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TWO STAGE/TWO CYLINDER AIR COMPRESSORS & UNITS
THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND SHOULD
ALWAYS BE AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT.
READ, UNDERSTAND AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS
EQUIPMENT TO PREVENT INJURY OR EQUIPMENT DAMAGE.
MODEL R15B COMPRESSOR
Form No. GF3231
Ver: 02 01/09/2004
FEATURING THE R10 & R15 PUMPS
C453-A
(Ref. Drawing)
OPERATION/MAINTENANCE
MANUAL & PARTS LIST
MODEL HR2-6 UNIT
C452-A
(Ref. Drawing)
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Table of Contents
Related Manuals for Gardner Denver HR5-8
Summarization of Contents
Maintain Compressor Reliability with Genuine Parts and Support
Instructions for Ordering Repair Parts
Guidance on specifying model, serial number, and part numbers for ordering repair components.
Safety and Operation Precautions
General Safety and Installation Guidelines
Includes reading instructions, following codes, grounding, and power cable protection.
Operational Safety and Maintenance Precautions
Covers pressure, speed limits, safety devices, guards, cleanliness, and air usage.
Explanation of Safety Symbols and Precautions
Explanation of Safety Symbols
Defines DANGER, WARNING, CAUTION, and NOTICE symbols used in the manual.
Specific Safety Warnings and Prohibitions
Details critical safety warnings regarding breathing air, non-approved uses, and special options.
Introduction to Gardner Denver R Series Compressors
Gardner Denver Compressor Warranty Information
Outlines the terms and conditions for the five-year and express limited warranties for compressor units and pumps.
Compressor Dimensions and Specifications
Dimensions of R10D & R15B Models
Provides a diagram and detailed measurements for the R10D and R15B compressor models.
Performance and Specification Data
Details key specifications and performance metrics for R10D and R15B compressor models.
Installation Procedures and Precautions
Installation Location and Requirements
Advises on proper placement, ventilation, and environmental conditions for compressor installation.
Installation Safety Warnings
Highlights critical safety instructions, including avoiding shut-off valves in discharge lines and using pressure regulators.
Electrical Power Supply and Wiring
Recommended Wire Sizes for Power Supply
Provides a table of recommended AWG wire sizes based on motor HP and voltage for copper wiring.
Magnetic Starter Wiring Diagrams
Illustrates wiring configurations for single-phase and three-phase magnetic starters for compressor units.
Duplex Magnetic Starter Wiring
Single Phase Duplex Magnetic Starters with Alternator
Shows the wiring diagram for duplex units with single-phase starters and an alternator.
Three Phase Duplex Magnetic Starters with Alternator
Displays the wiring diagram for duplex units with three-phase starters and an alternator.
Air Line Piping and Basic Operation
Air Line Piping Requirements and Recommendations
Specifies minimum pipe sizes, connection recommendations, and leak detection for air lines.
Simplex and Duplex Unit Operation Principles
Explains how pressure switches control simplex and duplex compressor unit operation.
Compressor Operation and Initial Startup
Head Unloader and Continuous Run Operation
Describes how head unloaders and pilot valves enable continuous run operation.
Step-by-Step Initial Startup Procedure
Provides a detailed guide for the initial startup of the compressor unit, including checks and safety steps.
Maintenance Schedule and Safety
Daily Maintenance Tasks
Lists essential daily checks including oil level and draining moisture from the tank.
Weekly Maintenance Tasks and Warnings
Outlines weekly cleaning, filter checks, and V-belt adjustments with associated safety warnings.
Periodic and General Maintenance
90-Day / 500-Hour Maintenance
Details tasks like oil changes, leakage checks, and valve inspection every 90 days or 500 hours.
General Maintenance Notes and Component Explanations
Explains function and maintenance of pressure relief valves, drain valves, switches, belts, and compressor valves.
Specific Component Maintenance
Unloader and Check Valve Maintenance
Covers maintenance for centrifugal unloaders, unloader release valves, and check valves.
Lubrication and Valve System Maintenance
Details compressor/motor lubrication, interstage relief valve, and pilot valve functions.
Pilot Valve Adjustment Procedures
Pilot Valve Pressure Adjustment
Provides steps to adjust the pressure setting of the pilot valve while the compressor is running.
Pilot Valve Differential Pressure Adjustment
Explains how to adjust the differential pressure setting for the pilot valve.
Lubrication and Torque Specifications
Compressor Oil Specifications and Types
Details recommended AEON hydrocarbon and synthetic lubricants, including notes on break-in and oil changes.
Torque Valve Settings for Compressor Components
Lists specific torque values for various bolts and fasteners used in compressor assembly.
Compressor Troubleshooting Guide
Motor and Starter Troubleshooting
Addresses issues like motor not starting or starter tripping repeatedly, with causes and corrective actions.
Pressure and Unloading Issues
Covers slow pressure build-up, pressure relief valve popping, and compressor not unloading.
Advanced Troubleshooting Scenarios
Centrifugal Unloader and Alternator Issues
Provides solutions for air escaping from the unloader and system non-alternation in duplex units.
Parts Illustration
Model Coverage for Parts Illustration
Lists the compressor models (HR1-3 to HR7F-12) covered by the accompanying parts illustration.
Repair Parts List - Models HR1-3 to HR7F-8
Pump, Gauge, and Guard Parts
Lists part numbers for pumps, pressure gauges, and belt guards for various models.
Valves, Motor, Tank, and Pulley Parts
Details part numbers for drain valves, check valves, motors, tanks, isolation valves, and pulleys.
Unit Repair Parts Illustration - VR Series
Model Coverage for VR Series Illustration
Specifies the VR series models covered by this unit parts illustration.
Repair Parts List - VR Series Models
Pump, Gauge, and Belt Guard Parts
Lists part numbers for pumps, pressure gauges, and belt guards for VR series models.
Tank, Motor, and Pulley Parts
Details part numbers for tanks, motors, isolation valves, pulleys, and belts for VR series models.
Unit Repair Parts Illustration - D Series
Model Coverage for D Series Illustration
Lists the HR2D, HR3D, HR5D, and HR7DF series models covered by this illustration.
Repair Parts List - D Series Models
Pump, Gauge, and Belt Guard Parts
Lists part numbers for pumps, pressure gauges, and belt guards for D series models.
Motor, Tank, and Pulley Parts
Details part numbers for motors, tanks, isolation valves, pulleys, and belts for D series models.
Unit Repair Parts Illustration & List - BR Series
BR Series Model Coverage and Pump/Guard Parts
Lists BR series models and part numbers for pumps and belt guards.
BR Series Motor, Pulley, and Belt Parts
Details part numbers for motors, pulleys, and belts for BR series models.
Detailed Compressor Repair Parts - R10D & R15B
Crankcase, Flywheel, and Governor Components
Lists parts such as crankcase, flywheel, governor housing, weights, and pins with their part numbers.
Release Valves, Pistons, and Cylinders
Details part numbers for release valves, pistons, cylinders, connecting rods, and bearings.
Detailed Compressor Repair Parts - R10D & R15B (Cont'd)
Discharge Valves, Manifolds, and Piston Rings
Lists part numbers for discharge valve assemblies, manifolds, piston ring sets, and cylinder components.
Intake Valves and Unloader Components
Details part numbers for intake valve assemblies, unloader parts, and pressure relief valves.
Detailed Compressor Repair Parts - R10D & R15B (Final)
Intake Valve Components and Filter Parts
Lists part numbers for intake valve seats, springs, cages, and intake filter elements.
Compressor Kits and Valve Sets
Covers part numbers for complete compressor kits, piston kits, ring sets, and valve sets.
Compressor Fittings and Intercooler Parts
Compression Fittings and Unloading Tubes
Lists part numbers for various compression fittings and unloading tubes with their quantities.
Breather Tubes and Intercooler Components
Details part numbers for breather tubes, compression fittings, and the intercooler with fittings.
Constant Speed Head Unloader
Low Pressure Head Unloader Parts
Lists part numbers for low pressure intake manifold, cylinder, and unloader components.
High Pressure and General Head Unloader Parts
Details part numbers for high pressure manifold, cylinder gaskets, and common fittings for the head unloader.
Hazard Decal Listings
Unit Hazard Decal Details
Lists unit hazard decals, their descriptions, and corresponding part numbers.
Pump Hazard Decal Details and Warnings
Details pump hazard decals, their descriptions, part numbers, and includes a critical power connection warning.
Visual Guide to Unit Hazard Decals
Decals for Pressure Settings and Safety Warnings
Displays decals related to unit pressure settings, draining tanks, breathing air, and general safety warnings.
Decals for High Voltage, Hot Surfaces, and Guards
Shows decals for high voltage, hot surfaces, fan guard removal, and valve maintenance precautions.
Visual Guide to Pump Hazard Decals
Pump Decals for Lubricants and Rotation
Illustrates pump decals for lubricants, rotation direction, and factory-filled oil types.
Pump Decals for Air Usage and Motor Protection
Shows pump decals for air usage, breathing air, and notice regarding motor burn-outs and warranty.
Maintenance Service Record
Daily and Weekly Maintenance Tasks
Provides sections for recording daily and weekly maintenance activities like checking oil and cleaning filters.
Monthly and Quarterly Maintenance Tasks
Offers spaces to log monthly inspections and every 3 months tasks like oil changes and valve checks.
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