® ® Q T & PL T Industrial PLT & Air Master Series 2 Stage Compr essors Compressors Instruction Manual This manual contains important safety information and should be made available to all personnel who operate and/or maintain this product. Carefully read this manual before attempting to operate or perform maintenance on this compressor Manual No.
Warranty Statement True Blue Warranty Quincy Compressor Two-Stage Reed Valve Reciprocating Products QT, PLT & AMT in PRO or MAX Configurations WARRANTY PERIODS LIMITATIONS Quincy Compressor (Seller) warrants basic compressors on factory assembled PRO or MAX units for five (5) years from date of start-up, provided Purchaser registers the product with Quincy Compressor and maintains the unit with Quincy genuine parts and lubricant. Rings and gaskets are covered for the entire five (5) year period.
WARRANTY Quincy Compressor Industrial Reciprocating Products QT & PLT Industrial / Air Master Two Stage Compressors GENERAL PROVISIONS Quincy Compressor (The Seller) warrants to each retail purchaser (Purchaser) products of the Seller's own manufacture against defects in material and workmanship. With respect to products not manufactured by the Seller, the Seller will, if practical, pass along the warranty of the original manufacturer.
Contents SECTION 1 SAFETY Safety First ............................................................................................................................................. 1 Summary of Changes .............................................................................................................................. 3 SECTION 2 SYSTEM DYNAMICS Description & Application ......................................................................................................................
SECTION 1 SAFETY Safety First At Quincy Compressor safety is not only a primary concern, but a faithfully performed practice. Beginning with the design stage, safety is built into “The World’s Finest Compressor”. It is the intention of this manual to pass along the “safety first” concept to you by providing safety precautions throughout its pages. “DANGER !”, “WARNING !”, and “CAUTION !” are displayed in large bold capital letters in the left hand column to call attention to areas of vital concern.
•Do not operate the unit with any of its safety guards, shields, or screens removed. •Do not remove or paint over any DANGER!, WARNING!, CAUTION!, or instructional materials attached to the compressor. Lack of information regarding hazardous conditions can cause property damage or personal injury. •Periodically check all pressure relief valves for proper operation.
troubleshooting guide for your compressor. Most warranty issues can be resolved by following proper maintenance procedures. Quincy Compressor neither states as fact, nor in any way implies that the above list of safety precautions is an all inclusive list, the observance of which will prevent all damage to property or injury to personnel. Every effort has been taken to ensure that complete and correct instructions have been included in this manual.
SECTION 2 SYSTEM DYNAMICS Description & Application Quincy Compressor QT Series and PLT Series compressors are heavy duty, air cooled, belt driven compressors. QT Series two stage compressors are splash lubricated and capable of delivering 175 PSIG of compressed air. The PLT Series compressors are pressure lubricated and capable of delivering 175 PSIG of compressed air.
Principles of Cooling Systems Fan blades of the compressor sheave force ambient air across fins of the cylinder head(s), and intercooler fins of two stage compressors, to cool the compressor. These compressors are designed to operate in a counterclockwise rotation. QT & PLT series compressors should be operated in temperatures under 104°F. Principles of Dryers & Filters Moisture occurs naturally in air lines as a result of compression.
Specifications QT-5 / PLT-5 QT-7.5 / PLT-7.5 QT-10 Cylinder Bore Dia. H.P. L.P. 2.250 / 2.251 4.00 / 4.001 2.500 / 2.501 4.502 / 4.503 2.753 / 2.752 5.003 / 5.002 Piston Skirt Dia. H.P. L.P. 2.247 / 2.246 3.995 / 3.994 2.497 / 2.496 4.499 / 4.498 2.749 / 2.748 4.997 / 4.995 Piston / Cylinder Clearance at Skirt H.P. L.P. 0.003 / 0.005 0.005 / 0.007 0.003 / 0.005 0.003 / 0.005 .003 / .005 .005 / .008 Crankshaft Dia. journals main bearing (pulley end) main bearing (opposite pulley end) 1.
SECTION 3 INST ALLA TION INSTALLA ALLATION Receiving Delivery Immediately upon receipt of compressor equipment and prior to completely uncrating, the following steps should be taken: WARNING ! Step 1) Inspect compressor equipment for damage that may have occurred during shipment. If any damage is found, demand an inspection from the carrier. Ask the carrier how to file a claim for shipping damages. (Refer to SECTION 3, Freight Damage for complete details.
Retain all containers and packing for inspection by the carrier. A claim form can be requested from the carrier: Standard Form for Presentation of Loss and Damage Claims (form # 3208). Your claim will need to be substantiated with the following documents: a.) form #3208 b.) original bill of lading c.) original paid freight bill d.) original invoice or certified copy e.) other particulars obtainable in proof of loss or damage (photos, damage inspection, etc.
Excessive noise can be effectively reduced through various methods. Total enclosures, intake silencers, baffle walls, relocating or isolating the compressor can reduce noise levels. Care must be taken when constructing total enclosures or baffle walls. If not properly constructed or positioned, they could contribute to unacceptable noise levels or overheating. Consult your local Quincy distributor if assistance is required. WARNING ! Unusual noise or vibration indicates a problem.
Install incoming power line connections at screw terminals L1, L2 & L3. Fig. 3-1 3 Phase Start / Stop Control Wiring Schematic WP1744A (Rev. D) Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 10 3501 Wismann Lane, Quincy Ill.
Install incoming power line connections at screw terminals L1 & L2. Fig. 3-2 Single Phase Start / Stop Control Wiring Schematic WP1744B (Rev. D) Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 11 3501 Wismann Lane, Quincy Ill.
Splice incoming power line connection to this white wire (wrapped in red tape). Install incoming power line connection at this screw terminal. Fig. 3-3 Start / Stop Control- Pressure Switch / Motor (for unit models 150934A712, 150935A712, 150959A712, 151047-712, 151048-712 & 151050-712) Wiring Schematic WP1753 (Rev. H) Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 12 3501 Wismann Lane, Quincy Ill.
Install incoming power line connections at screw terminals L1 & L2. Fig. 3-4 Single Phase MDR Pressure Switch / Overload Relay Connection Diagram (Rated 22-30 Amps) Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 13 3501 Wismann Lane, Quincy Ill.
Fig. 3-4 Start / Stop Control Piping Schematic WP1781B Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 14 3501 Wismann Lane, Quincy Ill.
Fig. 3-5 Continuous Run - Load / Unload Control Piping Schematic WP1781C Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 15 3501 Wismann Lane, Quincy Ill.
Fig. 3-6 Dual Control with Pilot Valve Unloading Piping Schematic WP1781A Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 16 3501 Wismann Lane, Quincy Ill.
Mounting Proper mounting of QT & PLT series compressor units is crucial to the safe operation and longevity of the equipment. The installation requires a flat and level concrete floor or pad (for mobile units see Mounting FLANGE NUT Mobile Units). Satisfactory results can usually be obLeave loose & lock tained by mounting the compressor unit on vibration with a back-up nut RECEIVER FOOT isolating pads available from your local Quincy distributor.
WARNING ! Excessive compressor RPM’s (speed) could cause a pulley or sheave to shatter. In an instant, the pulley or sheave could separate into fragments capable of penetrating the belt guard and causing bodily harm or death. Do not operate the compressor above the recommended RPM (refer to SECTION 2, Specifications). Guards All mechanical action or motion is hazardous in varying degrees and needs to be guarded.
Induction System Air Intake A clean, cool and dry air supply is essential to the satisfactory operation of your Quincy QT or PLT Series air compressor. The standard air filter that the compressor is equipped with when leaving the factory is of sufficient size and design to meet normal conditions, when properly serviced, in accordance with the maintenance section of this manual.
where moisture can be easily removed. All service line outlets should be installed above the moisture traps to prevent moisture from entering the tool or device using the air. Manual shutoff valves, protected by pressure relief valves, should be installed at all service line outlets to eliminate leakage while the tools are not in use. Fig.
pressure relief valve, pressure gauge, tank drain, & manual shutoff valve (refer to Fig. 3-8, Typical Drop Leg & Component Location). WARNING ! Follow ASME code for air reciever tanks and other pressure containing vessels. Pressure vessels must not be modified, welded, repaired, reworked or subjected to operating conditions outside the nameplate ratings. Such actions will negate code status, affect insurance status and may cause property damage, severe injury or even death.
WARNING ! Do not open a manual tank drain valve on any air tank containing more than 30 PSIG of air pressure! WARNING ! Never attempt to relieve an air tank by removing a pipe plug or any other system component! Manually Draining An Air Tank: Step 1) Disconnect & lockout the compressor from the power source (electric models) or disconnect the spark plug wire from the spark plug (gas engine models). Step 2) Tanks subjected to freezing temperatures may contain ice.
SECTION 4 ST AR T-UP & OPERA TION STAR ART-UP OPERATION Pre-starting Checklist WARNING ! Never assume a compressor is safe to work on just because it is not operating. It could restart at any time. Follow all safety precautions outlined in SECTION 5, Stopping For Maintenance. WARNING ! Failure to perform the pre-starting checklist may result in mechanical failure, property damage, serious injury or even death. Steps 1 through 12 should be performed prior to connecting the unit to a power source.
Step 12) After all the above conditions have been satisfied, the unit can be connected to the proper power source. Step 13) Jog the starter switch to check the rotational direction of the compressor. It should agree with the rotation arrow embossed on the compressor sheave. Step 14) Check for proper rotation of the cylinder cooling fan (fins inside sheave). The fan should blow cooling air across the cylinder.
Daily Starting Checklist Do not proceed until the Pre-starting Checklist and Initial Starting & Operating sub-sections have been read and are thoroughly understood. Step 1) Check lubricant level in crankcase. Step 2) Drain liquid from the air receiver and moisture trap (if so equipped). Step 3) Jog the starter button and check compressor rotation.
SECTION 5 MAINTENANCE & LUBRICA TION LUBRICATION Stopping for Maintenance The following procedures should be followed when stopping the compressor for maintenance or service: Step 1) WARNING ! Per OSHA regulation 1910.147: The Control of Hazardous Energy Source (Lockout/Tagout), disconnect and lockout the main power source. Display a sign in clear view at the main power switch stating that the compressor is being serviced. Never assume a compressor is safe to work on just because it is not operating.
uids.) If lubricant is contaminated, drain and replace. •Drain receiver tank, drop legs and traps in air distribution system. Receiver tanks subjected to freezing temperatures may contain ice. Store the compressor unit in a heated area before attempting to drain moisture from the tank. •Give compressor an overall visual inspection and be sure safety guards are in place. •Check for any unusual noise or vibration. •Check for lubricant leaks. •Check all pressurized components for rust, cracks or leaks.
Lubrication QT and PLT Series basic compressors and units are normally shipped from the factory with break-in lubricant in the crankcase. Before starting your compressor, check the lubricant level in the crankcase. The lubricant level of QT-5, PLT-5, QT-7.5, PLT-7.5, QT-10 & PLT-15 compressors must reach the bottom edge of the lubricant fill opening. The lubricant level of QT-15, QT-25 & QT-54 compressors must register between the high and low marks on the dipstick.
Pulley / Sheave Alignment & Belt Tension Improper pulley/sheave alignment and belt tension are causes for motor overloading, excessive vibration, and premature belt and/or bearing failure. To prevent this from happening, check the pulley/sheave alignment and belt tension on a regular basis (refer to SECTION 5, Maintenance Schedule). Periodically inspect the motor pulley(s) and compressor sheave(s) for oil, grease, nicks or burrs. Clean or replace if necessary. Make sure they are securely fastened.
Step 2) Determine the amount of deflection ( in inches) required to measure deflection force (in pounds) by multiplying the span length x 1/64 (.016) (i.e. 32” span length x 1/64 [.016] = 1/2”[.50] of deflection required to measure deflection force). POCKET CLIP Step 3) Lay a straightedge across the top outer surface of a drive belt from pulley to sheave.
WARNING ! Never exceed the designed pressure for the system or overload the motor beyond its Maximum Amp Draw. * Full Load Amps x Service Factor = Maximum Amp Draw WARNING ! Never assume a compressor is safe to work on just because it is not operating. It may be in the automatic stand-by mode and may restart any time. Follow all safety precautions outlined in SECTION 5, Stopping For Maintenance.
PILOT V AL VE ADJUSTMENTS VAL ALVE All adjustments made to the pilot valve must be performed by a qualified technician. The adjustments must be made while the unit is operating, therefore, extreme caution must be taken while working on the unit. Observe all necessary precautions. Always use a back-up wrench and make all differential and unload pressure adjustments in very small increments (1/8 turn). WARNING ! The pressure switch and / or pilot valve are set at the factory for maximum efficiency.
SECTION 6 Trouble TROUBLESHOOTING Probable Cause Low discharge pressure •Restricted inlet •Defective compressor valves or valve unloading mechanism •Leaks in the compressed air distribution system at fittings, connections, etc.
Trouble Probable Cause Excessive drive belt wear •Pulley/sheave out of alignment •Belt too loose or too tight •Belt slipping •Pulley/sheave wobbling •Pulley/sheave groove damaged or rough •Incorrect belts Low oil pressure •Oil sump strainer plugged •Excessive leakage at crankshaft seals •Low oil level •Oil pump incorrectly assembled to the bearing carrier (“o”ring not properly located between oil pump body & bearing carrier) •Oil pressure adjusting screw not set properly •Defective oil pressure gauge
Trouble Probable Cause Intercooler pressure abnormally low (Two stage models only) •Compressor valves or head unloaders in first stage not functioning properly or defective •Restricted air inlet filter or suction line •Pilot valve or pressure switch set incorrectly or defective •Pressurized air at head unloader not venting properly when demand for air is required •Compressor valve or head gasket leaking •Worn piston rings •Defective pressure gauge •Leaking air at intercooler or intercooler connections C
Trouble Probable Cause Excessive oil consumption •Compressor runs unloaded too long •Worn piston rings •Restricted intake system •Compressor running too hot •Breather valve not functioning properly •Oil level in crankcase too high •Oil viscosity wrong for the application •Connecting rod out of alignment, bent or twisted •Leaking oil seal •Piston rings not seated (allow 100 hours for seating) •Wrong oil (may be a detergent oil with a tendency to foam) •Inferior grade of oil Excessive current draw (To dete
SECTION 7 REFERENCE INFORMA TION INFORMATION Decal Locations Typical QT & PLT Series Unit with Horizontal Receiver Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 37 3501 Wismann Lane, Quincy Ill.
Typical QT & PLT Series Unit with Vertical Receiver Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 38 3501 Wismann Lane, Quincy Ill.
Typical QT & PLT Series Engine Driven Unit with Horizontal Receiver Industrial / Air Master Series 50161-105, March 2008 Quincy Compressor 39 3501 Wismann Lane, Quincy Ill.
QUINCY COMPRESSOR STANDARD TERMS AND CONDITIONS LEGAL EFFECT: Except as expressly otherwise agreed to in writing by an authorized representative of Seller, the following terms and conditions shall apply to and form a part of this order and any additional and/or different terms of Buyer’s purchase order or other form of acceptance are rejected in advance and shall not become a part of this order.
TITLE & LIEN RIGHTS: The equipment shall remain personal property, regardless of how affixed to any realty or structure. Until the price (including any notes given therefore) of the equipment has been fully paid in cash, Seller shall, in the event of Buyer’s default, have the right to repossess such equipment.
MAINTENANCE SCHEDULE CHECKLIST Use this form to develop a routine maintenance schedule and record of performed maintenance. In the numbered columns enter the initials of the person who performed the maintenance and the date. Enter additional maintenance procedures in the spaces provided in the left hand column as needed per your application. Equipment operating under humid or dirty conditions may require shorter intervals between scheduled maintenance.
Recipr ocating / Systems: Reciprocating 217.222.7700 Air Master 217.277.0270 E-mail: Website: info@quincycompressor.com quincycompressor.com quincyairmaster.com © 2006 Quincy Compressor, an EnPro Industries company All Rights Reserved. Litho in U.S.A.
