Oil-Free Compressor
Maintenance & Operating
Manual
.....Setting the New Standard
WARNING
AND CAUTION
All OSHA regulations should be observed when
operating Aggreko rental equipment. Wear eye
and hearing protection. Doors are to remain
closed during operation. Diesel engine powered
equipment should never be operated inside
buildings. All OSHA compressed air regulations
for breathing air or otherwise should be observed.
Please see breathing air warning on Page 18 of
this manual. Hot surfaces such as air pipes and
engine exhaust pipes should not be touched.
Additionally, never remove the cap from a hot
radiator. Do not remove any mechanical parts or
make any modifications to equipment. Repair of
replacement charges will be applicable when this
is not observed. If you have any questions, please
contact your local Aggreko Depot found on the
back cover of this manual.
Table of Contents:
Page 1 .................. Specifications
Page 2 .................. Parts Listing
Pages 3 & 4 ............ Starting Instructions
Page 5 .................. Stopping Instructions
Page 6 .................. Other Functions & Features
Page 7 .................. Lamp Indicators
Page 8 .................. Recommendations for Use
Page 9 .................. Proper Operation
Page 10 ................ Adjusting Output Pressure
Page 11 ................ Changing the Racor Filter
Page 12 ................ Priming Procedure
Pages 13 & 14 ........ Routine Service & Maintenance
Page 15 ................ Breathing Air Warning
1
Specifications
Compressor
Compressor type Kobelco, 2-stage, oil-free, rotary screw
Actual free-air delivery @ max speed 900 - 1500 CFM
Air discharge temperature 15°F Above ambient
Maximum effective pressure 135 psi
Minimum effective pressure 55 psi
Receiver capacity 150 U.S. gallons
Air discharge outlet 3" Boss coupling
Capacity of oil system 30 U.S. gallons (Quaker State ISO VG68 Turbine oil or equal)
Cooling system Air
Pressure differential Variable (3-10 psi)
Overall Dimensions & Noise Level
Length 18.25 ft
Width 6.8 ft
Height 7.6 ft
Weight (wet) 20,640 lbs
Noise level 75 dba @ 3 ft
Engine
Make/model Cummins N14-C475
Service Interval 250 Hours
Cooling system Water
Fuel tank capacity 216 U.S. gallons
Fuel consumption at full load 17.8 Gallons per hour
Capacity of oil system 10 U.S. gallons (15w40 multi-grade diesel engine oil)
Number of cylinders 6, In-line
Maximum rpm 2100 rpm
Minimum rpm 1500 rpm
Bhp @ maximum speed 474 hp
Electrical 24 Volts
2
Parts Listing
OFC-1500 PARTS LISTING
QTY Part # Description
2 LF-3000 Engine Oil Filter (Fleetguard)
2 FS-1212 Main Fuel Filter (Fleetguard)
1 FS-1206 Fuel/Water Separator (Fleetguard)
3 AF-928M Main Air Filter (Fleetguard)
1 HF-7606 Compressor Oil Filter (Fleetguard)
1 WF-2071 Engine Water Filter (Fleetguard)
3 17640 Fan Belt (Dayco)
1 K060435 Water Pump Belt (Dayco)
2 17465 Alternator Belt (Dayco)
10 gal. 15w40 Multi-grade Diesel Engine Oil
30 gal. ISO VG68 Turbine Oil (Quaker State)
Note: Equivalents to the above parts are acceptable in most cases.
3
Starting Instructions
1. Ensure unit/trailer is on a level surface and can support
system's total weight. Make sure the landing gear on trailerized
units is properly supported on soft surfaces.
2. Check engine oil level (see Fig. 8).
3. Check compressor oil level (see Fig. 10).
4. Check fuel level (see gauge on panel).
5. Below 32°F connect both the engine block heater and
compressor oil sump heater.
6. Make sure 3" discharge valve is closed.
7. Press “power on” switch.
8. “Power on” lamp will illuminate. If lamp does not illuminate,
check to ensure that emergency stop button is not depressed.
9. Press “start” button to initiate the start sequence.
10. The “starting” lamp will be illuminated.
11. The auxiliary oil pump starts immediately.
12. Engine cranking begins 2 seconds after oil pressure is
established.
Note: Do not use starting fluid when starting in cold weather. Engine damage may occur.
Figure 1
Aggreko OFC Control Panel
4
Starting Instructions (cont.)
13. Engine cranking is terminated when:
a. engine speed reaches 550 rpm.
b. 10 seconds elapses.
14. If the engine does not start in 10 seconds,
the oil pump shuts down and the “start”
button must be pressed to reinitiate the start
sequence.
15. After 3 attempts to start, the “overcrank” lamp
will come on and the “start” button will be
disabled until the “reset” button is pressed.
16. If 550 rpm is reached, cranking is terminated
and engine speed is held at 1500 rpm.
17. The “starting” lamp will go off. After 5
seconds, the compressor loads and a
maximum speed of 2050 rpm is achieved.
18. Open 3" discharge valve.
19. The compressor operates at this level until
system set pressure is reached.
20. Engine speed is throttled to match demand
or 1500 rpm minimum.
21. Engine speed increases if system pressure
decreases.
22. When the “differential” selector switch is in
the “high” position:
a. The compressor loads when system
pressure decreases 10 psi.
b. The compressor unloads when the
pressure setting (on the DPV valve) is met.
23. When the “differential” selector switch is in
the “low” position:
a. The compressor loads when system
pressure decreases 2.5 psi.
b. The compressor unloads when the
pressure setting (on the DPV valve) is met.
5
Stopping Instructions
Normal Stopping:
1. Press the “stop” button to initiate the stop sequence.
2. The “stopping” lamp will be illuminated.
3. The compressor unloads immediately.
4. The compressor continues to run for a 15 minute cool down
period.
5. The auxiliary oil pump starts.
6. The engine stop solenoid is de-energized.
7. The auxiliary oil pump will shut down when 0 rpm is reached.
8. The “stopping” lamp will go off.
9. Press the “power off” button, after the compressor is shut
down. This will turn the power off or there will be an automatic
power off after 30 minutes.
Emergency Stopping:
1. Press the “Emergency Stop” button which will immediately
stop the unit and turn off the power.
Use for emergency purposes only! (See Fig. 2)
Figure 2
Emergency Stop Button
6
Other Features & Functions
1. Manual Unload Button - Unloads the compressor.
a. The lamp becomes illuminated.
b. The engine speed is reduced to 1500 rpm while unloaded.
c. The compressor will remain unloaded until the button is pressed
again.
d. The lamp will go off.
2. Lamp Test Button - Will light all lamps as long as it is depressed.
3. Reset Button - Will reset the controller to normal mode after an alarm
condition if the condition has been corrected.
4. Service Alert Light - Will illuminate when 250 hour service interval has
elapsed. This indicates a need for engine oil and filter service.
a. Depress “Lamp Test” button and press the “reset” button 4 times to
clear light upon servicing.
5. Last Fault Shutdown Recall Button - Will display the last fault shutdown
for 5 seconds when depressed.
a. While the last fault is displayed, press the “reset” button or wait 5
seconds and the display will return to normal.
Note: The “power on” lamp must be on for these to work.
Figure 3
Panel
7
Lamp Indicators
1. Power On - Illuminated when “power on” push button
has been depressed. Indicates control power has
energized panel.
2. Starting - Illuminated when a sequential start is in
progress having pressed the “start” button. Goes off
when engine reaches 550 rpm.
3. Stopping - Illuminated when an orderly shutdown is in
progress having pressed the “stop” button. The lamp
will go off when 0 rpm has been detected.
4. Manual Unload - Illuminated when the “manual unload”
button has been pressed. The compressor will not load.
5. Loaded - Illuminated when the compressor is running
loaded.
6. Service - Illuminated when the engine oil needs
changing (every 250 hours). When lamp is flashing, this
indicates a service alert for the capacity control valve.
Consult your renting depot.
7. Aux. Oil Pump Run - Illuminated when oil pump motor
is running.
8. High Compressor Oil Temp - Illuminated when the
compressor shuts down due to high oil temperature
exiting the cooler (170°F set-point).
9. High 1st Stage Discharge Temp. - Illuminated when the
compressor shuts down due to high air discharge
temperature from the 1st stage (410°F).
10. High 2nd Stage Suction Temp. - Illuminated when the
compressor shuts down due to high air temperatures at
the intercooler discharge (150°F).
11. High 2nd Stage Discharge Temp. - Illuminated when the
compressor shuts down due to high air discharge
temperature from the 2nd stage (440°F).
12. Low Compressor Oil Pressure - Illuminated when the
compressor shuts down due to oil pressure loss (less
than 20 psig).
13. Over-crank - Illuminated when the engine has failed to
start in 3 attempts.
14. Low Engine Oil Pressure - Illuminated when the
compressor has shut down because the engine oil
pressure is below 20 psig.
15. Under-speed - Illuminated when the compressor shuts
down because the engine went below 1200 rpm.
16. Over-speed - Illuminated when the compressor has shut
down because the engine went over 2300 rpm.
17. Low Engine Water Pressure - Illuminated when the
compressor has shut down because the engine water
pressure is below 5 psig.
18. High Engine Water Temperature - Illuminated when the
compressor has shut down due to high engine water
temperature (220°F).
8
Recommendations for Use
1. Unit(s) should be positioned outside in a clear area
which allows for proper air movement and prevents re-
circulation of cooling air. Unit(s) should never be
positioned inside of a building. Unit(s) should also never
be located next to heat producing devices such as
boilers, blowers, steam lines, etc.
2. Job sites with multiple units should allow 4-6 feet
minimum between each unit which in turn provides for
efficient cooling. The maximum operating ambient
temperature is 110°F.
3. A quality supply of #2 diesel fuel should be used to
refill units. Aggreko regularly cleans on-board fuel tanks
keeping fuel contamination to a minimum. When
ambient temperatures drop below freezing, a winter
blend fuel must be used. This will prevent fuel from
gelling.
4. In operating temperatures below freezing, both engine
jacket heaters and compressor oil heaters must be
energized. Both will require a 20 amp, 120 volt circuit.
Additionally, external auto-drains should be insulated
and heat traced. Air movement through the unit should
be restricted at the air intake louvers in extremely cold
conditions (below 32°F) to prevent compressor oil from
gelling in the cooler.
5. An operator should make routine visual checks for any
possible problems with the unit(s).
6. In the event a problem does arise, as much information
as possible should be gathered including the last fault
indication if the unit is shut down or all temperature and
pressure readings if it is still in an operating mode. In
many instances, problems can be solved via the phone
resulting in less down time.
7. Customers are responsible for keeping units full of fuel
and the changing the Racor filter between services. If a
unit is run out of fuel, the customer is asked to assist in
re-priming the unit. If Aggreko has to respond to a unit
which is run out of fuel, there will be a charge for labor,
travel and mileage.
8. The Cummins engine powering the Aggreko oil-free
compressor is water cooled. You should check coolant
levels in the radiator on a regular basis. Low coolant levels
can cause engine failure for which the customer is
responsible. The radiator fill is located on the top side of
the unit at the air-intake end.
9
Proper Operation
In some cases, light or intermittent loads may cause the
compressor to load and unload frequently. This can damage the
air inlet valve, and waste fuel. If the problem persists and cannot
be corrected through pressure adjustments, please contact your
local Aggreko Depot for instructions. If necessary, the excess air
dump valve can be opened to keep the compressor loaded. (See
Figure 4)
Figure 4
Excess Air Dump Valve
10
Adjusting Output Pressure
1. Pressure adjustment is accomplished by either screwing
in or out on a bolt atop the DPV valve. When looking at
the control panel, the DPV valve is located on the left
hand side of the unit in the center canopy door. The valve
is gold in color and pear-shaped with easy accessibility.
(See Figure 5).
2. “Screwing in” on the bolt, or clockwise, will raise the
pressure. “Screwing out” on the bolt, or counter-
clockwise, will lower the pressure.
3. The pressure should be adjusted to the desired level
before the discharge valve is opened. The maximum
operating pressure for the Aggreko oil-free compressor
is 135 psi. The minimum operating pressure is 55 psi. Figure 5
DPV Valve
11
Changing the Racor Filter
1. The Racor filter is the unit’s first stage of fuel filtration.
Typically, this will become clogged first and the unit will
suffer from fuel starvation as a result. (See Figure 6)
2. To change, unscrew the tee handle on top of the Racor
assembly and remove the cover. Slowly twist and pull
out the old element.
3. Drain and clean bowl if necessary. Install new element
by slowly twisting and slowly pushing down until it
bottoms out.
4. Fill canister with clean fuel. Put cover and tee handle back
on, being careful not to damage the O-ring.
Figure 6
Racor Assembly
12
Priming Procedure
1. In the event the unit runs out of fuel or loses its prime, the
following steps should be followed to ensure proper re-
priming of the fuel system.
2. Fill the Racor filter assembly as described on the previous
page.
3. Remove the secondary, spin-on fuel filter located near the
injection pump. This needs to be filled and spun back on.
(See Figure 7)
4. The Cummins N14-C475 engine is self-priming. Once
these filters have been filled and reinstalled, the unit can
be cranked.
Figure 7
Secondary Fuel Filter
13
Routine Service and
Maintenance
Each Shift:
1. The on-board fuel tank will allow for run
times anywhere between 9-12 hours
depending on load. The tank should be
topped off on a per shift basis if running
around the clock.
2. The engine oil should be checked on a
regular basis never going over 24 hours
running between checks. All Aggreko oil-
free compressors have engine oil sight
glasses installed. (See Fig. 8)
3. A majority of the fleet will have manual
oilers with a one gallon reservoir tank. Oil
can be added by opening the valve on the
tank. (See Fig. 9) Units without these
manual oilers will have to be shut down in
order to add oil.
4. Always use 15w40 multi-grade diesel
engine oil.
Daily:
1. Compressor oil should be checked on a daily
basis. The level should be at least halfway up
the sight glass on the compressor oil sump.
(See Fig. 10)
2. Any water or sediment should be drained from
the Racor bowl. (See Fig. 6)
3. Automatic condensate drains located on the
outside skid of each unit should be checked
for proper operation. (See Fig. 12)
Every 250 hours:
1. Complete servicing (oil & filters) on the engine.
2. Check compressor oil level. (See Fig. 10)
3. Check the control system and look for
mechanical problems.
Note: Compressor oil and filter will need changing
on 2000 hour intervals.
Fig. 8 Engine Oil Sight Glass
Fig. 9 Manual Oiler
Fig. 10 Compressor Oil Sight Glass
Figure 10
Figure 9
Figure 8
14
Routine Service and
Maintenance (cont.)
Figure 11
Oil Filters, Sight Glass
& Dip Stick
Figure 12
Automatic Condensate Drain
Figure 14
Compressor Oil Fill
Figure 13
Air Filters
Figure 15
Lube Oil Sump Pump &
Breather Blow-By Reservoir
15
DANGER
BREATHING AIR WARNING
These air compressors are not to be used for breathing air purposes
without the addition of specialized breathing air quality equipment.
Should the purchaser and/or user fail to add such specialized equipment
and proceed to use the unit for breathing air service, the purchaser/
renter/user assumes all liability without any responsibility or liability
being assumed by Aggreko, Inc.
Notes
ALABAMA – Mobile
3120 Dial St, Whistler, AL 36612
Off# 251-452-0452 Fax# 251-452-1066
ARIZONA – Phoenix
2832 South 46th Street
Phoenix, AZ 85040
Off# 480-394-9301 Fax# 480-394-9297
CALIFORNIA – Hollywood
11180 Penrose Street
Sun Valley, CA 91352
Off# 818-767-7288 Fax# 818-767-7782
CALIFORNIA – Los Angeles
13230 Cambridge St.
Santa Fe Springs, CA 90670
Off# 562-802-7972 Fax# 562-802-8374
CALIFORNIA – San Francisco
160 W. Industrial Way
Benicia, CA 94510
Off# 707-746-8812 Fax# 707-746-8068
CANADA – Toronto, Ontario
300 Clarence St.
Brampton, Ontario L6W 1T5 Canada
Off# 905-459-3321 Fax# 905-459-3392
COLORADO – Denver
4820 Forest Street - Unit B
Commerce City, CO 80022
Off# 303-333-1866 Fax# 303-333-4284
FLORIDA – Jacksonville
8300 Phillips Highway
Jacksonville, FL 32256
Off# 904-731-7336 Fax# 904-731-0489
FLORIDA – Miami
9100 NW 97th Terrace
Medley, FL 33178
Off# 305-888-3830 Fax# 305-888-2782
FLORIDA – Orlando
104 Whitney St.
Kissimmee, FL 34744
Off# 407-846-2554 Fax# 407-846-2633
FLORIDA – Tampa
505 N. Sherrill Street
Tampa, FL 33609
Off# 813-288-1697 Fax# 813-288-1638
GEORGIA – Atlanta
2215 Lithonia Industrial Blvd.
Lithonia, GA 30058
Off# 770-987-2444 Fax# 770-987-0700
ILLINOIS – Chicago
16748 New Avenue
Lemont, IL 60439
Off# 630-257-8480 Fax# 630-257-8295
INDIANA - Gary
290 West 1050 North
Chesterton, IN 46304
Off# 219-764-9773 Fax# 219-764-8572
INDIANA - Indianapolis
1725 N. Wales Ave.
Indianapolis, IN 46218
Off# 317-358-8845 Fax# 317-358-0709
KANSAS – Kansas City
1020 Pawnee Drive
Kansas City, KS 66105
Off# 913-321-3140 Fax# 913-321-3569
KENTUCKY – Calvert City
4209 Gilbertsville Hwy.
Calvert City, KY 42029
Off# 502-395-7068 Fax# 502-395-4061
KENTUCKY – Louisville
7133 Global Drive
Louisville, KY 40258
Off# 502-933-8889 Fax# 502-933-8890
LOUISIANA – Baton Rouge
11522 Industriplex Blvd.
Baton Rouge, LA 70809
Off# 225-751-3525 Fax# 225-751-3527
LOUISIANA – Lake Charles
2698 East Napoleon
Sulphur, LA 70663
Off# 337-625-3450 Fax# 337-625-3502
LOUISIANA – New Iberia
4713 W. Admiral Doyle Dr.
P.O. Box 13190
New Iberia, LA 70560-0562
Off# 318-365-5479 Fax# 318-369-3355
LOUISIANA – New Orleans
180 West 3rd Street
Kenner, LA 70062
Off# 504-461-0556 Fax# 504-461-0551
MARYLAND – Baltimore
124 N. Langley Road
Glen Burnie, MD 21060
Off# 410-760-6200 Fax# 410-760-6488
MASSACHUSETTS – Boston
Hopedale Airport Industrial Park
11 Airport Rd., Hopedale, MA 01747
Off# 508-473-4401 Fax# 508-473-8274
MICHIGAN – Detroit
8119 Park Place, Brighton, MI 48116
Off# 248-486-4100 Fax# 248-486-5739
MINNESOTA – Minneapolis
1584 East Cliff Road
Burnsville, MN 55337
Off# 952-894-5992 Fax# 952-894-5997
MISSOURI – St. Louis
10317 Lake Bluff Drive
St. Louis, MO 63123
Off# 314-894-7787 Fax# 314-845-2010
MEXICO – Mexico City
Mar Cantabrico 20, Col. Popotla
Mexico D.F. 11400
Off# 525-386-3208 Fax# 525-386-3155
MEXICO – Monterrey
Jose Timoteo
Rosales No. 4826 Co. Nino Artillero
Monterrey, N.L. 64280
Off# 528-331-6365 Fax# 528-331-6366
NORTH CAROLINA – Fayetteville
560 Assembly Court
Fayetteville, NC 28306
Off# 910-424-5546 Fax# 910-424-5120
NEVADA – Las Vegas
4580 Alto Avenue, Las Vegas, NV 89115
Off# 702-643-5630 Fax# 702-643-5631
NEW JERSEY – Linden
3351-4 Tremley Point Road
P.O. Box 4070
Linden, NJ 07036-8070
Off# 908-474-1322 Fax# 908-474-1323
NEW YORK – Albany
3 Industry Drive, Waterford, NY 12188
Off# 518-235-9604 Fax# 518-235-9668
OHIO – Cincinnati
11964 Tram Way Drive
Sharonville, OH 45241
Off# 513-769-6550 Fax# 513-769-6636
OHIO – Cleveland
425 Munroe Falls Road
Tallmadge, OH 44278
Off# 330-733-3450 Fax# 330-733-3398
OKLAHOMA – Oklahoma City
5740 North I-35 Industrial Blvd.
Edmond, OK 73034
Off# 405-330-1341 Fax# 405-330-1382
OREGON – Portland
807 Jefferson Street
Vancouver, WA 98660
Off# 360-693-1603 Fax# 360-693-8353
PENNSYLVANIA – Philadelphia
2 Hawk Court, P.O. Box 490
Bridgeport, NJ 08014-0490
Off# 609-467-5656 Fax# 609-467-9477
PUERTO RICO
Hwy. 175 km 0.3 San Antonio
Caguas, PR 00725
Off# 787-704-2412 Fax# 787-704-2414
SOUTH CAROLINA –
Columbia
121 Vera Road
Lexington, SC 29072
Off# 803-957-7475 Fax# 803-957-7473
TENNESSEE – Memphis
7037 Ryburn Drive, Millington, TN 38053
Off# 901-873-4702 Fax# 901-873-4740
TENNESSEE – Nashville
8175 W.W. Williams Drive
Smyrna, TN 37167
Off# 615-459-0888 Fax# 615-459-0864
TEXAS – Beaumont
1185 Montrose, Beaumont, TX 77707
Off# 409-866-1824 Fax# 409-866-0434
TEXAS – Corpus Christi
6747 Leopard, Corpus Christi, TX 78409
Off# 361-289-5684 Fax# 361-289-5687
TEXAS – Dallas
627 Grigsby Way
Cedar Hill, TX 75104
Off# 972-293-0491 Fax# 972-293-0426
TEXAS – Houston
3732 Magnolia Street
Pearland, TX 77584
Off# 713-512-6700 Fax# 713-512-6794
TEXAS – San Antonio
413 FM 1103, Cibolo, TX 78108
Off# 210-566-4566 Fax# 210-566-4569
UTAH – Salt Lake City
5591 W. Leo Park Road
West Jordan, UT 84088
Off# 801-280-6800 Fax# 801-280-6804
VIRGINIA – Richmond
2114 Bellemeade Rd.
Richmond, VA 23224
Off# 804-233-8299 Fax# 804-233-7902
VIRGINIA – Norfolk
610 Woodlake Drive
Chesapeake, VA 23320
Off# 757-366-4025 Fax# 757-366-4077
WASHINGTON – Seattle
509 35th Street NE
Auburn, WA 98002
Off# 253-939-3443 Fax# 253-939-3790
WEST VIRGINIA – Charleston
4220 Woodrums Lane
Charleston, WV 25313
Off# 304-744-9434 Fax# 304-744-9443
www.aggreko.com