Alkin W4 Series Instruction Manual & Parts List
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Alkin W4 Series Instruction Manual & Parts List

High pressure breathing air compressors
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W4
B
REATHING AIR COMPRESSORS
S
ERIES

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Summary of Contents for Alkin W4 Series

  • Page 1 REATHING AIR COMPRESSORS ERIES...
  • Page 3 B R E A T H I N G A I R C O M P R E S S O R HIGH PRESSURE BREATHING AIR COMPRESSORS (W4 SERIES) Instruction Manual & Parts List I n s t r u c t i o n Manual...
  • Page 5 A L K I N C O M P R E S S O R S Breathing Air Compressors This manual or any parts thereof cannot be copied by any means, or used for any other purposes © other than servicing Alkin W4 series compressors, unless specific permission of Alkin ® in writing is received.

  • Page 7: Table Of Contents

    1.1.6 Toxic and Irritating Substances ......................7 1.1.7 Electrical Shock ............................ 8 1.1.8 Lifting ..............................8 2.0 General information on W4 series 4 Stage compressors ....... 10 2.1 General ..............................10 2.2 P&I (Process & Instrument) Diagram ..................12 2.3 Principles of Operation ........................13 2.4 Description of Major Components ....................
  • Page 8 5.6 500 hours maintenance ......................... 29 5.7 1000 hours maintenance....................... 29 5.8 2000 hours maintenance....................... 29 5.9 As required ............................29 5.10 MAINTENANCE TABLE........................ 30 5.11 Maintenance procedures ......................31 5.11.1 General ............................31 5.11.2 Torque values ..........................31 5.11.3 Servicing 1 stage valve ........................
  • Page 9 A I R C O M P R E S S O R Your new ALKIN air compressor will provide you with the solid and reliable performance that you should expect from a heavy-duty industrial air compressor. Please read this manual carefully before you operate your compressor. This will enable you to start-up your compressor in in the maintenance section of this manual.
  • Page 10 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R...

  • Page 11: Safety

    1.1 General 1.1.1 General safety information All ALKIN air and gas compressors are designed and manufactured with equipment & components that allow safe operation of the compressors. It is the user’s responsibility however; to safely operate and maintain the compressor, observe the rules and instructions, as well as the local safety codes, to minimize the risk of accidents and injury.

  • Page 12: Moving Parts

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Disconnect the power supply prior to attempting any repair or cleaning.

  • Page 13: Electrical Shock

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 1.1.7 Electrical Shock Keep the compressor, hoses, tools and personnel at least 3 meters (10ft) from power lines, panels and underground cables.
  • Page 14 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R...

  • Page 15: General Information On W4 Series 4 Stage Compressors

    The W4 series compressors are equipped with oversize copper intercoolers between the 1st & 2nd and 2nd & 3rd stage cylinders and stainless steel intercooler between the 3rd and 4th stage cylinders and stainless steel aftercooler downstream...
  • Page 16 The W4 series compressors incorporate stainless steel valves on all 4 stages. They are designed to have an onobstructed passage of air with no pressure loss; they are easy to maintain and replace. Particular attention must be paid to valve maintenance, as these valves are the basis for proper operation of the compressor package.

  • Page 17: P&I (Process & Instrument) Diagram

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 2.2 P&I (Process &...

  • Page 18: Principles Of Operation

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Figure 4 2.3 Principles of Operation The P &...

  • Page 19: Description Of Major Components

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R The intercoolers and the aftercooler are designed to dissipate the heat generated from the previous compression cycle, reducing the air temperatures, allowing the water vapors to condensate and settle in the bottom sections of the moisture separators.

  • Page 20: Major Components - System

    Pressure Switch: This unique Alkin device is installed on the right door, this switch both indicates the purifier pressure, and the set pressures on its dial, while serving as a double circuit pressure switch. It controls the start-stop operation of the compressor.

  • Page 21: Description Of Controls

    2.5 Description of Controls 2.5.1 Compressor Controls The W4 Series compressor may operate with the following two controls: Automatic Start – Stop Control (Single Pressure Only): This is the standard control type for all single pressure compressor systems. With this type of control, once the compressor is manually started, it will run till it reaches the high set pressure where is will automatically stop (the pressure where the motor will cut-out);...
  • Page 22 Pressure Swtich: The W4 series compressors are controlled by a pressure switch that cuts off the motor control line when the operating set pressure is reached; it cuts in when the pressure drops below the pre set low pressure limit, starting the motor again.

  • Page 23: Owner Records

    Belt Section Belt Size Number of belts Pressure Control Type Pressure switch Model Make Alkin Differential P. Cut out pressure Cut In press. Other Data Electrical Control Panel & Motor Starter Drawing Number Parts List Number Additional Electric Motors (Fan Motors)
  • Page 24 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Type Make Serial Number...

  • Page 25: Installation

    S E R I E S Section H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 3.0 Installation 3.1 Inspection The compressor should be inspected and checked for the following:...

  • Page 26: Electrical Check

    3.6 Sheaves and V-belt alignment check The W4 Series compressors are supplied with a self tightening rotary slide; therefore these are no adjustments need to be made. However it is a good practice to check at the initial start up the driver sheave and the compressor flywheel for parallel alignment of the V grooves.

  • Page 27: Operation

    4.2 Oil recommendation The oil level should be checked daily. Top up to the overfill point when required. On all W4 Series Compressors use the following oils only: Anderol 750-Anderol 755-Chemlube 751 • Do not use another type of oil without prior written approval of the manufacturer.

  • Page 28: Adjustment

    Compressor will stop when it reaches the adjusted upper pressure. Standard Pressure Switches used on Alkin Automatic Start/Stop controlled W4 units have standard differential of 20 Bar. In other words lower pressure is set automatically at 20 Bar below the upper pressure limit which is set.

  • Page 29: Safety Valve Adjustment

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R showing the times on it;...
  • Page 30 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R COMISSIONING REPORT –...
  • Page 31 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R START UP CHECKS Remarks Signature...
  • Page 32 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R ©ALKIN COMPRESSORS...

  • Page 33: Maintenance

    S E R I E S Section H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 5.0 Maintenance 5.1 General As you proceed through this section, it will be easy to see how simple is the compressor to maintain.

  • Page 34: Hours Maintenance

    5.9 As required Check the motor or engine manual for recommended service intervals. Check and replace worn piston rings. See the specific instruction sections for additional maintenance rules for the specific compressor and ancillary equipment delivered to your plant. ©ALKIN COMPRESSORS...

  • Page 35: Maintenance Table

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 5.10 MAINTENANCE TABLE Maintenance ...

  • Page 36: Maintenance Procedures

    (see Maintenance Table). 5.11.4 Servicing 2 stage valve 2nd stage valves are concentric ring type and are similar in construction. See the figure. To inspect and clean the 2nd stage valve, observe the following step-by-step procedure: ©ALKIN COMPRESSORS...

  • Page 37: Rd &4 Th Stage Valve

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Loosen the valve acorn nut as shown in Figure;...

  • Page 38: Piston Ring Replacement

    “O” rings are used. Figure 14 illustrates the relationship of these parts. It is important to install original Alkin “O” rings as these are made of special high temperature resistant material and ordinary o-rings will be promptly damaged causing failures 5.11.6 Piston ring replacement...
  • Page 39 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 2nd STAGE RING SET 1st STAGE RING SET 2nd STAGE RING...
  • Page 40 “deglazed” to provide a proper seating surface for the rings. Use a #80 grit abrasive cloth and go over the cylinder bore using a rotating, reciprocating motion. Do not overdo “deglazing”; dulling the glaze is usually sufficient and can be accomplished with light pressure. ©ALKIN COMPRESSORS...

  • Page 41: Crankshaft Bearing Replacement

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Caution! Do not attempt to deglaze the cylinder bore with a harsh abrasive agent.

  • Page 42: Oil Seal Replacement

    1st and 2 nd stage cylinders, and pull the 1 st stage cylinder off the top of the piston. Next, take out the attaching screws between the 2 nd stage cylinder and the crankcase. Pull the end of the connecting rod off the end of the crankshaft and lift the cylinder -with the piston inside- off the crankcase. The piston ©ALKIN COMPRESSORS...

  • Page 43: Air Head Replacement

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R can now be pushed out of the cylinder.

  • Page 44: Intercoolers And Aftercooler

    Install the adapter tool (3) which is supplied with Use a ratchet tool (1) to loosen the cover (5). the compressor, onto the cover (5), using the two bolts (2), that come with the adapter. ©ALKIN COMPRESSORS...
  • Page 45 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Insert the cartridge back into the purifier chamber.

  • Page 46: Trouble Shooting

    • Crankshaft bearing failure Replace bearings or crankshaft assembly • Connecting rod journal bearings worn. Replace the connecting rods; if worn,replace the crank pin bush as well • Wrist pins and journals are worn Replace complete pin and rod assembly. ©ALKIN COMPRESSORS...
  • Page 47 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 6.4 MILKY OIL IN RECERVOIR •...
  • Page 48 • Speed too slow Check the compressor speed. 6.15 RECEIVER PRESSURE BUILDS UP TOO FAST • Water in the storage cylinders/filters Drain the receiver frequently or install an automatic drain. • Speed too fast. Check the speed. ©ALKIN COMPRESSORS...
  • Page 49 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 6.16 RESET MECHANISM CUTS-OUT REPEATEDLY •...
  • Page 50 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R ©ALKIN COMPRESSORS...

  • Page 51: Part List

    S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.0 Part List Part List...

  • Page 52: Crankcase Assy

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.1 Crankcase Assy ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 53 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 54: Connecting Rods

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.2 Connecting Rods ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 55 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 56: 1St&2Nd Stage Assy

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.3 1st&2nd Stage Assy ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 57 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 58: 3Rd Stage Assy

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.4 3rd Stage Assy ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 59 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 60: 4Th Stage Assy

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.5 4th Stage Assy ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 61 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 62: Pistons

    H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.6 Pistons ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 63 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 64: Pipe Lines

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.7 Pipe Lines ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 65 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.
  • Page 66 H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 67 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 68: Intercoolers (1St&2Nd Stage)

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.8 Intercoolers (1st&2nd Stage) ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 69 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 70: 3Rd Stage Intercooler & 4Th Stage Aftercooler

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.9 3rd Stage Intercooler & 4th Stage Aftercooler ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 71 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 72: Water Separators

    B R E A T H I N G A I R C O M P R E S S O R 7.10 Water Separators 2nd Stage Water Separator 3rd&4th Stage Water Separator ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 73 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 74: Discharge Line

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.11 Discharge Line ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 75 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.
  • Page 76 H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 77 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 78: Filter Panel

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.12 Filter Panel ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 79 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.
  • Page 80 H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 81 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 82: Coelescer Filter Assy

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.13 Coelescer Filter Assy ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 83 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 84: Purifier Assy

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.14 Purifier Assy ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 85 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 86: Pressure Gauge Lines

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.15 Pressure Gauge Lines ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 87 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 88: Drive Assy

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.16 Drive Assy ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 89 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Parça No Açıklama Adet...

  • Page 90: General Connectors

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.17 General Connectors ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 91 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.
  • Page 92 H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 93 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 94: Filling Panel - Dual Pressure

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.18 Filling Panel – Dual Pressure ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 95 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 96: Filling Panel - 330 Bar

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.19 Filling Panel – 330 Bar ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 97 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Part no.

  • Page 98: Filling Panel - 225 Bar

    P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R 7.20 Filling Panel – 225 Bar ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...
  • Page 99 S E R I E S H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R Parça No Açıklama Adet...
  • Page 100 H I G H P R E S S U R E B R E A T H I N G A I R C O M P R E S S O R ©ALKIN KOMPRESÖR SANAYİ VE TİCARET LİMİTED ŞİRKETİ...

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