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Max-Air Systems 90 SFD 6000 Owner's Operating Manual
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Max-Air Systems 90 SFD 6000 Owner's Operating Manual

High pressure breathing air compressors
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High Pressure Breathing Air Compressors
Max-Air 90 SFD 6000
9.0 cfm
Owner's Operating Manual & Parts List
MAX-AIR • 2807 Peddler Lane • Kerrville, Texas 78028 • USA • 830-257-5006 • FAX 830-257-3720
www.max-air.com service@max-air.com
Max-Air is a registered trademark with the U.S. patent office – copyright 2009.
This manual cannot be reproduced without the express written permission of Max-Air.
Part# MA90'S-07/13

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Summary of Contents for Max-Air Systems 90 SFD 6000

  • Page 1 High Pressure Breathing Air Compressors Max-Air 90 SFD 6000 9.0 cfm Owner's Operating Manual & Parts List MAX-AIR • 2807 Peddler Lane • Kerrville, Texas 78028 • USA • 830-257-5006 • FAX 830-257-3720 www.max-air.com service@max-air.com Max-Air is a registered trademark with the U.S. patent office – copyright 2009.
  • Page 2 Thank you for choosing MAX-AIR, where quality and commitment give you the best in technology and support available today. Be sure to ask your MAX-AIR dealer about our complete line of compressors and accessories. This owner's manual uses signal words recommended by the American National Standards Institute (see ANSI Z535.4) to designate levels of hazards.
  • Page 3 YOU MUST READ AND UNDERSTAND THIS INFORMATION PRIOR TO FILLING BREATHING AIR CYLINDER!! BREATHING AIR PURIFICATION FILTER CARTRIDGE (DISPOSABLE) Part Number LF-1002 or X302414 Fits only compressor model Max-Air 55 and Max-Air 90 with standard filtration (Part Number PU-10000) Typical processing capacity (cartridge life) @ 72 F intake temperature for Grade “E”...
  • Page 4 PURIFICATION FILTER CARTRIDGE REMOVAL & INSTALLATION For Max-Air Compressor Models 55-70-90-180 MAKE SURE that the power and that all air pressure (high and low) is completely drained (bled) from the system. In a counter clockwise motion remove the pressure cap assembly “A”...
  • Page 5 2807 Peddler Lane Kerrville Texas 78028 Ph. 830-257-5006 Fax. 830-257-3720 Email service @max-air.com www.max-air.com Compressor Pumping Group Identification Sheet Model Max-Air 55, 90 and 180 Twin INSIDE Figure 1. Oil Level Sight Glass Intake filter housing Oil and water separator (high pressure) Valve Head 1st Stage 15.A.
  • Page 6 TECHNICAL DESCRIPTION Model: SE 5K/6k (9.0cfm) Weight: 480 lbs (125kg) w/ 7.5 HP motor Dimensions: 44"L x 28"W x 35"H Construction: Air cooled, three stage, three cylinder high pressure compressor, all stainless steel interstage cooling Max. pressure: 340 bar (5000 psig) Approx.
  • Page 7 2.2 Working System Ambient air, which must be free from exhaust fumes, is drawn through the intake filter and inlet valve into the 1st stage cylinder, where it is pre-compressed. A portion of the compression heat is dissipated through the valve head, piston, cylinder, crankcase and lubricating oil to the cooling airflow.
  • Page 8 DANGER 2.3.3 Safety valves The safety valves prevent damage to the compressor by overpressure and are factory set at the following pressures: 1st stage: 113 psi (8 bar) 2nd stage: 725 psi (50 bar) 3rd stage: 10% above filling pressure In case a safety valve blows, do not adjust to a higher pressure but check for the cause.
  • Page 9 Make use of the intake hose and secure it in such a way as to ensure that no engine exhaust fumes are taken in. Filling hoses must be in perfect condition, connecting threads faultless. Particular attention should be paid to damage of the connecting fittings. If the rubber is scored, the hose must not be used any longer because water can enter and attack the wire gauze.
  • Page 10 4.2 Starting-up Before starting engine check oil level in the crankcase of the horizontally placed compressor ( § 4.8.1) Use MAXLUBE #501 synthetic oil. Starting of the engine: Before starting electric motors, check voltage. Electric connections must comply with the respective regulations.
  • Page 11 4.4 Shutdown procedure On compressors using gasoline drive, close hand lever on carburetor and turn "On/Off" switch off. Close fuel cylinder valve and drain condensate out of compressor. In addition, check oil level of compressor, gasoline level in engine tank and carry out current service (§ 4.8). 4.5 Preparation for extended storage Prior to extended storage, the compressor should run a few minutes against a small backpressure of approximately 300PSI (20 bar), by partly closing filling valve in order to prevent possibility of corrosion.
  • Page 12 WARNING 4.8.2 Safety valve control The final safety valve protects the 3rd stage and the high-pressure cylinders and is factory set to 10% above the requested filling pressure. The safety valve of the 3rd stage must be checked for proper functioning periodically.
  • Page 13 Important for filter maintenance: Service only when unit is turned off and totally depressurized. Check filter case, threads and O-rings and maintain or replace if necessary. It is recommended to record the quantity of pressure cylinders filled in order to reassure that the precise replacement intervals are kept.
  • Page 14 Maintenance after operating hours: Hours Recommended Service Check valve heads. Intake piping must be hand warm; outlet piping must be hot (§2.2) First oil change (§4.8.1) check tension of v-belt (§4.8.3) Maintenance of intake filter (§4.8.4) Check tension of v-belts (§4.8.3) Check fixation of cooler and belt guard (§4.8.9) Oil change (§4.8.1) Check tension of v-belt (§4.8.3)
  • Page 15 4.9.4 Tightening torque screw thread max. torques hex. screw 1,0 kpm / 7 ft-lbs inner hex. Screw hex screw 2,5 kpm / 18 ft-lbs inner hex. Screw hex. screw M 10 4,5 kpm / 32 ft-lbs inner hex. screw Valve head screw requires torque wrench tightening...
  • Page 16 5. Trouble Shooting Trouble Cause Remedy Gas engine does not start See operating manual Electric motor does not start One phase failed Check fuses Safety valve 1 blows off 2nd stage valves Clean valves or defective replace Safety valve II blows off 3rd stage valves Replace defective...
  • Page 17 2807 Peddler Lane Kerrville TX 78028 U.S.A. 830-257-5006 phone 830-257-3720 fax Sales@max-air.com Re-order form for consumables – be sure to check periodically Bill To: Ship To: (if different than bill to) ______________________________________________________ _______________________________________________________ ______________________________________________________ _______________________________________________________ _______________________________________________________ ______________________________________________________ ______________________________________________________ Phone #:________________________________________________ Email___________________________________________________ Date Ordered Ship When...
  • Page 18 MAX-AIR 55/90/180 Series & Tropic-Max High Pressure Compressor For Breathing Air Compressor Pumping Group Parts Manual ISO 9001 : SINCE 2007 2807 Peddler Lane West • Kerrville • Texas 78028 • USA Tel. (830) 257-5006 • Fax (830) 257-3720 • e-mail: sales@max-air.com R E G I S T E R E D F I R M Max-Air is a registered trademark with the U.S.
  • Page 19 CRANKCASE Description Pos. Qty Code KIT1a 13-00-0050/R FILTER SIDE FLANGE MCH13/16 KIT 1.1a 13-00-0050 FILTER SIDE FLANGE MCH13/16 13-00-0062 FLANGE O-RING 2562 13-00-0042 FLANGE ROLLER BEARING NU305 13-00-0055 SEEGER RETAINING RING J 62 13-01-0042/N HALF MOON FLANGE 13-00-0048 SCREW ZINC. DIN 912 13-00-0137 SELF LOCKING NUT 13-00-0067...
  • Page 20 CRANKCASE KIT 1a - 13-00-0050/R KIT 1b - Tropical Plus - 13-00-0050/TR/R 1.1a 1.1b KIT2c - 05-00-001/1/R KIT2a - 13-00-0026/R Standard-Tech-MiniTech Standard-Tech-MiniTech KIT2d - 05-00-002/R KIT2b - 13-00-0001/R Compact-MiniSilent-SuperSilent-Mark Compact-MiniSilent-SuperSilent-Mark 2.1a 2.1b 2.1c 2.1d CRANKCASE MCH-8 CRANKCASE MCH-11-13-16 3.1a 3.1b P.
  • Page 21 CRANKSHAFT Description Pos. Qty Code KIT1 13-01-0107/R 1ST/3RD STAGE CON-ROD ASS.BLY KIT 13-00-0192 BEARING ROLLER 13-00-0126 HARDENED RING 13-00-0128 BEARING ROLLER 13-01-0107 1ST/3RD STAGE CON-ROD ASS.BLY 13-00-0106 SPACER KIT2 13-00-0105/R 2ND STAGE CON-ROD ASS.BLY MCH13/16 KIT 13-00-0192 BEARING ROLLER 13-00-0126 HARDENED RING IR 42X47X15,1 13-00-0128 BEARING ROLLER...

  • Page 22: Table Of Contents

    CRANKSHAFT KIT 1 13-01-0107/R KIT 1 13-01-0107/R KIT 2 13-00-0105/R 3rd STAGE 1st STAGE 2nd STAGE KIT 3 13-00-0098/R Spare Parts List Max-Air 55/90/180 & Tropic-Max Series Page 5...
  • Page 23 OIL LEVEL Mod: Standard - Tech - Minitech - Tropical Plus Description Pos. Qty Code 13-00-0021 FITTING 90° 13-00-0064 OIL LEVEL CHECK TUBE MCH13/16 13-00-0052 FITTING FOR OIL DISCHARGE 13-00-0053 COPPER GASKET 13-00-0063 OIL DRAIN PLUG 13-00-0090 OIL FILLING CAP 1/2 (RED) MCH13/16 WITH BREATHER 0,3 TUBRILSAN6X4 RILSAN HOSE 6X4 13-00-0065...

  • Page 24: Kit

    OIL LEVEL Mod: Standard - Tech - Minitech - Tropical Plus For models by 12-2013 for models up to 12-2013 Model: Standard - Tech - Minitech Model: Standard - Tech - Minitech 1.10 1.10 1.10 1.10 KIT1 13-00-0068/R 1.11 1.11 Model: Tropical Plus Oil level switch OPTIONAL...
  • Page 25 OIL LEVEL Mod: Compact - Compact M - Compact Evo - MiniSilent - SuperSilent Evo - Tropical - Mark1 - MCH 26-32/ET Compact Description Pos. Qty Code 13-00-0021 FITTING 90° 1/8 NPT 13-00-0064 OIL LEVEL CHECK TUBE MCH13/16 13-00-0139 PLUG 13-04-0333 LOWER OIL LEVEL FITTING FASC/2/10/18...
  • Page 26 OIL LEVEL Mod: Compact - Compact M - Compact Evo - MiniSilent - SuperSilent Evo - Tropical - Mark1 - MCH 26-32/ET Compact Model: Compact - Compact M - Compact Evo - MiniSilent - SuperSilent Evo - Tropical - Mark1 1.11 1.12 1.12...
  • Page 27 STAGE MCH-11-13-16-18 For models up to 12-2014 Description Pos. Qty Code KIT1 13-01-0006/R 1ST STAGE HEAD COVER MCH13/16 KIT 13-01-0006 1ST STAGE HEAD COVER MCH13/16 13-00-0012 STRAIGHT FITTING 1/4 TUBE 13-01-0013 O-R SUCTION FILTER 3137 NBR 70 13-01-0026 INTAKE FILTER SPRING 13-01-0011 INTAKE FILTER COVER O-RING MCH13/16 SC000370...

  • Page 28: Kit

    1 STAGE MCH-11-13-16-18 For models up to 12-2014 KIT 1 - 13-01-0006/R SUCTION FILTER CARTRIDGE KIT 2a MCH-11-13 - 13-01-0003/R KIT 2b MCH-16-18 - 16-01-0003/R 2.3a 2.3b KIT 4a MCH-11-13 - 13-01-0002/R KIT 4b MCH-16-18 - 16-01-0002/R 4.1a 4.1b KIT 3a MCH-11-13 - 13-01-0117/R 3.2a KIT 3b MCH-16-18 - 16-01-0117/R 3.2b...
  • Page 29 STAGE MCH-11-13-16-18 For models by 01-2015 Description Pos. Qty Code KIT1 13-01-0006/N/R NEW 1ST STAGE HEAD COVER MCH13/16 KIT 13-01-0006/N NEW 1ST STAGE HEAD COVER MCH13/16 13-07-041 FITTING 3/8 TUBE 13-01-0013 O-R SUCTION FILTER 3137 NBR 70 13-01-0026 INTAKE FILTER SPRING 13-01-0011 INTAKE FILTER COVER O-RING MCH13/16 SC000370...

  • Page 30: Kit

    STAGE MCH-11-13-16-18 For models by 01-2015 KIT 1 - 13-01-0006/R SUCTION FILTER CARTRIDGE 1.10 1.11 KIT 2a MCH-11-13 - 13-01-0003/R KIT 2b MCH-16-18 - 16-01-0003/R 2.3a 2.3b KIT 4a MCH-11-13 - 13-01-0002/R KIT 4b MCH-16-18 - 16-01-0002/R 4.1a 4.1b KIT 3a MCH-11-13 - 13-01-0117/R 3.2a KIT 3b MCH-16-18 - 16-01-0117/R 3.2b...

  • Page 31: 2Nd Stage

    STAGE Description Pos. Qty Code KIT1 13-02-0046-1/R SECOND STAGE HEAD MCH13/16 KIT 13-02-0045/E LONG STRAIGHT 1/4 PIPE FITTING 13-02-0046 SECOND STAGE HEAD MCH13/16 13-00-0075 SCREW ZINC. 13-02-0056 O-RING 4087 VITON NBR 90 SHORT 13-03-0029/90 O-RING VITON NBR 90 SHORT KIT2 13-02-0049/R 2ND STAGE PRESSURE VALVE ASS MCH13/16 KIT 13-02-0049...
  • Page 32 STAGE KIT2 - 13-02-0049/R KIT1 - 13-02-0046-1/R KIT5 - 13-02-0046/R KIT6a MCH-8-11-13 - 13-02-0043/R KIT6b MCH-16-18 - 16-02-0043/R KIT3 - 13-02-0044/R 6.1a 6.1b 4.2a 4.2b 4.1a KIT7 - 13-02-0037/R 4.1b KIT4a MCH-8-11-13 - 13-02-0112/R KIT4b MCH-16-18 - 16-02-0112/R Direction of assembly of segments Head cover Connecting rod Spare Parts List...
  • Page 33 STAGE G2 For models up to 03-2014 Description Pos. Qty Code KIT1 13-03-0027/R 3RD STAGE HEAD FOR MCH13/16 KIT 13-03-0028 3RD STAGE PRESSURE VALVE ASS MCH13/16 13-03-0029/90 O-RING VITON NBR 90 SHORT 13-03-0027 3RD ST.GE HEAD FOR MCH13/16 13-00-0025E FITTING 1/4 G -PIPE GUAR1319 COPPER WASHER 13-03-0020...
  • Page 34 STAGE G2 For models up to 03-2014 KIT 1 13-03-0027/R KIT 5 13-03-0030/R KIT 2 13-03-0126/R KIT 6 13-02-0017/R KIT 3 13-00-0019/R KIT 7 KIT 4 13-03-0190/R 13-03-0120/R Spare Parts List Max-Air 55/90/180 & Tropic-Max Series Page 17...
  • Page 35 STAGE G3 For models by 03-2014 Description Pos. Qty Code KIT1 13-03-0022-2/R 3RD STAGE NEW HEAD MCH-13-16 13-03-0026 SPINDLE SPRING VALVE 3RD STAGE 13-03-0029/90 O-RING VITON NBR 90 SHORT 36-04-017 INOX SPRING VITE0845 SCREW ZINC. DIN912 13-03-0027/1 KIT 3RD STAGE NEW HEAD MCH-13-16 13-00-0175E 1/4 G TUBE 8MM FITTING GUAR1319...
  • Page 36 STAGE G3 For models by 03-2014 Spring positioning KIT7 - 13-03-0027/1/R New head upgrade kit -KIT1 KIT 1 -KIT2 13-03-0022-2/R 1.13 1.13 KIT8 - 13-03-0022/15/R Service kit 3rd stage valves G3 1.10 1.11 KIT 2 1.12 13-03-0122/R 1.13 KIT 5 13-02-0017/R KIT 3 13-00-0019/R...
  • Page 37 PRESSURE CIRCUIT Description Pos. Qty Code KIT1 13-00-0085/R 1ST-2ND STAGE 10MM COOLING PIPE KIT 13-00-0085 1ST-2ND STAGE 10MM COOLING PIPE 13-02-0045E FITTING 1/4 G - TUBE 10MM HEAD 2°STD MCH 13/16 13-00-0178E FITTING TUBE10MM 1/4 NPT 13-00-0091 PIPE HOLDING BRACKET 45X15MM 10 13-00-0137 SELF LOCKING NUT 13-00-0067...
  • Page 38 PRESSURE CIRCUIT 3.12 3.10 3.12 3.11 KIT 4 13-00-0036/R KIT 3 13-03-0023/N/R P. 36 3.13 KIT 1 3.13 13-00-0085/R 2.10 1.10 KIT 2 13-00-0089/R Spare Parts List Max-Air 55/90/180 & Tropic-Max Series Page 21...
  • Page 39 PRESSURE CIRCUIT Mod: Tropical - Tropical Plus Description Pos. Qty Code KIT1 13-01-0085/TR/R COOLING PIPE 12MM 1ST-SEP. MCH13/16 TR-TRPL KIT 13-01-0085/TR COOLING PIPE 12MM 1ST-SEPARATOR MCH13/16 T-TP RACC/E2115121/4 STRAIGHT FITTING 1/4NPT TUBE 12MM SHORT RACCE212112LG1/2 FITTING E212-112L G1/2" WITH GASKET 13-00-0083 PIPE HOLDING BRACKET 75X15MM.
  • Page 40 PRESSURE CIRCUIT Mod: Tropical - Tropical Plus 1.11 KIT 4 13-00-0036/N/R P. 36 KIT 2 KIT 5 13-02-0086/TR/R 13-03-0025/TR/R P. 36 3.10 KIT 3 13-00-0089/TR/R 1.10 KIT 1 13-01-0085/TR/R Spare Parts List Max-Air 55/90/180 & Tropic-Max Series Page 23...
  • Page 41 SUPPORT Description Pos. Qty Code 13-00-0102 SEPARATOR CLAMP VITE0825 SCREW ZINC. REDUCED HEAD VITE0840 SCREW ZINC. 13-00-0018 MIDDLE NUT ZINC. 13-00-0094/1 HOLD-FILTERS PLATE MCH13/16 13-00-0093 FILTER HOLDING BRACKET MCH13/16 13-00-0101 SELF-LOCKING NUT VITE0820 SCREW ZINC. 13-00-0069 COUNTER FILTERS PLATE MCH13/16 Page 24 Max-Air 55/90/180 &...
  • Page 42 SUPPORT P. 36 P. 38 Spare Parts List Max-Air 55/90/180 & Tropic-Max Series Page 25...
  • Page 43 SUPPORT Mod: Tropical - Tropical Plus Description Pos. Qty Code 13-00-0102 SEPARATOR CLAMP 13-00-0101 8MM SELF-LOCKING NUT 13-00-0048 SCREW ZINC. DIN 912 13-00-0018 MIDDLE NUT ZINC. 13-00-0094/1 CONDENSATE SEPARATOR PLATE MCH13-16 ZINC. 13-00-0094/2 SQUARE CONDENSATE SEP. PLATE MCH13-16 ZINC. Page 26 Max-Air 55/90/180 &...
  • Page 44 SUPPORT Mod: Tropical - Tropical Plus P. 36 P. 36 Spare Parts List Max-Air 55/90/180 & Tropic-Max Series Page 27...
  • Page 45 FILTERING CIRCUIT FILTERING CIRCUIT Pos. Qty. Code Description Pos. Qty. Code Description 13-00-0174E FITTING 1/8 NPT TUBE 6 mm TUBO/MCH13/B/N SEPARATOR-FILTER TUBE CONNECTION 13-00-0174E FITTING 1/8 NPT TUBE 6 mm TUBO/MCH13/B/N SEPARATOR-FILTER TUBE CONNECTION 13-00-0174E FITTING 1/8 NPT TUBE 6 mm 13-00-0025E FITTING 1/4 G -TUBO 6mm 13-00-0174E...
  • Page 46 CONDENSATE SEPARATOR Description Pos. Qty Code KIT1 13-00-0118/R CONDENSATE SEPARATOR PLUG KIT 13-00-0118 CONDENSATE SEPARATOR PLUG OR-4143/90 O RING 4143 NBR 90 OR-2018/90 O RING 2018 NBR 90 SC000492/D CHECK VALVE SPRING SC000492/C CHECK VALVE PISTON OR-2021/90 O RING 2021 NBR 90 OR-114/90 O RING 114 NBR 90 13-00-0121...
  • Page 47 CONDENSATE SEPARATOR KIT4a 6-05-001A KIT4b 6-05-001A/600 KIT1 13-00-0118/R 1.10 TROPICAL KIT5 13-05-012/R KIT2 13-00-115/N/R KIT6 13-05-012/R KIT3 36-00-0600/180/R Page 30 Max-Air 55/90/180 & Tropic-Max Series Spare Parts List...
  • Page 48 CONDENSATE DISCHARGE CONDENSATE DISCHARGE Pos. Qty. Code Description CONDENSATE DISCHARGE Pos. Qty. Code Description 13-00-0162 CONDENSATE DISCHARGE NYLON SEAT KIT 2 13-00-0164/R CONDENSATE DISCHARGE WHEEL VALVE KIT 13-00-0162 CONDENSATE DISCHARGE NYLON SEAT 13-00-0164 CONDENSATE DISCHARGE KNOB NOT SOLD SEPARATELY SEE KIT 2 KIT 2 13-00-0164/R CONDENSATE DISCHARGE WHEEL VALVE KIT...
  • Page 49 CONDENSATE DISCHARGE Description Pos. Qty Code KIT1 13-00-0505/N/R CONDENSATE DISCHARGE VALVE KIT 12 36-07-070 SCREW TCEIZN M5X12-8.8 MCH36 13-00-0506 CONDENSATE DISCHARGE BODY VALVE CAP OR-2118 O RING 2118 70-75 SH (29.87X1.78) OR-2018 O RING 2018 70-75 SH (4,48X1,78) 13-00-0507/A CONDENSATE DISCHARGE VALVE PISTON OR-2100 O RING 2100 NBR 70SH SC000337/C/R...
  • Page 50 CONDENSATE DISCHARGE KIT2 - 13-00-0505/COM/R KIT1 - 13-00-0505/N/R Spare Parts List Max-Air 55/90/180 & Tropic-Max Series Page 33...
  • Page 51 SAFETY VALVE Pos. Qty. Code Description RV-504 FINAL SAFETY VALVE RV-504-12 REBUILD KIT FOR RELIEF VALVE PRESSURE MAINTAINING VALVE Pos. Qty. Code Description 13-00-0127 MANTAINING PRESSURE VALVE 1/8 - 1/4 13-00-0147/N1 MAINTENANCE VALVE SCREW OR-2025 O RING 2025 NBR 70 13-00-0149/N MAINTENANCE VALVE PISTON OR-2015...
  • Page 52 SAFETY VALVE - PRESSURE MAINTAINING VALVE SAFETY VALVE PRESSURE MAINTAINING VALVE 1.10 Spare Parts List Max-Air 55/90/180 & Tropic-Max Series Page 35...
  • Page 53 NOTES _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________...

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