YP135DF
Yacht ProTM 135 Automatic Compressor
Operator’s Manual
BROWNIE’S THIRD LUNG
940 NW First Street
Fort Lauderdale, FL 33311
Ph 954-462-5570
Fx 954-462-6115
www.tankfill.com / info@tankfill.com
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This information is believed to be accurate by Brownie’s Third Lung as of it’s date of publication, but Brownie’s
offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set forth herein.
Brownie’s 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 Brownie’s products, and is thus subject to Brownie’s standard
terms and conditions of sale. Brownie’s reserves the right to change this information and has no obligation to
update these materials. This information is Copyright © 2007 by Brownie’s Third Lung, and Brownie’s reserves
to itself all rights to this publication. Brownie’s customers have no right to reproduce, rewrite, modify, license or
permit anyone else’s use of this information, without the express written permission of Brownie’s Third Lung.
Edition 1.0 04/2007
Thank You for purchasing a Brownie’s Yacht ProTM Series Compressor System. This manual explains
the use and maintenance of your unit. All information here is based on the latest product data available
at the time of publication. Brownie’s Third Lung reserves the right to make unannounced changes at
any time without incurring any obligations whatsoever.
This Operator’s Manual is to be considered a part of the overall compressor package and should
remain with the compressor in the event of sale to another party.
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Table of Contents
CHAPTER 1: INTRODUCTION 5
1.1 How to Use this Manual 5
1.2 Manual Safety Notices 5
1.3 General Safety Precautions 6
1.4 Description of Unit 7
1.5 Standard Features 7
1.6 Compressor Quality Analysis Record 8
1.7 Product Data 9
1.8 Installation 10
CHAPTER: 2 OPERATIONS 11
2.1 Pre Start-up Checks 11
2.1.1 Check oil level 11
2.1.2 Check Visual Carbon Monoxide / Moisture Indicator 11
2.1.3 Check Air Intake 11
2.1.4 Pre-startup Maintenance/Inspection Notations 11
2.1.5 Tank Inspection 11
2.2 Tankfill Procedures 12
2.3 Lubrication Specifications 14
CHAPTER 3: MAINTENANCE AND PARTS 15
3.1 Recommended Maintenance 15
3.2 Compressor Block 16
3.3 Intake Filter 17
3.4 Oil Level Check 17
3.5 Oil Types 17
3.6 Oil Change Procedure 18
3.6.1 Oil Filter Replacement Procedure 18
3.6.2 Changing Oil Type 18
3.7 Check Drive Belt/Replace Belt 19
3.8 Intermediate Separators 20
3.9 Cooling System 22
3.9.1 Maintenance 22
3.9.2 Compressor Valves and Heads 22
3.9.3 Functional Description 22
3.10 Torque Valves and Sequencing 23
3.11 Valves 24
3.11.1 Valve Functioning 24
3.11.2 Initial Operational Check 24
3.11.3 Valve Change General Instructions 24
3.11.4 Changing 1st Stage Valves 24
3.11.4.1 Removal 24
3.11.4.2 Reassembly 25
3.11.5 Changing the 2nd Stage Valves 26
3.11.6 Changing the 3rd Stage Valves 27
3.11.6.1 Removal 27
3.11.6.2 Reassembly 28
3.11.7 Changing the 4th Stage Valves 29
3.11.7.1 Removal 29
3.11.7.2 Reassembly 30
* Any applicable addendums will be inserted just before the last page before the Warranty Information.
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3.12 Exploded View Diagrams
3.12.1 Crankcase Assembly 32
3.12.2 1st/2nd Stage Piston and Cylinder 34
3.12.3 3rd Stage Piston and Cylinder 35
3.12.4 4th Stage Piston and Cylinder 36
3.12.5 1st Stage Valve Head and Valve 37
3.12.6 2nd Stage Valves and Valve Head 38
3.12.7 3rd Stage Valves and Valve Head 39
3.12.8 4th Stage Valve and Valve Head 40
3.12.9 Intermediate Separator 41
3.12.10 3rd Stage Intermediate Separator 42
3.12.11 Intake Filter 43
3.12.12 Cooling System 44
3.12.13 Lubrication System 46
3.13 Sightglass CO/Moisture Element Replacement Procedure 48
3.14 Compressor Components 50
3.14.1 Compressor Details 51
3.14.2 Mechanical Separator 52
3.14.2.1 Chamber 52
3.14.2.2 Cartridge Construction 52
3.14.2.3 Cartridge Handling 52
3.15 Electrical Panel 53
CHAPTER 4: TROUBLESHOOTING 54
CHAPTER 5: OPERATION LOG 56
5.1 Yacht ProTM System Operation Log 56
5.2 Notes 62
CHAPTER 6: WARRANTY 63
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DANGER
CAUTION
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
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 indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices.
NOTE
NOTE advise of technical requirements that require particular attention by the operator or the maintenance
technician for proper maintenance and utilization of the equipment.
WARNING
This Instruction Manual and Replacement Parts List contains safety information and instructions for the
YachtProTM 135 Compressor. You must read, understand and follow all safety precautions and instructions. Not
doing so may result in damage to the system and/or personal injury or death.
CHAPTER 1: INTRODUCTION
1.1 HOW TO USE THIS MANUAL
This manual contains the operating and maintenance instructions for the Brownie’s Third Lung product(s) listed on
the front cover. In order to familiarize yourself with the compressor features, please read this manual thoroughly
before using the equipment.
All instructions in this manual should be observed and carried out as written to prevent damage or premature
wear to the product or the equipment served by it.
If your unit is equipped with nonstandard accessories and/or options, supplemental information is normally
included in other documentation; i.e. OEM Manuals or additional Brownie’s Third Lung Manuals.
While every effort is made to ensure the accuracy of the information contained in this manual, Brownie’s Third
Lung will not, under any circumstances be held accountable for any inaccuracies or the consequences thereof.
1.2 MANUAL SAFETY NOTICES
Important 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.
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1.3 GENERAL SAFETY PRECAUTIONS
Read the operating manual before installing or operating this compressor unit. Follow appropriate handling,
operation and maintenance procedures from the very beginning. The maintenance schedule contains mea-
sures 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 neces-
sary 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.
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 then installation
and operation of this compressor and accessories before operating the unit.
Do not operate this unit in excess of it’s rated capacity, speed, pressure, temperature, or otherwise than in ac-
cordance 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 withstand.
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, bracelets, hand
rags, etc. are potential hazards.
Provide adequate fire protection. Make sure fire extinguishers are accessible. Select alternate routes of es-
cape 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 operate the compressor if the compressor is damaged.
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 insure
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.
Allow the compressor to cool before servicing. Whenever the compressor is shut down and overheating 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 pressure valves in a compressor cylinder head can cause an extremely
dangerous condition. Refer to the appropriate section of this manual before installing or replacing valves.
Before doing any work involving maintenance or adjustment, be sure the electrical supply has been discon-
nected, 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.
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1.4 DESCRIPTION OF THE UNIT
Your Yacht ProTM Series is a fully automatic compressor, equipped with Automatic Condensate Drain (ACD). The
YP series has been designed specifically with the traveling yacht owner in mind. The compressor system is de-
signed for “HANDS FREE” operation.
1.5 STANDARD FEATURES
The complete Yacht ProTM Series package includes:
• One 316L Stainless Steel Base
• One High Pressure Compressor with a 10 HP Motor
One Digital Frequency Drive (see manufacturer’s owner’s manual)
• One Automatic Condensate Drains
• Two Condensate Collection Jugs
• Securus® Filtration System (see manufacturer’s owner’s manual)
One Dual Pressure Switch
• One Sightglass Element (moisture and CO monitor)
• Tool Kit
• One gallon, Synthetic Compressor Oil (Part Number CF-2000)
One Operator’s Manual
• One Four-way Manifold with 10-foot connection hose including stainless steel quick disconnect end
• One padded Custom Manifold Bag
Optional Equipment:
• Stainless Steel Quick Disconnect Set
• Custom Hose Lengths
• Remote Fill Plumbing Kit
• Cordura Nylon Cover
• Remote On/Off Switch (with installation only)
Use of Compressor:
The Yacht ProTM Series is intended for the compression of air and other gas mixtures. Make sure the air entering
the compressor is clean atmospheric air.
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Before working on the electrical system, be sure to disconnect the electrical supply from the system at the cir-
cuit 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.
Do not use gasoline, diesel fuel or other flammable products as a cleaning solution.
Do not operate the compressor near flammable substances or objects
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/user
assumes all liability resulting therefrom without any responsibility being assumed by Brownie’s Tankfill.
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 listed in this manual or purchased from Brownie’s Tankfill, Inc. may
create unsafe conditions over which Brownie’s has no control. Such unsafe conditions can lead to acci-
dents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment.
Therefore, Brownie’s Tankfill can bear no responsibility for equipment in which non-approved repair parts are
installed.
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Date:
Serial # Model # Order#
Motor Wiring V PH HZ
Belt Size Tension
Connections Tight Nuts & Bolts Tight
No Leaks Control Wiring Correct
Final Pressure Setting Tank Fill Time
Drain System Operation Interval
Oil Level Oil Removed
Hour Meter Reading Test Run Time
STANDARD EQUIPMENT
Securus® Filtration Frequency Drive
Manual Lubricant
4TKMAN Sightglass Elements
Block #
OPTIONAL EQUIPMENT & MISC
Remote Fill Panel
FC374-04RL (Additional for 4TKMAN Main) FT
Technician Installer
1.6 COMPRESSOR QUALITY ANALYSIS RECORD
(80 ft³ 500-3000 PSI)
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1.7 PRODUCT DATA
Category Specifications
COMPRESSOR DATA
Air Delivery Rate: 10.8 scfm2 FAD/ 142 LPM
* Operating Pressure (max): 6000 PSI
** Pressure setting, final: 3200 PSI pressure safety valve (STD)
Dimensions: 27.5”H x 36”L x 21”D (699mm x 914mm x 533mm)
Weight: 350 lbs. Approx (158.8 kg)
Use: Compression of atmospheric air
Intake Pressure: Atmospheric Pressure
Compressor RPM: 3600
Drive Belt Type: AP73
Number of Stages: 4
Number of Cylinders: 3
Cylinder Bore 1st Stage: 4.2 in (105 mm)
Cylinder Bore 2nd Stage: 4.15/3.46 in (105/88 mm)
Cylinder Bore 3rd Stage: 1.10 in (28 mm)
Cylinder Bore 4th Stage: 0.47 in (12 mm)
Piston Stroke: 1.57 in (40 mm)
Intermediate Pressure 1st Stage: 49.3-60.9 psig (3.4-4.2 bar)
Intermediate Pressure 2nd Stage: 203-261 psig (14-18 bar)
Compressor Block Oil Cap.: 3 qts / 2.8 liters
Recommended Oil Types: CF-2000 Synthetic Compressor Lubricant
Max. ambient temperature: +32º to +100º F (+0º to +37.8º C)
Recommended Operating Temp: 70º F (21.1ºC)
Max. permissible inclination: 15º in all directions
Duty Cycle at max pressure: Continuous
Vibration Mounts: Vulcanized neoprene over steel
Capacity Range: 190-380 lbs. (86-172kg) each
BTU’s: 27,880
MOTOR DATA
Motor: 10hp TEFC / 3-ph / 60 hz
Frame: 215T
Shaft Diameter: 1-3/8” (34.9mm)
Duty Cycle: Continuous
Motor RPM: 1760
Voltage: 208-230 or 380-460
F.L.A.: 24 / 12.6
BTU’s: 25,483
Rotation reconn.
Mounting rigid
Ball Bearing
* Unit has a max pressure rating of 6000 psi (3200 psi by default)
** May be set higher or lower based on Pressure Switch settings
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1.8 INSTALLATION
All persons operating the Yacht ProTM Series system must read this manual completely and fully understand the
procedures for system operation and the responsibilities of the operator to insure the safety of divers supplied
with air from the system. We recommend professional installation by our experienced installation technicians. The
Yacht ProTM Series must not be operated in an enclosure that does not meet the installation/operation guidelines
for the unit. Contact our Technical Department for advice.
The Yacht Pro™ series tank fill compressor must be installed in accordance with the following recommendations:
1. Ambient temperature during operation must not exceed 100 deg F (38 deg C) maximum. The unit will produce
heat when operating, therefore adequate ventilation must be provided to stay well within the maximum limit
listed above.
We recommend operating unit well below the maximum limit. Forced Ventilation must be used where poor air
circulation is present. Contact our Technical Department with questions regarding proper ventilation.
2. Proper clearances must be allowed for the following:
6” minimum from the fan cover to any bulkhead. This provides adequate air supply for the cooling fan.
8” minimum above the filter tower. This allows easy filter removal/replacement and easy access to remove
the oil dipstick for checking/changing oil.
Allow working access to the electrical box for service/repair.
The oil drain tube must have clearance for oil changes.
The condensate drain reservoir must be accessible for removal.
Hour meter, on/off switch, and visual monitor must be accessible for safe operation.
Belt Guard must be accessible for service of drive belt.
3. The unit must be installed on a flat, level surface. No more than 10 deg inclination must occur during operation.
4. The Yacht ProTM Series units are provided as a complete assembly ready for installation. Some installations
may require remote mounting of package components. This must be approved by our Technical Department.
5. Clean, fresh air must be provided to the air intake of the compressor as close to the operating ambient
temperature of the unit as possible. Remote air intake plumbing may be required. A non-collapsible plastic
hose with 3/4” ID is the simplest method. The 3/4” ID may be run for a length of 10’. Longer runs may be used
by following this guideline: For every 10’ of run the preceding 10’ diameter must be doubled. All 90 deg fittings
should be considered as 1 foot of length.
6. The unit must be protected from any type of water exposure. Such exposure will seriously effect the longevity
of the unit and may result in personal injury or death.
7. Electrical Requirements:
Yacht ProTM series compressors come standard with 220 VAC 60 HZ single phase electric motors. They are
equipped with 120 VAC 60HZ controls and components. All units require correct electrical supply components
be provided in accordance with local, state and federal codes for land installation and marine codes for on-board
installation. An electrician should be consulted for supply power recommendations. Standard units require that
a neutral wire be provided with the standard power supply, for correct operation. An optional remote transformer
can be used to provide control voltage if neutral is not available. Some voltage and cycle combinations will require
an optional transformer for correct operation.Yacht ProTM Series are available for other electrical requirements.
Please contact our Technical Department for specifications.
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WARNING
Improper installation may result in damage to the unit, personal injury or death.
NOTE
The intake must be protected from water entry, as this will cause severe damage to the unit.
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2.1 PRE START-UP CHECKS
Consult the system log to see if the following maintenance needs to be done:
Purification Cartridge inspection/replacement (see supplemental manuals).
Sightglass Element replacement (6 month installed life) (see page 48)
Oil Check/Change (see pages 17-18)
2.1.1 Check oil level
The oil level must be between the upper and lower marks on the dipstick (see page 17). If the oil is low, add oil
through the dipstick tube. Use only Brownie’s recommended oil. Do not mix oils or use non-recommended oils
which may adversely affect the life of the unit or even destroy the unit.
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2.1.2 Check Visual Carbon Monoxide / Moisture Indicator
The visual indicator has two elements. An outer blue ring for indicating the presence of moisture, and a central tan
to orange disc, indicating the presence of carbon monoxide. Any change in color, (the central disc (CO) turns dark
brown or has black spots, and/or the outer ring (moisture) turns pink or beige, indicates that the air leaving the
purification system is contaminated and not breathable. The visual monitor is the last monitor of the air leaving the
purification system, and must be checked during operation for any changes.
Good Conditions: Inner Ring - Yellow
Outer Ring - Blue
DANGEROUS
DO NOT USE AIR
CHANGE CARTRIDGE
SATURATED
GOOD
GOOD
WARNING
Divers lives depend upon proper operation of the system. Brownie’s Third Lung highly recommends that all
system operators take a System Training Course.
WARNING
Any color change in the elements of the visual indicator means that contaminated air has passed downstream.
All air lines, fill assemblies, and equipment must be cleaned or replaced. An Air Quality Test must be done to
insure thoroughness of all cleaning. Breathing contaminated air may result in personal injury or death.
WARNING
Failure to monitor or replace the purification cartridge WILL contaminate all air lines, fill assemblies, divers air
tanks, regulators, and may cause severe injury or even diver death. The system operator is responsible for the
lives and safety of the divers using air produced by the system.
CHAPTER 2: OPERATIONS
2.1.3 Check Air Intake
Remove and inspect the Air Intake Filter. If the system is equipped with a remote air intake, be sure it is properly
located, and clear of any water or obstructions.
2.1.4 Pre-startup Maintenance/Inspection Notations
Add all pre-startup maintenance/inspection notations to the system log with date, hours, and operator name.
2.1.5 Inspect ALL tanks to be filled:
• Make sure the tanks are in good condition with no deep scratches, gouges, or pitting.
• The tanks must be within current hydrostatic test and Visual Inspection dates.
• Do not fill empty tanks without first visually inspecting them for water intrusion.
• Make sure that the valves are in good condition and not in need of service. Do not fill tanks with damaged
valves.
• Do not fill tanks that have been exposed to extreme heat, i.e.: tanks that have been in or near fires.
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2.2 TANKFILL PROCEDURES
WARNING
Tanks must be secured (protected from falling or being
knocked over) during filling.
Tank Fill Whip Assemblies:
Shown are the tankfill whip ends for DIN and Yoke systems.
A. Yoke connector
B. DIN connector
C. bleeder valve
D. fill valve
B
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D
A
DC
1. Hook up fill manifold to compressor air outlet or remote fill
panel.
2. Open tank valve slightly to blow any moisture or particles clear
of connection surfaces.
3. Standard Yoke - Hook fill yokes to the tank valves and tighten
yoke hand wheel “finger tight” (Figure 1).
a. Close bleed screws (Figure 2)
b. Open tank valves counter-clockwise (Figure 3)
c. Open Fill Valves (Figure 4)
Counter-clockwise rotation of this valve will open the line
to the tanks. The tanks will now equalize any differences in
their pressures.
Din Yoke - Screw the male din yokes into the valves until the
“o-ring” is snugly in place against the base of the female din
valves.
a. Close bleed screws (Figure 2)
b. Open tank valves counter-clockwise (Figure 3)
c. Open Fill Valves (Figure 4)
Counter-clockwise rotation of this valve will open the line
to the tanks. The tanks will now equalize any differences in
their pressures.
4. Start the Compressor
The compressor will now operate automatically, draining
the condensate and shutting off when the tanks are full. The
operator need only check the operation from time to time during
the filling process to verify the following:
• Condensate is accumulating in the reservoir.
• No color change has occurred in the visual indicator.
• Pressure is building on the fill gauge.
Figure 1
Figure 2
Figure 3
Figure 4
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WARNING
Do not try to remove the quick disconnect while the system is pressurized. Doing so may result in property
damage or personal injury.
Fill times are based on filling a single standard 80 cu. ft aluminum
cylinder from 500 psi to 3000 psi and are approximately 5 minutes
per tank. Cylinder volume, starting tank pressure, and tank pressure
ratings will vary the fill times.
Note that the indicator light is still on after the compressor automati-
cally stops. This indicates that the compressor is in an AUTOMATIC
START MODE and will restart if the stop pressure drops approxi-
mately 500 psi.
If you intend to fill more tanks you may leave the on/off switch in the
“on” position while changing the tanks out. Simply opening the tank
and fill yoke valves will restart the compressor.
5. Remove full tanks by first closing the fill yokes and tank valves
(Figure 5). Depressurize the yokes by opening the bleed screws
(Figure 6). Remove the fill yokes from the tanks (Figure 7).
6. When you are done filling for the day, turn the on/off switch to the
off position. Empty the condensate reservoir.
7. Bleed the pressure from the fill manifold by opening one of the
fill yoke valves slowly until all pressure is vented and the gauge
reads zero.
8. Remove the manifold from the hose using the quick disconnect
fitting and store the manifold in its bag.
9. Allow the compressor to cool prior to installing the optional Cor-
dura fabric cover.
10. Update the system log, noting running hours of compressor and
any maintenance performed.
Figure 5
Figure 6
Figure 7
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2.3 LUBRICATION SPECIFICATIONS
Use Lubricant
O-rings, rubber and plastic parts, White Petroleum DAB9 # N19091 or WEICON WP 300
filter housing threads White part # N19752
Sealing Rings Universal grease
Paper Gaskets Apply silicone compound on both sides (WACKER
silicone compound part # N 18247) before assembly
Bolts, nuts, studs, valve parts, CU gaskets and pipe Compounds with Copper or MoS² additives (WEICON
connectors (threads, cap nuts, compression rings) ANTI-SEIZE AS 040 P part # N 19753)
High Temperature connections Temperature resistant compound (WACKER
(valve heads / cylinders) silicone compound, part # N 18247
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CHAPTER 3: MAINTENANCE AND PARTS
3.1 RECOMMENDED MAINTENANCE
WARNING
We recommend that any maintenance other than preventative be performed by an authorized service center
or technician. Contact Brownie’s for service center information.
INTERVAL TYPE OF MAINTENANCE DATE SERVICE CENTER
After 25 hrs initially,
and every 50 - 100 hrs
thereafter
Oil Change (every 50 hours when using regular
oil, and every 100 hours if using synthetics) or six
months
After 25 hrs initially,
and every 150 hours
thereafter
Check function and tightness of filling valve
Clean and change intake filter
Check tightness of o-rings
Check drive belt and condition
Check cooler brackets
Check zero on gauge when depressurized
After 1st year or 300
hours of operation
Air and tightness check
Replace filter chamber o-rings
Drive belt inspection (replace after 300 hrs)
Cleaning of air intake filter and filter unit.
After 2nd year or 600
hours of operation
Check air tightness and performance
Drive belt inspection (replace after 600 hrs)
Replace filter chamber o-rings
Cleaning of air intake filter and filter unit.
After 3rd year or 900
hours of operation
Check air tightness and performance
Drive belt inspection (replace after 900 hrs)
Replace filter chamber o-rings
Cleaning of air intake filter and filter unit.
After 4th year or 1200
hours of operation
Check air tightness and performance
Drive belt inspection (replace after 1200 hrs)
Replace filter chamber o-rings
Replacement of air vent hos
Replace cylinder head o-rings.
Clean air intake filter & unit.
After 5th year or 1500
hours of operation
Check air tightness and performance
Drive belt inspection (replace after 1500 hrs)
Replace filter chamber O-rings
Cleaning of air intake filter and filter unit.
After 6th year or 1800
hours, of operation
Check air tightness and performance
Drive belt inspection (replace after 1800 hrs)
Replace filter chamber o-rings
Cleaning of air intake filter and filter unit.
After 7th year or 2100
hours of operation
Check air tightness and performance
Drive belt inspection (replace after 2100 hrs)
Replace filter chamber o-rings
Cleaning of air intake filter and filter unit.
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3.2 COMPRESSOR BLOCK
The compressor block is used to compress air up to 6000 psi. This compressor is a four stage, three cylinder air
cooled, oil lubricated reciprocating compressor. The cylinders are arranged in a “W” configuration, the 1st/2nd
stage vertical stepped cylinder is in the center, 3rd stage on the right and 4th stage on the left looking from the
intake filter side. These compressor blocks are particularly suitable for continuous operation because of their rug-
ged design and corrosion resistant intermediate filter and cooler assemblies.
Compressor Block, Front View
1. Intake Filter
2. 1st Stage Safety Valve
3. 2nd Stage Intake Manifold
4. Oil Filler Neck
5. 4th Stage Cylinder
6. 3rd Stage Safety Valve
7. 3rd Stage Separator
8. 3rd Stage Intercooler
9. Oil Drain Plug
10. Condensate Drain Connector
11. 1st Stage Valve Head
12. 2nd Stage Pressure Manifold
13. 3rd Stage Cylinder
14. 2nd Stage Safety Valve
15. Oil Filter Housing
16. 2nd Stage Separator
17. 2nd Stage Intercooler
18. Compressed Air Outlet
19. 4th Stage Aftercooler
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3.4 OIL LEVEL CHECK
Check the oil level at the sight glass on the side of
the compressor block everyday before operating the
compressor. Note that the oil level must be between the
minimum and maximum notch.
Add oil if necessary and recheck level. Oil should not
exceed the maximum level, as this could result in carbon
build up on the valves
3.5 OIL TYPES
Using the correct oil is of utmost importance for proper
care and maintenance of the compressor, along with
keeping the life and function of your compressor at its
best.
Only use oils that:
• are low in deposits
• have no carbonizing effect, especially in the
valves
• have good anti-corrosive properties
• provide emulsification of the condensate in the
crankcase
• are physiologically and toxicologically suitable
Due to the thermal load on the compressor, only high
quality oil should be used.
For operating under severe conditions such
as continuous running and/or higher ambient
temperatures, we recommend Part No. CF-2000
(Synthetic Compressor Lubricant, Food Grade).
CF-2000 has been specially formulated for use in
high pressure compressors and will provide optimal
performance through a wide range of conditions.
Compressor systems are delivered with one gallon of
synthetic oil, Part No. CF-2000.
3.3 INTAKE FILTER
A dry, micronic filter is used to filter the intake air,
see image to the right. The filter cartridge must be
changed at regular intervals. See the Maintenance
Schedule for the recommended interval.
1. Unscrew and remove Knurled Nut (1)
2. Remove Washer (2) and Filter Housing (3).
3. Discard Filter Element (4) and replace with new
Filter Element Bauer.
4. Reassemble in reverse order.
Intake Filter
1. Knurled Nut
2. Washer
3. Filter Housing
4. Filter Element
1
2
3
4
maximum
minimum
Figure 1
18
3.6.1 OIL FILTER REPLACEMENT PROCEDURE
1. Remove the two bolts (Figure 5-1) using a 13mm wrench
2. Remove the oil cover(Figure 5-2)
3. Remove the oil filter from the rubber gasket at the cover (Figure 6)
4. Mount a new filter element (P/N N25326)
5. Replace and fasten oil cover
6. Slowly pour new oil* through the oil filler neck (Figure 2) until the
level reaches the maximum mark on the sight glass
7. Wait a few minutes and adjust the oil level if necessary before putting
the unit into operation
3.6.2 CHANGING OIL TYPE
1. Changing from synthetic type oil to petroleum type oil requires no
special procedures
2. Changing from petroleum type oil to synthetic type oil requires the
following steps to avoid severe damage to the compressor unit:
a. Drain petroleum based oil completely while it is warm
b. Replace or clean all deposits from valves, coolers, separators,
purifiers, tubes and hoses
c. Fill with 12 fluid ounces (360 mL) of synthetic oil
d. After 100 operating hours check oil for degree of contamination
and change oil again if necessary
e. On subsequent oil changes refill only with synthetic oil
* Brownie’s supplies CF-2000 food-grade synthetic compressor lubricant
with all compressors.
3.6 OIL CHANGE PROCEDURE
Care should be taken in draining oil into a proper container for disposal
per local guidelines and laws.
1. Turn on the compressor and run it until warm
2. Remove the red cap on the oil filler neck (Figure 2)
3. Remove the ball valve cap at the base of the compressor block
(Figure 3)
4. Attach appropriate drain valve and hose (Figure 4)
5. Open ball valve by rotating handle (Figure 4)
6. After oil is completely drained, close the ball valve (Figure 4)
7. Slowly pour new oil* through the oil filler neck (Figure 2) until the level
reaches the maximum mark on the sight glass
Figure 2
1
2
Figure 3
Figure 4
Figure 5
Figure 6
NOTE
Replace the oil filter every oil change. Failure to do so will
cause the filter to clog and bypass valve to open resulting
in unfiltered oil being circulated and possible damage to the
compressor.
19
3.7 CHECK DRIVE BELT/REPLACE BELT
The drive belt should be checked at least every 125 hours, assessing the belt for wear or damage. Should the belt
need to be replaced:
1. Remove the belt guard from the compressor unit. Lift the motor to release the tension on the belt (Figure 2).
2. Remove the old belt and replace.
3. Release the motor. The weight of the motor will adjust the tension of the belt (Figure 1). Replace the belt guard.
Figure 1 Motor at Normal Position
Figure 2 Motor Lifted to Relieve Tension on Belt
20
3.8 INTERMEDIATE SEPARATORS
Intermediate separators are mounted on the compressor between the 2nd and 3rd stage and between the 3rd
and 4th stages. These separators are designed to remove oil and water which accumulates due to the cooling of
the medium after the compression process. Separation is achieved by means of centrifugal action.
2nd Stage Intermediate Separator
1. Safety Valve
2. Separator Head
3. O-ring
4. Screw-in Insert
5. Knurled Nut
6. Separator Body
7. Gasket
8. Fitting
8
1
2
3
4
5
6
7
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