric power and loosen motor clamping
bolts. Slide motor towards pump. If the compressor has
a totally enclosed belt guard, remove it. Remove and
replace belt(s). Hold motor against belts when retighten-
ing so the belt(s) have no more than l/2 in. (13 mm)
total play. Make certain motor is square to belts. Reinstall
guard and turn on power.
NOTE: Sometimes new belts stretch excessively after
being installed. Recheck belt tension after one
week as stated in BELTS paragraph of MAIN-
TENANCE section.
MOTOR REPLACEMENT
Before replacing motor, see NOISY MOTOR and
WON’T START paragraphs in TROUBLESHOOTING
section. If motor is defective, disconnect power and
replace. Use motor of identical type, hp, voltage, speed,
and frame when reinstalling motor. Reset belt tension,
see BELTS paragraph in MAINTENANCE section.
CAUTION
Many motors are dual voltage and/or reversible.
Check motor’s internal wiring against diagram on
motor or inside of wiring cover plate for proper
connections for voltage being used and/or rotation.
The compressor will pump air if rotated backwards
but will not cool properly.
INTAKE AND EXHAUST VALVES,
UNLOADER
Intake valves, exhaust valves and unloader mechanisms
can be disassembled for inspection, cleaning, or repair
for all compressor sizes except the l/2 hp (0.37 kW).
The l/2-hp (0.37 kW) unit has a head sealed assembly.
In the event the valves are deemed defective, replace
entire head assembly.
For the l/3-hp (0.25 kW) unit, remove the two valve
locking nuts in the head. Remove valve parts for inspec-
tion See Fig. 8 for reassembly order.
i
DISCHARGE
/VALVE
ASS’Y
‘I
Fig. 8. Unloader for l/3-HP (0.25 kW) Unit.
The 3/4-hp (0.56 kW) and larger units have automatic
unloaders on the intake valve(s). Some preliminary
checks on unloaders are described in CIRCUIT BREAKER
TRIPS (FUSE OPENS) paragraph in TROUBLESHOOT-
ING section. The unloader for the l-hp (0.75 kW) unit
is shown in Fig. 9. All other units (3/4 hp, 0.56 kW;
l-l /2 hp, 1.1 kW; and up) use the unloader shown in
Fig. 10.
UNLOADER ASS’Y
INTAKE VALVE ASS’Y
6282
Fig. 9. Air Unloading of Intake Valves--l HP (0.75 kW).
15
75-7268

zii3x
UNLOADER
ASSEMBLY
-HEAD
6283
Fig. 10. Air Unloading of Intake Valves--3/4 HP (0.56
kW), l-1/2 HP (1.1 kW) and Up.
The unloader pilot is located on the crankcase and is
connected to the unloader by a copper line. The l/2-
and 3/4-hp (0.37 and 0.56 kW) units use a pilot that is
mechanically activated (see Fig. 11). All other units are
operated by oil pressure (see Fig. 12). Disassemble and
clean units if suspect. See PARTS LIST section for
repair kit numbers.
Fig. 11. Three-Way Valve Assembly-l/2- and 3/4-HP
(0.37 and 0.56 kW) Units.
Fig. 12. Hydraulic Unloader Assembly-l-IHP (0.75 kW)
Units and Larger.
PRESSURE REGULATING VALVE
(PRV) STATION
The l/3- to 2-hp (0.25 to 1.5 kW) units use a Honey-
well PP901 or PP902 PRV. For detailed maintenance
and repair information, see Form No. 75-2558.
The prv station used on the 3-11~ (2.2 kW) units is a
combination of a Pall-Trinity-Micro Corp. filter, and a
Norgren regulator and relief valve (see Fig. 15 and
Table 3).
To perform maintenance and repair work on the prv
station, shut off air supply from tank. Bleed down the
system by manually operating the drain (push red button
on drain valve).
CAUTION
All valves and dampers return to the normal posi-
tion when system is bled. Study job drawings for
critical problems before bleeding down system.
The regulator and relief valve can now be replaced or
repaired with the appropriate repair kit (see PARTS
LJST section).
After repairing or replacing, slowly turn air back on,
checking for leaks.
75-7268 16

PARTS LIST
INTAKE FILTERS
See Fig. 13 and 14.
R2373
Fig. 14. Quincy Air Maze Intake Filters.
FILTER-PRV ASSEMBLY
Replacement element kit for PI?901 -PI?902 PRV is
14003121-001. See Form 75-2558 for other prv parts.
Fig. 13. Honeywell Intake Filter, Part No. J&3895-4. See Fig. 15 and Table 5.
Table 5. 7-l /2 HP Filter-PRV Parts List.
Nomenclature 7-l/2 HP-WP241
Refer all inquiries to
Quincy Compressor
Refer all inquiries to
Quincy Compressor
17 75-7268

FRONT VIEW
6286
Fig. 15. Typical PALL-TRINITY-MICRO (PTM) Filter-PRV Assembly-for 7-l/2 HP (5.60 kW) Units.
OTHER COMPRESSOR PARTS
Table 6. WP241 Duplex Air Compressor Parts List .*
Qumcy Model No.
Model Compressor Only
Motor Horsepower (kW)
Motor Frame No
Motor Voitagc/Frcq/Phase
RPM- Compressor
V-Belt-Quantity, Type,
L,ength (In )
Air Intake Fdter
Unloader Dcvlce i-
Unloader Valve’
rkk Valve4
WP241Y WP24lB WP241C WP241D WP241E WP241F WP241G WP241H WP241J
FFHX2 FFlIlOh FFIIl08 FFII210 EFIJ216 FFH230 FFII325 FFH340 FF11370
X2 Plain 106 Loadless 108 Loadiess 2 IO Loadlegs 2 16 Loadless 230 Loadless 325 Loadless 340 Loadless 370 Loadless
l/3 (0 ‘5) l/2 (0 37) 3/4 (0 56) 1 (0 75) l-l/2(1 1)
2(1 5) 3 (2 2)
5 (3 7) 7-l/7 (S 6)
-48 -56 -56 -14x -145T -145T -182T
184T .71:-y - -
1 I S/60/ 1 ‘08/60/3 ‘30/60/3 460/60/3 208/60/3 230/60/3 460/60/3 460/60/3 460/60/3
500 410 460 480 460 400 570 550 610
I -A-44 I -B-5 1 1 -B-5 1 I-B-45 I -B-54 2-B-60 2-B-60 3-B-8 1 3-B-X 1
Iloneywell Part No AK38954 7069% 70704 7071*
None 3444 3444 7970x 7970x 7970x 7970x 7970x 7970x
5993 7483X 7483X 8125 7483X 7483X 7483X 718iY 7483X
8405 8405 None None None None None hone
VCXlC
75-7268
18

ORDERING INFORMATION
(In United States)
When ordering parts, it is important to supply infor-
mation shown on the nameplate.
QUINCY PARTS
Order from local Quincy representative or:
Colt Industries
Quincy Compressor Division
Quincy, IL 62301
NOTE: Supply complete Quincy compressor serial
number as stamped on the nameplate of each
compressor when ordering parts or discussing
servicing or problems on a specific compressor.
See Fig. 16. A list of Quincy service depots is
included with the instructions packed with each
compressor.
~~
Colt hdustries Quincy Compressor Division QUWKY, ~IIIIKHS us A
DATE CODE 1
j
6287
Fig. 16. Compressor Nameplate.
PTM (Pall-Trinity-Micro) PARTS
Local distributor or:
Pall-Trinity-Micro Corporation
Cortland, NY 13045
Supply exact part number.
NORGREN PARTS
Local distributor or:
C .A. Norgren Company
Littletown, CO 80 120
Supply exact part number.
HONEYWELL PARTS
Local Honeywell Serviceline Center.
Supply part number and compressor model number,
Mechanical devices must be serviced periodically if they are expected to give continued satisfactory performance,
and controls are not an exception. How accurate and how troublefree your control system will be in the years to
come depends largely on the maintenance given it. For best results, all devices in your system should be serviced
at one time.
Time and trouble can be saved by arranging with Honeywell for a maintenance agreement which will guarantee
expert, economical care, and insure maximum life and efficiency from your system.
19
75-7268

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