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ERVOR (SCA) - 6, Rue Désiré Granet - Z.I. du Val d'Argent - 95100 ARGENTEUIL FRANCE

(33) 01 34 11 50 00

(33) 01 34 11 50 10

Web : www.ervor.com - Email : [email protected]

Manual G06
Edition: 10/2015 - rev A

13 - E - PISTON DRIVE ASSEMBLY

PLANCHE N° 4

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Summary of Contents for G06

Page 1: ... Edition 10 2015 revA ERVOR SCA 6 Rue Désiré Granet Z I du Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com AIR COMPRESSOR OPERATING AND MAINTENANCE MANUAL ...

Page 2: ...essories and corresponding documentation without notice No part of this manual may be reproduced without the written permission of Ervor SCA Model Reference G06 STD ref 8 101 028 G06 Bureau Veritas ref 8 101 032 G06 Bureau Veritas with oil level switch ref 8 101 075 G06 Lloyd s Register of Shipping with oil level switch ref 8 101 035 8 101 028 G06 PERSONNEL SAFETY Whenever work is to be carried ou...

Page 3: ...ON 8 2 C OPERATING CHARACTERISTICS 9 FAD and power graph 10 3 DANGER SIGNALS 11 Danger zones 11 4 LAYOUT 12 Internal view 13 5 STORAGE 14 5 A UNDER 3 MONTHS 14 5 B 1 YEAR MAXIMUM 14 5 C OVER 1 YEAR AND EACH SUCCESSIVE YEAR 14 5 D STORAGE OIL 14 6 INSTALLATION 15 Installation example 15 7 USING THE COMPRESSOR FOR THE FIRST TIME 16 7 A SAFETY REMINDERS 16 7 B SAFETY MEASURES 16 7 C FIRST START UP 17...

Page 4: ...ENANCE 24 Tightening torque 24 10 A COMPRESSOR LUBRICATION 24 General characteristic of recommended oil 25 10 B CYLINDER HEADS VALVES 26 10 B 1 MAINTENANCE OF VALVES 27 Dismounting of valves 27 Remounting of valves 27 Tightening of the valve nuts 27 Frequency 27 10 C MOVING PARTS 28 Dismounting of the crankshaft 28 Remounting of the crankshaft 29 Fitting of crankshaft connecting rod piston shaft 2...

Page 5: ... 33 11 B RUNNING FAILURE 33 11 B 1 THE COMPRESSOR STARTS BUT TRIPS 33 11 B 2 THE COMPRESSOR RUNS BUT THERE IS NO DELIVERY PRESSURE 33 11 B 3 THE COMPRESSOR OVERHEAT 33 12 SPARE PARTS LIST 34 12 A RECOMMENDED SPARE PARTS 34 13 EXPLODED VIEW AND PARTS LIST 35 13 A GENERAL ASSEMBLY 35 13 B VENTILATION ASSEMBLY 36 13 C HIGH PRESSURE ASSEMBLY 38 13 D LOW PRESSURE ASSEMBLY 40 13 E PISTON DRIVE ASSEMBLY ...

Page 6: ...lwayskeepitwiththecompressor where you or any other operator can easily and quickly refer to it Read this manual and make sure you understand it fully before operating your compressor It can help you avoid making mistakes in its operation Pay special attention to the points marked These points deal with operations which can cause damage or injury if the instructions are not followed Always follow ...

Page 7: ...us This compressor has been specifically designed for the compression of air with an optimal working ratio of 1 3 2 3 working stop It is guaranteed for one year against faulty construction and defective material provided that the user complies with the instructions given in this manual The Ervor guarantee only covers the free replacement of parts that have been proved defective by our Technical De...

Page 8: ...traction 5 1 kW 4000 kCal h Cooling copper coil between stages Oil Splash Lubrication Powered by electric motor or combustion engine petrol or diesel Direct coupling with semi elastic blades or indirect coupling by drive pulley and belts Ambient temperatures for operation with standard equipment from 10 c to 40 c Weight with AC2 coupling 60 Kg approx Oil capacity 1 9 Litres approx 2 B MATERIAL DES...

Page 9: ...nd compression valves Valves Intake and compression valves are made of annular discs which operate automatically Manifold Aluminium manifold for improved cooling with integrated pulsation damper Cooling Efficient cooling ensured by light alloy turbine and Polycarbonate cowling 2 C OPERATING CHARACTERISTICS Working at 1500 rpm 50Hz Discharge pressure 30 bar 40 bar Nominal flow Nm h according to ISO...

Page 10: ... graph Ambient temperature 25 C Flow Power Pressure 4 2 5 2 5 55 5 95 6 4 6 65 6 8 6 95 7 05 40 36 33 5 32 5 32 3 31 8 31 32 31 05 30 8 0 5 10 15 20 25 30 35 40 Pressure bar FAD m h power consumption kW G06 Pressure bar FAD m h FAD Litres h Power consumption 0 40 665 4 2 5 36 600 5 2 10 33 5 560 5 55 15 32 5 540 5 95 20 32 3 538 6 4 25 31 8 530 6 65 30 31 32 522 6 8 35 31 05 518 6 95 40 30 8 514 7...

Page 11: ... 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com 3 DANGER SIGNALS Non breathable air noise hot parts High pressure Rotating fan Moving parts Fluid ejection Danger zones Dangerous electric voltage ANY WORK ON ELECTRICAL INSTALLATION EVEN OF MINOR IMPORTANCE MUST BE CARRIED OUT BY QUALIFIED PERSONNEL ...

Page 12: ...Page 12 ERVOR SCA 6 Rue Désiré Granet Z I du Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com ManualG06 Edition 10 2015 revA 4 LAYOUT ...

Page 13: ...Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com Internal view Crank shaft Double bearing Monobloc piston Connecting rod with bronze bushing Copper coil between stages Fan cowling Valves Pulsation damper Air filter ...

Page 14: ...linder heads Fill the compressor with storage oil Start the compressor and run for 10 min off load introduce 20cl of oil into the compressor air intake A sealed package long term category 4C with dehydrating packs conforming to S E I norms 5 C OVER 1 YEAR and EACH SUCCESSIVE YEAR Drain storage oil carefully Fill up with new storage oil Start the compressor and run for 10min off load Start the comp...

Page 15: ...he compressor must be placed at a minimum distance of 200 mm from any wall or any other machine for efficient cooling of the compressor Install the compressor on a mounting plate or on a solid floor IF THE COMPRESSOR ROOM IS TOO SMALL TEMPERATURE REGULATION SHOULD BE INSTALLED THE TEMPERATURE OF THE COMPRESSOR ROOM SHOULD NOT EXCEED 40 C AT ANY TIME Installation example 1 Compressor 2 Check valve ...

Page 16: ...Y QUALIFIED PERSONNEL WHO ARE CONVERSANT WITH THE INSTRUCTIONS IN THIS MANUAL SHOULD OPERATE AND OR MAKE ADJUSTMENTS TO THE COMPRESSOR AND ELECTRIC MOTOR DO NOT ATTEMPT TO CARRY OUT MAINTENANCE OR REPAIRS WHILE THE MOTOR IS RUNNING NEVER START THE COMPRESSOR WITHOUT THE COUPLING PROTECTION NEVER CLOG THE AIR FILTER 7 B SAFETY MEASURES BEFORE THE FIRST START UP CHECK THE OIL LEVEL CHECK THE SUPPLY ...

Page 17: ... vibrations and variations between the compressor and its drive motor It can be used with an electric motor drive as well as a combustion engine COUPLING TYPE AC2 NUMBER OF BLADES 24 MAXIMUM POWER TRANSMITTED 15 hp 11kW It is absolutely necessary that after mounting both plates should move angularly in relation to each other The measurement between these two plates must be maintained while mountin...

Page 18: ...ommendations for assembly Fit the short hub coupling plate on the end of the compressor drive shaft Fit the long hub coupling plate on the end of the motor drive shaft Mount the drive motor onto the common frame Assemble the semi elastic blades between the intermediate plate and the plate on the motor drive side as shown below Align the compressor and motor by adjusting the coupling according to t...

Page 19: ...the high pressure side The observer in front of the exposed compressor drive shaft will see the rotation of the coupling according to the figure below THE OBSERVER IN FRONT OF THE EXPOSED COMPRESSOR DRIVE SHAFT DRIVING BY AN ELECTRIC MOTOR THREE PHASE SUPPLY When the power supply of the motor is connected check the direction of rotation The direction of rotation of an electric motor can be reverse...

Page 20: ...ed by recommended oil Check oil level Coupling Check distance between coupling plates tightness and alignment Check the coupling guard is correctly installed Driving Electric motor Check the electric motor circuit breaker protection has appropriate adjustment Check the direction of rotation Check the power supply Combustion engine Check oil and fuel level CHECK THAT THE VOLTAGE SUPPLY IS IN ACCORD...

Page 21: ...ERATE AND OR MAKE ADJUSTMENTS TO THE COMPRESSOR AND ELECTRIC MOTOR Before any adjustments Stop the compressor Cut off the power supply Ensure power supply cannot be re established accidentally Isolate the compressor from the air network by closing the compressed air delivery isolating valve Vent the compressor Wait a few minutes for the compressor s internal pressure to equal atmospheric pressure ...

Page 22: ...ase of automatic drain 9 B EVERY 25 HOURS Check the oil level 9 C AFTER THE FIRST 50 HOURS Drain oil and refill with fresh oil 9 D EVERY 250 HOURS Replace the air intake filter 9 E EVERY 500 HOURS OR EVERY YEAR Drain oil and refill with fresh oil Check intake and compression valves 9 F EVERY 1500 HOURS Replace intake and compression valves Replace gaskets Replace the air intake filter Check the oi...

Page 23: ...ing coil assembly Check the piston rings Check the coupling Check the cylinder heads Check the connecting rod Check the pistons and the cylinders Replace the cooling coil assembly Replace intake and compression valves Replace gaskets Replace the air intake filter Replace the cylinder heads Replace the oil plug and the oil drain plug Replace the piston rings Drain oil and refill with fresh oil Clea...

Page 24: ...ge due to leaks or clogging of the oil pipe However it is imperative to maintain the oil level in the casing above the minimum level that the compressor runs over its minimum speed of 600 rpm to respect the indicated direction of rotation see chapter Direction of Rotation to respect a max inclination of 30 on the two axis WASTE OIL DISPOSAL MUST BE IN ACCORDANCE WITH COUNTRY LEGISLATION M6 M8 M10 ...

Page 25: ...8 550 001 Can 2L To consult us for superior temperatures in 40 C OIL CAPACITY 1 9 LITRES approx WARNING ERVOR CANNOT BE RESPONSIBLE FOR BREAKDOWNS DUE THE USE OF NON RECOMMENDED LUBRICANTS SOME LUBRICANTS ARE NOT MISCIBLE WITH OTHER LUBRICANTS WE ADVISE THE MAXIMUM PRECAUTIONARY MEASURES BEFORE CHANGING LUBRICANTS EVERY 8 HOURS OF USE OIL LEVEL CHECK AFTER 50 HOURS OF USE FIRST DRAINING EVERY 500 ...

Page 26: ...lG06 Edition 10 2015 revA 10 B CYLINDER HEADS VALVES Intake and compression valves are made of annular discs which operate automatically Good water tightness is necessary between the discs and their seats avoid running the compressor with clogged valves with carbon deposits oil carbon or more importantly with broken valves Low Pressure stage High Pressure stage ...

Page 27: ...LEAN THE VALVES WITH INFLAMMABLE LIQUIDS E G PETROLEUM Remounting of valves Remount valve on the cylinder head according to the figure on the previous page Do not forget the belleville washer and split pin which prevent the slackening of the valve stem nut Tightening of the valve nuts After tightening the castellated nut to a torque reading of 10 Nm continue to tighten the nut until the first notc...

Page 28: ...mble the coupling plate or the drive pulley and the air fan mounted on each end of crankshaft in case of difficulty remove the parts with a bearing puller With a bearing puller remove the bearing housing on the coupling side Remove the casing cover Take out the grooved pin in counterweight Remove the counterweight Remove the remaining bearing housing with the crankshaft on the fan side and rotate ...

Page 29: ...correct orientation Place the spacer on the side towards the circlips Fit the bearing housing Remount the air fan and the coupling plate or the drive pulley IMPORTANT AFTER REASSEMBLY MANUALLY CHECK THAT THE CONNECTING ROD REVOLVES FREELY THE SPACER MUST HAVE LATERAL PLAY BETWEEN THE CONNECTING ROD AND BEARING Fitting of crankshaft connecting rod piston shaft Connecting rod crakshaft Piston shaft ...

Page 30: ...f the piston rings Check the play at the cut of each new piston ring by placing it carefully in the cylinder bore Piston ring diameter play at cut max ANTI LEAK 125 mm 1 00 mm SCRAPER 125 mm 1 00 mm ANTI LEAK 50 mm 0 60 mm SCRAPER 50 mm 0 70 mm 0 040 0 025 0 0 0 0 0 06 0 05 LOW PRESSURE HIGH PRESSURE CYLINDERS Ø125 H7 Ø50 H7 PISTON Ø124 7 Ø49 8 Diameter mm Play at cut Thickness mm Anti leak 2 125 ...

Page 31: ...h holes for the return flow of oil to the casing are fitted in the grooves see figure below Mounting of scraper piston rings There is no special direction for mounting Mounting of anti leak piston rings Anti leak piston rings used in ERVOR compressors are conical Therefore it is imperative to mount them in the correct direction A mark is etched on one of the faces of the anti leak piston rings The...

Page 32: ... good condition Before mounting cylinders make sure that each gap of the piston ring is rotated 120 approximately in relation to the gap of the preceeding piston ring Mounting of cylinders For remounting of the cylinders start by remounting the low pressure cylinder on the piston fitted with its rings then mount the high pressure cylinder Wear of the piston ring grooves The efficiency of a compres...

Page 33: ...1 B 2 THE COMPRESSOR RUNS BUT THERE IS NO DELIVERY PRESSURE 11 B 3 THE COMPRESSOR OVERHEAT Source of errors Solution No power supply Check voltage Coupling broken Replace Piston jams Replace piston and fill with oil level Source of errors Solution Airing broken Replace decompression device Loose cable Check the wiring Source of errors Solution Broken piston Replace Broken output valve Replace Sour...

Page 34: ...et of piston rings LP HP 1 8 970 089 U V C V C Cooling coil assembly G06 1 8 141 539 V C V C Cooling coil shock absorber set G06 1 8 960 084 V C V C Set of AC2 coupling blades 1 8 970 054 U V V V V Oil sight glass 2 7 233 006 U V C V C Oil plug gasket 1 7 603 062 U V C V C Oil discharge plug 2 7 603 017 U V C V C Oil discharge plug gasket 2 7 503 002 U V C V C Intake filter mounting clip 2 8 200 0...

Page 35: ...IL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com 13 EXPLODED VIEW AND PARTS LIST 13 A GENERAL ASSEMBLY ITEM DESCRIPTION ILLUSTRATION 001A VENTILATION ASSEMBLY 1 010A HIGH PRESSURE ASSEMBLY 2 020A LOW PRESSURE ASSEMBLY 3 030A PISTON DRIVE ASSEMBLY 4 040A CASING COVER 5 ...

Page 36: ...L FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com ManualG06 Edition 10 2015 revA 13 B VENTILATION ASSEMBLY ILLUSTRATION N 1 120 For assembly check that the arrow is positioned downward The contact is opened when the float is in low position ...

Page 37: ......

Page 38: ...CA 6 Rue Désiré Granet Z I du Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com ManualG06 Edition 10 2015 revA 13 C HIGH PRESSURE ASSEMBLY ILLUSTRATION N 2 ...

Page 39: ...asket 8 970 174 3 500 005 050A 2 Valve stem 8 970 177 3 925 002 060A 1 Intake stop 8 970 177 3 936 007 070A 4 Valve spring Ø30 8 970 177 3 933 012 080A 1 High pressure cylinder head 8 970 179 3 932 008 090A 2 High pressure valve Ø30 8 970 177 3 933 003 100A 4 Belleville washer 8 970 177 7 421 009 110A 2 Castellated nut 8 970 177 3 933 024 120A 2 Split pin 8 970 177 7 436 004 130A 1 High pressure m...

Page 40: ...CA 6 Rue Désiré Granet Z I du Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com ManualG06 Edition 10 2015 revA 13 D LOW PRESSURE ASSEMBLY ILLUSTRATION N 3 ...

Page 41: ...70 177 7 436 004 080A 8 Belleville washer 8 970 177 7 421 009 090A 4 Castellated nut 8 970 177 3 933 024 100A 2 Low pressure compression stop 8 970 177 3 936 020 110A 10 Valve spring Ø35 8 970 177 3 933 013 120A 4 Low pressure valve Ø35 8 970 177 3 933 042 130A 1 Low pressure cylinder head 8 970 178 3 932 007 140A 2 Low pressure intake stop 8 970 177 3 936 010 150A 6 Valve stem 8 970 177 3 925 002...

Page 42: ...R SCA 6 Rue Désiré Granet Z I du Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com ManualG06 Edition 10 2015 revA 13 E PISTON DRIVE ASSEMBLY PLANCHE N 4 ...

Page 43: ... 930 018 oil level switch ref 7 710 024 090A 2 Oil sight glass 1 7 233 006 100A 2 Oil discharge plug 7 603 017 110A 2 Woodruff key 8 920 011 120A 1 Cranckshaft 8 920 011 130A 2 Counterweight 8 920 011 140A 2 Ø6 Slotted spr pin 8 920 011 150A 1 Spacer 3 921 011 160A 1 Ø 72 Internal Circlip 170A 1 Read bearing housing 3 936 011 180A 4 Soc hd cap screw M8 x 25 190A 4 Crinkle washer M8 200A 2 Ø 30 Int...

Page 44: ...Granet Z I du Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com ManualG06 Edition 10 2015 revA 13 F CASING COVER 14 F 1 WITHOUT INTEGRATED REGULATION ILLUSTRATION N 5 030A ...

Page 45: ... info ervor com TO ORDER SPARE PARTS SEE CHAPTER 12 ILLUSTRATION N 5 ITEM QUANTITY DESCRIPTION SPARE PARTS REFERENCE 001A 1 Casing cover gasket 8 970 174 010A 1 Casing cover 3 941 055 020A 2 Soc hd capscrew M8 x 20 030A 1 Complete cranckcase breather 8 938 003 040A 2 Soc hd capscrew M8 x 85 050A 1 Connection M 1 8 x Ø6 for rilsan 4x6 8 970 180 This part is not illustrated ...

Page 46: ... Granet Z I du Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com ManualG06 Edition 10 2015 revA 14 TOOLS 14 A GENERAL RECOMMENDATIONS Choose good tools and don t inch mm ...

Page 47: ...l tolls are metric dimensions 1 Torque wrench 1 Set combination spanners open ended ring 1 Socket set 1 Set allen key 1 Adjustable spaner maximum open 46mm 1 Adjustable spaner maximum open 55mm 1 Piston ring expenders Ø50 1 Piston ring expenders Ø125 1 Piston guide Ø50 1 Piston guide Ø125 1 Pair external circlip pliers Ø30 1 Pair external circlip pliers Ø72 1 Bearing puller 1 Set screwdriver 1 res...

Page 48: ...Page 48 ERVOR SCA 6 Rue Désiré Granet Z I du Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com ManualG06 Edition 10 2015 revA NOTES ...

Page 49: ...Page 49 ManualG06 Edition 10 2015 revA ERVOR SCA 6 Rue Désiré Granet Z I du Val d Argent 95100 ARGENTEUIL FRANCE 33 01 34 11 50 00 33 01 34 11 50 10 Web www ervor com Email info ervor com ...

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