Bauer Compressors Junior II WT Manuel

Instruction Manual and Replacement Parts List

BAUER Compressors, Inc. Phone: (757) 855-6006

1328 Azalea Garden Road Fax: (757) 855-6224

Norfolk, Virginia 23502-1944 www.bauercomp.com

April 26, 2007 1st ed. Rev 0 Chg 3 MNL-0391

BAUER

COMPRESSORS

Junior II

High Pressure Air Compressor Unit

Junior II WT

Page i 1st ed. Rev 0 Chg 3

BAUER

COMPRESSORS

This information is believed to be accurate by Bauer Compressors, Inc., as of it’s date of publication,

but Bauer offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information

set forth herein. Bauer shall not be liable for inaccuracies in, or consequences resulting from, your use

of this information. All information supplied is in connection with sales of Bauer’s products, and is thus

subject to Bauer’s standard terms and conditions of sale. Bauer reserves the right to change this infor-

Inc., and Bauer reserves to itself all rights to this publication. Bauer’s customers have no right to repro-

duce, rewrite, modify, license or permit anyone else’s use of this information, without the express writ-

ten permission of Bauer Compressors, Inc.

EDITIONS, REVISIONS AND CHANGES

• An Edition is the original or a complete rewriting of the entire Manual.

• A Revision occurs whenever a complete Section or Appendix is rewritten or added.

• A Change occurs when individual pages, drawings or tables are changed.

^ WARNING ^

This Instruction Manual and Replacement Parts List contains safety information and instructions for the

Junior II WT High Pressure Air Compressor Unit.

You must read, understand and follow all safety precautions and instructions.

1st Edition

Rev Chg Date Notes Auth

0 0 02/28/2005 JD

0 1 9/9/2005 Changed Intermediate Separator to P/N 081800 JD

0 2 07/11/2006 Changes to Fig 3-14 JD

0 3 04/26/2007 Updated compressor block to Parts List TJ-4/7 from BKM JD

MNL-0391

April 26, 2007 Page ii

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COMPRESSORS

TABLE OF CONTENTS

CHAPTER 1:- - - - - - - - - - - - - - - - - - - - - INTRODUCTION

1.1 HOW TO USE THIS MANUAL.........................................................................................................................................1

1.1.1 Manual Safety Notices.......................................................................................................................................................1

1.2 HOW TO USE THE REPLACEMENT PARTS LIST....................................................................................................2

1.3 HOW TO USE THE APPENDIX.......................................................................................................................................3

1.4 DESIGN................................................................................................................................................................................4

1.5 AIR FLOW DIAGRAM......................................................................................................................................................5

1.5.1 Junior II WT.......................................................................................................................................................................6

1.5.2 Compressor Block Technical Specifications......................................................................................................................6

1.5.3 Compressor Drive Technical Specifications......................................................................................................................6

CHAPTER 2:- - - - - - - - - - - - - - - - - - - - - - - OPERATION

2.1 PREPARATION FOR OPERATION................................................................................................................................7

2.2 STARTING THE UNIT. .....................................................................................................................................................7

2.3 FILLING PROCEDURE ....................................................................................................................................................7

2.3.1 General Procedures ..........................................................................................................................................................8

2.3.2 Bottle Filling Procedures....................................................................................................................................................8

2.3.3 Connecting to the Air Storage Bottle.................................................................................................................................9

2.3.4 Filling the Bottle.................................................................................................................................................................9

2.3.5 Removing the Bottle...........................................................................................................................................................9

2.4 SHUT-DOWN PROCEDURES..........................................................................................................................................9

CHAPTER 3:- - - - - - - - - - - - - - - - JUNIOR II COMPRESSOR

3.1 LUBRICATION.................................................................................................................................................................10

3.1.1 Oil Level Check ...............................................................................................................................................................10

3.1.2 Type of Oil ....................................................................................................................................................................10

3.1.3 Oil Changes......................................................................................................................................................................11

3.1.3.1 Oil Change Procedures.................................................................................................................................................11

3.2 INTAKE FILTER..............................................................................................................................................................11

3.2.1 Description.......................................................................................................................................................................11

3.2.2 Maintenance.....................................................................................................................................................................11

3.2.3 Telescope Intake Tube .....................................................................................................................................................12

3.2.4 Intermediate Separator .....................................................................................................................................................12

3.2.5 Maintenance.....................................................................................................................................................................13

3.3 COMPRESSOR VALVES ................................................................................................................................................13

3.3.1 Description.......................................................................................................................................................................13

3.3.2 Initial Operational Check ................................................................................................................................................13

3.3.3 Changing the Valves ........................................................................................................................................................13

3.3.4 Changing the 1st Stage Valves.........................................................................................................................................14

3.3.5 Changing the 2nd Stage Valves .......................................................................................................................................15

3.3.6 Changing the 3rd Stage Valves........................................................................................................................................16

3.4 REPAIR AND TROUBLESHOOTING...........................................................................................................................17

3.4.1 General Repair Instructions..............................................................................................................................................17

3.4.2 Troubleshooting Tables ...................................................................................................................................................18

Junior II WT

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COMPRESSORS

3.4.2.1 Electric Motor...............................................................................................................................................................18

3.4.2.2 Gasoline Engine............................................................................................................................................................18

3.4.2.3 Compressor Block.........................................................................................................................................................18

3.5 REPLACEMENT PARTS LIST ......................................................................................................................................20

CHAPTER 4:- - - - - - - - - - - - - - - - - - - JRIIMAINTENANCE

4.1 MAINTENANCE RECORD.............................................................................................................................................33

4.2 MAINTENANCE SCHEDULE........................................................................................................................................33

4.2.1 After the First 25 Operating Hours...................................................................................................................................33

4.2.2 Every 125 Operating Hours..............................................................................................................................................34

4.2.3 Every 2000 Operating Hours or Biennially......................................................................................................................34

4.2.4 Annually or As Required..................................................................................................................................................35

4.2.5 After Repair Work............................................................................................................................................................36

4.2.6 After Storage and Preservation.........................................................................................................................................38

CHAPTER 5:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

5.1 GENERAL..........................................................................................................................................................................39

5.1.1 General Purification System Procedures..........................................................................................................................39

5.1.2 Chamber Safety Bore .......................................................................................................................................................39

5.1.3 Manual Condensate Drainage...........................................................................................................................................40

5.1.4 Model, Serial Number and Part Number Identification ...................................................................................................40

5.1.4.1 Compressor Dataplate...................................................................................................................................................40

5.1.4.2 Purification System Dataplate ......................................................................................................................................40

5.1.4.3 Cartridge Installation Dataplate....................................................................................................................................40

5.1.5 Industrial Purification System Configurations ................................................................................................................41

5.1.6 Cartridge Operating Life ..................................................................................................................................................41

5.1.6.1 Calculating the Maximum Cartridge Operating Hours.................................................................................................42

5.1.6.2 Calculating the Adjusted Cartridge Operating Hours...................................................................................................42

5.1.6.3 Purification Cartridge Operating Hours Form..............................................................................................................44

5.2 P0 PURIFICATION SYSTEM.........................................................................................................................................45

5.2.1 Description .......................................................................................................................................................................45

5.2.2 Maintenance .....................................................................................................................................................................46

5.2.2.1 Replacing the Cartridge ................................................................................................................................................46

5.2.2.2 Chamber Replacement Interval ...................................................................................................................................47

5.2.3 Replacement Parts List.....................................................................................................................................................49

CHAPTER 6:- - - - - - - - - - - - - - - - - - - - MISCELLANEOUS

6.1 SAFETY VALVES.............................................................................................................................................................51

6.1.1 Description .......................................................................................................................................................................51

6.1.2 Maintenance .....................................................................................................................................................................51

6.1.2.1 Checking Function........................................................................................................................................................51

6.1.2.2 Checking Blow Off Pressure ........................................................................................................................................51

6.2 PRESSURE GAUGE .........................................................................................................................................................51

6.2.1 Maintenance .....................................................................................................................................................................51

6.3 COMPRESSOR DRIVE SYSTEM..................................................................................................................................52

6.3.1 Description .......................................................................................................................................................................52

6.3.2 Checking the Drive Belt...................................................................................................................................................52

6.3.3 V-belt Tension Adjustment ..............................................................................................................................................52

6.3.4 Electric Maintenance........................................................................................................................................................52

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6.4 COOLING SYSTEM.........................................................................................................................................................53

6.4.1 General.............................................................................................................................................................................53

CHAPTER 7:- - - - - - - - - - - - - - - - - - - - - - - - APPENDIX

7.1 SAFETY..............................................................................................................................................................................54

7.1.1 General Safety Precautions ..............................................................................................................................................54

7.1.2 Safety Warning Labels.....................................................................................................................................................56

7.2 INSTALLATION...............................................................................................................................................................57

7.2.1 Corrosion Resistance........................................................................................................................................................57

7.2.2 Outdoor Location .............................................................................................................................................................57

7.2.3 Indoor Location................................................................................................................................................................57

7.2.3.1 Electrical Installation....................................................................................................................................................57

7.3 STORAGE AND PRESERVATION...............................................................................................................................58

7.3.1 Storage..............................................................................................................................................................................58

7.3.2 Preservation......................................................................................................................................................................59

7.3.2.1 Preparation for Preservation.........................................................................................................................................59

7.3.2.2 Preserving the Compressor...........................................................................................................................................59

7.3.2.3 Preserving the Motor or Engine....................................................................................................................................59

7.3.2.4 Preventive Maintenance During Storage......................................................................................................................59

7.3.2.5 Reactivating the Compressor Unit................................................................................................................................60

7.4 TABLES AND REFERENCE DATA ..............................................................................................................................61

7.4.1 Tightening Torque Values ............................................................................................................................................61

7.4.2 Pipe Connections (swivel nuts)........................................................................................................................................61

Junior II WT

Page v 1st ed. Rev 0 Chg 3

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COMPRESSORS

LIST OF FIGURES

CHAPTER 1:- - - - - - - - - - - - - - - - - - - - - INTRODUCTION

Figure 1-1 Junior II WT ............................................................................................................................................................4

Figure 1-2 Internal Air Flow Diagram ......................................................................................................................................5

CHAPTER 2:- - - - - - - - - - - - - - - - - - - - - - - OPERATION

Figure 2-1 Air Storage Bottle Valve Operating Sequence........................................................................................................8

CHAPTER 3:- - - - - - - - - - - - - - - - JUNIOR II COMPRESSOR

Figure 3-1 Oil Dipstick Markings ...........................................................................................................................................10

Figure 3-2 Intake Filter............................................................................................................................................................11

Figure 3-3 Intermediate Separator...........................................................................................................................................12

Figure 3-4 Valve Function.......................................................................................................................................................13

Figure 3-5 1st Stage Plate Valve .............................................................................................................................................13

Figure 3-6 1st Stage Valve Head.............................................................................................................................................14

Figure 3-7 2nd Stage Valve Head ...........................................................................................................................................15

Figure 3-8 3rd Stage Valve Head............................................................................................................................................16

Figure 3-9 Removing the 3rd Stage Valves ............................................................................................................................17

Figure 3-10 Crankcase, Driving Gear and Fanwheel................................................................................................................20

Figure 3-11 Pistons and Cylinders ............................................................................................................................................22

Figure 3-12 Valve Heads and Valves........................................................................................................................................24

Figure 3-13 Cooler ....................................................................................................................................................................26

Figure 3-14 Intake Filter and Intermediate Separator ...............................................................................................................28

Figure 3-15 Frame with Accessories.........................................................................................................................................30

Figure 3-16 Special Tools .........................................................................................................................................................32

CHAPTER 4:- - - - - - - - - - - - - - - - - - - JRIIMAINTENANCE

There are no Figures in this Chapter

CHAPTER 5:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

Figure 5-1 Cartridge Safety Venting.......................................................................................................................................39

Figure 5-2 Purification System Dataplates (typical)...............................................................................................................40

Figure 5-3 Correction Factor for Cartridge Operating Hours .................................................................................................43

Figure 5-4 Example Record of Adjusted Operating Hours.....................................................................................................43

Figure 5-5 P0 Purification Chamber........................................................................................................................................45

Figure 5-6 P0 Purification System Cross Section ...................................................................................................................46

Figure 5-7 P0 Purification System Parts List..........................................................................................................................49

CHAPTER 6:- - - - - - - - - - - - - - - - - - - - MISCELLANEOUS

Figure 6-1 Final Pressure Safety Valve...................................................................................................................................51

Figure 6-2 Gauges ...................................................................................................................................................................51

Figure 6-3 Checking V-belt Tension.......................................................................................................................................52

Figure 6-4 V-belt Pulley Alignment........................................................................................................................................52

CHAPTER 7:- - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX

Figure 7-1 Incoming Power Wiring Label ..............................................................................................................................58

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COMPRESSORS

CHAPTER 1: INTRODUCTION

1.1 How To Use This Manual

This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod-

uct(s) listed on the front cover.

All instructions in this manual should be observed and carried out as written to prevent damage or pre-

mature wear to the product or the equipment served by it.

If your unit is equipped with nonstandard accessories and/or options, supplemental information is nor-

mally included in other documentation; i.e. OEM Manuals or additional Bauer Manuals.

While every effort is made to ensure the accuracy of the information contained in this manual, Bauer

Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the

consequences thereof.

1.1.1 Manual Safety Notices

Important instructions concerning the endangerment of personnel, technical safety or operator safety

will be specially emphasized in this manual by placing the information in the following types of safety

notices.

^ DANGER ^

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury. This is limited to the most extreme situations.

^ WARNING ^

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death

or injury.

^ CAUTION ^

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury. It may also be used to alert against unsafe practices.

^ NOTE ^

NOTE advise of technical requirements that require particular attention by the operator or the

maintenance technician for proper maintenance and utilization of the equipment.

JUNIOR II WT

Page 2 1st ed. Rev 0 Chg 3

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COMPRESSORS

1.2 How to Use the Replacement Parts List

• A lozenge ◊in the Item Number column indicates the part number for a complete assembly.

• A dagger (†) in the Qty column with or without an ellipsis (…) in the Part Number column means the

part is illustrated for assembly purposes only and is not available for sale as an individual component.

This part can be obtained by ordering the complete assembly.

• AR in the Qty column means that the item is cut or manufactured to the size which the customer spec-

ifies.

• A dash (—) in the Item Number column indicates that there is more than one part number applicable

to the preceding Item Number.

• The letter(s) in the columns labeled Kit indicate the number of operating hours when the part is to be

replaced; a = replaced every 1,000 hours, b = replaced every 2,000 hours and c= replaced every 4,000

hours.

• NS in the Item Number column indicates the part is not illustrated but is available.

When placing an order for spare parts, please provide the following information to ensure delivery of

the correct parts. The model number, date of manufacture and serial number can be found of the com-

pressor unit identification plate on the compressor unit’s frame.

Information Example

Model Number TCOM25

Serial Number 32165

Date of Manufacture 02/2005

Quantity required 2

Part Number N04860

Part Description Valve

^ WARNING ^

The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe

conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-

threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, BAUER

Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are installed.

MNL-0391

April 26, 2007 Page 3

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COMPRESSORS

1.3 How to Use the Appendix

Information contained in the Appendix to this manual includes the following.

• The safety instructions applicable to this product. They must be read, understood and complied with

prior to operating the product.

• The instructions for installing this product. They must be read, understood and complied with prior to

operating the product.

• The instructions for long term storage (over 90 days) of this product.

Junior II WT

Page 4 1st ed. Rev 0 Chg 3

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COMPRESSORS

1.4 Design

The Junior II WT compressor units consists of the following major assemblies.

• Compressor Block

• Electric Motor Drive

• P0 Purification System

• Fill Hose Assembly

• Base Plate and Frame

Figure 1-1 Junior II WT

1. Oil Dipstick

2. Final Pressure Valve

3. P0 Purification System

4. Pressure Maintaining Valve

5. CO and Moisture Indicator

6. Fill Adapter

7. Pressure Gauge

8. AIr Intake Filter

9. Fill Hose

10. Electric Cable and Plug

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