OPERATOR’S, MAINTENANCE AND PARTS MANUAL AIR COMPRESSOR MMD 70 MMD Equipment Inc. 121 High Hill Road Swedesboro, NJ 08085 Tel: (800) 433-1382 Fax: (856) 467-5235 www.mmdequipment.
TABLE OF CONTENTS Operation & Maintenance Section Page Specifications ... 2 Safety ... 3-15 Description of Components ... 16-21 Compressor Operation ... 22-26 Compressor Inspection, Lubrication, And Maintenance ... 27-37 Troubleshooting ... 38-41 Recommended Spare Parts List ... 42 Warranty Section Warranty Information/Claims ...
ENGINE SPECIFICATIONS COMPRESSOR SPECIFICATIONS MODEL AC70 TYPE OIL FLOODED ROTARY SCREW DELIVERY (CFM) 70 CFM @ 100 PSIG (1.98m3/min) OPERATING PRESSURE RANGE HONDA 4-CYCLE, V-TWIN OHV AIR COOLED GASOLINE MODEL GX620K1-BOSS POWER @3600RPM HP (kw) 20 HP (15kw) 80-115 PSIG AMBIENT OPERATING TEMP. RANGE OIL SUMP CAPACITY TYPE DISPLACEMENT - cu. in. 37.5 cu. in. (614cc) (cc) -20 DEG TO +105 DEG F BORE & STROKE B - 3.03in (77mm) & S - 2.60in (66mm) OIL CAPACITY w/ FILTER 1.5 QUARTS (1.
SAFETY WARNING ALL UNITS ARE SHIPPED WITH A DETAILED OPERATOR’S, INSTALLATION AND PARTS MANUAL. THIS MANUAL CONTAINS VITAL INFORMATION FOR SAFE AND EFFICIENT OPERATION OF THIS UNIT. CAREFULLY READ THE OPERATORS MANUAL BEFORE STARTING THE UNIT. FAILURE TO READ AND COMPREHEND THE INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE. GENERAL The compressor is designed and manufactured to operate with relative safety.
SAFETY PARKING OR LOCATING COMPRESSOR Locate compressor on level areas, if possible. If not, locate compressor across grade, so the compressor does not tend to roll down hill. Do not locate compressor on grades exceeding 15 degrees (27%). Make sure compressor is parked or located on a firm surface that can support its weight.
SAFETY PRESSURE RELEASE (CONT.) Secure all hose connections by wire, chain or other suitable retaining devices to prevent tools or hose ends from being accidentally disconnected and expelled. Open compressor oil filler cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the sump (open service valve) pressure to zero before removing the oil filler cap.
SAFETY FIRE AND EXPLOSION (CONT.) Disconnect the ground (negative) battery connection prior to attempting any repairs or cleaning inside the enclosure. Tag the battery connection so others will not unexpectedly reconnect it. Keep electrical wiring, including the battery terminals and other terminals, in good condition. Replace any wiring that has cracked, been cut, abraded, or otherwise has degraded insulation; or terminals that are worn, discolored or corroded. Keep all terminals clean and tight.
SAFETY FIRE AND EXPLOSION (CONT.) Antifreeze compound used in air line anti-ice systems contains methanol, which is flammable. Use systems and refill with compound only in well-ventilated areas away from heat, open flames, or sparks. Do not expose any part of these systems or the antifreeze compound to temperatures above 150 degrees F (65 degrees C). Vapors from the antifreeze compound are heavier than air. Do not store compound or discharge air in confined or unventilated area.
SAFETY HOT SURFACES, SHARP EDGES AND SHARP CORNERS, INTAKE VACUUM Avoid bodily contact with hot oil, hot coolant, hot surfaces and sharp edges and corners. Keep all parts of the body away from all points of air discharge and away from hot exhaust gases. Wear personal protective equipment, including gloves and head covering when working in, on, or around the compressor. Keep a first aid kit handy. Seek medical assistance promptly in case of injury.
SAFETY TOXIC AND IRRITATING SUBSTANCES (CONT.) Fuels, oils, coolants, lubricants and battery electrolyte used in this compressor are typical of the industry. Care should be taken to avoid accidental ingestion and/or skin or eye contact. In the event of indigestion, seek medical treatment promptly. Do not induce vomiting if fuel is ingested. Wash with soap and water in the event of skin contact. Wear an acid resistant apron and a face shield or goggles when servicing the battery.
SAFETY LIFTING This compressor is provided with a lifting bail for routine lifting, loading onto trucks, etc. Compressors to be air lifted by helicopter must not be supported by the lifting bail, but instead by slings with appropriate spreader bars. In any event, lift only in full compliance with OSHA standards 29 CFR 1910 subpart N. Inspect lifting bail and points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting.
SAFETY JUMP STARTING Observe all safety precautions mentioned elsewhere in this manual. Batteries may contain and/or generate gases that are flammable and explosive. Keep flames, sparks and other sources of ignition away. Batteries contain acid that is corrosive. Do not allow battery acid to contact eyes, fabrics, or painted surfaces, as serious personal injury or property damage may result. Flush any contacted areas thoroughly with water immediately.
SAFETY JUMP STARTING (CONT.) Use only jumper cables that are clean, in good condition, and are heavy enough to handle the starting current. Avoid accidental contact between jumper cable terminal clips or clamps and each other or any metallic portion of either the compressor or the starting vehicle to minimize the possibility of uncontrolled arcing, which might serve as a source of ignition.
SAFETY NOTE THE OWNER, LESSOR, OR OPERATOR OF THE COMPRESSOR IS HEREBY NOTIFIED AND FOREWARNED THAT ANY FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS MAY RESULT IN DAMAGE OR INJURY. MMD EXPRESSLY DISCLAIMS RESPONSIBILITY OR LIABILITY FOR ANY INJURY OR DAMAGE CAUSED BY FAILURE TO OBSERVE THESE SPECIFIED PRECAUTIONS OR BY FAILURE TO EXERCISE THAT ORDINARY CAUTION AND DUE CARE, REQUIRED WHEN OPERATING OR HANDLING THE COMPRESSOR IS TAKEN, EVEN THOUGH NOT EXPRESSLY SPECIFIED ABOVE.
SAFETY P/N 300040 P/N 300042 P/N 300968 P/N 104-90032 P/N 104-90034 14
SAFETY P/N 300516 P/N 104-90027 P/N 305107 P/N 305121 P/N 305106 15
DESCRIPTION OF COMPONENTS POWER UNIT The power unit used to drive the compressor is a gasoline engine that has been carefully selected for its ability to provide an efficient and reliable source of power. For detailed information on the power unit, refer to the Engine Operator’s Manual provided separately. COMPRESSOR ASSEMBLY The AC70 compressor assembly is a positive displacement, oil flooded, rotary screw type unit employing one stage of compression to achieve the desired pressure.
DESCRIPTION OF COMPONENTS OIL SUMP Compressed, oil-laden air enters the sump from the compressor. Most of the oil is separated from the air as it passes through a series of baffles and defusing plates. The oil accumulates at the bottom of the sump for re-circulation. Some small droplets of oil remain suspended in the air and are passed on to the coalescer. See Discharge System in the illustration section. SAFETY VALVE The pop safety valve is set at 175 PSI and is located at the top of the air/oil sump.
DESCRIPTION OF COMPONENTS COMPRESSOR COOLING SYSTEM The compressor cooling system consists of an oil cooler, electric fan and motor. See Cooler and Parts System in the illustration section. An automated thermostatic control system maintains a continuous temperature check of the lubricant. The fan sensor trips a normally open relay which sends power to the fan motor once compressor oil temperature reaches 190°F. The fan sensor stops power to the fan motor once the compressor oils temperature drops to 160°F.
DESCRIPTION OF COMPONENTS Note:If the compressor shutsdown on high discharge air pressure or high discharge air temperature, find and fix the problem before restarting. CONTROL SYSTEM The prime components of the compressor control system include the compressor inlet valve and an air cylinder. The control system is designed to match air supply to air demand and to prevent excessive discharge pressure when compressed air is not being used.
DESCRIPTION OF COMPONENTS INLET VALVE The compressor inlet valve is a piston operated disc valve that has a dual function of regulating the inlet opening to control capacity and serving as a check valve at shutdown. DISCHARGE PRESSURE REGULATOR VALVE This valve is used to select the desired discharge pressure within the operating pressure range. Turning the regulator screw clockwise increases the working pressure, a counter-clockwise movement of the screw reduces working pressure.
DESCRIPTION OF COMPONENTS ELECTRICAL AND PROTECTIVE CIRCUIT SYSTEM The compressor electrical system is a 12-volt negative ground type. It is equipped with a protective circuit to minimize damage which could be caused by high compressor discharge temperature, or high discharge pressure. See wiring diagram and electrical system in the illustrations section. The following conditions will cause automatic shutdown of the compressor: 1. Compressor discharge temperature switch exceeds approximately 250°F. 2.
COMPRESSOR OPERATION GENERAL Every AC70 compressor has been operated and tested at the factory before shipment. This testing assures that the unit is operating properly and that the compressor will deliver its rated capacity. Regardless of the care taken at the factory, there still exists a possibility that damage may occur during shipment. For this reason, it is recommended that the unit be carefully inspected for evidence of damage in shipment.
COMPRESSOR OPERATION NORMAL STARTING - GASOLINE ENGINE 1. Inspect the compressor, engine, and other assemblies for loose connections or damage that might have occurred since the last operation. 2. Check engine oil and fluid levels. 3. Check compressor oil sump level. 4. Close service valves. 5. Pull the choke out as required, but avoid flooding the engine. Operate the engine without choking as soon after starting as possible. 6.
COMPRESSOR OPERATION HOT WEATHER OPERATION Keep the engine filled with clean oil and check the oil level more frequently than usual. Keep the outside of the compressor oil cooler clean. Locate the unit in a well-ventilated area. When operating in humid conditions, it is recommended that the compressor oil change interval be shortened. DUSTY OR SANDY AREAS When possible, wet down the area surrounding the operating site to keep dust and blowing sand to a minimum. Inspect air filters more frequently.
COMPRESSOR OPERATION While MMD EQUIPMENT has built into its compressor several controls and indicators to assure you that it is running properly, you will want to recognize and interpret the readings which will call for service or indicate the beginning of a malfunction. Before starting the compressor, read this section thoroughly. Familiarize yourself with the controls and indicators, their purpose, location, and use.
COMPRESSOR OPERATION OPERATING CONDITIONS The following conditions should exist for maximum performance of the compressor. The compressor should be as close to level as possible when operating. The compressor will operate on a 15-degree sideward, lengthwise tilt without any adverse problems. Fluid carryover and oil starvation may occur if operated beyond this tilt.
COMPRESSOR INSPECTION, LUBRICATION AND MAINTENANCE This section contains instructions for performing the inspection, lubrication and maintenance procedures required in maintaining the compressor in proper operating condition. The importance of performing the maintenance described herein cannot be over emphasized. Periodic maintenance procedures to be performed on the equipment covered by this manual are listed below.
COMPRESSOR INSPECTION, LUBRICATION, AND MAINTENANCE CHART INTERVAL ACTION 1. 2. EVERY 10 HOURS OR 3. DAILY 4. 5. Check Check Check Check Check compressor's oil level. air filter. for oil and air leaks. fuel supply after running. for fuel, oil and compressor fluid leaks. 1. Drain water from compressor oil at sump. EVERY 50 HOURS OR 2. Check belt tension. WEEK LY 3. Drain water and sediment from fuel tank. EVERY 500 HOURS OR 6 MONTHS 1. Change compressor oil and oil filter. 2.
COMPRESSOR INSPECTION, LUBRICATION, AND MAINTENANCE NOTE OBSERVE ALL GAUGE READINGS. NOTE ANY CHANGE FROM THE NORMAL READING AND DETERMINE THE CAUSE. HAVE NECESSARY REPAIRS MADE. “NORMAL” IS THE USUAL GAUGE READING WHEN OPERATING AT SIMILAR CONDITIONS ON A DAY-TO-DAY OPERATION. FIRST COMPRESSOR OIL AND OIL FILTER ELEMENT CHANGE SHOULD BE MADE AT 50 HOURS. ALSO, MORE FREQUENT OIL CHANGES WILL BE REQUIRED UNDER EXTREME OPERATING CONDITIONS OF EXTREMELY HIGH OR LOW TEMPERATURES, AND HIGH HUMIDITY.
LUBRICATION LUBRICANT RECOMMENDATIONS WARNING IT IS IMPORTANT THAT THE COMPRESSOR FLUID BE OF A RECOMMENDED TYPE AND THAT THIS OIL, AS WELL AS THE AIR FILTER, OIL FILTER AND SEPARATOR ELEMENTS BE INSPECTED AND REPLACED AS STATED IN THIS MANUAL.
LUBRICATION APPLICATION GUIDE Not all lubricating oils are suitable for rotary screw compressor use. The most satisfactory oils are the non-detergent types that contain high levels of corrosion, oxidation, and foam inhibitors. Your AC70 compressor is factory filled with Dextron III ATF. Other non-detergent motor oils, SAE 10W, class SE or CD, and SAE 30 that meet the requipments below can be used. However, MMD recomends that you use Dextron III ATF.
LUBRICATION NOTE UNKNOWN INFLUENCES OF ENVIRONMENTAL FACTORS SUCH AS THE INTAKE OF REACTIVE GASES OR VAPORS IN THE AIR MAY LEAD TO CHEMICAL CHANGES IN ANY OIL. THIS MAY CAUSE PREMATURE FAILURE OF THE LUBRICANT AND THE USEFUL LIFE OF ALL “EXTENDED LIFE” LUBRICANTS MAY BE SHORTER THAN QUOTED BY THE LUBRICANT SUPPLIER.
MAINTENANCE COMPRESSOR OIL SUMP FILL, LEVEL, AND DRAIN Before adding or changing compressor oil make sure that the sump is completely relieved of pressure. Oil is added at the fill cap on the side of the compressor. A drain plug is provided at the bottom of the sump. The proper oil level, when unit is shutdown and has had time to settle, is at the midpoint of the upper oil sightglass. The unit must be level when checking the oil. DO NOT OVERFILL.
MAINTENANCE AIR/OIL COALESCER The air/oil coalescer employs an element permanently housed within a spin-on canister. This is a single piece unit that requires replacement when it fails to remove the oil from the discharge air. See Discharge System in the illustration section. To replace element, P/N 302600, proceed as follows: 1. 2. 3. 4. 5. 6. Shutdown compressor and wait for complete blow down (zero pressure). Turn element counterclockwise for removal (as viewed from bottom).
MAINTENANCE OIL FILTER The compressor oil filter is a cartridge, throw away type. It is designed with a built in by-pass so that if there is a large restriction, due to cold oil or a clogged element, the compressor will still be lubricated. To replace filter proceed as follows: 1. 2. 3. 4. 5. 6. 7. Make sure system pressure is relieved. Unscrew with 14mm allen wrench. Remove oil filter from housing. Remove gasket and clean or replace the screen.
MAINTENANCE NOTE PARTS REQUIRED FOR ENGINE MAINTENANCE MAY BE FOUND IN THE ENGINE PARTS MANUAL, A COPY OF WHICH IS PROVIDED WITH EACH UNIT. FULL LOAD SPEED Using an air flow silencer, open service air valve until 100 PSI is being held on receiver pressure gauge. Be sure there is no air leakage from pressure regulator vent hole. With the use of an electronic photo tachometer, set the full load speed at 3500 - 3600 RPM. The governor spring tension held by an anchor bolt allows adjustments to be made.
COMPRESSOR INSPECTION, LUBRICATION, AND MAINTENANCE CHART INTERVAL ACTION 1. 2. EVERY 10 HOURS OR 3. DAILY 4. 5. Check Check Check Check Check compressors oil level. air filter. for oil and air leaks. fuel supply after running. for fuel, oil and compressor fluid leaks. 1. Drain water from compressor oil at sump. EVERY 50 HOURS OR 2. Check belt tension. WEEK LY 3. Drain water and sediment from fuel tank. EVERY 500 HOURS OR 6 MONTHS 1. Change compressor oil and oil filter. 2.
TROUBLESHOOTING This section contains instructions for troubleshooting the equipment following a malfunction. The troubleshooting procedures to be performed on the equipment are listed below. Each symptom of trouble for a component or system is followed by a list of probable causes of the trouble and suggested procedures to be followed to eliminate the cause.
TROUBLESHOOTING UNPLANNED SHUTDOWN When the operation of the machine has been interrupted by an unexplained shutdown, check the following: 1. Check to determine if compressor oil is at proper level. 2. Check the engine oil level with the engine stopped and in a level position. If the oil level is low, remove the oil filler cap, and fill to the upper limit mark on the dipstick with the recommended oil. 3. Check oil cooler for dirt, slush, ice on the fins, or any other obstructions to cooling airflow. 4.
TROUBLESHOOTING BLOW DOWN VALVE If after the compressor is shutdown, pressure does not automatically blow down, check for: 1. Automatic blow down valve may be inoperative. 2. Blockage in air line from compressor to blow down valve at coalescer head. 3. Muffler at blow down clogged. ENGINE OVERHEATING 1. 2. 3. 4. Low oil level, refill. Air blockage into engine from blower/PTO side. Air blockage from exhaust side of engine. Dirty oil in engine.
TROUBLESHOOTING HIGH COMPRESSOR DISCHARGE TEMPERATURE 1. 2. 3. 4. 5. 6. Check compressor oil level. Add oil if required (see section for oil specifications). Check electric fan and switch. Clean outside of oil cooler. Clean oil system (cooler) internally. Plugged compressor oil filter. Change element. Plugged oil return line, clean orifice and check valve. INSUFFICIENT AIR DELIVERY 1. Plugged compressor air filter, clean or replace. 2. Plugged air/oil separator.
RECOMMENDED SPARE PARTS LIST ENGINE MAINTENANCE PARTS DESCRIPTION Engine Oil Filter Engine Fuel Filter Engine Air Cleaner Element Spark Plugs Spare Keys MMD P/N 304968 304969 304967 304971 305404 COMPRESSOR MAINTENANCE PARTS DESCRIPTION Drive Belts (Need two) Compressor Air Cleaner Element Compressor Oil Filter Compressor Coalescing Element Fan Sensor Regulator Repair Kit Compressor Shaft Seal Compressor Manual MMD P/N 300742-530 302091 302601 302600 302865 300187 302193 304963 42
WARRANTY CLAIMS 43
WARRANTY MMD Equipment (MMD) warrants that this Rotary Screw Compressor unit conforms to applicable drawings and specifications. The compressor assembly will be free from defects in material and workmanship for a period of two (2) years from the date of initial operation or thirty (30) months from the date of shipment, whichever period first expires.
SUMMARY OF MAIN WARRANTY PROVISIONS As claims, policies and procedure are governed by the terms of MMD Equipment’s warranty, it is necessary to outline some of the more important provisions. The MMD Equipment warranty applies only to new and unused products which, after shipment from the factory, have not been altered, changed, repaired or mistreated in any manner whatsoever. Normal maintenance items such as lubricants, filters, and shaft seals are not warrantable items.
WARRANTY INTRODUCTION The warranty policy and procedures outlined here within are detailed to provide the claimant with the information necessary when filing a warranty claim, and enabling MMD Equipment the ability to serve its customers best. WARRANTY CLAIMS - GENERAL An approved claim depends on the following provision: 1. A warranty claim/service report number must be issued by MMD Equipment. (See filing procedures). 2.
WARRANTY CLAIMS PREPARATION OF PART RETURN Parts returned to MMD Equipment must be properly packaged to prevent damage during shipment. Damage to a part as a result of improper handling or packing could be cause for claim’s rejection. When addressing the package for shipment, the following information must be on the outside of, or clearly tagged on the package. 1. Warranty Return Authorization Number. (WRA#) 2. Dealer’s or end-user’s return address. 3. Correct address for MMD Equipment. 4.
SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM Replacement air-ends are available from the factory. For current prices and availability, contact MMD Equipment or an authorized dealer. Prices are F.O.B. shipping point. Prices do not include labor for removal or installation.
PART NUMBER & ILLUSTRATION SECTION 49
50
51
52
53
54
55
56
57
58
59
60
