Oilless Reciprocating Air Compressor Pumps Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference. Description GENERAL Powerex utilizes cutting-edge compressor technology to provide the most advanced oilless reciprocating air compressor in the industry. The Powerex reciprocating compressor is available in single and two stage models. Continuously lubricated, sealed bearings provide oil-free compressed air and long compressor life. The onboard fan, nned ywheel and temperature reducing composite piston create lower operating temperatures. DRY TYPE INLET FILTER The inlet lter on the oilless compressor assures 99% of particulate free air, down to 10 micron, is admitted to the unit. Change every 2500 hours or more often in dirty locations (See Figure 5). PISTON AND PISTON RINGS The Powerex oilless reciprocating compressor pistons are made of a high-strength, self-lubricating composite using the most advanced technology available. These heat reducing pistons eliminate the effect of excessive grease leakage at the wrist pin bearing. PTFE rings reduce wear and provide self lubrication. Piston rings should be replaced every 10,000 hours of operation (See Figure 12). Specications (Series) Product OPS / OPT Series Powerex Air Compressor Pumps Performance Specications Grease-lled Bearing Pressure Settings Cut-In: 90 psig Cut-Out: 120 psig Cut-In: 125 psig Cut-Out: 145 psig (High Pressure Unit) BEARING REGREASE The wrist pin bearings of the OPS and OPT oilless compressors are needle bearings protected by two outer lip seals. This needle bearing becomes impacted and requires regreasing at 5,000 hours (See Figure 15). BEARING SEALS The wrist pin bearing lip seals prevent the lubricating grease from leaking from the bearing area. The two lip seals on each connecting rod require replacement every 10,000 hours (See Figure 16-22 or page 9). Powerex • 150 Production Drive • Harrison, OH 45030 • USA 1-888-769-7979 • www.powerexinc.com

Oilless Reciprocating Air Compressor Pumps Specications (Performance) Max. PSIG Safety Guidelines This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols. Notice indicates important information, that if not followed, may cause damage to equipment. Clearance must allow for safe, effective inspection and maintenance. Caution indicates a potentially minor or moderate injury. Never install the compressor where the ambient temperature...

Oilless Reciprocating Air Compressor Pumps Installation (Continued) Powerex oilless compressors operate at a standard pressure of 120 PSIG. Two stage compressors operate at a maximum of 145 PSIG and are equipped for continuous run operation. Compressor RPM’s are established by Powerex based on horsepower and operating pressure. Refer to the general safety guidelines manual. 1. Make sure the piping is lined up without being strained or twisted when assembling the piping for the compressor. Appropriate expansion loops or bends should be installed at the compressor to avoid stresses caused by changes...

Oilless Reciprocating Air Compressor Pumps Maintenance Schedule Operating Hours Item Action needed Drain moisture Inspect, Replace Remarks Drain tank daily Every 2500 hours or less Compressor Fins Inspect, Replace Compression Rings Inspect, Replace Every 2500 hours or less Inspect, Replace Inspect, Replace Bearing Seal Wrist Pin Inspect, Replace Inspect Replace Inspect and perform maintenance periodically according to maintenance schedule. The maintenance schedule relates to the normal operating conditions. If the circumstances and load condition are adverse, shorten the cycle time and do maintenance...

Oilless Reciprocating Air Compressor Pumps 5000 Hours - Valve Inspection / Replacement Per OSHA regulations, ALL power must be locked out before performing any maintenance. Remove head bolts from cylinder head. Remove cylinder head and valve set. If it is difcult to remove by hand, insert screwdriver between cylinder and valve set and remove (See Figure 6 and 7). Check if exhaust valve (A) sticks to seat or is damaged (See Figure 8). Check if there is breakage, gouge or damage to appearance of intake valve (B). Lift intake valve 10 mm (3/8 inch) and check if there is peeling and/or wear on coating...

Oilless Reciprocating Air Compressor Pumps Cylinder Inspection / Replacement Per OSHA regulations, ALL power must be locked out before performing any maintenance. Remove cylinder head and valve set. Pay attention not to lose semicircular (black plastic) seat inserted at top surface of cylinder (see Figure 9). Remove cylinder bolts and pull off cylinder slowly. Make sure piston does not drop down and get damaged. Note cylinder orientation. Inspect cylinder surface. If treated area is worn and metal is exposed, replace. If there are several vertical scratches at a narrow distance, replace (see...

Oilless Reciprocating Air Compressor Pumps 10,000 Hours - Piston Ring Replacement Per OSHA regulations, ALL power must be locked out before performing any maintenance. Remove cylinder head tubing and cylinder bolts. Pull cylinder and head assembly off slowly. Do not allow piston to drop out of cylinder and get damaged. Remove piston rings. Do not use ring tool to remove ring. Expand by hand only wide enough to remove from piston. Note orientation of each for proper replacement. NOTE: Expanding ring too much and deforming can cause wear and leakage. (See Figure 12). Mark upper surface (not lower...

Oilless Reciprocating Air Compressor Pumps 3. For high pressure wrist pin bearings, replace wrist pin (#91924680). (OPT Pumps Only) Replace cylinder/head assembly and piston as in procedures above. 10,000 Hours - Piston Ring Replacement (Continued) Tighten all ttings and bolts to designated torques. WRIST PIN BEARING REGREASE 1. Remove cylinder/head assembly and piston. For low pressure wrist pin bearings, ll needle area with IP634500AJ Powerex approved grease. Piston Orientation Chart for Oilless OPS / OPT Series Pump Compressor Model No. of Piston Rings per Piston Mark on Top of Piston Flywheel...