bauer mariner_owners-service manual.pdf

Instruction Manual and Replacement Parts List

BAUER Compressors, Inc. Phone: (757) 855-60061328 Azalea Garden Road Fax: (757) 855-6224Norfolk, Virginia 23502-1944 www.bauercomp.com

June 1, 2010 2nd Edition, Rev. 2 Chg. 4 MNL-0237©1997 - 2010 Bauer Compressors, Inc.

GSA UnitsHigh Pressure Breathing Air Compressor UnitC-D/DV/Navy

C-D/DV/Navy

Page i 2nd Edition, Rev. 2 Chg. 4

This information is believed to be accurate by Bauer Compressors, Inc., as of it’s date of publication, but Bauer offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set forth herein. Bauer shall not be liable for inaccuracies in, or consequences resulting from, your use of this information. All information supplied is in connection with sales of Bauer’s products, and is thus subject to Bauer’s standard terms and conditions of sale. Bauer reserves the right to change this information and has no obligation to update these materials. This information is copyrighted by Bauer Compressors, Inc., and Bauer reserves to itself all rights to this publication. Bauer’s customers have no right to reproduce, rewrite, modify, license or permit anyone else’s use of this information, without the express written per-mission of Bauer Compressors, Inc.

Editions, Revisions and Changes• An Edition is the original or a complete rewriting of the entire Manual.

• A Revision occurs whenever a complete Section or Appendix is rewritten or added.

• A Change occurs when individual pages, drawings or tables are changed

^ WARNING

This Instruction Manual and Replacement Parts List contains safety information and instructions for the C-D/DV/Navy High Pressure Breathing Air Compressor Unit.You must read, understand and follow all safety precautions and instructions.

MNL-0237

June 1, 2010 Page ii

1st Edition: April 1997

Rev Chg Date Notes Auth

0 0 April 1997 JB

2nd Edition: January 2002

Rev Chg Date Notes Auth

0 0 Jan. 2002 JH

1 0 Apr. 2002 Addition of Moisture Indicator, Frame & Supplemental Man-ual for ENG-0045. Deletion of SCUBA Fill Hose Parts List JD

1 1 July 2002 Deletion of OIL-0001 from recommended oil JD

1 2 July 2003 Correcting Item indexing of Figure 7-1 JD

1 3 Jan. 2004 Change to OIL-0015, Add HAN-0048 JD

1 4 Aug. 2004 Added MSDS for Molsiv Adsorbents JD

1 5 Feb. 23, 2005 Added Separator Clamp, Changed Fill Hose Assembly parts JD

1 6 July 22, 2005 Typographical Error Corrections JD

1 7 Jan. 31, 2006 Update and correction to current as built JD

1 8 Apr. 11, 2006 Calibration of Safety Valves & GAG-0010W/CAL JD

1 9 July 12, 2006 Changed P/N of 3rd Stage Intake Valve JD

1 10 Aug. 17, 2006 Corrected Oil Pressure Specification to 750 psi JD

1 11 Jan. 1, 2007 Corrected reference to further paragraphs. JD

1 12 May 30, 2007 Cross References updated, Introduction added JD

1 13 Jan. 16, 2008 Updated Final Safety Valve P/N from 011523 to 065410-330 CLA

1 14 Feb.29, 2008 Added Vibration Isolator replacement to Drive Chapter CLA

1 15 June 26, 2008 Corrected 3rd Stage Valve Replacement Procedure SS

2 0 Oct. 6, 2008 Updated to Standard Manual Format CLA

2 1 Oct. 17, 2008 Added Drive Section with Parts List SS

2 2 Nov. 14, 2008 Updated Specifications SS

2 3 Oct. 7, 2009 Updated Block P/Ns SS

2 4 June 1, 2010 Updated Block P/Ns SS

C-D/DV/Navy

Page iii 2nd Edition, Rev. 2 Chg. 4

EFFECTED PAGES of CHANGES

Edit./Rev. / Chg. Effected Pages Edit. / Rev. / Chg. Effected Pages

1st Edition All Rev. 1, Chg. 7 All

2nd Edition All Rev. 1, Chg. 8 62

Revision 1 62, 61, 68 & Appendix G Rev. 1, Chg. 9 31

Rev. 1, Chg. 1 3 Rev. 1, Chg. 10 4

Rev. 1, Chg. 2 73 Rev. 1, Chg. 11 5

Rev. 1, Chg. 3 12 & 70 Rev. 1, Chg. 12 1 — 8

Rev. 1, Chg. 4 MSDS Sheets Rev. 1, Chg. 13 59, Item 11

Rev. 1, Chg. 5 27, added page 62 Rev. 1, Chg. 14 64, Item 8

Rev. 1, Chg. 6 21 — 24 Rev. 1, Chg. 15 28

Revision 2 All Rev. 2, Chg. 3 35, 39

Rev. 2, Chg. 1 63 — 65 Rev. 2, Chg. 4 33

Rev. 2, Chg. 2 6

MNL-0237

June 1, 2010 Page iv

TABLE OF CONTENTS

CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION

1.1 HOW TO USE THIS MANUAL......................................................................................................................................... 11.1.1 Manual Safety Notices ....................................................................................................................................................... 1

1.2 HOW TO USE THE REPLACEMENT PARTS LIST .................................................................................................... 2

1.3 HOW TO USE THE APPENDIX....................................................................................................................................... 3

1.4 DESCRIPTION AND SPECIFICATIONS ....................................................................................................................... 41.4.1 Unit Description ................................................................................................................................................................. 4

1.5 THEORY OF OPERATION .............................................................................................................................................. 51.5.1 Drive................................................................................................................................................................................... 51.5.2 Air Flow ............................................................................................................................................................................. 51.5.3 Cooling ............................................................................................................................................................................... 5

1.6 C-D/DV/NAVY SPECIFICATIONS .................................................................................................................................. 6

CHAPTER 2: - - - - - - - - - - - - - - - - - - - - - - - OPERATION

2.1 INITIAL USE ....................................................................................................................................................................... 72.1.1 General ............................................................................................................................................................................... 72.1.2 Preoperational Tasks .......................................................................................................................................................... 7

2.2 ROUTINE USE .................................................................................................................................................................. 102.2.1 Prestart Checks................................................................................................................................................................. 102.2.2 Diesel Engine Start-up Procedure .................................................................................................................................... 102.2.3 Post Start Procedures........................................................................................................................................................ 112.2.4 Bottle Fill Procedures....................................................................................................................................................... 122.2.5 Shutdown Procedures ....................................................................................................................................................... 13

CHAPTER 3: - - - - - - COMPRESSOR BLOCK - KC-FH CAPITANO

3.1 MAINTENANCE AND PARTS ....................................................................................................................................... 143.1.1 Description ....................................................................................................................................................................... 143.1.2 Component Location ........................................................................................................................................................ 143.1.3 Lubrication System (See Figure 3-2) ............................................................................................................................... 143.1.3.1 Type of Oil.................................................................................................................................................................... 153.1.3.2 Oil Level Check............................................................................................................................................................ 153.1.3.3 Oil Change .................................................................................................................................................................... 163.1.3.4 Venting the Oil Pump ................................................................................................................................................... 173.1.3.5 Oil Pressure Regulator.................................................................................................................................................. 183.1.4 Intake Filter ...................................................................................................................................................................... 193.1.4.1 Description.................................................................................................................................................................... 193.1.4.2 Intake Filter Maintenance ............................................................................................................................................. 193.1.5 Intermediate Separator ..................................................................................................................................................... 193.1.5.1 Maintenance.................................................................................................................................................................. 203.1.6 Cooling ............................................................................................................................................................................. 213.1.6.1 Maintenance.................................................................................................................................................................. 213.1.7 Compressor Valves and Heads......................................................................................................................................... 213.1.7.1 Functional Description. ................................................................................................................................................ 213.1.7.2 General Instructions for Changing the Valves.............................................................................................................. 213.1.7.3 Tolerances and Limits ................................................................................................................................................ 23

C-D/DV/Navy

Page v 2nd Edition, Rev. 2 Chg. 4

3.1.7.4 Changing the 1st Stage Valves .....................................................................................................................................243.1.7.4.1 Removing the 1st Stage Pressure Valve .......................................................................................................................243.1.7.4.2 Removing the 1st Stage Inlet Valve .............................................................................................................................253.1.7.4.3 Reassembly of the 1st Stage Valves .............................................................................................................................253.1.7.5 Changing the 2nd Stage Valves ....................................................................................................................................263.1.7.5.1 Removing the 2nd Stage Pressure Valve. .....................................................................................................................263.1.7.5.2 Removal of the 2nd Stage Inlet Valve ..........................................................................................................................273.1.7.5.3 Reassembly of the 2nd Stage Valve Head and Valves .................................................................................................273.1.7.6 Changing the 3rd Stage Valve ......................................................................................................................................293.1.7.6.1 :Removal of the 3rd Stage Pressure Valve ...................................................................................................................293.1.7.6.2 Removal of the 3rd Stage Inlet Valve...........................................................................................................................303.1.7.6.3 Reassembly of the 3rd Stage Valves.............................................................................................................................303.1.8 Replacement Parts List .....................................................................................................................................................313.1.8.1 Troubleshooting and Repair..........................................................................................................................................453.1.8.1.1 Troubleshooting Table ..................................................................................................................................................453.1.8.1.2 Repair............................................................................................................................................................................46

3.2 MANUAL CONDENSATE DRAIN SYSTEM ...............................................................................................................473.2.1 Description .......................................................................................................................................................................473.2.2 Operation ..........................................................................................................................................................................473.2.3 Unloaded start...................................................................................................................................................................47

CHAPTER 4:- - - - - - - - - - - - - - MAINTENANCE SCHEDULE

4.1 C-D/DV/NAVY MAINTENANCE INTERVALS ...........................................................................................................484.1.1 Maintenance Records ......................................................................................................................................................49

CHAPTER 5:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

5.1 PURPOSE ...........................................................................................................................................................................505.1.1 General .............................................................................................................................................................................50

5.2 P1 PURIFICATION SYSTEM .........................................................................................................................................505.2.1 Component Description....................................................................................................................................................515.2.1.1 Coalescing Oil/Water Separator. ..................................................................................................................................515.2.1.2 Condensate Drain Valve ...............................................................................................................................................515.2.1.3 Moisture Indicator.........................................................................................................................................................525.2.1.4 Purification Chamber ....................................................................................................................................................525.2.1.4.1 Purifier Cartridge ..........................................................................................................................................................525.2.1.5 Vent Valve ....................................................................................................................................................................525.2.1.6 Pressure Maintaining Valve..........................................................................................................................................525.2.1.7 Safety Valve..................................................................................................................................................................525.2.2 Maintenance .....................................................................................................................................................................535.2.2.1 Cartridge Operating Life...............................................................................................................................................535.2.2.2 Calculating the Maximum Purification Cartridge Operating Hours.............................................................................535.2.2.3 Calculating the Adjusted Purification Cartridge Operating Hours ...............................................................................535.2.2.4 Adjusted Cartridge Operating Hours ............................................................................................................................535.2.2.5 Coalescing Oil/Water Separator ...................................................................................................................................555.2.2.6 Moisture Indicator.........................................................................................................................................................565.2.2.7 Purification Chamber ....................................................................................................................................................575.2.2.8 Cartridge Leaking after Installation ..............................................................................................................................575.2.3 Replacement Parts List .....................................................................................................................................................59

MNL-0237

June 1, 2010 Page vi

CHAPTER 6: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

6.1 DIVE UNITS ...................................................................................................................................................................... 636.1.1 Maintenance of the V-belt and Sheave ............................................................................................................................ 636.1.1.1 Checking the Sheave..................................................................................................................................................... 636.1.1.2 Checking the V-belt ...................................................................................................................................................... 64

6.2 REPLACEMENT PARTS LIST ...................................................................................................................................... 65

CHAPTER 7: - - - - - - - - - - - - - - - - - - - - MISCELLANEOUS

7.1 VALVES.............................................................................................................................................................................. 667.1.1 Nonadjustable Valves....................................................................................................................................................... 667.1.2 Pressure Maintaining Valve ............................................................................................................................................. 667.1.3 Safety Valves.................................................................................................................................................................... 677.1.3.1 Safety Valve Adjustment.............................................................................................................................................. 67

7.2 CALIBRATION OF SAFETY VALVES AND PRESSURE GAUGES ....................................................................... 67

7.3 FILL HOSE REPLACEMENT PARTS LIST................................................................................................................ 68

CHAPTER 8: - - - - - - - - - - - - - - - - - - - - - - - - APPENDIX

8.1 MAINTENANCE REFERENCE DATA ......................................................................................................................... 698.1.1 Tightening Torque Values................................................................................................................................................ 698.1.1.1 Torque Sequence Diagrams.......................................................................................................................................... 698.1.2 Approved Lubricants Chart .............................................................................................................................................. 708.1.3 Glossary of Abbreviations and Acronyms ....................................................................................................................... 70

8.2 SAFETY PRECAUTIONS................................................................................................................................................ 718.2.1 General ............................................................................................................................................................................. 718.2.2 Safety Warning Labels ..................................................................................................................................................... 73

8.3 LONG TERM STORAGE AND PRESERVATION ...................................................................................................... 738.3.1 General ............................................................................................................................................................................. 738.3.2 Preparations...................................................................................................................................................................... 738.3.2.1 Units Equipped with a Filter System............................................................................................................................ 748.3.3 Preserving the Compressor............................................................................................................................................... 748.3.4 Preventive Maintenance During Storage.......................................................................................................................... 748.3.5 Lubrication Oils for Preservation..................................................................................................................................... 748.3.6 Reactivating the Compressor Unit ................................................................................................................................... 75

8.4 INSTALLATION ............................................................................................................................................................... 758.4.1 Unpacking and Handling.................................................................................................................................................. 758.4.2 Ventilation........................................................................................................................................................................ 768.4.2.1 Outdoor Installation ...................................................................................................................................................... 768.4.2.2 Indoor Installation......................................................................................................................................................... 768.4.2.3 Natural Ventilation ....................................................................................................................................................... 76

8.5 REPRODUCIBLE MAINTENANCE RECORD FORMS ............................................................................................ 778.5.1 Scheduled Maintenance Form ......................................................................................................................................... 778.5.2 Record of Operating Hours .............................................................................................................................................. 80

8.6 ADDITIONAL DATA ....................................................................................................................................................... 81

8.7 DRIVE MOTOR SUPPLEMENT.................................................................................................................................... 81

C-D/DV/Navy

Page vii 2nd Edition, Rev. 2 Chg. 4

LIST OF FIGURES

CHAPTER 1:- - - - - - - - - - - - - - - - - - - - - INTRODUCTIONFigure 1-1 Compressor Identification Plate ..............................................................................................................................2Figure 1-2 C-D/DV/NAVY Air Compressor ............................................................................................................................4Figure 1-3 Air Flow Diagram....................................................................................................................................................5

CHAPTER 2:- - - - - - - - - - - - - - - - - - - - - - - OPERATIONFigure 2-1 Compressor Oil Dipstick .........................................................................................................................................7Figure 2-2 Purification Cartridge Installation ...........................................................................................................................8Figure 2-3 Fill Hose ..................................................................................................................................................................8Figure 2-4 Hose Connection......................................................................................................................................................9Figure 2-5 Air Intake Hose........................................................................................................................................................9Figure 2-6 Moisture Indicator and Bleed Valve........................................................................................................................9Figure 2-7 Manual Drains .........................................................................................................................................................9Figure 2-8 Fuel Valve..............................................................................................................................................................11Figure 2-9 START/STOP Control ..........................................................................................................................................11Figure 2-10 Recoil Starter .........................................................................................................................................................11Figure 2-11 Decompression Lever ............................................................................................................................................11Figure 2-12 Final Relief Valve..................................................................................................................................................12Figure 2-13 Filling Storage Bottles ...........................................................................................................................................13

CHAPTER 3:- - - - - - COMPRESSOR BLOCK - KC-FH CAPITANOFigure 3-1 KC-FH Capitano Compressor Block, Front View.................................................................................................14Figure 3-2 Lube Oil Circuit.....................................................................................................................................................15Figure 3-3 Compressor Oil Dipstick .......................................................................................................................................16Figure 3-4 Oil Dipstick Markings ...........................................................................................................................................16Figure 3-5 Venting the Oil Pump ............................................................................................................................................17Figure 3-6 Oil Pressure Regulator...........................................................................................................................................18Figure 3-7 Intake Filter............................................................................................................................................................19Figure 3-8 3rd Stage Intermediate Separator...........................................................................................................................20Figure 3-9 Valve Operation.....................................................................................................................................................21Figure 3-10 Permissible Tolerances ..........................................................................................................................................23Figure 3-11 Checking the Piston ...............................................................................................................................................23Figure 3-12 1st Stage Valve Head and Valves..........................................................................................................................24Figure 3-13 2nd Stage Valves ...................................................................................................................................................26Figure 3-14 Peening the Inlet Valve..........................................................................................................................................28Figure 3-15 3rd Stage Valve Head and Valves .........................................................................................................................29Figure 3-16 Removing the 3rd Stage Pressure Valve ...............................................................................................................30Figure 3-17 Crankcase Assembly..............................................................................................................................................31Figure 3-18 1st Stage Valve Head and Valves..........................................................................................................................34Figure 3-19 2nd Stage Valve Head and Valves.........................................................................................................................35Figure 3-20 3rd Stage Valve Head and Valves .........................................................................................................................37Figure 3-21 Intermediate Separator...........................................................................................................................................38Figure 3-22 Intake Filter............................................................................................................................................................39Figure 3-23 Cooling System......................................................................................................................................................41Figure 3-24 Lubrication System................................................................................................................................................43Figure 3-25 Manual Condensate Drains....................................................................................................................................47

CHAPTER 4:- - - - - - - - - - - - - - MAINTENANCE SCHEDULEThere are no Figures in this Chapter

MNL-0237

June 1, 2010 Page viii

CHAPTER 5: - - - - - - - - - - - - - - - - PURIFICATION SYSTEMFigure 5-1 Purification Dataplate............................................................................................................................................ 50Figure 5-2 P1 Purification System .......................................................................................................................................... 51Figure 5-3 Moisture Indicator ................................................................................................................................................. 52Figure 5-4 Correction Factor for Cartridge Operating Hours ................................................................................................. 54Figure 5-5 Example Record of Adjusted Operating Hours..................................................................................................... 54Figure 5-6 Oil and Water Separator ........................................................................................................................................ 55Figure 5-7 Moisture Indicator ................................................................................................................................................. 56Figure 5-8 Purifier Cartridge Replacement............................................................................................................................. 57Figure 5-9 Oil/Water Separator............................................................................................................................................... 59Figure 5-10 P1 Purification Chamber ....................................................................................................................................... 61Figure 5-11 Moisture Indicator ................................................................................................................................................. 62

CHAPTER 6: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEMFigure 6-1 Dive Unit Drive ..................................................................................................................................................... 63Figure 6-2 Tensioning ............................................................................................................................................................. 63Figure 6-3 C-D/DV/Navy Drive ............................................................................................................................................. 65

CHAPTER 7: - - - - - - - - - - - - - - - - - - - - MISCELLANEOUSFigure 7-1 Pressure Maintaining Valve .................................................................................................................................. 66Figure 7-2 Safety Valves......................................................................................................................................................... 67Figure 7-3 Calibration Label, LBL-0300 ................................................................................................................................ 67Figure 7-4 Fill Hose Assembly ............................................................................................................................................... 68

CHAPTER 8: - - - - - - - - - - - - - - - - - - - - - - - - APPENDIXFigure 8-1 6 Bolt and 4 Bolt Torque Sequence....................................................................................................................... 69

C-D/DV/Navy

Page 1 2nd Edition, Rev. 2 Chg. 4

CHAPTER 1: INTRODUCTION1.1 How To Use This Manual

This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod-ucts listed on the front cover.

All instructions in this manual should be observed and carried out as written to prevent damage or prema-ture wear to the product or the equipment served by it.

If your unit is equipped with nonstandard accessories and or options, supplemental information is nor-mally included in other documentation; i.e. OEM Manuals or additional Bauer Manuals.

While every effort is made to ensure the accuracy of the information contained in this manual, Bauer Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the con-sequences thereof.

1.1.1 Manual Safety NoticesImportant instructions concerning the endangerment of personnel, technical safety or operator safety will be specially emphasized in this manual by placing the information in the following types of safety notices.

^ DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or seri-ous injury. This is limited to the most extreme situations.

^ WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

^ CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-erate injury. It may also be used to alert against unsafe practices.

NOTICE

NOTE advise of technical requirements that require particular attention by the operator or the mainte-nance technician for proper maintenance and utilization of the equipment.

MNL-0237

June 1, 2010 Page 2

1.2 How to Use the Replacement Parts List• A lozenge ♦ in the Item Number column indicates the part number for a complete assembly.

• a dagger (†) in the Qty column with or without an ellipse (…) in the Part Number column means the part is illustrated for assembly purposes only and is not available for sale as an individual component. This part can be obtained by ordering the complete assembly.

• AR in the Qty column means that the item is cut or manufactured to the size which the customer spec-ifies.

• A dash (—) in the Item Number column indicates that there is more than one part number applicable to the preceding Item Number.

• The letters in the columns labeled Kit indicate the number of operating hours when the part is to be replaced; a = replaced every 1,000 hours, b = replaced every 2,000 hours and c= replaced every 4,000 hours.

• NS in the Item Number column indicates the part is not illustrated but is available.

When placing an order for spare parts, please provide the following information to ensure delivery of the correct parts. The model number, date of manufacture and serial number can be found of the compressor unit identification plate on the compressor unit frame.

Information Example

Model Number TCom-25

Serial Number 32165

Date of Manufacture 02/2005

Quantity required 2

Part Number N04860

Part Description Valve

Figure 1-1 Compressor Identification Plate

BAUERCOMPRESSORS

BAUER COMPRESSORS, INC.NORFOLK, VIRGINIA U.S.A

LBL-004

MODEL NO. BLOCK NO.

CAPACITY CFM CHG. RATE CFM

MOTOR HP SPEED RPM

SERIAL NO. PRESSURE PSIG

VOLTS PH HZ AMPS

DATE OF MANUFACTUREDATE OF MANUFACTURE

C-D/DV/Navy


1.3 How to Use the AppendixInformation contained in the Appendix to this manual includes the following.

• The safety instructions applicable to this product. They must be read, understood and complied with prior to operating the product.

• The instructions for installing this product. They must be read, understood and complied with prior to operating the product.

• The instructions for long term storage (over 90 days) of this product.

• Reproducible Forms

• Reference Data• Torque Values• Torque Sequence• Conversion Formulas• Approved Lubricants• Glossary of Abbreviations & Acronyms

• Additional Documents

^ WARNING

The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Bauer Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are installed.

MNL-0237

June 1, 2010 Page 4

1.4 Description and Specifications

1.4.1 Unit DescriptionThe Diving Version high pressure air-compressor unit is used for application in the high pressure range, up to 5000 psig (345 bar), to compress and purify air for breathing air purposes. These units feature three-stage, three-cylinder, air-cooled KC-FH high pressure air compressor blocks. The Diving Version com-pressor units are designed with the engine and compressor arranged horizontally in a lightweight frame for portability. The drive belt and sheaves are enclosed by a belt guard.

Standard equipment includes an intermediate filter after the 2nd stage, a P1 purification system, a CO and Moisture Indicator, a diesel engine and an hourmeter.

These compressor units are comprised of the following major assemblies:

• Compressor block • Drive engine• Frame and belt guard assembly • Manual condensate drain valves• P1 purification system • Prefilter assembly• Two fill hose assemblies • HourmeterThe design of this compressor unit is indicated in the following illustration.

Figure 1-2 C-D/DV/NAVY Air Compressor

1. Belt guard2. Compressor block3. 6 HP diesel engine4. Moisture Indicator

5. Purification Cartridge6. Heavy-duty caster7. Tubular unit frame8. Lift Handles

1 2

3 4 5 6 7 8

C-D/DV/Navy


1.5 Theory of Operation

1.5.1 DriveThe drive motor of the C-D/DV/Navy is a 6 horsepower, Yanmar diesel motor. The drive shaft of the motor transfers its power through use of a sheave and V-belt to the compressor’s combination flywheel and cooling fan. The compressor’s flywheel rotates the compressor’s driveshaft, which operates the pis-tons and oil pump.

1.5.2 Air Flow (See Figure 1-3). The air is drawn in through intake filter (1), compressed to the final pressure in cylin-ders (2, 3, 4,) and cooled by intercoolers (5, 6) and aftercooler (7). The safety valves (8,9, 10) protect from overpressure in the individual stages. The compressed air is filtered by intermediate separator (11) and oil/water separator (12). The intermediate separator (11) and oil and water separator (12) are drained by condensate drain valves (13). The compressed air proceeds from the oil water separator to the purifica-tion chamber (14) and is filtered through a purification cartridge (15). The compressed air exits the puri-fication assembly (16) where it proceeds to the pressure maintaining valve and air outlet.

1.5.3 CoolingThe C-D/DV/Navy is air cooled by the combination flywheel/cooling fan. The cooling fan blows air across the cylinder cooling fins, the inter-coolers and after-coolers. The C-D/DV/Navy is designed to operate in ambient temperature ranges of 32° F — 115° F.

Figure 1-3 Air Flow Diagram

1. Intake Manifold2. 1st Stage Cylinder3. 2nd Stage Cylinder4. 3rd Stage Cylinder5. 1st Stage Intercooler6. 2nd Stage Intercooler

7. Aftercooler8. 1st Stage Safety Valve9. 2nd Stage Safety Valve10. Final Pressure Safety Valve11. Intermediate Separator

12. Oil and Water Separator13. Manual Condensate Drain Valve14. Purification Chamber15. Purification Cartridge16. Air Outlet

1

2

34

1 1

9

6

7

8

5

10

12

13

7

1 415

1316

MNL-0237

June 1, 2010 Page 6

1.6 C-D/DV/NAVY SpecificationsAll specifications are subject to change without prior notice.

Medium airCharging Rate 6.0 scfm (170 l/min.)1

Free Air Delivery 5.0 scfm (140 l/min.)2

Inlet pressure atmosphericOperating pressure, max. 5,000 psig (345 bar)Ambient temperature range 32 to 115 °F (0 to 45 °C)Approximate weight 265 lbs

Compressor block KC-FH (Capitano)No. of stages 3No. of cylinders 3Cylinder bore, 1st stage 2.76 in (70 mm).Cylinder bore, 2nd stage 1.42 in. (36 mm)Cylinder bore, 3rd stage 0.58 in. (14 mm)Piston Stroke 1.58 in. (40 mm)Intermediate pressure, 1st stage 44 - 58 psigIntermediate pressure, 2nd stage 464 - 551 psigFinal pressure, 3rd stage 5,000 psigDirection of rotation when facing flywheel CCWCompressor speed 1,250 RPMOil capacity 1.8 qts.(1.7 ltr)Oil Pressure approx. 725 psig (50 bar)Recommended oil BAUER OIL-0015 (TEP 2190)

Compressor Drive Diesel Engine

1. Based on recharging an 80 cubic foot tank from 500 to 3000 PSIG

2. Referenced to standard inlet conditions of 68°F and 36% humidity at 14.70 psia.

Bauer Part # Fuel Cap. Oil Cap. Power Speed Cylinders

ENG-0045 0.92 gal (3.5 l) 1.16 qt. (1.1 l) 6.0 hp (4.5 kw) 3,600 rpm 1

C-D/DV/Navy


CHAPTER 2: OPERATION2.1 Initial Use

2.1.1 GeneralThe safety, unpacking, handling and installation instructions applicable to this product are contained in the Appendix. They must be read, understood and complied with prior to operating the product.

Observe and maintain an ambient temperature range of 32° F to 115° F. The area in which the compressor unit is installed should be well lit and easily accessible to facilitate servicing and routine maintenance.

2.1.2 Preoperational TasksBefore activating the compressor unit for the first time the following tasks must be completed.

1. Visually check the oil dipstick shown in Figure 2-1 to verify the amount of oil in the crankcase. The oil dipstick is located just to the left of the intake filter. The oil level should fall between the mini-mum and maximum marks.

2. Using a Bauer purification wrench (Bauer part number WRH-0005) remove the purification cham-ber cap and install the purification cartridges as shown in Figure 2-2. Make sure all dust caps are removed, the O-rings are lubricated, the cartridge seats properly and the chamber vent valve is closed. Reseal the purification chamber cap using the purification wrench.

Figure 2-1 Compressor Oil Dipstick

^ CAUTION

Do not overfill the compressor with oil.

MNL-0237

June 1, 2010 Page 8

3. Ensure the fill hose (Figure 2-3) is connected to the adapter that attaches to the pressure maintaining valve as seen in Figure 2-4. Tighten the fitting hand tight plus one half of a turn being careful not to cross thread or strip the threads on the hose connection.

Figure 2-2 Purification Cartridge Installation

Figure 2-3 Fill Hose

PullUp

C-D/DV/Navy


4. Once the hose connections are secured install the compressor air intake hose (See Figure 2-5) to the intake filter, located on the 1st stage of the compressor. Secure the hose with a proper sized hose clamp. Ensure that the compressor air intake is supplied with fresh air. The intake air must not con-tain any exhaust fumes or flammable vapors such as paint solvents, which may cause an internal fire. Make sure that the intake air is unobstructed and moisture in the intake air is kept to a mini-mum. It is important that units draw in clean air. The quality of the incoming air determines the quality of the compressed air.

5. Bleed off any internal pressure by opening the bleed valve and manual drain valves. Then Close them prior to starting the unit. The bleed valve is located at the outlet side of the purification cham-ber (See Figure 2-6). The manual drain valves are on the bottom of the intermediate separator and the bottom of the oil/water separator (See Figure 2-7).

Figure 2-4 Hose Connection Figure 2-5 Air Intake Hose

Figure 2-6 Moisture Indicator and Bleed Valve Figure 2-7 Manual Drains

Manual Drains

MNL-0237

June 1, 2010 Page 10

6. The last step before the initial start of the compressor is to visually inspect the moisture indicator, (See Figure 2-6) for evidence of cartridge saturation. Under normal conditions the element in the moisture indicator is blue and changes to pink with elevated levels of moisture.

2.2 Routine Use

2.2.1 Prestart Checks

1. Ensure that all scheduled maintenance is completed. Refer to Chapter 4, Maintenance Schedule.

2. Check compressor oil level. Refer to Paragraph 2.1.2

3. Read and understand the Yanmar Engine Manual supplied with this manual.

4. Check compressor drive engine oil level. Refer to the Yanmar Engine Manual.

5. Visually inspect the moisture indicator, for evidence of cartridge saturation, See Figure 2-6. Under normal conditions the element in the moisture indicator is blue and changes to pink with elevated levels of moisture.

2.2.2 Diesel Engine Start-up Procedure

1. Complete all pre-start checks.

2. Verify that all connections downstream of the compressor are secure.

3. Open the bleed valve and manual drain valves to relieve any internal pressure then close them.

4. Check the fuel level and refill the fuel tank if required.

5. Open the fuel valve. (See Figure 2-8).

6. Move the START/STOP control to the START position (See Figure 2-9)

7. Pull recoil starter handle until resistance is felt then return it slowly (See Figure 2-10).

8. Push down the Decompression Lever and release it. (See Figure 2-11). This relieves the pressure in the engine allowing the engine to start unloaded.

9. Quickly pull recoil starter handle out to its full length. Repeat this process as many times as neces-sary to start engine. Do not use excessive force as this might damage the recoil starter internal com-ponents.

^ CAUTION

Do Not Attempt To Start The Engine Until Step 7 Is Completed!Failure to complete this step could result in damage to the recoil starter.

C-D/DV/Navy


.

2.2.3 Post Start Procedures

1. Listen to the unit as it operates. A loud knocking sound may be heard until the final stage pressure is equalized. If excessive knocking or vibrations are observed or they continue past ten seconds, shut down the compressor.

2. The compressor flywheel should be rotating counterclockwise. If it is not, shut down the compres-sor and contact the Bauer Customer Service Department.

3. Allow the compressor to build pressure until the Final Relief Valve lifts. This confirms that the sys-tem has no leaks. The Final Relief Valve is located on top of the Oil and Water Separator. (See Fig-ure 2-12).

4. Once Step 3 is completed the compressor is ready to fill bottles.

5. The manual condensate drain valves must be opened and the condensate allowed to drain for 6 sec-onds every 15 minutes while the compressor is operating.

Figure 2-8 Fuel Valve Figure 2-9 START/STOP Control

Figure 2-10 Recoil Starter Figure 2-11 Decompression Lever

MNL-0237


6. Due care must be taken to ensure that any oil which is drained with the condensation is disposed of properly.

7. For compressor troubleshooting See Paragraph 3.1.8.1.1.

2.2.4 Bottle Fill Procedures

1. Attach approved storage bottles to the fill hose assembly. Use only bottles approved for the intended service.

2. Adjust the fill pressure regulator to the proper fill pressure. Never exceed the storage bottle rating.

3. With the proper storage bottle connected, open the fill valve then the bottle valve.

4. After the bottle is filled close the bottle valve first then the fill valve.

5. Open the Vent valve to vent the fill hose assembly.

6. Carefully disconnect the fill hose assembly and remove the filled bottle.

7. Repeat Step 1 through Step 6 as necessary.

Figure 2-12 Final Relief Valve

^ CAUTION

Minimum bend radius for the fill hose is 1½ inches. Less than this will cause damage to or failure of the fill hose. Place the bottle so that the bend radius of the hose is greater than 1½ inches.

C-D/DV/Navy


2.2.5 Shutdown Procedures

1. Verify all bottle valves and fill valves are closed.

2. Move the START/STOP control to the STOP position. (See Figure 2-9).

3. Close the fuel valve. (See Figure 2-8)

4. After shutting down the compressor drive, open the condensate drain valves to relieve any remain-ing pressure and drain any moisture from the intermediate separators and the oil and water separa-tor.

5. Close the condensate drain valves after all pressure is released.

6. If the compressor is to remain idle for six months or longer, refer to Appendix, Long Term Storage for preservation instructions.

Figure 2-13 Filling Storage Bottles

1.

2.1.

2.

Closing SequenceAttaching the Fill Yoke Opening Sequence

MNL-0237


CHAPTER 3: COMPRESSOR BLOCK - KC-FH CAPITANO3.1 Maintenance and Parts

3.1.1 DescriptionThe KC-FH Capitano compressor is used to compress air up to 5,000 psi.

This compressor is a three stage, three cylinder air cooled, oil lubricated reciprocating compressor. The cylinders are arranged in a “W” configuration, the 1st stage cylinder is in the center, 2nd stage on the right and 3rd stage on the left looking from the filter side. These compressor blocks are particularly suit-able for continuous operation because of their rugged design and corrosion resistant intermediate filter and cooler assemblies.

3.1.2 Component Location

3.1.3 Lubrication System (See Figure 3-2)The compressor is provided with force-feed lubrication for the third stage. The oil pump (1) is driven by a cam on the crankshaft. It pumps oil into the oil pressure regulator (2) at the 3rd stage. The oil pressure regulator maintains the proper working pressure.

Any oil not needed by the 3rd stage cylinder returns to the crankcase through the feedback tube (3). The oil, splashed by the drive gear, lubricates the other moving parts, such as the crankshaft, connecting rods,

Figure 3-1 KC-FH Capitano Compressor Block, Front View

1. Manual Condensate Drain Valve2. 2nd Stage Intercooler3. 2nd Stage Intermediate Separator4. Oil Pressure Regulator5. 3rd Stage Cylinder6. Oil Filler Cap and Dipstick7. 2nd Stage Safety Valve

8. Intake Filter9. 1st Stage Cylinder10. Oil and Water Separator11. 1st Stage Safety Valve12. 2nd Stage Cylinder13. 1st Stage Intercooler14. Oil Drain Plug

12

3

4

5 6 7 8 9 1011

12

13

14

C-D/DV/Navy


cylinders and pistons, and returns into the oil sump. The cylinder and piston of the 1st stage are addition-ally lubricated by oil vapors from the crankcase vent feedback line (4).

3.1.3.1 Type of OilFor proper care and maintenance of the compressor, using the correct oil is of vital importance. Due to the thermal load on the compressor only high quality oil should be used. You are recommended to restrict oils to those which have been approved by us and are listed in Section 1.4.

3.1.3.2 Oil Level CheckCheck the oil level daily before starting the compressor.

1. Vent any residual air pressure from the system by opening and then closing the manual condensate drain valves.

2. Open the filler cap slowly, allowing any residual pressure to vent from the crankcase.

3. Remove the cap/dipstick from the oil filler neck. (See Figure 3-3)

4. Wipe the dipstick with a lint-free cloth.

5. Return the oil cap/dipstick to the filler neck completely, then remove and note the oil level on the dipstick. The oil level must be between the marks on the dipstick (See Figure 3-4).

6. Add or drain oil as necessary.

Figure 3-2 Lube Oil Circuit

^ CAUTION

The oil level must not exceed the maximum level mark on the dipstick, as this will cause excessive lubrication of the compressor and may result in coking of the valves.

1

43

2

MNL-0237


3.1.3.3 Oil Change(See Figure 3-1)

1. Run the compressor until it is warm.

2. Shutdown compressor.

3. Remove the cap from the oil filler neck.

4. Drain oil while it is still warm by removing the oil drain plug.

5. Reinstall the oil drain plug.

6. Slowly pour new oil through the oil filler neck until the level reaches the maximum mark on the dipstick.

7. Wait a few minutes and adjust the oil level if necessary before putting the unit into operation.

8. Dispose of the used oil in a safe manner complying with all local waste disposal codes.

9. Check the operation of the oil pump. It is working properly if no bubbles are visible in the oil pres-sure regulating valve sight glass. If bubbles are visible then the oil pump must be vented.

Figure 3-3 Compressor Oil Dipstick Figure 3-4 Oil Dipstick Markings

Max.

Min.

C-D/DV/Navy


3.1.3.4 Venting the Oil PumpIf little or no oil pressure builds up after starting the unit, especially after maintenance or repair work, venting the oil pump will be necessary. Refer to Figure 3-5 and proceed as follows:

1. With the compressor and the inlet supply shut off, the power disconnected (if applicable) and the crankcase vented, remove the tube nut and tube (1) from the oil pump.

2. Turn the compressor by hand until bubble-free oil emerges from the fitting. This should only take a few seconds.

3. Position the tube and tube nut (1) and retighten.

Figure 3-5 Venting the Oil Pump

1

MNL-0237


3.1.3.5 Oil Pressure Regulator (See Figure 3-6)

The oil pressure regulator is mounted on the 3rd stage cylinder. The regulator valve can be adjusted by removing the cap nut (1) and turning the set screw (2) in the oil pressure regulator block (3). Adjustment should only be performed by a trained technician. The oil pressure regulator should be adjusted while the unit is in operation.

Use an oil pressure gauge connected to the oil pressure regulator test connector (4) to read the oil pres-sure. For units with an installed oil pressure gauge, observe the oil pressure indicated on the instrument panel.

Figure 3-6 Oil Pressure Regulator

NOTICE

Turning the screw clockwise increases pressure; counterclockwise reduces pressure.

3

2

1

4

C-D/DV/Navy


3.1.4 Intake Filter

3.1.4.1 DescriptionA dry, micronic filter is used to filter the intake air. See Figure 3-7.

3.1.4.2 Intake Filter MaintenanceThe filter cartridge must be cleaned and changed at regular intervals. See the Maintenance Schedule for the recommended interval.

1. Clean the filter cartridge with a brush or by blowing air from the inside of the cartridge to the out-side.

2. Turn the cartridge 90° when replacing it. Change the cartridge filter after it has been turned three times and thus is dirty on all sides.

3. Clean the inside of the filter body with a damp cloth. take care to prevent dust from entering the intake pipe.

4. Replace the O-rings if necessary.

3.1.5 Intermediate SeparatorAn intermediate separator is mounted on the compressor after the 2nd stage. This separator is designed to remove oil and water which accumulates due to the cooling of the air after the compression process. Sep-aration is achieved by means of centrifugal action. In the separator the centrifugal action is provided by a vortex plate additionally a sintered metal filter is provided to remove dirt contamination.

Figure 3-7 Intake Filter

MNL-0237


3.1.5.1 Maintenance Proper operation of the compressor requires that the intermediate separator be properly serviced. See the Maintenance Schedule, Section 4 for the correct interval. See Figure 3-8 and proceed as follows:

1. Remove piping connected to the filter head.

2. Screw off the knurled nut.

3. Remove filter head along with the sintered metal filter.

4. Remove the center screw and separate the sintered metal filter, baffle cone, and vortex plate from the filter head.

Figure 3-8 3rd Stage Intermediate Separator

^ WARNING

Dynamic LoadingThe rapid depressurizing and repressurizing of the intermediate separator during condensate draining

subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or death the intermediate separator must be replaced after 85,000 load cycles. A load cycle equals one depressurization- repressurization. The Bauer recommended frequency of condensate draining is every fifteen minutes and is a balance between maximizing the life of the oil and water separator chamber and

maintaining the quality of the delivered air.

Filter Head

Knurled Nut

Distribution Plate

Baffle Funnel

Filter Insert

Center Screw

C-D/DV/Navy


5. Use hot soapy water to clean the filter insert, rinse and blow it dry with compressed air.

3.1.6 Cooling The cylinders of the compressor, the intermediate coolers and the after cooler are air cooled. For this pur-pose the compressor is equipped with a fanwheel which draws the cooling air through the unit. The fan-wheel is driven by the drive motor V-belt and is also used as the compressor flywheel.

3.1.6.1 MaintenanceWhen dirty, clean the finned tubes, valve heads and cylinders by blowing off the dirt and dust with low pressure compressed air (80 -125 psi)

3.1.7 Compressor Valves and Heads

3.1.7.1 Functional Description.

The intake and pressure valves are fitted inside the valve heads. Note that the valves are operated by the flow of the medium. On the intake stroke, the intake valves open and the medium flows into the cylin-ders. At the start of the pressure stroke the intake valve closes and the medium opens the pressure valve.

3.1.7.2 General Instructions for Changing the Valves• Always replace valves as a complete set.

• Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in Varsol and clean with a soft brush.

• Check the individual components for excessive wear. If the valve seat or valve discs are dented, replace the valves.

• Check the valve space in the valve heads for dirt, and clean if necessary.

• Use only satisfactory gaskets and O-rings during reassembly.

• Observe the correct sequence when reassembling.

Figure 3-9 Valve Operation

Intake Discharge

MNL-0237


• After finishing all maintenance work on the valves, turn the compressor manually using the flywheel and check whether all items have been correctly installed.

• 30 minutes after restarting the compressor, stop the unit, let it cool down to ambient temperature, and retighten valve studs and cap nuts. Otherwise the gasket set may cause a leak.

• Remove and check the valves every 1000 operating hours, unless otherwise specified in the Mainte-nance Schedule.

• Replace the valves every 2000 operating hours to avoid fatigue failure, unless otherwise specified in the Maintenance Schedule.

C-D/DV/Navy


3.1.7.3 Tolerances and Limits

Figure 3-10 Permissible Tolerances Figure 3-11 Checking the Piston

Table 3-1: 1st Stage Pressure Valve Limits

Pressure Valve Spring Specified Length - 24 mmLimit - 21 mm

Pressure Valve Stroke Minimum - 1.0 mmMaximum - 1.25 mm

Valve Seat Bore Diameter - 12.5 mm

Table 3-2: 2nd Stage Pressure Valve Limits Table 3-3: 2nd Stage Inlet Valve Limits

Pressure valve spring Specified length - 24 mmLimit - 21 mm Inlet valve spring

Specified length - 10.5 mmLimit - 9 mm

Pressure valve stroke Minimum - 0.8 mmMaximum - 1.05 mm Inlet valve stroke Minimum - 1.0 mm

Maximum - 1.25 mm

Valve seat bore Diameter - 8.0 mm Valve seat bore Diameter - 12.5 mm

Table 3-4: 3rd Stage Valve Limits

Inlet valve stroke Minimum - 0.8 mmMaximum - 1.2 mm

Pressure valve stroke Minimum - 0.9 mmMaximum - 1.2 mm

max 1.0 mm

or 3/64"

Valve Plates

17+0.1 mm

43/64+.004"

Valve Cover

max

0.2

mm

or 1

/128

"

Valve Seats

17+0.1 mm

43/64+.004"

Valve Body

Flush

MNL-0237


3.1.7.4 Changing the 1st Stage Valves3.1.7.4.1 Removing the 1st Stage Pressure Valve

See Figure 3-12 and proceed as follows:

1. Remove the dome nut (17) and gasket (16). Inspect the gasket and replace it if it is damaged.

2. Unscrew and remove the socket set screw (15) and pressure valve cover (14).

3. Remove the disc spring (13) and the O-ring (12). The O-ring should be undamaged and non-porous. Replace it if it is damaged.

4. Extract the pressure valves assembly (6).

5. Discard the valve gasket (7) and replace it with a new one.

6. Inspect the valve components for wear or damage. See Figure 3-10 and Table 3-1. If the tolerances have been exceeded or damage has occurred then the valve assembly (5) should be replaced.

Figure 3-12 1st Stage Valve Head and Valves

1. Valve Head2. O-ring3. O-ring4. Intake Valve Plate 5. Pressure Valve Assembly6. Pressure Valve

7. Valve Gasket8. Valve Seat9. Valve Plate10. Compression Spring11. Pressure Valve Body12. O-ring

13. Disc Spring14. Pressure Valve Cover15. Set Screw16. Gasket17. Dome Nut

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

C-D/DV/Navy


7. Inspect the valve seat (8). The sealing surface must be in good condition, devoid of pitting or cracks. The maximum valve seat width is 3/64” (1.0 mm).

8. Clean and inspect the valve plate (9). The maximum acceptable groove depth must not exceed 1/28” (0.2 mm).

9. Check the tolerance of the inside diameter of the valve body (11). The valve body must not show any grooves at ID 17 = 0.1 mm.

10. The valve spring (10) is serviceable if it shows no outside scuffing and the spring ends have not picked up on the next coil.

3.1.7.4.2 Removing the 1st Stage Inlet ValveSee Figure 3-12 and proceed as follows:

1. Remove all tubing connections to the valve head.

2. Inspect the O-ring (2). Replace it if it is damaged.

3. Unscrew and remove the socket head screws and lift valve head (1) from cylinder.

4. The valve plate (4) rests free on the piston cylinder, it is not spring operated.

5. Inspect the valve plate (4). It should be flat and free of grooves. The maximum concentric groove depth should not exceed 0.002” (0.05 mm).

6. The top of the piston should be flush with the valve seat. (See Figure 3-11).

7. Inspect the O-ring (3). It should be undamaged and non-porous. Replace it if necessary.

3.1.7.4.3 Reassembly of the 1st Stage ValvesSee Figure 3-12 and proceed as follows:

1. Place the valve plate (4) and O-ring (3) into the valve seat of the piston cylinder.

2. Apply a temperature resistant non-age hardening RTV sealing compound to the surface of the valve head (1).

3. Replace valve head (1) on cylinder and install socket head cap screws. Torque socket head cap screws to 18 ft.-lbs (25 Nm).

4. Install the pressure valve assembly (6) and tighten set screw (15).

5. Position the gasket (16) and tighten the dome nut (17).

6. Replace all tubing connections to the valve head.

NOTICE

To avoid damage to the valve body (11), the valve head must be installed and torqued before the 1st stage pressure valve set screw (15) is tightened.

MNL-0237


3.1.7.5 Changing the 2nd Stage Valves3.1.7.5.1 Removing the 2nd Stage Pressure Valve.

See Figure 3-13 and proceed as follows:

1. Remove the dome nut (18) and the gasket (17). Inspect the gasket. The gasket should be replaced if it is damaged.

2. Unscrew and remove the socket set screw (16) and the pressure valve cover (15).

3. Remove the spring washer (14) and the o-ring (13). The o-ring should be in perfect condition: undamaged and non-porous. Replace it if necessary.

4. Extract the pressure valve assembly (8).

Figure 3-13 2nd Stage Valves

1. Valve Head2. Inlet Valve Assembly3. Inlet Valve Cover4. Compression Spring5. Inlet Valve Plate6. Inlet Valve Seat7. Valve Gasket

8. Pressure Valve Assembly9. Pressure Valve Seat10. Pressure Valve Plate11. Compression Spring12. Pressure Valve Body13. O-ring14. Spring Washer

15. Pressure Valve Cover16. Socket Set Screw17. Gasket18. Dome Nut19. Safety Valve

16

15

13

93

1 12

11

10

58

14

7

17

4

5

6

7

2

18

C-D/DV/Navy


5. Discard the valve gasket and replace it with a new gasket.

6. Inspect the valve seat (9). The sealing surface must be in good condition: devoid of pitting or crack-ing. The maximum valve seat width is 3/64” (1.0 mm).(See Figure 3-10).

7. Clean and inspect the valve plate (10). The maximum acceptable groove depth must not exceed 1/128” (0.2 mm). (See Figure 3-10)

8. Check the tolerance of the inside diameter of the valve body (12). The valve body must not show any grooves at ID 17 + 0.1 mm. (See Figure 3-10).

9. The valve spring (11) is reusable if it shows no outside scuffing and the spring ends have not picked up on the next coil.

10. The limits shown in Table 3-2 should also be checked. If the tolerances have been exceeded then the valve assembly (8) should be replaced.

3.1.7.5.2 Removal of the 2nd Stage Inlet ValveTo remove the 2nd stage inlet valve, it is necessary to first dismantle the valve head. Refer to Figure 3-13 and proceed as follows.

1. Remove the tube nuts, tubes and ferrules from the tube connections to the valve head (1).

2. Unscrew and remove the socket head cap screws.

3. Lift the valve head off the piston cylinder.

4. Unscrew the valve cover (3) from the bottom of the valve head (1) using the valve tool provided with the compressor unit.

5. Extract the inlet valve assembly (2) and discard the valve gasket (7). Replace the old gasket with a new gasket.

6. Inspect the valve seat (6). The sealing surface must be in good condition: devoid of pitting or crack-ing. The maximum valve seat width is 3/64” (1.0 mm). (See Figure 3-10).

7. Clean and inspect the valve plate (5). The maximum acceptable groove depth must not exceed 1/128” (0.2 mm). (See Figure 3-10).

8. Check the tolerance of the inside diameter of the valve cover (3). It must not show any grooves at ID 17 + 0.1 mm. (See Figure 3-10).

9. The valve spring is reusable if it shows no outside scuffing and the spring ends have not picked up on the next coil.

10. The limits shown in Table 3-2 should also be checked. If any of these tolerances have been exceeded, the valve assembly (2) should be replaced

3.1.7.5.3 Reassembly of the 2nd Stage Valve Head and ValvesTo reassemble the valve head and valves, refer to Figure 3-13 and proceed as follows.

1. Before fitting the inlet valve to the valve head, grease the inlet valve plate slightly and place it cor-rectly on the valve seat to make reassembly easier.

MNL-0237


2. After having assembled the inlet valve, peen the valve head twice, once on each side of the valve, to lock the threads in place.

3. Apply a temperature-resistant, non-age hardening RTV sealing compound to the sealing surface of the valve head.

4. Torque the valve head cap screws to 18 ft lb. (25 Nm) in accordance with the sequence shown in Appendix A before tightening the socket set screw (3) in order to avoid damage to the valve body (8).

5. Tighten the socket set screw (3) with the appropriate size hex key.

6. Position the gasket (2) and dome nut (1) and tighten it with an open end wrench.

7. Reinstall the tube connections (13) to the valve head (22).

Figure 3-14 Peening the Inlet Valve

C-D/DV/Navy


3.1.7.6 Changing the 3rd Stage Valve See Figure 3-15 and proceed as follows

3.1.7.6.1 :Removal of the 3rd Stage Pressure Valve

1. Remove the dome nut (1) and the gasket (2). Unscrew the socket set screw (3) three or four turns. If the gasket is damaged, replace it with a new gasket.

2. Remove the valve head screws (9) that secure the valve head (7), then remove the valve head cover (8).

3. Place two screwdrivers into the groove of the pressure valve body (See Figure 3-16) and lift out the pressure valve (5) together with the o-ring (4). If necessary, loosen the valve first, using a 13 mm open-end wrench on the flat surfaces.

4. Check the o-ring. It should be in perfect condition (undamaged and non-porous). Replace it if nec-essary.

Figure 3-15 3rd Stage Valve Head and Valves

1. Dome Nut2. Gasket3. Set Screw

4. O-ring5. Pressure Valve6. Inlet Valve

7. Valve Head8. Valve Head Cover9. Valve Head Screw

1

2

3

4

5

6

7

8

9

MNL-0237


5. If the pressure valve does not close tightly, it should be replaced. The bore diameter of the valve seat should be 4.0 mm.

3.1.7.6.2 Removal of the 3rd Stage Inlet Valve

1. Remove the tube connections to the valve head (7).

2. Unscrew and remove the socket head cap screws (9).

3. Remove the valve head cover (8).

4. Extract the inlet valve (6) using the valve tool provided with the unit.

5. The inlet valve should be replaced if it no longer closes tightly. The bore diameter of the valve seat should be 4.0 mm.

3.1.7.6.3 Reassembly of the 3rd Stage Valves

1. Reassemble the inlet valve (6) in the reverse sequence of its removal.

2. Insert the pressure valve (5) with the O-ring (4) into the valve head (7).

3. Position the valve head cover (8). Do not use a sealing compound on the third stage valve head.

4. Insert and torque the valve head cap screws (9) to 18 ft-lb. (25 Nm = 2.5 kgm) in accordance with the sequence shown in the Appendix before tightening the socket set screw (3) in order to avoid damage to the valve body (8).

5. Screw in the set screw (3) by hand. Fit the Copper Gasket (2) and the Cap Nut (1) and tighten with an open end wrench.

6. Reinstall the tube connections to the valve head (7).

Figure 3-16 Removing the 3rd Stage Pressure Valve

C-D/DV/Navy


3.1.8 Replacement Parts List

Item Qty Part No. Description Notes1 6 SCR-0025 Hex head cap screw2 18 WAS-0021 Flat washer3 1 014998 Bracket for cooler4 1 N00220 Shaft seal5 1 014878 Bearing cover6 1 N03705 O-ring7 1 N03703 Roller bearing8 1 014030 Crankshaft assembly, complete Items 9 - 139 1 N00166 Shaft key10 † 001529 Shim11 1 SCR-0138 Socket head cap screw12 1 WAS-0001 Split lock washer13 1 NUT-0119 Hex lock nut14 1 N03702 Roller bearing15 1 014874 Crankcase

Figure 3-17 Crankcase Assembly

1 2

3

4

56

7

9

8

11, 12, 13

61

14

3266

676463 6862

6059

57

58

56

42 2 38

37

4039

36

35

422

41

44 48

33

33

30

31

50 49

2728

27

29

26

25

24

1617

1719

21

20

2322

15

10

34

43

45

46

4747

42

2

51

52

5354

55

65

MNL-0237


Figure 3-17 (cont.) Crankcase Assembly

Item Qty Part No. Description Notes16 1 003196 Drive cam17 1 014888 Hold-down plate)18 2 SCR-0065 Hex head cap screw19 1 N03726 O-ring20 1 058159 Filter mount21 3 SCR-0179 Socket head cap screw22 1 073270 Oil drain pipe23 1 N03707 Hex head pipe plug24 1 014892 Crankcase vent filter assembly Items 25 - 2925 AR N03736 Flexible tube26 1 N03737 Male connector27 † N03207 Crankcase vent filter28 1 N03712 O-ring29 1 N00293 Copper gasket30 1 072887 Connecting rod 1st stage31 1 072884 Connecting rod 2nd stage32 1 072885 Connecting rod 3rd stage33 3 004180 Shaft spacer34 8 N00215 Stud35 1 014886 Dipstick rod36 1 N03521 O-ring37 1 014887 Oil fill tube38 1 012560 Flange gasket39 2 SCR-0145 Socket head cap screw40 2 N03026 Wave washer41 1 006540 1st stage piston cylinder 70 mm42 12 NUT-0119 Hex lock nut43 1 001867 Piston cylinder gasket44 1 069948 Piston assembly, 1st stage Items 46 - 4945 1 010704 1st stage piston 70 mm46 † — Piston pin 1st stage47 † — Retaining ring48 1 N03856 Piston ring set 70 mm49 1 010875 2nd stage piston cylinder 36 mm50 1 003110 Piston cylinder gasket 36 mm51 1 069949 Piston assembly, 2nd stage Items 53 - 5652 † — Piston, 2nd stage 36 mm53 1 N04158 Piston ring set 36 mm

C-D/DV/Navy


Figure 3-17 (cont.) Crankcase Assembly

Item Qty Part No. Description Notes54 † — Piston pin 2nd stage55 † — Retaining ring56 1 065094 Finned cooling plate57 1 078043 Floating piston assembly(mod 8) Items 58 - 59 58 1 N23755 O-ring59 2 N02320 O-ring60 1 121632 Piston cylinder(mod 8) 14 mm 61 1 N04064 O-ring62 1 056141 Guide cylinder 45 mm63 1 001866 Guide cylinder gasket 45 mm64 1 069950 Piston assembly, 3rd stage Items 65 - 6765 1 N00823 Guide piston 45 mm66 † — Piston pin 3rd stage67 † — Retaining ring68 4 N04065 Stud

MNL-0237


Item Qty Part No. Description Notes♦ 1 014906 Valve head assembly, 1st stage Complete1 1 014907 Valve head2 1 N01539 O-ring3 1 N02169 O-ring4 1 009884 Inlet valve plate5 1 014583 Pressure valve assembly Items 6 - 176 1 012840 Pressure valve Items 7 - 117 1 000240 Valve gasket8 † — Valve seat9 † — Valve plate10 † — Compression spring11 † — Pressure valve body12 1 N03521 O-ring13 1 014332 Disc spring14 1 014124 Pressure valve cover15 071064 Socket set screw16 1 N03625 Copper gasket17 1 N00084 Dome nut

Figure 3-18 1st Stage Valve Head and Valves

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

C-D/DV/Navy


Item Qty Part No. Description Notes♦ 1 014696 Valve head assembly Complete1 1 014123 Valve head2 1 012841 Intake valve assembly3 † — Inlet valve cover4 † — Compression spring5 † — Valve plate6 † — Inlet valve seat7 2 000240 Valve gasket8 1 012835 Pressure valve assembly Complete9 † — Pressure valve seat10 † — Compression spring, Cylindrical11 † — Pressure valve body12 1 N03521 O-ring13 1 014332 Disc spring

Figure 3-19 2nd Stage Valve Head and Valves

16

15

13

93

1 12

11

10

58

14

7

17

4

5

6

7

2

18

MNL-0237


Figure 3-19 (cont.) 2nd Stage Valve Head and Valves

Item Qty Part No. Description Notes14 1 014124 Pressure valve cover15 1 071064 Socket set screw16 1 N03625 Copper gasket17 1 N00084 Dome nut18 1 010670 Safety Valve

C-D/DV/Navy


Item Qty Part No. Description Notes♦ 1 069954 Valve head assembly Complete1 1 N03623 Dome nut2 1 N03625 Copper gasket3 1 071065 Socket set screw4 1 N02789 O-ring5 1 014121 Pressure valve6 1 081409 Intake valve7 1 014117 Valve head8 1 014118 Valve head cover9 6 N01282 Socket head cap screw

Figure 3-20 3rd Stage Valve Head and Valves

1

2

3

4

5

6

7

8

9

MNL-0237


Item Qty Part No. Description Notes♦ 1 067612 Intermediate Separator1 1 013930 Filter Head2 1 012784 Vortex Plate3 1 012785 Baffle Cone4 1 N02726 Sintered Metal Filter5 1 012786 Center Screw6 1 N03556 O-ring7 1 014150 Filter Housing8 1 013937 Threaded Collar9 1 N01316 Gasket NSN 5530-01-461-489910 1 ADP-0021SS Adapter11 1 011656 Safety Valve NSN 4820-01-460-844312 1 004479 Gasket

Figure 3-21 Intermediate Separator

1

2

3

4

5

6

7

8

11

12

9

10

C-D/DV/Navy


Item Qty Part No. Description Notes♦ 1 013758 Intake Filter Assembly Items 2 - 71 † — Intake Filter Cover2 1 010528 Compression Spring3 1 N04451 O-ring4 1 N00070 Filter Element5 1 013757 O-ring6 † — Intake Filter H ousing♦ 1 HOS-0163 Inlet Hose Assembly with Prefilter Items 7 - 107 3 CMP-0025 Worm Gear Hose Clamp8 10 ft TUB-R-00083 Flexible Tube9 1 ADP-0314 Reducing Adapter10 1 057691 Prefilter

Figure 3-22 Intake Filter

1 2 3 4 5 6

7

879710

1 2

34

598

6

10

7

This page is inserted to provide proper page sequencing

C-D/DV/Navy


Item Qty Part No. Description Notes1 4 SCR-0159 Socket head cap screw2 5 WAS-0001 Split lock washer3 1 012754 Cooling fan/compressor flywheel4 1 SCR-0182 Socket head cap screw5 1 013666 Cooling fan hub6 1 069960 Aftercooler7 8 SCR-0051 Hex head cap screw8 1 014998 Cooler bracket9 8 013662 Tube clamp 3-groove10 9 NUT-0118 Hex lock nut11 2 014564 Tube clamp 2-groove12 4 013663 Intercooler bracket13 † — Intercooler 2nd stage14 2 014370 P-clamp15 20 WAS-0024 Flat washer16 2 SCR-0192 Hex head cap screw

Figure 3-23 Cooling System

15 14

7

10

611

15

15

241

2

3

4 2 5

16

715

10

1515

15

12

923

11

22

2120

198

18

10 17

MNL-0237


Figure 3-23 (cont.) Cooling System

Item Qty Part No. Description Notes17 2 014139 Tube clamp 2-groove18 2 SCR-0110 Hex head cap screw19 1 069957 Connecting tube 1st stage to intercooler20 1 N20189 Male connector21 † — Intercooler 1st stage22 1 014624 Intercooler assembly 1st stage, air-cooled23 1 058991 Intercooler assembly 2nd stage, air-cooled

C-D/DV/Navy


Item Qty Part No. Description Notes1 1 002010 Oil pump gasket2 1 N00083 Oil pump3 1 058138 Oil pressure regulator Items 4 - 214 1 072439 Ball valve assembly Items 5 - 75 † 058119 Ball valve seat6 † N02768 Precision ball7 1 ---- Ball guide8 4 N07091 O-ring9 1 057132 Square flange10 2 N20237 Male connector11 1 N04530 Tube plug12 1 002623 Compression spring13 11 058121 Valve plate14 1 058102 Oil pressure regulator body15 1 N04051 Copper gasket16 1 056302 Glass tube

Figure 3-24 Lubrication System

1

2

3

4

56

7

8

9

1011

1213

8

14

1516

17

18

20

21

22

23

24

25

MNL-0237


Figure 3-24 (cont.) Lubrication System

Item Qty Part No. Description Notes17 1 056301 Oil sight glass fitting18 1 N02969 Slotted set screw19 1 N03625 Copper gasket20 1 N00084 Dome nut21 2 SCR-0177 Socket head cap screw22 2 N03407 Socket head cap screw23 1 069966 Oil supply tube24 3 WAS-0021 Flat washer25 3 SCR-0136 Socket head cap screw

C-D/DV/Navy


3.1.8.1 Troubleshooting and Repair3.1.8.1.1 Troubleshooting Table

Trouble Cause Remedy

No oil pressure 1. Low oil level2. Vapor Lock at Oil Pump

1. Check oil level 2. Vent Oil Pump

Oil foam in crankcase

1. Last stage piston worn2. Last stage pressure valve

defective

1. Operate compressor with final stage valve head removed. If oil flows continuously out of cylinder, replace piston and sleeve.

2. Replace last stage valves.

Compressor output insufficient

1. Condensate drain valves or fittings leaking.

2. Premature opening of final safety valve.

3. Piston rings worn4. Excessive piston clearance5. Pipes leaking

1. Tighten and reseal.2. Replace3. Replace4. Replace5. Tighten

Safety valves between stagesreleasing pressure

1. Intermediate pressure too high

2. Valves not closing properly3. Relief Valve not set prop-

erly

1. Service and clean valves.2. Service and clean valves.3. Service and clean valves.

Compressor running too hot.1. Insufficient cooling air.2. Intake or outlet valve not

closing properly

1. Check for adequate ventilation2. Check and clean valves,

replace as necessary

Oil residue in delivered air

1. Improper maintenance of filters, purifier cartridge saturated.

2. Wrong oil type

1. Service filters, change purifier cartridge.

2. Change to proper oil and clean valves.

MNL-0237


3.1.8.1.2 RepairPreventive maintenance usually involves replacing the valves, gaskets, and sealing rings as well as carry-ing out the maintenance work. Repair work can be carried out on the compressor block to a certain extent but a certain level of experience and skill is necessary. It should be noted however that no repair should be carried out on the crankshaft nor on the bearings. Also safety valves are not repaired but always replaced.

C-D/DV/Navy


3.2 Manual Condensate Drain System

3.2.1 DescriptionThe purpose of the manual condensate drain system is to provide a means to drain the filters of accumu-lated condensation.

The manual condensate drain system consists of the following items:

1. Manual condensate drain valves on the intermediate filter and the oil and water separator.

2. Interconnecting tubing.The manual drains on the intermediate and final separators should be tubed to a condensate collection tank.

3.2.2 OperationThe manual condensate drain valves must be opened and the condensate allowed to drain every 15 min-utes while the compressor is operating.

3.2.3 Unloaded start On shut-down, open the intermediate and final separator manual condensate drain valves to drain con-densation and remove pressure from the block. Close the drain valves after start up.

This operation performs two functions:

1. As pressure builds, the separators are cleared of accumulated condensation.

2. There is no load on the compressor during start-up.

NOTICE

Condensate drained from the separators may be mixed with oil. Ensure that any oil which is drained with the condensate is disposed of in accordance with local, state and federal regulations.

Figure 3-25 Manual Condensate Drains

1. Intermediate Separator Drain2. Final Separator Drain

1 2

MNL-0237


CHAPTER 4: MAINTENANCE SCHEDULE4.1 C-D/DV/Navy Maintenance Intervals

Maintenance Task

Maintenance Intervals in Hours of Operation

8 50 130 500 1000 2000 3000 17500Operatoror ServiceTechnician

Check compressor oil level Operator

Manually drain condensate Operator

Check for oil pump venting Operator

Check for leaks Operator

Check for abnormal sounds Operator

Check for abnormal vibrations Operator

Check for short cycling Operator

Check for damage to unit Operator

Check moisture indicator Operator

Retorque valve head fasteners Operator

Inspect all hoses Operator

Inspect all guards Operator

Inspect fanwheel Operator

Inspect all drive belts Operator

Replace intake filter element Technician

Test all safety valves Technician

Change oil (petroleum) Technician

Change oil (synthetic) Technician

Clean all cooling fins Technician

Check for corrosion Technician

Clean intermediate separators Technician

Replace compressor valves Technician

Inspect pistons and rings Technician

Replace oil and water separator Technician

C-D/DV/Navy


4.1.1 Maintenance RecordsWe recommend that all maintenance work be recorded, showing the date and details of the work carried out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to make a claim against the warranty, it will help to have proof that regular maintenance has been carried out and that the damage has not been caused by insufficient maintenance. For this purpose Maintenance Record Sheets are included in the Appendix and may be copied as required. Additionally a form for recording operating hours is included and may be copied also.

^ CAUTION

All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme conditions like high temperatures, humidity or continuous operation may shorten the

intervals significantly. If in doubt, please contact the Bauer service department.

MNL-0237


CHAPTER 5: PURIFICATION SYSTEM5.1 Purpose

The purpose of all Bauer breathing air purification systems is to remove oil, water, taste and odor from the compressed air stream before final delivery. For this reason Bauer purification systems are installed immediately before the compressed air delivery point. Refer to the compressor unit purification dataplate on the purifier cartridge to determine your purification system specifications (See Figure 5-1).

5.1.1 GeneralThe C-D/DV/Navy compressor unit is available only with the P1 Purification System.

5.2 P1 Purification SystemThe P1 Purification System shown in Figure 5-2 approximates the physical location of the components on a P1 Purification Panel. The P1 Purification System that is an integral part of your compressor unit may have a different physical layout but will be functionally identical.

Figure 5-1 Purification Dataplate

CARTRIDGE FOR

CARTRIDGE NO.

LBL-

CARTRIDGE TO BEINSTALLED

1328 Azalea Garden Road - Norfolk Virginia 23502-1944Phone: (757) 855-6006 Fax: (757) 855-8224

MODEL NO.

MAX. PRESSURE

AIR PROCESSED

O-RING

BACK-UP RING

psig

cu. ft.

LBL-

PURIFICATIONSYSTEM

C-D/DV/Navy


5.2.1 Component Description

5.2.1.1 Coalescing Oil/Water Separator.The coalescing oil and water separator works by means of a sintered metal micro-filter element which reliably separates liquid oil and water particles from the compressed air.

5.2.1.2 Condensate Drain ValveA manually operated valve used before start-up and during operation to drain the condensed liquids from the coalescing oil and water separator. It is recommended not to drain the condensate more than four times per hour of operation.

Figure 5-2 P1 Purification System

1. Coalescing Oil/Water Separator2. Condensate Drain Valve3. Check Valves4. Purifier Chamber

5. Vent valve6. Pressure Maintaining Valve7. Final Pressure Safety Valve

OU

IN

1 2 3

4 5

6

3

7

MNL-0237


5.2.1.3 Moisture IndicatorUnder normal conditions the element in the moisture indicator is blue and changes to pink with elevated levels of moisture.

5.2.1.4 Purification ChamberThe Purification Chamber is made of anodized aluminum alloy.

5.2.1.4.1 Purifier CartridgeThe casings of the purifier cartridge as well as the cover and bottom are aluminum. The purifier cartridge is packed with a molecular sieve to absorb moisture, activated charcoal to absorb odor and a catalytic agent to convert Carbon Monoxide to Carbon Dioxide.

5.2.1.5 Vent ValveA manually operated valve used to release the pressure in the purifier chamber before maintenance.

5.2.1.6 Pressure Maintaining ValveThe pressure maintaining valve ensures that pressure is built up in the purification system from the start of delivery, thus achieving constant optimum purification. It also assures proper working conditions for the final stage of compression.

5.2.1.7 Safety ValveThe safety valve is located on the coalescing oil and water separator and acts as the safety valve for the final stage of the compressor.

Figure 5-3 Moisture Indicator

NOTICE

The used purifier cartridge must be disposed of in accordance with local regulations.

C-D/DV/Navy


5.2.2 Maintenance

5.2.2.1 Cartridge Operating LifeEvery P1 purification system is designed to process a certain volume of air before the purification car-tridges require replacement. By using special test equipment that measures the quality of air at the outlet any quality reduction may be detected. However as most compressor owners do not have this test equip-ment the recommended method of determining purification cartridge operating life is to maintain a record of the volume of air processed by the purification system.

Each compressor block is rated to produce a standard volume of air per minute and by using this figure and the air processing capability of the purification system it is possible to calculate the maximum operat-ing hours before the purification cartridges need to be replaced. See Paragraph 5.2.2.2 for the method of determining this figure.

Ambient temperature of the intake air supply also causes changes to the operating life of purification car-tridges. The standard ambient temperature is 68° F (20° C). Operating at other temperatures changes the time before purification cartridge replacement is required. See Paragraph 5.2.2.3 for the method of calcu-lating this adjustment factor. A form, titled Air Purification Cartridge Operating Hours for recording the ambient temperature, operating time and adjustment factor is found in Section I. It is suggested that it be copied, placed in a protective folder and kept with the unit to record the adjusted operating hours. An example of how this form is used is shown in Figure 5-5.

5.2.2.2 Calculating the Maximum Purification Cartridge Operating Hours

1. From the purification dataplate on the unit determine the Air Processed (cu. ft.)

2. From the compressor unit dataplate determine the Capacity (CFM).

3. Divide the Air Processed by the Capacity to obtain the Maximum Operating Time in minutes

4. Divide the Maximum Operating Time in minutes by 60 to obtain the Maximum Operating Hours.

5. Record the answer on the Air Purification Cartridge Operating Hours form.

5.2.2.3 Calculating the Adjusted Purification Cartridge Operating Hours

1. Using the Air Purification Cartridge Operating Hours form record the Date, Operating Hours and Ambient Air Temperature.

2. Using either the graph or the chart in Figure 5-4 determine the Correction Factor.

3. Divide the Operating Hours by the Correction Factor and record it under the column labeled Today.

4. Add the hours recorded in Today to the previous Total and record it as the current Total.

5. When the Total approaches the Maximum Operating Hours replace the Purification Cartridges.

5.2.2.4 Adjusted Cartridge Operating HoursWhen operating at temperatures other than 68oF, divide the number of hours operated at that temperature by the correction factor as indicated in figure Figure 5-4.

MNL-0237


Figure 5-4 Correction Factor for Cartridge Operating Hours

Figure 5-5 Example Record of Adjusted Operating Hours

°F [°C x 9/5 +32]

°C [(°F - 32) x 5/9] Correction Factor

50 122 0.21

40 104 0.34

30 86 0.58

20 68 1.00

10 50 1.81

0 32 3.44

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

0 10 20 30 40 50Ambient Temperature in °C

Con

vers

ion

Fact

or

Date OperatingHours

Ambient Temp.during Compression

CorrectionFactor

Adjusted Cartridge HoursToday Total

10/19/04 8 92°F (33 °C) 0.48 16.66 16.66

11/01/04 4 45°F (7.2 °C) 2.25 1.78 18.44

C-D/DV/Navy


5.2.2.5 Coalescing Oil/Water Separator

1. See Figure 5-6. Disconnect the power and shut off the inlet supply line if applicable.

2. Depressurize the system by means of the vent valve.

3. Remove the tubes connected to the side of the filter head (1).

4. Unscrew and remove the filter head.

5. Unscrew the sintered metal filter element (2) from the filter head.

6. Remove the center screw (3) to remove the sintered metal filter element.

7. Clean the sintered metal filter element using hot soapy water. Blow dry with compressed air.

8. After cleaning the element, record the number of operating hours to ensure exact attention to the maintenance intervals.

9. Lubricate the threads and O-rings as well as the threaded part of the sintered metal filter element with petroleum jelly. Apply sparingly.

10. Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the micro-filter element.

11. In the event you discover corrosion, replace the corroded parts with new Bauer parts.

Figure 5-6 Oil and Water Separator

1. Filter Head2. Center Screw

3. Sintered Metal Filter4. O-rings

1

2

3

4

MNL-0237


5.2.2.6 Moisture IndicatorTo install the indicator element see Figure 5-7 and proceed as follows:

1. Release the pressure from the system.

2. Unscrew the indicator cap (2) from the indicator base (5).

3. Remove the old element (3).

4. Place the new indicator element with the active side facing the indicator window (1).

5. Reinstall the indicator cap (2), ensuring the spring (4) is in place and holding the indicator element against the window.

6. Tighten the indicator cap (2) hand tight.


1. Indicator Cap2. Indicator Element

3. Spring4. Indicator Base

12

3

4

5

C-D/DV/Navy


5.2.2.7 Purification ChamberTo change the cartridge, proceed as follows. See Figure 5-8

Disconnect the power and shut off the inlet supply line, if applicable.

1. Depressurize the system by means of the vent valve.

2. Unscrew the filter head using the special wrench supplied.

3. Pull out the cartridge using the lifting ring on top of the cartridge.

4. Dry the inside of the purification chamber with a clean cloth and check for corrosion.

5. Replace all corroded parts with new Bauer parts.

6. Remove the shipping covering and the protective cap from the bottom of the cartridge.

7. Lubricate the O-rings with white petroleum jelly. Apply sparingly.

8. Install the new cartridge. Be sure the cartridge snaps into place.

9. Reinstall the filter head.

10. Close the vent valve, restore the power and reconnect the inlet supply line, if applicable.

5.2.2.8 Cartridge Leaking after Installation

1. Remove the cartridge following steps to 3. in Paragraph 5.2.2.7.

2. Install cartridge if missing.

3. Remove cartridge and inspect O-rings

4. Replace O-rings if necessary.

NOTICE

If air is detected bleeding out from the bottom of the purification chamber, the cartridge has not been installed properly or is missing. Follow the instructions in Paragraph 5.2.2.8

Figure 5-8 Purifier Cartridge Replacement

PullUp

MNL-0237


5. Ensure protective caps and devices have all been removed.

6. Replace cartridge following steps 7. to 10. in Paragraph 5.2.2.7.

Protective Cap

PurificationCartridge

C-D/DV/Navy


5.2.3 Replacement Parts List

Item Qty Part No. Description Notes♦ 1 090058 Oil/Water Separator Assembly Items 1 through 61 † — Separator Head Available only with 0900582 2 N04586 O-ring3 1 N15133 O-ring4 1 061860 Filter Element5 † — Separator Housing Available only with 0900586 † — Bottom Plug Available only with 0900587 1 011430 Manual Drain Valve8 1 058165 U-bolt9 2 WAS-0021 Washer

Figure 5-9 Oil/Water Separator

1

2

3

4

5

6

7

8

9

9

10

10

121314

15

1617

17

17 18

1919

2021

16

22

22

11

2

17

23

MNL-0237


Figure 5-9 (cont.) Oil/Water Separator

Item Qty Part No. Description Notes10 2 N00084 Self Locking Hex Nut11 1 065410-330 Safety Valve12 1 N04499 Gasket13 2 SCR-0136 Socket Head Cap Screw14 1 064013 Flange Adapter15 1 N04882 O-ring16 2 N16875 Plug17 4 N01316 Gasket18 1 063999 Flange Elbow Items 19 through 2219 2 N04178 O-ring20 1 063998 Flange Adapter21 1 063997 Flange Elbow22 2 CON-0061SS Male Connector23 4 SCR-0133 Socket Head Cap Screw

C-D/DV/Navy


Item Qty Part No. Description Notes♦ 1 080143 Purification Chamber Assembly 6,500 psi, 10” Cartridge1 2 012293 Tool Post Screw2 1 061237 Cover Plate3 † 080147 Filter Head Available only with 0801434 2 N04736 Back-up Ring5 2 N04735 O-ring6 † 080146 Filter Housing Available only with 0801437 † 080148 Filter Bottom Available only with 0801438 1 058821A Purifier Cartridge 10” MS/AC/MS/HP9 1 N04731 O-ring10 1 N04566 O-ring11 2 N04499 Gasket12 2 ADP-0020SS AdapterN.S. 2 CMP-0002 Clamp

Figure 5-10 P1 Purification Chamber

1

2

3

4

4

5

5

7

6

9

10

8

MNL-0237


Item Qty Part No. Description Notes♦ 1 IND-0015 Moisture Indicator1 † — Indicator Cap Available only with IND-00152 1 ELM-0056 Indicating Element3 † — Spring Available only with IND-00154 † — Indicator Base Available only with IND-0015


1

2

3

4

C-D/DV/Navy


CHAPTER 6: COMPRESSOR DRIVE SYSTEM6.1 Dive Units

The compressor is driven by the drive motor or engine through a V-belt. The direction of rotation, as seen facing the flywheel, is counterclockwise. Observe the arrow on the compressor block.

Tightening of the V-belt is accomplished by screwing down the tensioning nut. By lowering the motor or engine’s position the distance between the flywheel and sheave is increased, thus tightening the V-belt.

6.1.1 Maintenance of the V-belt and Sheave

6.1.1.1 Checking the Sheave. Before a new drive belt is installed, the condition of the sheave should be checked. A dirty or rusty sheave impairs the drive’s efficiency and abrades the cover of the belt, which results in premature failure.

Figure 6-1 Dive Unit Drive

1. Compressor Flywheel2. V-belt3. Compressor Mount

4. Drive Mount (engine/motor)5. V-belt Sheave & Bushing6. Tensioning Nut & Spring

Figure 6-2 Tensioning

1

2

3 4

5

6

TensioningNutTensioningNut

MNL-0237


A worn sheave shortens belt life as much as 50%. If the groove is worn to the point where the belt bot-toms, slippage may result and the belt may burn. If the side wall is “dished out,” the bottom shoulder ruins the belt prematurely by wearing off the bottom corners.

6.1.1.2 Checking the V-belt Inspect the V-belt regularly for damage and wear. Replace if necessary.

C-D/DV/Navy


6.2 Replacement Parts List

Item Qty Part No. Description Notes

♦ C-D/DV/Navy; Diesel Engine Drive

1 1 KC-FH/P0 Compressor Block2 1 BET-0013 V-belt3 1 FRM-0267 Complete Dive Frame Includes Compressor Base4 1 BAS-0079 Engine Base5 1 SHE-0142 V-belt Sheave— 1 BUS-0011 Sheave Bushing6 1 NUT-0154 Tensioning Nut— 1 SPG-0003 SpringNS 1 ENG-0045 Diesel Engine Yanmar, 6.4 Hp

Figure 6-3 C-D/DV/Navy Drive

1

2

3 4

5

6

TensioningNutTensioningNut

MNL-0237


CHAPTER 7: MISCELLANEOUS7.1 Valves

7.1.1 Nonadjustable ValvesThe condensate drain valve, vent valve and check valves are not adjustable. The condensate drain valve and vent valve have seats and seals which should be replaced if the valve leaks. Check valves are not adjustable or repairable and must be replaced if they malfunction.

7.1.2 Pressure Maintaining ValveThe pressure maintaining valve is adjusted at the factory to the required pressure and does not normally require maintenance or readjustment. The factory settings are:

Final Pressure Setting Minimum PMV Setting2,000-5,000 psi (138-345 bar) 2,175 psi (150 bar)

If readjustment does become necessary proceed as follows.

1. Loosen the locking nut (1).

2. Set the adjusting screw (2) to the required pressure using an appropriate hex type wrench.

3. Turn clockwise to increase pressure, counterclockwise to decrease pressure.

4. Determine if the PMV is properly adjusted:a. Depressurize the final separator and purifier chamber by slowly opening the vent valve.b. Close the vent valve and start the compressor.c. Observe the final pressure gauge and note the pressure at which the valve opens (delivers). d. If the pressure is not at the specified pressure ± 200 psi, readjust the PMV.

Figure 7-1 Pressure Maintaining Valve

C-D/DV/Navy


7.1.3 Safety Valves

The safety valve must be checked periodically for proper functioning.

1. Operate the compressor with the shut-off valve closed until the safety valve vents.

2. Note the pressure registered on the pressure gauge.

7.1.3.1 Safety Valve AdjustmentThe safety valve is adjusted at the factory to the required pressure and does not normally require mainte-nance or readjustment. In case readjustment does become necessary, have the safety valve adjusted by a Bauer qualified technician or contact the Bauer Product Support Department for instructions on returning the valve to the factory for adjustment.

7.2 Calibration of Safety Valves and Pressure Gauges

Bauer sets all safety valves using a calibrated gauge traceable back to a U.S. National Institute Of Stan-dards and Technology (NIST) Registry. Safety Valves set by Bauer have a LBL-0300 affixed to show set date and pressure set. This is recorded on a Calibration report and kept by the QA Department.

GAG-0010W/CAL is also calibrated using a NIST standard, the gauge is checked to assure it is operating within it accuracy range of 3% of full scale deflection. By doing this a one year time frame is established before recertification of the gauge is required. Records are also kept on the calibration of each gauge and shipped with the gauge in all applications

Figure 7-2 Safety Valves

Figure 7-3 Calibration Label, LBL-0300

MNL-0237


7.3 Fill Hose Replacement Parts List.

Item Qty Part No. Description Notes♦ 1 C-D/DV/Navy/FHFill Hose Assembly Items 1 through 111 1 HOS-0080 High pressure hose2 1 CON-0348 Male connector3 1 VAL-0391 Needle valve4 1 ADP-0325 Adapter5 1 CON-0017SS Hex nipple connector6 1 CON-0042SS Male Run Tee7 1 VAL-0169 Safety valve 300 to 6000 psi8 1 ADP-0113 Fill adapter CGA, 4500 psi SCBA9 1 N04483 O-Ring10 1 GAG-0010W/CALPressure gauge11 1 CVR-0002 Protection cover Rubber12 2 CON-133SS Bulkhead Fitting13 2 WAS-0060 Flat Washer14 2 ADP-0058 Adapter

Note: Two Fill Hose Assemblies are shipped with each C-D/DV/Navy unit.

Figure 7-4 Fill Hose Assembly

Hose Storage Assembly

12

1314

1

2

3

45

6

7

89 10

11

C-D/DV/Navy


CHAPTER 8: APPENDIX8.1 Maintenance Reference Data

8.1.1 Tightening Torque Values

1. Unless otherwise specified in text, the torque values in Table 1 apply.

2. The indicated torque values are valid for bolts in greased condition.

3. Self locking nuts must be replaced on reassembly

4. Pipe connections (swivel nuts) should be tightened just enough so that leakage is stopped. Not more than finger tight plus up to an additional ½ turn.

8.1.1.1 Torque Sequence Diagrams

Table 8-1: Torque Values

Bolt or Screw Thread Max. Torque

Hex and socket head ¼” (M 6) 7 ft. lbs. (10 Nm)

Hex and socket head 5/16” (M 8) 18 ft. lbs. (25 Nm)

Hex and socket head 3/8” (M 10) 32 ft. lbs. (45 Nm)

Hex and socket head ½” (M 12) 53 ft. lbs. (75 Nm)

Hex and socket head 9/16” (M 14 85 ft. lbs. (120 Nm)

Hex and socket head 5/8” (M 16) 141 ft-lbs (200 Nm)

Figure 8-1 6 Bolt and 4 Bolt Torque Sequence

12

3

4

5

6

12

4

3

MNL-0237


8.1.2 Approved Lubricants ChartUnless otherwise specified in text, use the lubricants in Table- 8-2.

8.1.3 Glossary of Abbreviations and AcronymsACD automatic condensate drainASME American Society of Mechanical EngineersCW clockwiseCCW counterclockwiseCGA Compressed Gas AssociationDIN Deutsches Institut für NormungE1 single phase electrical supplyE3 three phase electrical supplyNEC National Electrical CodeNEMA National Electrical Manufacturers AssociationNFPA National Fire Protection AssociationNHA Next Higher AssemblyOSHA Occupational Safety & Health AdministrationODP open drip-proof (motor)DOT Department of TransportationPara. ParagraphPMV pressure maintaining valve

Table 8-2: Lubricant Chart

Usage Lubricants

O-rings, rubber and plastic parts; filter housing threads, sealing rings Parker Super “O” Lube

Bolts, nuts, studs, valve parts, Copper gaskets and tube connection parts (threads, cap nut and compression rings)

Never-Seez® NSWT, Pipe Dope or teflon tape

Paper gaskets DOW Corning 732 or equivalent silicone com-pound applied on both sides before assembly,

High temperature connections DOW Corning 732 or equivalent temperature resistant compound,

Tube connection ferrules, Never-Seez® NSWT

C-D/DV/Navy


8.2 Safety Precautions

8.2.1 General• Read the operating manual before installing or operating this compressor unit. Follow appropriate

handling, operation and maintenance procedures from the very beginning. The maintenance plan contains measures required to keep this compressor unit in good condition. Maintenance is simple, but must be executed regularly to achieve safe operation, maximum efficiency and long service life.

• We recommend that all maintenance work be recorded in a service book, showing the date and details of the work carried out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to make a claim against the warranty, it will help to have proof that regular maintenance has been carried out and that the damage has not been caused by insufficient mainte-nance.

• This compressor unit must be installed, operated, maintained and repaired only by authorized, trained and qualified personnel.

• Consult and follow all OSHA, NEMA, ASME and local regulations, laws and codes covering the installation and operation of this compressor and accessories before operating the unit.

• Do not operate this unit in excess of its rated capacity, speed, pressure, temperature, or otherwise than in accordance with the instructions contained in this manual. Operation of this unit in excess of the conditions set forth in this manual will subject the unit to limits which it may not be designed to with-stand.

• Keep safety guards in place.

• Do not modify the compressor or its systems.

• Do not wear loose clothing around machinery. Loose clothing, neckties, rings, wrists watches, brace-lets, hand rags, etc. are potential hazards.

• Provide adequate fire protection. Make sure fire extinguishers are accessible. Select alternate routes of escape and post such routes.

• Make sure you are equipped with all required safety equipment; hearing protection, safety glasses, hard hats, safety shoes and fire extinguisher.

• Visually inspect the unit before starting. Remove and/or replace any loose or broken components, tools, valves, missing equipment, etc.

• Do not tamper with, modify, or bypass safety and shutdown equipment.

• Do not tighten or adjust fitting or connections under pressure.

• The use of plastic pipe or rubber hose in place of steel tube or iron pipe, soldered joints or failure to ensure system compatibility of flex joints and flexible hose can result in mechanical failure, property damage, and serious injury or death.

• The use of plastic or nonmetallic bowls on line filters without metal guards can be dangerous.

• Replace damaged fan blades promptly. Fan assemblies must remain in proper balance. An unbalanced fan can fly apart and create an extremely dangerous condition.

MNL-0237


• Allow the compressor to cool before servicing. Whenever the compressor is shut down and over-heating is suspected, a minimum period of 15 minutes must elapse before opening the crankcase. Premature opening of the crankcase of an overheated unit can result in an explosion.

• Incorrect placement of the inlet and discharge valves in a compressor cylinder head can cause an extremely dangerous condition. Refer to the appropriate section of this instruction manual before installing or replacing valves.

• Before doing any work involving maintenance or adjustment, be sure the electrical supply has been disconnected, and the complete compressor system has been vented of all internal pressure. Failure to follow these warnings may result in an accident causing personal injury and/or property damage.

• Before working on the electrical system, be sure to disconnect the electrical supply from the system at the circuit breaker or other manual disconnect. Do not rely on the ON/OFF switch to disconnect the electrical supply.

• Installer must provide an earth ground and maintain proper clearance for all electrical components.

• All electrical installation must be in accordance with recognized national, state, and local electrical codes.

• A compressor which has been used for gas service is unsuitable for air applications. Should the purchaser and/or user proceed to use the compressor for air service after it has been used for gas, the purchaser and/or user assumes all liability resulting therefrom without any responsibility being assumed by Bauer Compressors, Inc. The purchaser is urged to include the above provision in any agreement for resale of this compressor.

• The use of repair parts other than those included in the Replacement Parts List may create unsafe conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Bauer Compressors, Inc. can bear no responsibility for equipment in which non-approved repair parts are installed

C-D/DV/Navy


8.2.2 Safety Warning LabelsNotes, labels and warning signs are displayed on the compressor unit according to model, application or equipment and may include any of the following.

8.3 Long Term Storage and Preservation

8.3.1 GeneralIf the compressor unit will be out of service for more than six months, it should be preserved in accor-dance with the following instructions:

5. Make sure that the compressor is kept indoors in a dry, dust-free room.

6. Cover the compressor with plastic sheets only if no condensation will form under the sheet.

7. Remove the sheet from time to time and clean the outside of the unit.

8. If this procedure cannot be followed, or if the compressor will be out of service for more than 24 months, please contact the Bauer Service Department for special instructions.

8.3.2 PreparationsPrior to preserving the compressor unit, it must be run until warm, i.e., up to the specified service pres-sure. Operate the unit for approximately 10 minutes, then carry out the following checks.

1. Check all pipes, filters and valves (including safety valves) for leakage.

2. Tighten all couplings, as required.

HOT SURFACES DO NOT TOUCH!Danger of burning if cylinders, cylinder heads, or pressure lines of individual

compressor stages are touched.

HIGH VOLTAGE!Life threatening danger of electrical shock. Maintenance work on electric units or operating equipment should be carried out by a qualified electrician or by a person supervised by a qualified electrician according to electrical regulations.

AUTOMATIC COMPRESSOR CONTROLUNIT MAY START WITHOUT WARNING!

Before carrying out maintenance and repair work, switch off at the main switch and ensure the unit will not restart.

THE INSTRUCTIONS MUST BE READ BEFORE OPERATING UNIT!The instruction manual and all other applicable instructions, regulations, etc.

must be read and understood by the operating personnel before using the machine.

HEARING PROTECTION MUST BE WORN!Hearing protectors must be worn when working on a machine which is running.

DIRECTION OF ROTATION!When switching on the machine, check the arrow to ensure correct direction of

rotation by the drive motor.

MNL-0237


3. After 10 minutes, open the outlet valve and operate the compressor at adjusted minimum pressure using the pressure maintaining valve for approximately 5 minutes.

4. After the 5 minutes, shut the compressor unit down and completely drain all separators and filters. Close all valves.

5. Remove filter heads and lubricate the threads with white petroleum jelly.

8.3.2.1 Units Equipped with a Filter System

1. Ensure that filter elements remain in the filters! This will prevent oil from entering the outlet lines as a result of preservation procedures.

2. Remove the intake filter/intake pipe completely.

8.3.3 Preserving the Compressor

1. Operate the compressor again and slowly spray approximately 0.35 oz. (10 cc) of oil into the inlet port while the compressor is running. Keep the shut-off valve open and the condensate drain valves closed.

2. After spraying the oil into the inlet port, run the compressor unit for an additional 5 minutes before shutting the compressor unit down.

3. Close the shut-off valve.

4. Close the inlet port with a dust cap and/or tape.

8.3.4 Preventive Maintenance During StorageOperate the compressor once every six months as follows:

1. Remove the dust cap from the inlet port and install the inlet filter.

2. Open the outlet valve and allow the system to run approximately 5 minutes until there is outflow from the valve and oil is visible in the sight glass of the oil regulating valve.

3. Shut down the compressor.

4. Open the condensate drain valves, depressurize the unit, then close the drain valves again.

5. Remove the intake filter and replace the dust cap on the inlet port.

8.3.5 Lubrication Oils for Preservation

1. After prolonged storage periods, the oil will age in the compressor crankcase. The oil must be drained at least every 24 months and replaced with fresh oil.

2. The stated period can only be attained when the crankcase is sealed during the preservation period in accordance with the preservation requirements.

3. After changing the oil, the compressor must be operated according to the instructions above.

4. Check the lubrication of the compressor during the every-six-month brief operation or when turning the compressor.

C-D/DV/Navy


5. The oil pump is functioning properly when oil can be seen flowing through the sight glass of the oil pressure regulator or if the oil pressure gauge indicates the prescribed pressure.

8.3.6 Reactivating the Compressor Unit

1. Remove the dust cap from the inlet port and install the intake filter.

2. Check the oil level of the compressor. If necessary, change the oil.

3. The motor must be thoroughly dry before applying power.

4. For units with a filter system, change all filter cartridges.

5. Run the compressor with open outlet valve for approximately 10 minutes. Check for proper opera-tion of the lubricating system.

6. After 10 minutes, close the shut-off valve and run the system up to final pressure until the final pressure safety valve vents. On compressor units with a compressor control system, raise the pres-sure switch setting the switch above normal limits to override the pressure switch. Be sure to reset the switch after checking.

7. Check the interstage safety valves for leakage.

8. Establish the cause of any faults and remedy.

9. Stop the unit when it is running properly. The compressor is then ready for operation.

8.4 Installation

8.4.1 Unpacking and HandlingThis compressor unit is packaged according to the requirements for shipping via the requested type of carrier service. It is possible that the compressor unit could have been damaged during shipping. For this reason, we urge you to thoroughly examine the unit for possible damage and report any such damage to the shipping company immediately.

Care must be taken in unpacking the compressor unit. Serious damage could result by not checking for clearance between the item to be unpacked and the packaging to be removed.

This compressor unit may be furnished with one or more shipping braces for shipping and handling only. After installation and before operation, these braces must be removed entirely. Under no circumstances should the braces remain installed during operation or the manufacturer’s warranty for the compressor unit will be voided. The braces are all tagged and labelled.

The floor at the site must be capable of supporting the weight of the unit. Position the unit so that it is level. Permissible inclination of the compressor unit is 10° forward or backward, 10° right or left.

^ CAUTION

These values are valid only if the oil level of the compressor in normal position is level with but does not exceed the upper mark of the oil dipstick or oil level sight glass.

MNL-0237


8.4.2 VentilationDuring normal compression, heat is generated by the compressor and by the drive motor or engine. For air-cooled compressor units, this heat needs to be vented away by sufficient ventilation.

8.4.2.1 Outdoor InstallationIt is recommended that all gasoline and diesel engine driven compressor units be installed outdoors. Additionally, electrically driven compressor units may be installed outdoors only if enclosed with weath-erproof enclosure panels.

8.4.2.2 Indoor InstallationThe best location to install the compressor unit indoors is against an outside wall with a suitably large air vent in front of the cooling fan. Additionally, it is necessary to position an exhaust opening in the oppo-site wall, close to the ceiling or in the ceiling.

As a basic rule of thumb, the room should be ventilated sufficiently so as to prevent the ambient room temperature from exceeding 105° F. Additional heat generating equipment or piping should be avoided or must be well insulated.

8.4.2.3 Natural VentilationNatural ventilation should only be used up to a maximum drive power of 20 hp. To determine the size of the required intake and exhaust openings, consider the following table:

Drive hp

Intake and Exhaust Openings Dependent on Room Volume (V) and Height (h)

V = 1750 ft³ h = 6.5 ft V = 3500 ft³ h = 10 ft V = 7000 ft³ h = 13 ft

Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²)

3 1.3 1.1 --- --- --- ---

5 3.2 2.7 1.3 1.1 --- ---

7.5 4.5 3.8 2.6 2.2 1.3 1.1

10 9.7 8.1 6.5 5.4 2.6 2.2

15 14.5 12.4 9.7 8.1 5.8 4.8

20 20.6 17.2 15.6 12.9 9.7 8.1

C-D/DV/Navy


8.5 Reproducible Maintenance Record Forms

8.5.1 Scheduled Maintenance Form

Daily Para. Date Signature

MNL-0237


Weekly or as required. Para. Date Signature

500 Operating Hours. Para. Date Signature

1,000 Operating Hours. Para. Date Signature


C-D/DV/Navy



Annually. Para. Date Signature

Annually, or as required. Para. Date Signature

Biennially. (Every two years) Para. Date Signature

MNL-0237


8.5.2 Record of Operating Hours

Date Minutes Total Date Minutes Total

Subtotal: Subtotal:

C-D/DV/Navy


8.6 Additional Data• Any included drawings, wiring diagrams, pneumatic flow diagrams, etc., will be bound in this manual

next to the back cover.

• OEM Manuals and other Bauer manuals may be included in the documentation shipping package.

8.7 Drive Motor SupplementBauer Part Number ENG-0045 is a 6 hp diesel engine manufactured by Yanmar Diesel Engine Company. The Yanmar model number is L60AED.