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Maxair MEGA-MAX OPEN VERTICAL 6000 Use And Maintenance Manual

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WARNING!
DO NOT USE WITH ENRICHED AIR
SYSTEMS, ABOVE 21% OXYGEN,
(THE USE OF ENRICHED AIR WILL
VOID MANUFACTURES WARRANTY)
2807 PEDDLER LANE, KERRVILLE TEXAS USA 78028
MEGA-MAX
OPEN
VERTICAL 6000
MEGA-MAX VERTICAL-6000
USE AND MAINTENANCE MANUAL
Revised 6-30-21

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  • Page 1 MEGA-MAX OPEN VERTICAL 6000 WARNING! DO NOT USE WITH ENRICHED AIR SYSTEMS, ABOVE 21% OXYGEN, (THE USE OF ENRICHED AIR WILL VOID MANUFACTURES WARRANTY) MEGA-MAX VERTICAL-6000 USE AND MAINTENANCE MANUAL 2807 PEDDLER LANE, KERRVILLE TEXAS USA 78028 Revised 6-30-21...
  • Page 2 Model No. Mega-Max 6000 Date Mfg. ____________________ Serial No. ______________________________________________________ Final Pressure Switch Set At ____________________ Final Safety Relief Set At ____________________ o Single Phase o Three Phase o 50hz o 60hz Horse Power ____________________ Voltage ____________________ Page 2 Mega-Max 6000 Use and Maintenance Manual acp0117...
  • Page 3 MEGA-MAX 6000 HIGH PRESSURE COMPRESSOR FOR BREATHING AIR WARNING! DO NOT USE WITH ENRICHED AIR SYSTEMS, ABOVE 21% OXYGEN (the use of enriched air, above 21% oxygen, will void manufacturer’s warranty) IMPORTANT: BEFORE USING THE COMPRESSOR READ THIS MANUAL CAREFULLY 2807 Peddler Lane West •...
  • Page 4 Dear Customer, Thank you for choosing Max-Air, where quality and commitment give you the best in technology and support available today. This manual is provided together with the compressor to aid you in the use of the machine and ensure that your compressor produces the best possible results. Please read all the instructions and information provided on the following pages.

  • Page 5: Table Of Contents

    CONTENTS CHAPTER 1 - GENERAL 1.1 Preliminary information 1.2 Required operator training 1.3 Important information for the user 1.4 Foreword 1.5 Warranty 1.6 Assistance 1.7 Responsibility 1.8 Purpose of the machine 1.9 Where the machine may be used 1.10 Running in and testing the compressor CHAPTER 2 - BASIC INFORMATION ON THE COMPRESSOR 2.1 Description of the compressor 2.2 Identifying the compressor...
  • Page 6 CONTENTS CHAPTER 5 - HANDLING AND INSTALLATION 5.1 Unpacking 5.2 Handling 5.3 Installation 5.3.1 Positioning 5.3.2 Air intake extension connection 5.3.3 Reload hose connection 5.3.4 Electrical connection CHAPTER 6 - USING THE COMPRESSOR 6.1 Preliminary checks before using for the first time 6.1.1 Filling with lubricant oil 6.1.2 Checking for proper electrical connection 6.2 Checks to be run at the start of each working day...
  • Page 7 CONTENTS CHAPTER 7 - MAINTENANCE 7.1 Foreword 7.2 General 7.3 Unscheduled maintenance 7.4 Scheduled maintenance table 7.5 Troubleshooting 7.6 Checking and changing the lubricating oil and filter 7.6.1 Oil table 7.6.2 Checking the oil level 7.6.3 Changing the lubricating oil and filter 7.7 Changing the intake filter 7.8 Checking the safety valve 7.9 Transmission belts...

  • Page 8: Chapter 1 - General

    Chap. 1 - General 1 - GENERAL 1.1 - PRELIMINARY INFORMATION Do not destroy or modify the manual and update it with additional inserts only. Manual P/N: MM-6000-UMM06 Revision no: 00 Edition: 09/2006 Machine type: High pressure compressor for breathing air Model: MEGA-MAX 6000 Manufacturer’s data: Max-Air...

  • Page 9: Required Operator Training

    Chap. 1 - General 1.2 - REQUIRED OPERATOR TRAINING This manual must be read carefully: - all compressor operators / maintenance personnel must read this entire manual with due care and attention and observe the instructions/information contained herein. - employers must ensure that the operator has the required aptitude for operation of the compressor and that he/she has read the manual.

  • Page 10: Foreword

    Chap. 1 - General 1.4 - FOREWORD The regulations/instructions for use contained in this manual constitute an essential component of the supplied compressor. These regulations/instructions are intended for an operator who has already been trained to use this type of compressor.

  • Page 11: Assistance

    Chap. 1 - General A compressor that has been acknowledged as faulty on account of flaws in design, workmanship or materials shall be repaired or replaced free of charge by Max-Air at its plant in Kerrville, Texas; costs regarding transport, delivery of spare parts and any materials subject to wear shall be met by the customer.

  • Page 12: Purpose Of The Machine

    Chap. 1 - General 1.8 - PURPOSE OF THE MACHINE The compressor mod. Mega-Max 6000 has been designed and built for the purpose of obtaining excellent quality breathing air by drawing it from the surrounding environment. The air is free from any harmful fumes. The air is passed through an intake filter and, after the filtration cycle, is stored in bottles constructed to contain air at high pressure.
  • Page 13 Chap. 1 - General DANGER: - After switching off the compressor wait about 30 minutes before carrying out any maintenance tasks so as to prevent burns. - The high pressure flex hose that connects to the bottle (also called the refill hose) must be in good condition, especially in the areas near the fittings.

  • Page 14: Where The Machine May Be Used

    Chap. 1 - General 1.9 - WHERE THE MACHINE MAY BE USED The compressor mod. Mega-Max 6000 has been designed and built for the purpose of obtaining excellent quality breathing air by drawing it from the surrounding environment, free from any harmful fumes. The air is passed through an intake filter and, after the filtration cycle, is stored in bottles constructed to contain air at high pressure.

  • Page 15: Chapter 2 - Basic Information On The Compressor

    Chap. 2 - Basic information on the compressor 2 - BASIC INFORMATION ON THE COMPRESSOR 2.1 - DESCRIPTION OF THE COMPRESSOR High pressure compressor for breathing air. Compatible process gases: - Carbon dioxide - Nitrogen (also dry) - Benzene - Butadiene - Helium - Sulphur hexafluoride - Natural gas...

  • Page 16: General Instructions

    Chap. 2 - Basic information on the compressor 2.3 - GENERAL INSTRUCTIONS WARNING: - This manual must be read carefully before transporting, installing, using or carrying out any maintenance on the compressor. - It must be preserved carefully in a place known to compressor users, managers and all transport/installation/maintenance/repair/final dismantling personnel.

  • Page 17: Chapter 3 - Safety Regulations

    Chap. 3 - Safety regulations 3 - SAFETY REGULATIONS 3.1 - GENERAL SAFETY RULES 3.1.1 - KNOW THE MACHINE The compressor must only be used by qualified personnel. They must have an understanding of the arrangement and function of all the controls, instruments, indicators, warning lights and the various info plates/labels. 3.1.2 - WEAR PROTECTIVE CLOTHING All operators must use accident prevention items such as gloves, hard hat, eye goggles, accident prevention shoes...

  • Page 18: Know The Machine

    Chap. 3 - Safety regulations 3.2 - GENERAL PRECAUTIONS The EEC Machinery Directive 89/392 provides the following definitions (appendix 1, 1.1.1): «DANGEROUS ZONE»: zone inside and/or near machine which presence of an exposed person constitutes a risk for his/her security and health. «EXPOSED PERSON»: any person wholly or partially inside a dangerous zone.

  • Page 19: Important Safety Information

    Chap. 3 - Safety regulations IMPORTANT: - Never place hands or introduce screwdrivers, keys or other tools into moving parts. - Never clean with flammable fluids. - Periodically check the info plates/labels and restore/replace them where necessary. - The workplace must be kept clean, tidy and free from objects that might hinder movement. - Operators must avoid carrying out “awkward”...

  • Page 20: Safety Info Labels: Location

    Chap. 3 - Safety regulations 3.2.5 - SAFETY INFO LABELS: DESCRIPTION Warning label. Unauthorized, unqualified personnel are forbidden from opening the control panel. The power supply must always be disconnected before carrying out any work on the control panel Cooling fan direction of rotation info label (located on top rear panel).
  • Page 21 Chap. 3 - Safety regulations Label warning against presence of live parts. Warning plate; read the use and maintenance manual and the appendices carefully before running the compressor. Label with ideogram indicating that hard hat must be worn. Label with ideogram indicating that protective gloves must be worn.

  • Page 22: Residual Risk Zones

    Chap. 3 - Safety regulations 3.2.6 - RESIDUAL RISK ZONES DANGER: In some compressor zones there remain residual risks that were not possible to eliminate at the design stage or for which safety guards could not be provided without compromising the functionality of the Mega-Max 6000. To prevent accidents all operators must be aware of the residual risks on this compressor.

  • Page 23: General Safety Regulations

    Chap. 3 - Safety regulations 3.3 - GENERAL SAFETY REGULATIONS 3.3.1 - CARE AND MAINTENANCE Damage and accidents are often caused by maintenance errors, such as: - no oil, - insufficient cleaning, - compressed air circuit inefficiency (flex hoses damaged, loose pipes, screws etc.). Maintenance work must be carried out with due care and attention: your safety depends on it.

  • Page 24: Maintenance Precautions

    Chap. 3 - Safety regulations 3.4 - MAINTENANCE PRECAUTIONS 3.4.1 - CARE AND MAINTENANCE Before doing any maintenance work, turn off power at main breaker and make sure the compressed air system is completely depressurized, including the filtration. If other people start the compressor or act on the control or off/auto switch while maintenance work is in progress there is a risk of serious injury or death.

  • Page 25: Chapter 4 - Technical Data

    Chap. 4 - Technical data 4 - TECHNICAL DATA 4.1 - TECHNICAL CHARACTERISTICS 4.1.1 - MONOBLOCK, CRANKSHAFT, PISTONS, CYLINDERS The monoblock is made of aluminium alloy; the flange with the roller bearings that support the crankshaft is kept oil-tight with the monoblock by O-rings. The crankshaft and the connecting rods run on roller bearings only.

  • Page 26: Technical Specifications Table

    Chap. 4 - Technical data 4.1.6 - TECHNICAL SPECIFICATIONS TABLE Construction high pressure compressor with forced air cooling and 4 compression stages Max. peak non-continuous pressure 414bar - 6000PSI Flow rate approx. 600 l/min. 12, 19, 21 cfm Cylinder diameter 130 - 60 - 32 - 14 mm Piston stroke 50 mm RPM 1000 - 1300 rpm Intermediate pressures 1st stage 3.5 bar –...

  • Page 27: Dimensions And Weight

    Chap. 4 - Technical data 4.1.8 - DIMENSIONS AND WEIGHTS Use and Maintenance Manual Mega-Max 6000 Page 27...

  • Page 28: Machine Parts

    Chap. 4 - Technical data 4.1.9 - MACHINE PARTS Description: Frame Control panel Gauges Refill taps Oil level sight glass Condensate collection container Condensate expansion tank Electric motor Compressor block Oil filter Air filter Safety mesh (removable) Anti-vibration devices Cooling fan Belt Active carbon air filter chamber Dryer only air filter cartridge...

  • Page 29: Chapter 5 - Handling And Installation

    Chap. 5 - Handling and installation 5 - HANDLING AND INSTALLATION 5.1 - UNPACKING The Mega-Max 6000 compressor is sent fully assembled, but with the supplied flex hoses separate. The compressor is packed in a cardboard box; the latter is placed on a pallet to simplify handling and transport. The box containing the compressor must be moved according to the instructions shown on the box itself.

  • Page 30: Air Intake Extension Connection

    Chap. 5 - Handling and installation 5.3.2 - AIR INTAKE EXTENSION CONNECTION If the compressor is installed in an area without the necessary ventilation requisites described in section 5.3.1 “Positioning”, it will be necessary to install an air intake extension leading in from outdoors or a place with the cited ventilation requisites.

  • Page 31: Electrical Connection

    Chap. 5 - Handling and installation 5.3.4 - ELECTRICAL CONNECTION To connect up to the power supply insert the wires into the main power panel. Check that the data on the compressor ID plate is compatible with mains power supply, especially as regards rated current and voltage.

  • Page 32: Chapter 6 - Using The Compressor

    Chap. 6 - Using the compressor 6 - USING THE COMPRESSOR 6.1 - PRELIMINARY CHECKS BEFORE USING FOR THE FIRST TIME The operator must check that the compressor is supplied with: - use and maintenance manual; - appendix to the use and maintenance manual; If the compressor is sold on the customer/user must provide the purchaser with a complete, undamaged use and maintenance manual.

  • Page 33: Checks To Be Run At The Start Of Each Working Day

    Chap. 6 - Using the compressor 6.2 - CHECKS TO RUN AT THE START OF EACH WORKING DAY Inspect the exterior of the compressor (couplings, pipes, pneumatic components etc.) and check for any oil leaks. 6.2.1 - LUBRICATING OIL LEVEL CHECK Check that the level of lubricating oil (a) is within acceptable limits (just above center of top sight glass).

  • Page 34: Control Panel

    Chap. 6 - Using the compressor 6.3 - CONTROL PANEL Key: 6.3.1 - POWER INDICATOR LIGHT When the power indicator light (1) is on the compressor is powered. Page 34 Mega-Max 6000 Use and Maintenance Manual...

  • Page 35: Stop-Emergency Pushbutton

    Chap. 6 - Using the compressor 6.3.2 - STOP-EMERGENCY PUSHBUTTON Press the stop-emergency pushbutton (2) to shut down the compressor. Check that the emergency pushbutton is working properly at the start of each working day: do this by switching on the compressor and pressing the pushbutton; if the compressor does not stop immediately after pressing disconnect the compressor from the main power supply and contact MAX-AIR.

  • Page 36: Hour Counter

    Chap. 6 - Using the compressor 6.3.3 - HOUR COUNTER The hour counter (3) indicates the hours of effective compressor operation: use this information to observe maintenance schedules. 6.3.4 - LUBRICATING OIL CIRCUIT PRESSURE GAUGE The gauge indicates the pressure inside the lubricating oil circuit.

  • Page 37: 1St Stage Pressure Gauge

    Chap. 6 - Using the compressor 6.3.6 - 2 STAGE PRESSURE GAUGE The gauge indicates the pressure inside the 2nd compression stage. If pressure is not between 16 bar (230 PSI) and 20 bar (290 PSI) switch off the compressor and contact MAX-AIR.

  • Page 38: Machine Status Fault Light

    Chap. 6 - Using the compressor 6.3.9 - MACHINE STATUS FAULT LIGHT INDICATOR PROBLEM/FAULT SOLUTION 1. Low oil alarm shutdown Check oil level and pressure 2. CO alarm shutdown (optional) Check CO PPM settings and possible CO contamination - call Max-Air 3.

  • Page 39: Preliminary Tasks

    Chap. 6 - Using the compressor 6.4 - PRELIMINARY TASKS 6.4.1 - SAFETY VALVE CHECKS Check that safety valves are working properly by starting the compressor with the end taps closed: this will raise circuit pressure fast and trip the valves when their pressure setting is reached. The valves are pre-adjusted to 414 bar (6400 PSI).

  • Page 40: Automatic Condensate Discharge

    Chap. 6 - Using the compressor 6.4.2 - AUTOMATIC CONDENSATE DISCHARGE The condensate gathered in the container (a) must be drained as described below every day. The release of vaporized water with lubricating oil during bottle refill is normal: the quantity depends on the level of humidity in the air.
  • Page 41 Chap. 6 - Using the compressor To refill the bottles proceed as follows: - Fit the hose connector (a) to the bottle tap (b) - Screw in the fixing knob (c) until it is completely tightened - Check that the bleed tap (f) is closed by rotating it clockwise - Open the tap (d) by rotating it counterclockwise - Open the tap (e) by rotating it counterclockwise - Start the compressor...

  • Page 42: Chapter 7 - Maintenance

    Chap. 7 - Maintenance WARNING: Maintenance tasks must only be carried out by the MAX-AIR Customer Assistance Service or qualified personnel. DANGER: All maintenance tasks must be carried out with the compressor off and the power lead unplugged from the main socket. 7.1 - FOREWORD To obtain the best possible performance from the compressor and ensure a long working life for all its parts it is essential that personnel follow the use and maintenance instructions with extreme diligence.

  • Page 43: Scheduled Maintenance Table

    Chap. 7 - Maintenance 7.4 - SCHEDULED MAINTENANCE TABLE 7.5 - TROUBLESHOOTING Problem Cause Solution - The electric motor • Phase missing • Check fuses or overload does not start - Rotation speed and flow • Motor power too low •...

  • Page 44: Checking And Changing The Lubricating Oil And Filter

    Chap. 7 - Maintenance 7.6 - CHECKING AND CHANGING THE LUBRICATING OIL AND FILTER After putting the compressor into service the oil filter and the lubricating oil must be changed after the first 50 (fifty) working hours. Replacement of the oil filter and the lubricating oil must be done every 65 hours working hours or annually.

  • Page 45: Changing The Lubricating Oil And Filter

    Chap. 7 - Maintenance 7.6.3 - CHANGING THE LUBRICATING OIL AND FILTER The lubricating oil must be changed every 65 working hours or annually. Every time the lubricating oil is changed the oil filter must be changed too. To change the oil proceed as described: - position a recipient under the drain hose (a1) so that the oil flows into the exhausted oil recipient (a2) (recipient capacity of at least 3.8 liters (1...

  • Page 46: Changing The Intake Filter

    Chap. 7 - Maintenance 7.7 - CHANGING THE INTAKE FILTER After putting the compressor into service the intake filter must be changed after the first 50 working hours. The air filter must then be changed every 250 working hours or annually. Every 50 working hours rotate the filtration cartridge inside the filter 90°.

  • Page 47: Checking The Safety Valve

    Chap. 7 - Maintenance 7.8 - CHECKING THE SAFETY VALVE The final safety valve protects bottles from being filled with air at too high a pressure; the valve setting is made at the time of testing the compressor to customer requirements. IMPORTANT: Should the safety valve fail to operate properly contact the MAX-AIR technical assistance service.

  • Page 48: Condensate Discharge

    Chap. 7 - Maintenance 7.10 - CONDENSATE DISCHARGE The condensate jug must be drained at the end of every working day or when it reaches the max level of ½ full. DANGER: Do not carry out these tasks if the compressor has only just shut down; wait for the compressor to cool.

  • Page 49: Active Carbon Filters / Molecular Sieve

    Chap. 7 - Maintenance 7.11 - ACTIVE CARBON FILTERS / MOLECULAR SIEVE The active carbon filter must be replaced at intervals calculated on the basis of the characteristics of the environment in which the compressor is located. To calculate these intervals refer to the table below. The filter must nevertheless be replaced before the air becomes malodorous.
  • Page 50 Chap. 7 - Maintenance - remove the filter plug (c); - remove the dryer and active carbon filter cartridge (d) and replace it with a new one; - check/grease the O-ring (f) and back up ring on the plug (c) every time the filter is changed; - close the filter and screw it on with the wrench (a).

  • Page 51: Changing The Flex Hoses

    Chap. 7 - Maintenance 7.12 - CHANGING THE FLEX HOSES IMPORTANT: The hoses must be changed periodically (yearly or every 1000 hours) or when they show signs of abrasion/ wear/damage. The bending radius of the hoses must not be less than 250 mm (9¾”). DANGER: Do not carry out these tasks if the compressor has only just shut down;...

  • Page 52: Chapter 8 - Storage

    Chap. 8 - Storage 8 - STORAGE Should the compressor not be used, it must be stored in a dry sheltered area at an ambient temperature of between 0°C and 40°C (32° F and 104° F). Store the compressor away from sources of heat, flames or explosive. 8.1 - STOPPING THE MACHINE FOR A BRIEF PERIOD If you do not intend to use the compressor for a brief period proceed with general cleaning.

  • Page 53: Chapter 9 - Dismantling And Putting Out If Service

    Chap. 9 - Dismantling and putting out of service 9 - DISMANTLING AND PUTTING OUT OF SERVICE Should you decide not to use the compressor or any of its parts any longer you must proceed with its dismantling and putting out of service. These tasks must be carried out in compliance with the standards in force. WARNING: Should the compressor, or a part of it, be out of service its parts must be rendered harmless so they do not cause any danger.

  • Page 54: Chapter 10 - Instructions For Emergency Situations

    Chap. 10 - Instructions for emergency situations 10 - INSTRUCTIONS FOR EMERGENCY SITUATIONS 10.1 - FIRE In the event of fire use a CO extinguisher in compliance with the relevant standards in force and contact your local fire department. Page 54 Mega-Max 6000 Use and Maintenance Manual...

  • Page 55: Chapter 11 - Maintenance Register

    Cap.11 _ Maintenance register Chap. 11 - Maintenance register 11 - MAINTENANCE REGISTER 11 - MAINTENANCE REGISTER Date Component Task and notes Signature Use and Maintenance Manual Mega-Max 6000 Page 55 M C H - 3 6 Use and maintenance manual pag.
  • Page 56 Cap.11 _ Maintenance register Chap. 11 - Maintenance register 11 - MAINTENANCE REGISTER 11 - MAINTENANCE REGISTER Date Component Task and notes Signature Page 56 Mega-Max 6000 Use and Maintenance Manual M C H - 3 6 Use and maintenance manual pag.
  • Page 57 Cap.11 _ Maintenance register Chap. 11 - Maintenance register 11 - MAINTENANCE REGISTER 11 - MAINTENANCE REGISTER Date Component Task and notes Signature Use and Maintenance Manual Mega-Max 6000 Page 57 M C H - 3 6 Use and maintenance manual pag.

  • Page 58: Chapter 12 - Notes

    Chap. 12 - Notes 12 - NOTES 12 - NOTES Page 58 Mega-Max 6000 Use and Maintenance Manual M C H - 3 6 Use and maintenance manual pag.
  • Page 59 Chap. 12 - Notes 12 - NOTES 12 - NOTES Use and Maintenance Manual Mega-Max 6000 Page 59 M C H - 3 6 Use and maintenance manual pag.
  • Page 60 Chap. 12 - Notes 12 - NOTES 12 - NOTES Page 60 Mega-Max 6000 Use and Maintenance Manual M C H - 3 6 Use and maintenance manual pag.
  • Page 61 CARBON MONOXIDE ELEMENT #MI-4002R DESCRIPTION This detector consists of a ‘Visual” indicator (#MI-4000), into which a small (15 mm diameter) replaceable disc is inserted. The ‘Visual’ indicator has a clear sight lens through which the disc may be seen. The disc changes color in the presence of low concentrations of carbon monoxide within 5 to 10 minutes of exposure and therefore acts as a clear visible warning before the proportion of gas reaches an unacceptable level.
  • Page 62 Assembly and Disassembly BLEED ALL PRESSURE FROM UNIT AND SHUT OFF POWER Model MI-4000 Visual Indicator Unscrew by hand , counter-clockwise, to remove and replace elements. Reinstall cap hand tight. Item Part No. Description Body Window 592-1 O ring 2-018 592-2 O ring 2-019 592-3...
  • Page 63 Remove top half of element housing and invert. Place the blue moisture indicator down inside element against the glass taking care not to touch the blue element with your fingers. Place the beige element on top of the spring if monitoring for CO Re-attach the top half of the element housing hand tight.
  • Page 64 2807 Peddler Lane West • Kerrville • Texas 78028 • USA Tel. (830) 257-5006 • Fax (830) 257-3720 • e-mail: service@max-air.com www.max-air.com Max-Air is a registered trademark with the U.S. Patent Office - copyright 2006. This manual cannot be reproduced without the express, written permission of Max-Air.
  • Page 65 SPARE PARTS LIST HEAVY DUTY HEAVY DUTY LINE: • MCH-22-30-36-45/OPEN • MCH-22-30-36-45/SILENT Rev. 8/20/21...
  • Page 66 INDEX PAG. CRANKCASE ASSEMBLY CRANKSHAFT ST STAGE ND STAGE RD STAGE TH STAGE CONDENSATE SEPARATOR 1ST/2ND STAGE PRESSURE CIRCUIT 3RD/4TH STAGE PRESSURE CIRCUIT LUBRICATION CIRCUIT PNEUMATIC CIRCUIT CONDENSATE DISCHARGE CIRCUIT HYPERFILTER - CONDENSATE SEPARATOR MANTENANCE VALVE - SAFETY VALVE GASKETS PUMPING GROUP NOTES HEAVY DUTY Spare parts price list...
  • Page 67 CRANKCASE ASSEMBLY POS. CODE DESCRIPTION KIT1 36-00-004/R CRANKCASE KIT CRANKCASE MCH-36 OIL FILLER TAP O-RING 4131 NBR 90 (D32,92x3.53) TIE ROD M10X40-8.8 SELF-LOCKING NUT M10 TIE ROD M8X42-8.8 SELF-LOCKING NUT M8 INOX TIE ROD M8X90-8.8 WASHER M8 1.10 GASKET CRANKCASE-BASE 1.11 TIE ROD M8X35 1.12...
  • Page 68 CRANKCASE ASSEMBLY KIT3 - 36-00-033/R KIT4 - 36-00-041/R KIT1 - 36-00-004/R 1.14 1.15 1.13 1.12 1.10 1.11 KIT5 - 36-00-043/R 2.11 2.10 KIT2 - 36-00-001/R HEAVY DUTY Spare parts price list 3 - 32...
  • Page 69 CRANKSHAFT POS. CODE DESCRIPTION KIT1 36-00-024/R CRANKSHAFT + CONNECTING ROD KIT COUNTERWEIGHT NUT Ø8 SCREW TCEIZN M8X65-8.8 CRANKSHAFT SPLINE SNAP RING BEARING N308 EC CRANKSHAFT SPACER SNAP RING 1.10 BEARING NUP208 EC 1.11 CONNECTING ROD BEARING NUP206 EC/C4 1.12 FIFTH WHEEL 30X42X0,5 MCH36 1.13 2ND STAGE CONNECTING ROD MCH-36 1.14...
  • Page 70 CRANKSHAFT KIT1 - 36-00-024/R 1.10 1.15 1.16 1.17 1.18 1.11 1.11 1.12 1.12 1.12 1.13 1.11 1.14 2nd STAGE 1st STAGE 1.11 1.12 4th STAGE 1.17 1.18 3rd STAGE Direction of assembly 1st stage connecting-rod IV° I° Stage Stage II° III°...
  • Page 71 STAGE POS. CODE DESCRIPTION KIT1 36-05-0503/K KIT INTAKE FILTER 36-05-0504 INTAKE FILTER CARTRIDGE INTAKE FILTER PIPE O-RING INTAKE FILTER MCH-30-36 KIT2 36-01-001/R KIT 1ST STAGE PISTON 130MM 1ST STAGE PISTON 130MM 1ST STAGE PISTON PIN 130MM MCH36 SEEGER RETAINING RING 36-01-004 1ST STAGE PISTON RINGS (3) 130MM MCH36 KIT3...
  • Page 72 STAGE KIT5 36-01-021/R KIT6 36-01-024/R KIT1 36-05-0503/K KIT4 36-01-010/R KIT3 36-01-006/R KIT2 36-01-001/R Direction of assembly of segments Head cover Connecting HEAVY DUTY Spare parts price list 7 - 32...
  • Page 73 STAGE POS. CODE DESCRIPTION KIT1 36-02-001/R KIT 2ND STAGE PISTON 2ND STAGE PISTON 60MM MCH36 2ND STAGE PISTON PIN SNAP RING 36-02-004 SERIES N°4 SEGMENTS 2ND STAGE PISTON KIT2 36-02-006/R 2ND STAGE CYLINDER KIT O-RING 2275 NBR90SH (69.57X1.78) 2ND STAGE CYLINDER Ø60 MCH-36 STUD SCREW M8X42-8.8 NUT M8 INOX SCREW T.C.E.
  • Page 74 STAGE KIT 1 36-02-001/R KIT2 36-02-006/R KIT3 36-02-009/R KIT4 36-02-012/R Direction of assembly of segments Head cover KIT5 36-02-015/R Connecting Spare parts price list HEAVY DUTY 9 - 32...
  • Page 75 STAGE POS. CODE DESCRIPTION KIT1 36-03-006/R KIT 3RD STAGE PAD+PISTON MCH36 3RD/4TH STAGE PAD Ø60 MCH36 3RD/4TH STAGE PISTON PIN B22X48 SNAP RING 3RD STAGE PISTON Ø32 MCH36 36-03-007 SERIES N°4 SEGMENTS 3RD STAGE PISTON KIT2 36-03-005/R KIT 3RD STAGE GUIDE CYLINDER Ø60 MCH36 O-RING 2275 NBR90SH (69.57X1.78) 3RD STAGE GUIDE CYLINDER Ø60 MCH36 O-RING 3237 NBR90SH (60.00X2.62)
  • Page 76 STAGE KIT2 36-03-005/R KIT1 36-03-006/R KIT3 36-02-009/R KIT5 36-03-018/R KIT4 36-03-015/R HEAVY DUTY Spare parts price list 11 - 32...
  • Page 77 STAGE POS. CODE DESCRIPTION KIT1 36-03-001/R KIT 3RD/4TH STAGE PAD Ø60 MCH36 3RD/4TH STAGE PAD Ø60 MCH36 3RD/4TH STAGE PISTON PIN B22X48 SNAP RING KIT2 36-04-005/R KIT 4TH STAGE CYLINDER O-RING 2275 NBR90SH (69.57X1.78) 4TH STAGE CYLINDER STUD SCREW M8X42-8.8 NUT M8 INOX SUCTION 4TH STAGE HEAD FITTING ERMETO G3/8 M18x1,5 TUBE Ø12...
  • Page 78 4° STADIO - 4 STAGE Spring positioning KIT5 36-04-025/R KIT3 36-04-009/15/N/R KIT4 36-04-011/1/R KIT2 36-04-005/R KIT1 36-03-001/R Direction of assembly of segments Cylinder 4 stage 13-03-0158/15 n°5 Segments Ø15mm 13-03-0158/15/RASC n°1 Oil scraper Ø15mm 36-04-035/N/R Kit sostituzione nuova testa New head replacement kit Oil scraper: red side on the left Piston 4 stage...
  • Page 79 CONDENSATE SEPARATOR POS. CODE DESCRIPTION KIT1a 36-05-007/R 2ND STAGE CONDENSATE SEPARATOR KIT1b 36-05-012/R 3RD STAGE CONDENSATE SEPARATOR 1.1a 2ND STAGE G1/2 SEPARATOR LEFT BODY 1.1b 3RD STAGE G3/8 SEPARATOR RIGHT BODY O-RING 2212 NBR90SH (53.67X1.78)MCH36 SEPARATOR RING CONDENSATE SEPARATOR PIPE, STAINLESS OR- 2150 (37,82X1,78) NBR90SH MCH-13/16 SEPARATOR FITTING INTERNAL PLUG NEW CONDENSATE SEPARATOR DIFFUSER MCH13/16...
  • Page 80 CONDENSATE SEPARATOR KIT1a KIT1b KIT1a 36-05-007/R KIT2 KIT1b 36-05-012/R 1.1a 1.1b KIT2 36-05-026/R 1.10 4 - 7 The valve must be tightened with a torque of 20Nm HEAVY DUTY Spare parts price list 15 - 32...
  • Page 81 PRESSURE CIRCUIT POS. CODE DESCRIPTION KIT1 36-05-001/R KIT 1ST STAGE COOLING PIPE (1ST PART) 1ST STAGE COOLING PIPE (1ST PART) SCREW TCEI INOX M8X25 SCREW TSPEIZN M8X35-10.9 1ST STAGE (1ST PART) COOLING PIPE "L" BRACKET PIPE BRACKET Ø18 / Ø8 KIT2 36-05-004/R KIT 1ST STAGE COOLING PIPE (2ND PART)
  • Page 82 PRESSURE CIRCUIT KIT3 36-05-006/R KIT2 36-05-004/R KIT4 36-05-040/R KIT1 36-05-001/R Spare parts price list HEAVY DUTY 17 - 32...
  • Page 83 PRESSURE CIRCUIT POS. CODE DESCRIPTION KIT1 36-05-011/R KIT 3RD/4TH STAGE COOLING PIPE 3RD/4TH STAGE COOLING PIPE INOX NUT M6 SCREW 6X45 T.C.E. ZINC. DIN 912 INTERNAL PIPE BRACKET Ø15 SEVEN-WAY EXTERNAL PIPE BRACKET Ø15 EIGHT-WAY SCREW TCEI M6X40 KIT2 36-05-040/R KIT COOLING PIPE SUPPORT MCH-36 COOLING PIPE SUPPORT MCH-36 SCREW TCEI INOX M8X25-8.8...
  • Page 84 PRESSURE CIRCUIT KIT2 36-05-040/R KIT3 36-05-018/R KIT1 36-05-011/R HEAVY DUTY Spare parts price list 19 - 32...
  • Page 85 LUBRICATION CIRCUIT POS. CODE DESCRIPTION KIT1 36-06-050/R KIT OIL FILTER SUPPORT FITTING OGIVE TUBE Ø8 14X1.5-1/8 NPT OIL FILTER SUPPORT FITTING M 1/8 NPT - M 1/8 NPT SC000688 OIL FILTER CARTRIDGE (FO0243V) NON-RETURN VALVE SPRING OIL PRESSURE RECOVERY PISTON OIL PRESSURE RECOVERY CYLINDER O-RING NBR 90 SH°...
  • Page 86 LUBRICATION CIRCUIT KIT4 - 13-10-0001/TP/R KIT1 36-06-050/R KIT3 36-06-022/R KIT2 36-06-009/R HEAVY DUTY Spare parts price list 21 - 32...
  • Page 87 PNEUMATIC CIRCUIT POS. CODE DESCRIPTION KIT1 13-10-0001/TP/R KIT FITTINGS 1/4 CONNECTION 2 HYYPERFILTER FITTING ERMETO 1/4 - TUBE Ø8 NUT FOR FITTING ERMETO TUBE Ø8 OGIVE RING Ø8M FITTING ERMETO G1/4-M14X1.5 COPPER WASHER 1/4 13-00-0161-1/4N/P KIT CONDENSATE DISCHARGE VALVE G1/4 NPT 13-00-0162 CONDENSATE DISCHARGE NYLON 13-00-0144...
  • Page 88 PNEUMATIC CIRCUIT Pag.27 Ref.15 O I L F I L T Pag.21 Ref.4 KIT1 - 13-10-0001/TP/R The valve must be tightened with a torque of 20Nm Spare parts price list HEAVY DUTY 23 - 32...
  • Page 89 CONDENSATE DISCHARGE CIRCUIT POS. CODE DESCRIPTION KIT1 36-10-0001/R KIT NOZZLES CONDENSATE DRAIN MCH-30-36 1.1A NOZZLE CONDENSATE DRAIN Ø0,8 1.1B NOZZLE CONDENSATE DRAIN Ø1,5 1.1C NOZZLE CONDENSATE DRAIN Ø2,5 O RING 2106 NBR 90 SH (29,9x1,78) O RING 2018 90SH (4,48X1,78) O RING 2100 VITON 90 (25.12x1.78) KIT2 36-10-0002/R...
  • Page 90 CONDENSATE DISCHARGE CIRCUIT KIT3 - 36-10-0003/R SILENT Pag.25 Ref.21 KIT UPGRADE NEW CONDENSATE DISCHARGE OPEN KIT2 KIT1 - 36-10-0001/R 1.1A 1.1B 1.1C KIT2 - 36-10-0002/R Ø0,8 Ø1,5 Ø2,5 2.10 HEAVY DUTY Spare parts price list 25 - 32...
  • Page 91 HYPERFILTER - CONDENSATE SEPARATOR - MA NTENANCE VALVE - SAFETY VALVE POS. Q.TY CODE DESCRIPTION KIT1 RE100368 HYPER FILTER (without Hyper cartridge) HYPERFILTER CARTRIDGE SPRING HYPERFILTER BODY 110MM SCREW T.C.E INOX 10X16 DIN912 UPPER PLUG WITHOUT SENSOR OR-6250 O RING 6250 NBR 90 (62,87X5,34) LOWER CAP HYPERFILTER HOLES TO 1/4G KIT2 RE100366...
  • Page 92 HYPERFILTER - CONDENSATE SEPARATOR - MA NTENANCE VALVE - SAFETY VALVE 6-05-015/3/232 M12x1,25 AL 5a 232bar PS 500 BAR TS-20 +80°C 232 BAR S/N 14L 0151 AEROTECNICA COLTRI S.p.A. 6-05-015/3/250 M12x1,25 AL 5b 250bar PS 500 BAR TS-20 +80°C 250 BAR S/N 14E 0825 AEROTECNICA COLTRI S.p.A.
  • Page 93 GASKETS PUMPING GROUP POS. CODE DESCRIPTION 10 OR-2250 O RING 2250 NBR90SH(63,22X1,78) 10 36-00-039 OIL SPLASH GUARD A 40X55X7 NBR 36-00-034 GASKET CRANKCASE FLANGE 10 OR-4131/90 O-RING 4131 NBR 90 (D32,92x3.53) 10 OR-2018/90 O-RING NBR 90 SH° (4.48x1.78) 10 36-06-021 OIL PUMP FLANGE GASKET 36-00-003 GASKET CRANKCASE-BASE...
  • Page 94 GASKETS PUMPING GROUP HEAVY DUTY Spare parts price list - 32...
  • Page 95 NOTES HEAVY DUTY Spare parts price list 30 - 32...
  • Page 96 NOTES HEAVY DUTY Spare parts price list 31 - 32...
  • Page 97 NOTES HEAVY DUTY Spare parts price list 32 - 32...

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