Schrader International 7.5 & 10 HP Electric Manual

1
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3010 Air Compressor Pump
Operation & Maintenance Manual
7.5 & 10 HP Electric
16 HP Gas
Duplex
7.5 & 10 HP Electric
Model #:
Serial #:
82-36 Manual

WARNING
CAREFULLY READ THE INSTRUCTION MANUAL INCLUDED WITH THE PRODUCT BEFORE OPERATION.
RISK OF ELECTRICAL SHOCK - Has live electrical parts when power is connected. To reduce the risk of electric
shock, do not expose to rain, excessive humidity or running water. Store indoors.
Must be grounded according to all
National, State and Local electrical codes to avoid electrical shock.
RISK OF INJURY - Has moving parts. Do not direct air stream at body. Use eye protection. May start or stop automatically
when power is connected. Should not be operated in places where there are children or pets.
RISK OF FIRE OR EXPLOSION
“Must be installed and operated in well ventilated area that is free from
flammable gases, excessive humidity or running water”.
Do not carry while painting. Use a minimum of 15
feet of hose when connecting the spray gun to the compressor. Do not spray combustible / flammable liquid in a
confined area. Do not smoke while spraying or spray where spark or flame is present. Keep compressor at least
20 feet away from spraying area.
RISK OF BURSTING - If the air tank becomes defective due to mechanical or chemical problems it must be
replaced. Never attempt to weld on or perform any other repair on the tank. Do not adjust regulator to result in
output pressure greater than marked maximum pressure of tool attached.
The tank is a pressure vessel and should
be inspected on regular intervals by an accredited inspector.
Disconnect, tag and lock-out power source, then release all pressure from the compressor / tank before
attempting to install, service, relocate or perform any maintenance.
(O.S.H.A. Regulation 1910.147).
288917
INSTALLATION
This compressor must be removed from wooden skid and permanently mounted to a
concrete floor. Recommend use of "Air Compressor Mounting Kit". See owner's
manual for mounting recommendations.
Install the compressor in an open area, well ventilated, free of dust, toxic gases,
humidity or any other type of hazardous conditions.
To guarantee adequate ventilation and to facilitate the cleaning and maintenance,
Install the compressor at least 30" from any wall or obstacle.
If connected to a circuit protected by fuses, use time-delay fuse marked “D”.
MAINTENANCE
Check for proper oil level.
Drain tank condensation using petcock located on bottom of tank.
Check for unusual noise or vibration.
Clean air filter or replace if necessary.
Clean external parts of compressor and motor.
Test safety valves on pump and tank.
Inspect entire air system for leaks.
Inspect oil for contamination and change if necessary.
Check belt tension and belt wear.
TECHNICAL SERVICE
1-800-288-1804
Do not use an extension cord with this compressor. Extension cords experience voltage drops and can result in
damage to the electric motor.
Daily:
Weekly:
Monthly:
Air from this compressor will cause severe injury or death if used for breathing or food processing. Air used
for these processes must meet O.S.H.A. 29 c.f.r. 1910.134 or f.d.a. 178.3570 regulations.
7" x 8.25"
Permanent Adhesive, 2 colors with overlaminate
Bore & Stroke # Cyl. Mounting Holes Oil Capacity Wt. Max. Pressure
4 1/4" L, 2 1/8" H X 3 1/2" 2 9 5/8" X 7 3/4" 1 3/4 qts. 214 lbs. 200 PSI
PUMP
PERFORMANCE SPECiFiCAtiONS
Description L X W X H Phase Voltage Disp. CFM SCFM Pump Cyl. Pump RPM
7.5 HP Electric Horizontal 80 Gallon Tank 65" X 25" X 46" 1 230 32.6 24 4 600
7.5 HP Electric Horizontal 120 Gallon Tank 71" X 24" X 50" 1 230 32.6 24 4 600
7.5 HP Electric Vertical 80 Gallon 41" X 24” X 73” 1 230 32.6 24 4 600
7.5 HP Electric Horizontal 80 Gallon Tank 65" X 25" X 46" 3 208/230/460 32.6 24 4 600
7.5 HP Electric Horizontal 120 Gallon Tank 71" X 24" X 50" 3 208/230/460 32.6 24 4 600
7.5 HP Electric Vertical 80 Gallon 41" X 24" X 73" 3 208/230/460 32.6 24 4 600
10 HP Electric Horizontal 80 Gallon Tank 65" X 25" X 46" 3 208/230/460 43.5 32 4 800
10 HP Electric Horizontal 120 Gallon Tank 71" X 24" X 45" 3 208/230/460 43.5 32 4 800
10 HP Electric Vertical 80 Gallon 39.5" X 24" X 73" 3 208/230/460 43.5 32 4 800
10 HP Electric Vertical 120 Gallon 39.5" X 28" X 73" 3 208/230/460 43.5 32 4 800
(2) 7.5 HP Electric Horizontal 120 Gallon 81" X 26.5" X 52" 1 230 65.3 48 4 600
(2) 7.5 HP Electric Horizontal 120 Gallon 81" X 26.5" X 52" 3 208/230/460 65.3 48 4 600
(2) 10 HP Electric Horizontal 120 Gallon 81" X 26.5" X 52" 3 208/230/460 87.1 64 4 800
(2) 10 HP Electric Horizontal 200 Gallon 81" X 26.5" X 52" 3 208/230/460 87.1 64 4 800
16 HP Briggs & Stratton Gas Horizontal
30 Gallon Tank 50" X 23.5" X 43" 41 32 4 800

Avoid electric shock- Unit must be dry before connecting to electricity and
during use.
Duplex Unit is powered by two motors from two separate electrical
power sources. The motors start and stop automatically to maintain
tank pressure. Electric motors are programed to start with a delay. Avoid
injury: disconnect, tag, and lock-out both electrical power sources and
release air pressure from tank and air lines before attempting to install,
relocate or perform any maintenance or repair.
Grounding and static conductivity - Ground unit as required by national
and local electrical codes. Added grounding, static-conductive belts and
other static-conductive controls may be needed in environments such as
grain elevators and chemical plants- ask a qualied engineer.
READ THE COMPLETE OWNER’S MANUAL AND ALL LABELS ON THIS
UNIT BEFORE INSTALLING OR USING.
Contents Page
Performance Specs...............................................................................................................................................2
Safety Instructions.................................................................................................................................................4
Mounting Stationary Air Compressor ....................................................................................................................5
Wiring Recommendations.....................................................................................................................................6
Wiring Diagram......................................................................................................................................................7
Troubleshooting.....................................................................................................................................................8
823010 Compressor Diagram.............................................................................................................................10
823010 Compressor Parts List............................................................................................................................11
Cylinder Head Parts Diagram .............................................................................................................................12
Centrifugal Unloader/Electric Motor Maintenance...............................................................................................13
Electric Unit Diagram and Parts List...................................................................................................................14
Gas Unit Diagram and Parts List ........................................................................................................................15
Unloader Adjustment...........................................................................................................................................16
Duplex Unit Diagram and Parts List....................................................................................................................17
Duplex Selective Switch Instructions ..................................................................................................................18
Duplex Wiring Diagram Single Phase.................................................................................................................19
Duplex Wiring Diagram Three Phase..................................................................................................................20
Duplex Wiring Diagram Three Phase 460 Volts..................................................................................................21
Maintenance Schedule - Check Chart ................................................................................................................22
Maintenance Records .........................................................................................................................................23
Refrigerated Dryers, Pressure Washers, and Nitrogen Generators ..................................................................24
Battery Connections (Gas Engines)....................................................................................................................25
Warranty..............................................................................................................................................................26

SAFETY INSTRUCTIONS
When using air compressors and compressed air accesso-
ries, basic safety rules and precautions should always be
followed including the following:
1. Read all instructions fully before operating this
compressor.
2. Never use a compressor that is defective, operating
abnormally, making strange noises, or otherwise
appears defective. Stop using compressor immediately
and arrange for repairs by an authorized service center.
3. Do not modify compressor. Always contact the autho-
rized service center for any repairs.
4. Use only the manufacturer’s replacement parts.
Replacement parts not manufactured by Schrader
Bridgeport may void your warranty and can lead to
compressor malfunction and personal injuries.
Replacement parts are available from the manufac-
turer.
5. Wiring, starters, breakers and other related electrical
equipment should conform to electrical codes when
operating any electric air compressors. Electrical con-
nections should be made by a licensed electrician.
6. Always disconnect compressor from its power source
and remove the compressed air from the tank before
servicing, inspecting, cleaning, replacing, or checking
any parts.
7. Do not operate compressor without belt guard. If main-
tenance or servicing requires the removal of a guard or
safety feature, be sure to replace the guard or safety
feature before resuming operation of the compressor.
8. Do not use gasoline compressor if Load Genie does
not operate properly. Have defective Load Genie
replaced by an authorized service center.
9. Avoid unintentional starting. Do not move the compres-
sor while connected to its power source or when the air
tank is filled with compressed air.
10.Turn off the compressor when not in use. Then open
the drain cock to discharge the compressed air from
the air tank.
11. Do not expose compressor to rain. The compressor
should be stored in a dry clean environment.
12.Do not use compressor in the presence of flammable
liquids or gases. Compressor can produce sparks dur-
ing operation. Never use compressor in sites containing
lacquer, paint, benzine, thinner, gasoline, gases, adhe-
sive agents and other materials, which are combustible
or explosive.
13.Use only recommended air handling parts acceptable
for minimum pressure. Never use pressurized air
accessories or parts in the air system that are not suit-
able for the maximum air pressure involved. The risk
of bursting exists with use of unsuitable equipment.
Always maintain maximum pressure specified by the
manufacturer.
14.If your compressor is used for spraying, do not spray
in vicinity of open flame or other sources of ignition.
Always direct paint or sprayed material away from
compressor and locate compressor to minimize over
spray accumulation on compressor or sprayer parts.
15.Do not wipe plastic parts with solvent. Solvents such
as gasoline, thinner, benzine, carbon tetrachloride
and alcohol may damage and crack plastic parts.
Wipe plastic parts with a soft cloth, lightly dampened
with soapy water and dry thoroughly. When using
cleaning solvent, follow the instructions provided by
the solvent manufacturer.
16.Keep pressure relief devices free from paint or other
accumulation. The motor air vent must be kept clean
so that air can freely flow at all times. Check for dust
build-up frequently.
17.Do not install Shutoff valves in the discharge line
between the compressor and the receiver unless
a safety valve, with adequate flow capacity and
pressure setting, is located between shutoff valve and
the compressor. Never operate a compressor without
all guards or safety features in place and in proper
working order.
18.Proper maintenance and care is necessary to ensure
safe operation of air compressor. Check compressor
according to the maintenance schedule provided in
this manual. Maintain compressor with care. Follow
instructions for lubrication. Keep all screws, bolts, and
plates tightly mounted. Check for damaged parts and
air leaks, daily. Check for alignment of moving parts,
binding of moving parts, guard, breakage of parts, and
any other conditions that may affect the operation of
compressor. Drain tank daily to prevent rust formation
and damage.
19.Do not operate any compressor with damaged wir-
ing or hosing, or after the compressor or air handling
parts have been dropped, damaged or show signs of
deterioration, weakness or leakage. Do not use them
if a deficiency is found. A unit that is damaged should
be properly repaired or replaced by an authorized ser-
vice center unless otherwise indicated elsewhere in
this Instruction Manual.
20.Keep clear of compressor while operating It may
become extremely hot during operation. To reduce
the risk of burns, do not touch tubes, heads, cyl-
inders or motors.
21.Never touch moving parts. Always wear safety gog-
gles or equivalent eye protection. Dress properly. Do
not wear loose clothing or jewelry. These can be
caught in moving parts. Wear protective hair covering
to contain long hair.
22.Never aim compressed air at anyone or any part of
the body.
23.Never operate a compressor in damp or wet location.
Protect yourself against electric shock. Prevent body
contact with grounded surfaces such as pipes, radia-
tors, ranges and refrigeration enclosures.
4

Concrete Floor
Lag Screw
Bushing
Compressor Foot
Rubber Pad
Lag Shield
Stationary Air Compressor Mounting Kit
For Electric Models only. Order 824678.
Stationary Air Compressor Mounting Instructions
1. Select a location for mounting unit on a firm and
level floor.
2. Position unit and mark feet location in center hole of
each foot.
3. Prepare to drill holes by removing unit.
4. Drill each of the marked holes 3" in depth using a 3/4"
concrete drill bit. Blow out holes and insert lag shield
making sure they are flush with the floor.
5. Position unit over drilled holes.
6. Place one rubber isolation pad under each foot.
7. Assemble 1 1/2" metal/rubber washer and lag bolt into
each lag shield. Do not over tighten.
Flex Air Line Installation
1. Install 3/4" NPT nipple into tank outlet hole
2. Install 3/4" NPT Ball Valve.
3. Install 3/4" x 36" Flexible Hose.
Note: Teflon Tape should be used on all thread connections.
MOUNTING FOR STATIONARY AIR COMPRESSOR ONLY.
Correct Wrong
Disconnect power and release air pressure before
installing and/or performing maintenance.
UNPACKING INSTRUCTIONS
The two stage compressor was inspected at the factory and
packaged to protect against shipping damage. When you
unpack your unit, inspect for damaged or missing parts. If
there are any damaged or missing parts, the transportation
company’s agent should make a notation to the effect on
the Bill of Lading. Claims, should be settled directly with the
transportation company.
All Vertical Compressors are top heavy and can easily
tip over. Use appropriate lifting device for moving unit
to desired location. When using air compressors and
compressed air accessories, basic safety rules and
precautions should always be followed. Read the
compressor operating instruction before attempting to
assemble, install, operate, or maintain the product. Failure
to comply with the safety instructions could result in
personal injury and/or property damage.
The compressor must be placed in a clean and well
ventilated room. Compressor should be located at least
18-30 inches away from a wall or other obstruction that
will impede air flow through the fan-bladed flywheel. Do
not place compressor where heat is excessive. Provide
adequate fresh air and exhaust ventilation from area in
which the compressor is located.Place compressor on
a firm, level floor. Remove wood shipping skid before
installation. Failure to remove from wooden skid will void
all warranties. Permanent installations should be bolted to
the floor. Bolting holes are provided in the base feet. Shim
compressor level before bolting down to floor. Avoid putting
stress on your new compressor by using our Mounting Kit
(824678).
Tank Drain
D. Flex Hose
C. Ball Valve
A. Nipple
B. Outlet Hole
B
C
D
36" Flex Hose
Warning: May bend & curve; do not kink.
A
5

6
DIRECTION OF ROTATION
As the compressor starts, check the rotation of the units.
Standard rotation is clockwise, viewing the compressor from
the side of the sight glass. A rotation arrow is placed on
the flywheel at the factory. Should the rotation be incorrect,
disengage the power and correct the motor wiring.
Warning: After the compressor is started, it will operate
automatically.
When the air pressure in the receiver reaches the preset
high pressure level the pressure switch opens, electrically
stopping the compressor drive motor. As the air is
used from the receiver the pressure drops allowing the
pressure switch to close at the preset low pressure level,
which restarts the driver motor. Meets ISO 100 viscosity
requirements (high viscosity SAE 30W to low viscosity
SAE40W). For ambient temperatures below 41˚F use oil
that meets ISO 68 viscosity requirements (high viscosity
SAE 20W). For ambient temperatures above 77˚F use oil
that meets ISO 150 viscosity requirements (high viscosity
SAE 40W).
LUBRICATION
Compressor may or may not be shipped with oil.
Change oil after first 50 hours (or two weeks) of operation.
Afterwards, change petroleum-based oils every 1000 hours
of operation.
Before operating, check the sight glass for oil level which
should be at halfway. Add oil to crankcase if level is below
halfway level. Do not over fill. This compressor requires a
non-detergent, 30 wt. oil such as Manufacturer # 826020.
Initial start up oil should be changed after first two weeks of
operation.
Do not overfill!
Use a high quality, non-detergent petroleum-based
compressor oil containing anti-oxidant and corrosion-
inhibiting additives such as Manufacturer # 826020 to
lubricate the compressor pump.
Do not use detergent oils in the pump.
If oil turns milky replace oil and move unit to less humid
conditions.
For normal ambient termperatures between 41˚F and
77˚F use oil that meets ISO 100 viscosity requirements
(high viscosity SAE 30W to low viscosity SAE40W). For
ambient temperatures below 41˚F use oil that meets ISO
68 viscosity requirements (high viscosity SAE 20W). For
ambient temperatures above 77˚F use oil that meets ISO
150 viscosity requirements (high viscosity SAE 40W).
Ambient
Temp.
Viscosity
@
100ºF SSU
ISO
Viscosity
CS + SAE No.
0º - 40º 250-350 46-68 20
40º - 80º 450-550 100 30
80º - 120º 650-750 150 40
Under 0º -
Over 120º Consult Factory
WARNING
WIRING RECOMMENDATIONS
Note: All wiring recommendations, performance, torque
readings are listed for each separate pump. All wire
sizes and breaker sizes are listed for each motor. Each
motor must be separate with it’s own breaker and wire
and have it’s own separate power source as listed in
charts.Installation or modifications should be made by a
Competent Electrician being sure that:
1. Magnetic starters with Thermal Overload are required for
motor warranty and protection.
2. The power source is sufficient and service has adequate
ampere rating. (See following chart).
3. The line wire is the proper size and that no other equip-
ment is operated from the same line. The following chart
gives minimum recommended wire sizes for compressor
installations. For longer lines, call manufacturer.
4. The Duplex air compressor must have two separate
power sources, each motor must be wired independently
of the other, using the chart below.
Various national and local codes and standards have been
set up covering electrical apparatus and wiring. These
should be consulted and local ordinances observed. Our
recommended wire sizes may be larger than the minimum
set up by local ordinances to prevent excessive line voltage
drop.
5. Failure to comply with all wiring instructions, including
breaker sizes, wire sizes, and recommended wire length
will void all warranties on electrical parts.
Wire Size (Rubber Covered)
HP Wire Length Single Phase
& DC Three Phase
208 V 230 V 230 V 460V
5 50' or less 8 8 10 14
7.5 50' or less 6 6 10 14
10 50' or less 8 14
15 50' or less 6 10
20 50' or less 4 10
25 50' or less 3 8
30 50' or less 2 8
Breaker Size
Single Phase Three Phase
5 208 V 230 V 230 V 460V
5 60 60 30 15
7.5 80 80 45 20
10 60 25
15 80 40
20 120 60
25 150 75
30 180 90
Increase wire size up to next size
for each additional 50' feet.

7
WIRING DIAGRAM
1. Rewire motor per data plate on motor or instruction sheet.
2. Check pressure switch electric rating and replace if
necessary.
3. Check electric rating of thermal over load switch or
magnetic starter and replace complete switch or thermal
overload elements as required.
Incoming Power to be wired to Mag Starter only!
L1, L2, L3 indicates supply line terminals.
T1, T2, T3 indicates load terminals.
L1 L3
T2
L2
T1 T3
JUMPER
MOTOR
LINE
MOTOR
INCOMING POWER
SINGLE PHASE
THREE PHASE
Pressure Switch
Pressure
Switch

8
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
1. Compressor will not operate. 1. No electrical power. 1. No electrical power.
2. Pressure switch not making
contact 2. See pressure switch adjustment.
2. Excessive noise in operation
1. Loose pulley, ywheel, belt,
belt guard 1. Tighten.
2. Lack of oil in crankcase. 2. Check for possible damage to
bearings, replenish oil.
3. Piston hitting the valve plate. 3. Remove the compressor cylinder
head and inspect for foreign
matter on top of the piston. Add
a new gasket and reassemble
the head.
4. Compressor oor mounting
loose. 4. Tighten.
5. Defective crankcase. 5. Repair or replace.
6. Excessive crankshaft end play. 6. Adjust and shim properly.
3. Knock - same cycle as R.P.M. 1. Main bearings. 1. Replace bearings.
2. Connecting rod bearing. 2. Tighten.
4. Knock occurs while compressor
is loading.
1. Connecting rod bearings. 1. Replace rod.
2. Wrist pins, wrist pin bearings. 2. Replace complete piston
assembly
5. Excessive oil consumption.
1. Restricted air intake. 1. Clean or replace air lter.
2. Oil leaks. 2. Tighten bolts or replace gasket.
3. Worn piston rings. 3. Replace piston rings.
4. Wrong oil viscosity. 4. Drain oil, rell with oil or proper
viscosity.
See Lubrication Section.
5. Compressor tilted too much. 5. Level compressor.
6. Scored cylinder 6. Replace cylinder.
6. Oil in discharge air.
1. Compressor air intake restricted. 1. Clean air lter element and
check for other restrictions in the
intake system.
2. Worn piston rings. 2. Replace rings.
3. Excessive oil in compressor. 3. Drain down to full mark on sight
gauge.
4. Wrong oil viscosity. 4. Check viscosity.
See Lubrication Section.
5. Piston rings installed up-side
down. 5. Install ring in proper position.
7. Compressor vibrates.
1. Mounting bolts loose. 1. Tighten.
2. Compressor not properly
mounted 2. Level compressor so that all feet touch the oor before tightening
down.
3. Pulley and ywheel misaligned. 3. Realign.
4. Belts loose. 4. Tighten belts. See Maintenance
Section.
5. Bent crankshaft. 5. Replace crankshaft.

9
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
8. Air blowing out of inlet 1. Broken rst stage inlet valve. 1. Replace valve assembly.
9. Insufcient pressure at point of
use.
1. Leaks or restriction. 1. Check for leaks or restriction or
piping. Repair.
2. Restricted air intake. 2. Clean or replace air lter element.
3. Slipping belts 3. Tighten belts. See maintenance
section.
4. Service hose too small. 4. Replace with larger hose
5. Excessive air requirement. 5. Limit air requirement to compressor
capacity.
10.Receiver does not hold
pressure when compressor
is unloaded
1. Faulty check valve. 1. Bleed tank! Disassemble check
valve assembly, clean or Replace
faulty parts.Danger
Do not disassemble the check valve with air in
tank. Note: check valve is always the rst valve in
the line from the compressor to the
compressor.
11.Excessive belt wear.
1. Pulley out of alignment. 1. Realign motor pulley with
compressor ywheel.
2. Belts too tight. 2. Adjust tension.
3. Belts too loose. 3. Adjust tension. See maintenance
section.
4. Pulley or ywheel wobble. 4. Check for worn crankshaft, keyway
or pulley bore, resulting from
running with a loose pulley.
5. Nick in belt grove of pulley or
ywheel. 5. File smooth.
12.Excessive discharge air
temperature.
1. Dirty cooling surfaces. 1. Clean cooling surfaces of cylinder,
intercooler and discharge tube.
2. Poor ventilation. 2. Improve ventilation or relocate
compressor. See install instructions.
3. Blown head gasket. 3. Replace head gasket.
4. Restricted air intake 4. Clean or replace air lter element.
5. Worn valves. 5. Repair or replace valves.
13.Receiver pressure builds
up slowly. 1. Dirty air lter. 1. Clean or replace lter element.
2. Blown cylinder head gasket. 2. Install new gasket.
3. Worn or broken low pressure
intake or discharge valves. 3. Install new head gasket.
4. Air leaks. 4. Tighten joints.
5. Loose belts. 5. Tighten belts. See maintenance
section.
6. Speed too slow. 6. Check speed.

10
823010 COMPRESSOR PUMP
Recommended Torque Readings Foot
pounds
Head Bolts 50-55
Valve Retainer 80-90
Rod Bolts 30
Crankcase Bolts 30-40
Side Cover Bolts 30-40
Front and Rear Cover Bolts 30-40
Manifold Bolts 30-40
Flywheel Bolts 65-70
Intercooler Bolts 30-40
H.P.
INTAKE
VALVE
L.P.
INTAKE
VALVE
L.P.
EXHAUST
VALVE
L.P.
INTAKE
VALVE
H.P.
EXHAUST
VALVE
45
64
29
81
31
10
80
79
78
75
77
6
13
36
30
6
13
1735 16
5
40
66
43
22
16
35
949
74
75
76
71
45
6
13
33
54
23
32
27
17
44
25
41
37 56
43
6358
66
67
28
12 8
2
3
12
4
7
39
38
70
26
51
52
46
14
13
6
60
53
42
50
47
14
21
20
19
18
13
24
16
72
15
55
61
6
59
69
13
62
68
48
57
1613
65
1
11
34
NA210
44
25
41
NA210EX 3010 111607.ai DD
823010 Compressor Pump

11
Item Part Description QTY Item Part Description QTY
1 82708001 Crankcase 1 43 82706001 ElbowAftercooler 2
2 82709001 Crankshaft 1 44 82703015 Elbow Copper 2
3 82050158 Bearing Front 1 45 82727136 Elbow Intercooler 2
4 82701000 Cap Front Bearing 1 46 82720002 Piston - HP 2
5 82070163 Gasket Front Cap 1 47 82050122 Insert Rod - Bearing 4
6 *G.H Cap screw Hex M8X20 18 48 82727001 ValveAssembly - HP Inlet 2
7 82060068 Seal - Shaft 1 49 82090095 Shim .015 BrgAdjustment 1
8 82050159 Bearing Rear 1 49 82090094 Shim .010 BrgAdjustment 1
9 82070172 Gasket Rear Cap 1 49 82090093 Shim .005 Brg Adjustment 1
10 82728004 Centrifugal Unloader Adapter Plate 1 50 82100101 DowelAlignment 8
11 82713000 Flywheel 19” 1 51 82719088 Set HP Piston Rings 2
12 See 3 & 8 Bearing - Cap 2 52 82729006 Wristpin HP Piston 2
13 82070201 Gasket Copper 24 53 *G.H Lockwasher 10 8
14 82705107 Rod Connecting Steel w/ Needle Bearing 4 54 82070203 Gasket Copper 12
15 82727000 ValveAssembly - LP Inlet 4 55 82727003 Spacer Inlet Valve 6
16 *G.H Pipe plug 7 56 82951 Valve Safety 200 PSIASME 1
17 82020147 Cover Crankcase Side 2 57 82727002 ValveAssy HP/LP Discharge 4
18 82200100 Snap ring - Internal 8 58 *G.H. Capscrew SKT Head M8X25 8
19 82729000 Wrist pin - LP Piston 2 59 82727136 Cover Valve 6
20 82720000 Piston LP 105mm 2 60 *G.H Capscrew SKT Head M10X45 8
21 82719064 Piston Ring Set LP 2 61 82727134 Retainer Inlet Valve 6
22 82070162 Gasket Cylinder To Crankcase 2 62 82727135 Retainer Discharge Valve 4
23 *G.H. Cap screw Hex M10X25 12 63 *G.H Lockwasher 8 8
24 *G.H. Cap screw Hex M12X70 16 64 82718017 T-Fitting Copper 2
25 82728002 Holder Unloader 1 65 *G.H. Capscrew Hex M8X85 8
26 *G.H. Cap screw Hex M16X80 1 66 82070167 GasketAftercooler 4
27 82070161 Gasket Cylinder Head 2 67 82070169 Gasket Intercooler 4
28 82710000 Head Cylinder 1 68 82727004 Spacer Discharge Valve 4
29 82703011 Breather 1 69 82070170 Gasket Valve Cover 6
30 *G.H Oil Drain Plug 3/8” NPT 1 70 *G.H Lockwasher 16 1
31 *G.H. Cap screw Skt HD M6X20 4 71 82703013 Breather Tube 2
32 82711000 Cylinder 1 72 82070202 Copper Valve Seat Gasket 10
33 8232574 Filter InletAssembly 2 73 826155-S Elbow Valve & Unloader 1
34 822580 Filter Inlet Element 2 74 82701029 Cap Rear 1
35 82070165 Gasket Side Cover 2 75 82100100 Pin - Hinge 2
36 82288700 Oil Level Sight Glass (Copper) 1 76 82728000 Weight Unloader 1
37 82706000 Intercooler 1 77 82723003 Spring Unloader 1
38 *G.H. Nut Hex - M16 1 78 82728003 Plunge Unloader 1
39 82080029 Key Flywheel 1 79 82070166 Gasket Unloader Cover 1
40 82706003 Aftercooler 1 80 82120058 NutAdjustment Lock 1
41 82947 Valve Safety 60 PSI ASME 2 81 82160002 Bushing Reducing 2
42 82705003 Dipper Oil 4 n/a 82720123
Complete PlungerAssembly (for unloader ) 1
823010 TWO-STAGE 4 PISTON COMPRESSOR PUMP
*Notes:
*G.H. General Hardware
820185 - Gasket set inclues: complete set of gaskets for pump.
820707 - Overhaul kit includes: Gasket set, ring set and valve assemblies for pump and two air filters
820182 - Valve & Head Overhaul Kit includes gaskets for pump head, two air filters and valve assemblies.

12
L. P
Intake
Valve
L. P
Intake
Valve
L. P
Exhaust
Valve
H.P
Exhaust
Valve
H.P
Intake
Valve
H.P ExhaustL. P Intake
Valve Components
13 - Copper Washer
59 - Cap
69 - Gasket
62 - Valve Retainer
68 - Retainer Spacer
48 - Valve
72 - Valve Seat
Air Filter Intake
L. P & H.P
Exhaust
Torque: Foot Lbs.
Headbolts: 55
Valve Retainer: 80
Air Compressor Cylinder Head
Parts Breakdown
6
61 - Valve Retainer
55 - Retainer Spacer
15 - Valve
57 - Valve
CYLINDER HEAD
Order # 82288787 Spanner Tool,
to remove Valves.

13
CENTRIFUGAL UNLOADER
Ill. # Description Part No.
10 Cap - Rear 82701029
97 Holder - Unloader 82728002
98 Weight - Unloader 82728000
100 Pin - Hinge 82100100
103 Spring - Unloader 82723003
107 Plunger - Unloader 82728003
96 Cover - Centrifugal
Unloader 82728004
105 Gasket - Unloader Cover 82070166
102 Capscrew - Skt Hd
M6x20 G.H.
99 Elbow - Valve & Unloader 826155-S
99
102
103
100
107
98 10
71
06
98
96 105
97
Lubrication Intervals:
Recommended lubrication intervals are approximately every
9500 hours.
Lubrication Procedure:
Be sure that the grease you are adding to the motor is
compatible with the grease already in the motor. Consult
your Baldor distributor or an authorized service center if a
grease other than the recommended type is used.
With Grease Outlet Plug.
1. Clean all grease fittings.
2. Remove grease outlet plug.
3. If the motor is stopped, add the recommended amount of
grease. If motor is to be greased while running, a slightly
greater quantity of grease will have to be added. Add
grease slowly until new grease appears at shaft hole in
the endplate or purge outlet plug.
4. Re-install grease outlet plug.
Without Grease Outlet Plug.
1. Disassemble motor.
2. Add recommended amount of grease to bearing and
bearing cavity. (Bearing should be about 1/3 full of grease
and outboard bearing cavity should be about 1/2 full of
grease). Note: bearing is 1/3 full when only one side of
bearing is completely full of grease).
3. Assemble motor.
Lubrication Amounts
Weight of Grease
to be added: 0.61 Ounces 17 Grams
Volume of
Grease to be
added: 1.2 Cubic in. 3.9 Teaspoon
MAINTENANCE & TROUBLE SHOOTING
FOR ELECTRIC MOTOR
Warning: Disconnect power before servicing
Electric Motor.
General Inspection
Inspect the motor at regular intervals, approximately every
500 hours of operation or every 3 months, whichever
occurs first. Keep the motor clean and the ventilation
openings clear. The following steps should be performed at
each inspection:
1. Check that the motor is clean. Check that the interior
and exterior of the motor is free of dirt, oil, grease,
water, etc. Oily vapor, paper pulp, textile lint, etc. can
accumulate and block motor ventilation. If the motor
is not properly ventilated, overheating can occur and
cause motor failure.
2. Use a "Megger" periodically to insure that the integrity
of the winding insulation has been maintained. Record
the Megger readings. Immediately investigate any signifi
cant drop in insulation resistance.
3. Check all electrical connectors to be sure that they
are tight.
Lubrication & Bearings
Bearing Grease will lose its lubricating ability over time,
not suddenly. The lubricating ability of grease (over time)
depends primarily on the type of grease, the size of the
bearing, the speed at which the bearing operates and the
severity of the operating conditions. Good results can be
obtained if the following recommendations are used in your
maintenance program.
Type of Grease:
A high grade ball or roller bearing grease should be used.
Recommended grease for standard service conditions is
Polyrex EM (Exxon Mobile). Equivalent and compatible
greases include: Texaco Polystar, Rykon Premium #2,
Pennzoil Pen 2 Lube, and Chevron SRI.

14
ELECTRIC AIR COMPRESSOR
ILL. # Description Single Phase
Horizontal Three Phase Horizontal Single Phase Vertical Three Phase Vertical
1 Pump 3010 3010 3010 3010
2 Electric Motor 7.5 HP 827500MA 827500MB 827500MA 827500MB
2 Electric Motor 10 HP 821000MB 821000MB
3 Magnetic Starter 230 Volt 8215PW 823710PW 8215PW 823710PW
3 Magnetic Starter 460 Volt 823710PW460 823710PW460
4 Tank 80 Gallon 8282 8282 8281 8281
4 Tank 120 Gallon 8283 8283 82288673
5 Motor Pulley 7.5 HP 823806 82306 82306 82306
5 Motor Pulley 10 HP 823764 823764
6 Check Valve 82C7510 82C7510 82P7510 82P7510
7 Belt Guard & Belt Guard Pan 82660 82660 82660 82660
Belt Guard Brace 82661 82661 82661 82661
8 Belts 7.5 HP 82890 82890 82890 82890
8 Belts 10 HP 82826 82826 82826 82826
9 Tank Drain 82650 82650 82650 82650
10 Pressure Gauge 82513 82513 82516 82516
11 Pressure Switch 140/175 82775 82775 82775 82775
12 Bleeder Tube 82600 82600 82600 82600
13 Discharge Tube 82603 &
AC Model# 82603 & AC Model # 82603H & AC Model # 82603H & AC Model #
14 3/4" Brass Adaptor 82623 82623 82623 82623
15 Safety Valve 200 PSI 82951 82951 82951 82951
16 3/4 Street Elbow 82654 82654 82654 82654
17 Air Filter Assembly 1" Intake 8232574 8232574 8232574 8232574
17
14
116 17
2
4
7
5
6
13 8
12
9
15
10
11
3

15
ELECTRIC AIR COMPRESSOR
ILL. # Description Single Phase
Horizontal Three Phase Horizontal Single Phase Vertical Three Phase Vertical
1 Pump 3010 3010 3010 3010
2 Electric Motor 7.5 HP 827500MA 827500MB 827500MA 827500MB
2 Electric Motor 10 HP 821000MB 821000MB
3 Magnetic Starter 230 Volt 8215PW 823710PW 8215PW 823710PW
3 Magnetic Starter 460 Volt 823710PW460 823710PW460
4 Tank 80 Gallon 8282 8282 8281 8281
4 Tank 120 Gallon 8283 8283 82288673
5 Motor Pulley 7.5 HP 823806 82306 82306 82306
5 Motor Pulley 10 HP 823764 823764
6 Check Valve 82C7510 82C7510 82P7510 82P7510
7 Belt Guard & Belt Guard Pan 82660 82660 82660 82660
Belt Guard Brace 82661 82661 82661 82661
8 Belts 7.5 HP 82890 82890 82890 82890
8 Belts 10 HP 82826 82826 82826 82826
9 Tank Drain 82650 82650 82650 82650
10 Pressure Gauge 82513 82513 82516 82516
11 Pressure Switch 140/175 82775 82775 82775 82775
12 Bleeder Tube 82600 82600 82600 82600
13 Discharge Tube 82603 &
AC Model# 82603 & AC Model # 82603H & AC Model # 82603H & AC Model #
14 3/4" Brass Adaptor 82623 82623 82623 82623
15 Safety Valve 200 PSI 82951 82951 82951 82951
16 3/4 Street Elbow 82654 82654 82654 82654
17 Air Filter Assembly 1" Intake 8232574 8232574 8232574 8232574
119
2
4
6
20
3
5
11
7
10
8
9
13
16
Pulley and Bushing
Pressure Gauge and Safety Valve
Discharge Tube
VENT
3/4
1/2
13
917
14 12
15
3
7
5
11
GAS AIR COMPRESSOR
ILL.# Description Part Number
1 Pump 823010
2 Briggs Gas Engine 82847V
3 Engine Pulley 823804
4 Tank 8279
5 Check Valve unloader 82709
6 Belt Guard & Belt Guard Pan 82660R
7 Belts 82827
8 Tank Drain 82650
9 Pressure Gauge 82516
10 Bleeder Tube 82600
11 Discharge Tube 82603H & Model Number
12 3/4" Brass Adaptor 82623
13 Safety Valve 200 PSI 82951
14 3/4" Street Elbow 82654
15 1/2" X 3/4" Brass Elbow 82595
16 Throttle Cable 82205BNK
17 1/4" Tee 82652
18 1/2" Street Elbow 82672
19 Air Filter Assembly 1" NPT Intake 8232574
20 Belt Guard Bracket 82661
Replacement Air Filter Element 822580

16
UNLOADER ADJUSTMENT
Installation
The Load Genie has 1/2 NPT “IN” and “OUT” ports
and is suitable for compressors with a discharge
of up to 32 SCFM . The Load Genie is typically
installed onto the tank with a short pipe nipple. The
“OUT” port must be connected directly to the tank
with no other check valves in between the tank and
the Load Genie.
Note:
On some retrofit applications, there may have been
a type of check valve known as an “In Tank” check
valve previously installed. Make sure there is a
clear air path between the tanks and “OUT” port
before installing the Load Genie. The compressor
discharge line can now be routed into the “IN” port
of the Load Genie.
The installation is now complete.
Regulator Adjustment
Cutout pressure is adjustable from 60 PSI to 175
PSI with the standard silver spring. The differential
(difference between cut-out and cut-in pressures)
is typically set at the factory at approximately 15%
of the cut-out pressure. This is usually a suitable differential
and will not normally need to be readjusted.
1. Loosen range screw jam nut first.
2. Turn range screw clockwise to raise cut-out and cut-in
pressure levels and counter clockwise to decrease
cut-out and cut-in levels.
3. Start compressor and note cut-out and cut-in pressures.
Make adjustments as necessary using range adjustment
screw, when acceptable, tighten range adjustment
screw jam nut.
4. Adjust the cut-in pressure to the desired level per steps
#1, #2, and #3, as shown.
5. Loosen differential screw jam nut and turn differential
screw clockwise to raise cut-out pressure and counter
clockwise to decrease the cut-out pressure. Tighten
differential screw jam nut when desired cut-out pressure
is set. Since step 5 should not change the desired cut-in
pressure set in step # 4, adjustment is now complete.
Use with Gasoline Engine Throttle
Controls
A 1/8 NPT tapped port in the end of the Load Genie allows
the use of a throttle control to slow down the driving engine
when in the cutout (venting) mode. The throttle control is
simply a small (e.g., 1/2” dia. X 1” stroke) single-acting,
spring return air cylinder which moves the throttle lever
on the engine to the idle position when the cylinder is
pressurized while in the cut-out mode.
Throttle control is specifically designed for this application. It
is important that the throttle control air cylinder is leak-tight
and that all connections between that Load Genie and the
air cylinder are leak-tight.
VENT
Inlet (Connected to Compressor)
1/8 NPT
Throttle Control Port
Differential Jam Nut
Differential Adjustment Screw
Range Jam Nut
Range Adjustment Screw
Out (Connected to Tank)
Vent Port
(See rear, open to
Atmosphere)
Loadgenie3 112807.ai
Easy Start Lever
Start Position Run Position
Load Genie 82709
Starting Unit
Easy Start: Place Easy Start Lever in upright position, Start
Unit, when running smoothly flip lever to run position.

17
17 1
22
55
3
14 15
11
6
12 16 13 10
4
897
6
17 17 17
1
14 15
DUPLEX ELECTRIC AIR COMPRESSOR
ILL.# Description Single Phase Three Phase 460 Three Phase
1 Pump 823010 823010 823010
2 Electric Motor 7.5 HP 827500MA 827500MB 827500MB
2 Electric Motor 10 HP 821000MB 821000MB
3 Controller 82289051 82289710 82289050
4 Tank 120 Gallon 82289048 82289048 82289048
4 Tank 200 Gallon 82289049 82289049
5 Motor Pulley 7.5 HP 823806 823806 823806
5 Motor Pulley 10 HP 823764 823764
6 Check Valve 82P7510 82P7510 82P7510
7 Belt Guard & Belt Guard Pan 82660R 82660R 82660R
8 Belt Guard & Belt Guard Pan `82660 82660 82660
9 Belts 7.5 HP 82890 82890 82890
9 Belts 10 HP 82826 82826
10 Tank Drain 82650 82650 82650
11 Pressure Gauge 82516 82516 82516
12 Pressure Switch 140 / 175 82775 82775 82775
13 Pressure Switch 130 / 165
(need to adjust) 82775 82775 82775
14 Bleeder Tube 82600 82600 82600
15 Discharge Tube Left 82603H & Model
Number + left 82603H & Model Number + left 82603H & Model Number + left
15 Discharge Tube Right 82603H & Model
Number + right 82603H & Model Number + right 82603H & Model Number + right
16 Safety Valve 200 PSI 82951 82951 82951
17 Air Filter Assembly 1" NPT Intake 8232574 8232574 8232574

18
Selective Selective Switch Instructions.
The Duplex control panel controls the operation of two
compressor motors by sharing the load between the two
motors. The panel contains 2 contactors with re-settable
motor-overload protective devices, and a Siemens LOGO™
logic device. Motor-A & Motor-B are supplied separate input
power sources. The power is connected to each of the
contactors. The LOGO device and the control circuits take
power from the Motor-A source.
Operation
When power is applied to the Motor-A and/or Motor-B
contactors, the panel is “hot”. That is, the pressure switch
wires and motor output leads may be “hot”.
Selector-Switch in LEFT position (Motor-A)
Motor-A operates when the 175-psi switch is made. The
135-psi switch is not used. Motor-B doesn’t operate.
Selector-Switch in RIGHT position (Motor-B)
Motor-B operates when the 175-psi switch is made. The
135-psi sensor is not used. Motor-A doesn’t operate.
Selector-Switch in CENTER position (Auto)
This position is for automatic operation. One motor
operates with a 15 second delay when the 175-psi switch
is made while the 135-psi switch does not. If the 175-psi
switch is made for more than 5 minutes, the second motor is
started. If both the 175-psi and 135-psi switches are made,
then both motors start with a 15 second delay between
starting of motors. Once air pressure is satisfied and both
motors stop, the motor that didn’t run last will start next.
That is, when the 175-psi switch is made, the motor which
had started second the last time is started first the next time.
Troubleshooting
1. Check that Motor inputs terminals are wired securely
and are powered.
2. Check the motor connections are complete and secure.
3. Check pressure switch connections.
4. Check two control power fuses mounted in terminal
blocks.
5. Check motor overloads – may need resetting.
6. Check LOGO controller light : OFF=no power, RED =
powered but faulted, GREEN= powered and running OK.
See wiring diagram.
Air
Compressor
A
Air
Compressor
B
AUTO
DUPLEX UNITS ONLY
Duplex Unit is powered by two motors from two
separate electrical power sources. The motors start
and stop automatically to maintain tank pressure.
Electric motors are programed to start with a delay.
Avoid injury: disconnect, tag, and lock-out both
electrical power sources and release air pressure
from tank and air lines before attempting to install,
relocate or perform any maintenance or repair.
WARNING

19
DUPLEX UNITS ONLY Wiring Diagram for 82289051
Single Phase 208/230 Volt Controller / Magnetic Starters
240 VOLT 1 PHASE
L1 I1 I2 I4 I5L2
PRESSURE SW B
PRESSURE SW A
FUSE 1 FUSE 2
L1 Q1 L1 Q2
COMP A COMP B
O.L. O.L.
MOTOR A MOTOR B
COMP
A
COMP
B
STARTER STARTER
L1 L2 L1 L2
T1 T3 T1 T3T2T2
L3 L3
EZ512-AC-RCX
COMP A BOTH COMP B
X
X
.5 A .5 A
RED
BLACK
RESET RESET
COIL COIL
A1
A2
A1
A2
LINE IN LINE IN
FROM DISCONNECT A FROM DISCONNECT B

20
DUPLEX UNITS ONLY Wiring Diagram for 82289049
Three Phase 208/230 Volt Controller / Magnetic Starters
L1 I1 I2 I4 I5L2
PRESSURE SW B PRESSURE SW A
FUSE 1 FUSE 2
L1 Q1 L1 Q2
COMP A COMP B
O.L. O.L.
MOTOR A MOTOR B
COMP
A
COMP
B
STARTER STARTER
THREE PHASE 240 VOLT
L1 L2 L3 L1 L2 L3
T1 T2 T3 T1 T2 T3
.5 A .5 A
X
X
RED
BLACK
EZ512-AC-RCX
COMP A BOTH COMP B
RESET RESET
LINE IN LINE IN
FROM DISCONNECT A FROM DISCONNECT B
COIL COIL
A1
A2
A1
A2