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MORSE GENERATORSMODEL GCRS-30-140
30 KW OPEN SKIDSAFETY, MAINTENANCE
AND PARTS MANUAL
30 KW PRIME POWER32 KW STAND-BY POWER
P/N:3070492/19/2008
4P/N: 307049
SAFETY, MAINTENANCE, AND PARTS MANUALMORSE GENERATORS GCRS-30-140
Operation & Maintenance Section
TABLE OF CONTENTS
Operation & Maintenance Section
Introduction .............................................................................................................. 6
Safety ........................................................................................................................ 7
General Description ................................................................................................ 10
Hazards ................................................................................................................... 11
Warnings ................................................................................................................. 12
Preparation for Initial Start-Up ................................................................................ 13
Normal Starting and Stopping................................................................................. 14
Model GCRS-30-140............................................................................................... 17
Compressor Operation ........................................................................................... 18
Compressor Inspection, Lubrication and Maintenance .......................................... 20
Troubleshooting ...................................................................................................... 28
Compressor Recommended Spare Parts ............................................................... 30
Warranty .................................................................................................................. 31
Warranty Registration .............................................................................................. 37
Illustration Drawings ............................................................................................... 39
6 P/N: 307049
INTRODUCTION
Every effort has been expended to make sure that the information in this manual is both accurateand current. However, Morse Industrial Inc. reserves the right to change, alter or otherwiseimprove the product at any time without prior notice.
Bold printed DANGER boxes point out important safety instructions, which if not followed, couldendanger personal safety and/or property.
Read this manual, the engine manual, and the generator manual thoroughly for both the DieselEngine and the Generator prior to operating this unit. Follow all instructions in all three manuals. Ifyou do not understand any portion of the manuals, contact your Morse Generator authorizeddealer for starting operating and servicing procedures.
MUFFLER
ENGINE
RADIATOR
GENERATOR
AIRCOMPRESSOR
ENGINECONTROL PANEL
ENGINE AIR FILTER
7P/N: 307049
SAFETY
DANGER
GROUND BOLT
IF THIS UNIT IS USED FOR BACK-UP POWER IN THE EVENT OF A UTILITY POWERFAILURE, THE FOLLOWING STEP MUST BE TAKEN BEFORE CONNECTING THEGENERATOR TO AN ELECTRICAL SYSTEM. OPEN THE MAIN CIRCUIT BREAKEROR MAIN SWITCH SERVING THE SYSTEM TO ISOLATE THE GENERATOR SYSTEMFROM THE ELECTRIC UTILITY. FAILURE TO ISOLATE THE GENERATOR ANDUTILITY SYSTEMS MAY RESULT IN DAMAGE TO THE GENERATOR AND MAY ALSORESULT IN INJURY OR DEATH TO ELECTRIC UTILITY WORKERS, DUE TO ABACKFEED OF ELECTRICAL ENERGY.
DANGER
THIS UNIT PRODUCES DANGEROUS HIGH VOLTAGE THAT CAN CAUSEEXTREMELY HAZARDOUS ELECTRICAL SHOCK. AVOID CONTACT WITH BAREWIRES, TERMINALS, ETC. NEVER PERMIT AN UNQUALIFIED PERSON TOOPERATE OR SERVICE THIS UNIT.
NEVER HANDLE ANY ELECTRICAL CORDS OR DEVICES WHILE STANDINGIN WATER, BAREFOOT, OR HANDS AND FEET ARE WET. HARMFUL ORFATAL ELECTRICAL SHOCK CAN RESULT.
LOCAL ELECTRICAL CODES MAY REQUIRE THE USE OF ANAPPROVED EARTH GROUND TO THE FRAME OF THE GENERATOR. THEGENERATOR IS EQUIPPED WITH A MOUNTING GROUND BOLT AND NUTFOR PROPER CONNECTION. CONSULT WITH A LOCAL ELECTRICIAN FORGROUNDING REQUIREMENTS IN YOUR AREA.
8 P/N: 307049
DANGER
NEVER ADD FUEL WHILE UNIT IS RUNNING.
DO NOT SMOKE WHEN PUTTING FUEL IN THE TANK
DO NOT OVERFILL THE FUEL TANK
DIESEL ENGINE EXHAUST CONTAINS DEADLY CARBON MONOXIDE GAS.IF BREATHED IN SUFFICIENT CONCENTRATIONS, IT CAN CAUSEUNCONSCIOUSNESS OR EVEN DEATH. MAKE SURE THE GENERATOR HASADAQUETE VENTILATION FOR THE EXHAUST.
BOTH THE DIESEL ENGINE AND THE GENERATOR REQUIRE FRESH AIRFOR COOLING. MAKE SURE SUFFICIENT VENTILATION IS AVAILABLEFOR BOTH THE GENERATOR AND ENGINE FANS.
OPERATE GENERATOR ON LEVEL SURFACES UP TO + OR - 10% GRADE
DO NOT OPERATE GENERATOR WHERE IT WILL BE EXPOSED TOEXCESSIVE MOISTURE, DIRT, DUST OR CORROSIVE VAPORS.
NEVER START OR STOP THE GENERATOR WITH ELECTRICAL LOADSCONNECTED AND THE CONNECTED DEVICES TURNED ON! START THEENGINE FIRST AND LET IT STABILIZE BEFORE TURNING ON THEELECTRICAL LOADS. TURN OFF ALL ELECTRICAL LOADS BEFORESHUTTING DOWN THE ENGINE.
9P/N: 307049
SAFETY RULES
• Morse Industrial Equipment Inc. recommends that the installation, initial start-up andmaintenance of this generator is carried out by a Morse Generator Dealer. Do not attempt toinstall, start, wire or perform maintenance on this generator unless you are trained andqualified to do so. Personal injury or death may occur.
• Keep hands, feet, clothing, etc. away from drive belts, fans, and other moving parts. Neverremove drive belts or fan guards while the unit is running.
• Keep hands and all body parts away from the hot engine exhaust. This includes the muffler,turbo charger, and all exhaust pipes. Other parts of the engine and radiator are also hot.
• When working on this generator, remain alert at all times. Wear protective clothing includingsafety glasses. Never work on this equipment when you are mentally or physically fatigued.
• Before performing any maintenance on this equipment, disconnect the battery cables to preventaccidental start-up. Take care not to “arc” the battery posts (do not touch positive (+) tonegative (-)) with the ends of the cable or tools used to remove the cables. Disconnect thenegative (-) cable first. Reconnect the negative (-) cable last.
• Never wear jewelry when working on this generator. Jewelry can conduct electricity resulting inelectric shock, or may get caught in moving components such as fans or belts causing injury.
• Study the DANGER WARNINGS and SAFETY RULES carefully. Become familiar withboth the Engine and Generator safety rules and warnings found in their respective manuals.
• Morse Industrial Equipment Inc. cannot anticipate every possible circumstance that mightinvolve a safety hazard. The warnings in this manual and also the engine and generator manualsare not all-inclusive and one must use common sense to satisfy oneself that this equipment is safefor you and others to operate and/or service.
10 P/N: 307049
• This generator can be used for prime or stand by power and can be wired 3 phase or 1 phaseat a frequency of 60 hertz. Voltage can be 120/240 1-PH or 208 to 240; and 416 to 480volt 3-PH. Please refer to the Generator Manual for details.
• Follow all local electrical codes that may require proper grounding of the generator and itselectrical system.
• In case of an accident caused by electric shock, immediately shut down the generator. Movethe rotary OFF-RUN-START switch on the control panel to the “OFF” position. Do not try tofree the victim with the generator running; the electric shock could pass from the victim toanyone in contact with the victim. Make sure the generator is off and the electric system isde-energized. Seek medical attention immediately.
OFF-RUN-START SWITCH
GENERAL DESCRIPTION
This generator is a frame mounted. diesel engine driven, revolving field, alternating current (AC)generator. The generators revolving field is driven at 1800 rpm by the diesel engine.
11P/N: 307049
HAZARDS
ELECTRICAL SHOCK HAZARDS
• This generator produces dangerous electrical voltages that can cause fatal electrical shock.Avoid contact with bare wires, terminals, connections, etc. while the unit is running. Makesure all appropriate covers, guards, and barriers are in place before operating thegenerator.
• Do not assume that there is not power flow to the terminals, connections, bare wires, etc.when the generator is not running. The unit could be connected to another power sourcethat could back feed through the generator wire leads. Always test the wire leads for powerbefore working on the unit.
• The National Electrical Code (NEC) requires the frame and external electrically conductiveparts of the generator to be connected to an approved earth ground unless the generator isvehicle mounted. See article 250.34 of the NEC handbook if the generator is to bemounted in a portable vehicle.
FIRE HAZARDS
• For fire safety, the generator must be operated and maintained properly. Operation mustalways comply with applicable codes, standards, laws and regulations. Adhere strictly to localstate and national electrical and building codes. Comply with regulations of the OccupationalSafety and Health Administration (OSHA). Ensure the generator and engine are operated inaccordance with the manufacturer’s instructions and recommendations. Do not alter theconstruction of the generator or engine or change controls which might create an unsafeoperating condition.
• Keep a fire extinguisher near the generator at all times. Make sure the extinguisher is rated“ABC” by the National Fire Protection Association. Keep the extinguisher properly chargedand be informed on instructions for use.
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe any fuel or oil spills immediately. Make surethereare no combustible materials near or on the generator that can cause a FIRE or EXPLOSION.Keep the area surrounding the generator clean and free from debris.
12 P/N: 307049
WARNINGS
• Operators must not tamper with engine governed speed. High operating speeds are dangerousand increase risk of personal injury or damage to equipment. The generator supplies correctrated frequency and voltage only when running at proper governed speed. Incorrect frequencyand/or voltage can damage some connected electrical loads.
• Electrical surges and spikes can cause serious damage to your system and everything pluggedinto it. Proper surge protectors should be used between the receptacles and every electricalsystem being used. Improperly tuned engines can force the electronic engine speed control tospike and fade thus creating damaging electrical surges.
• Never weld to truck or trailer chassis, as this will cause damage to many electrical or electroniccomponents grounded to vehicle chassis.
DO NOT START OR STOP GENERATOR WITH ANY CONNECTED ELECTRICALDEVICE TURNED ON. GENERATOR MUST NOT BE STARTED OR STOPPED WITHANY TYPE OF ELECTRICAL LOAD ON THE GENERATOR. LOAD GENERATORAFTER THE GENERATOR IS WARMED UP.
13P/N: 307049
PREPARATION FOR INITIAL START-UP
Every GCRS-30-140 is tested at the factory before shipment. This testing assures that the unit isoperating properly and that the generator and compressor will deliver its rated capacity.Regardless of the care taken at the factory, there still exists a possibility that damage may occurduring shipment. For this reason, it is recommended that the unit be carefully inspected for evidenceof damage during shipment. The unit is shipped with the negative battery cable removed. The negativebattery cable will need to be connected before starting.
NOTE
All wiring connections to the generator should be made by a qualified electrician and inspected to meetall local standards and codes. Make sure the unit is safe to run before attempting to start.
BATTERY CABLE INSTALLED BATTERY CABLE REMOVED
14 P/N: 307049
NORMAL STARTING AND STOPPING
NORMAL STARTING
1. Inspect the generator, engine, compressor and other assemblies for loose connections ordamage that might have occurred since the last operation.
2. Check engine oil, engine fuel, compressor oil and anti-freeze levels; add fluids ifnecessary.
3. Close service valve.
4. Push in GLOW PLUG and BYPASS BUTTON and hold.
5. Turn the engine OFF-RUN-START switch to START and hold until engine starts, but donot hold any longer than ten seconds at a time.
6. Release GLOW PLUG and BYPASS BUTTON after engine has started and run for five toten seconds.
7. Let the engine warm-up. Once engine is warm the generator and compressor are ready forfull- load operation (normal engine temperature is 160 to 190 degrees Fahrenheit).
NORMAL STOPPING
1. Make sure all electrical devices are turned off. Do not turn off the generator while loaded!
2. Close service valve.
3. Run generator unloaded for several minutes to allow engine to cool down.
4. Turn OFF-RUN-START switch to the OFF position.
GLOW PLUG/BY-PASSBUTTON
OFF-RUN-START SWITCH
15P/N: 307049
Weight =2210 lbs. (1002 kg)Fuel Capacity = 50 gal (189 liters)
ENGINEModel: Perkins 1104c-44tPower @ 1800 rpm: 90hp (68 kw) @ 1800 RPMNumber of Cylinders: 4Bore and Stroke: 4.1 x 5.0 in (105 x 127 mm)Displacement: 268 in3 (4.4 L)Aspiration: Turbo-chargedBattery: 12 v 650 cca @ 0 degrees Fahrenheit
GENERATORModel: Meccalte spa Type ECO 28-VL/4Output kw: 30 kw Prime, 32 kw Stand-byVoltage: 208 - 240, 3 ph, 60 hzAmps: 138 @ 208 v, 131 @ 220v, 120 @ 240v
COMPRESSORModel: NK100 Integrated Air CompressorType: Oil Flooded Rotary ScrewDelivery: 140 cfm (3.96 m3 /min)Operating Pressure Range: 80 to150 PSIG (5.5 to 10.3 bar)Ambient Operating Temp Range: -20 degrees Fahrenheit to + 105 degrees Fahrenheit
(-29 degrees Celsius to 41 degrees Celsius )Oil Sump Capacity: .75 gal (2.83 L)Total System Capacity: 1.0 gal (3.80 L)Type Cooling System: Oil to AirAir Intake Filter: Single Stage DryType of Control: 0-100% DemandAir Service Connection: 3/4” NPT
SPECIFICATIONS
MODEL GCRS-30-140
16 P/N: 307049
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17P/N: 307049
This machine is a positive displacement air compressor that supplies its rated capacity (cfm) and itsrated pressure (psi) continuously (100% duty cycle). Please see figure above for location of thecompressors main components.
COMPRESSOR OPTION
MODEL GCRS-30-140
Your Morse Generator is equipped with a direct drive geared integrated rotary screw air compressor.
MINIMUM PRESSUREVALVE
SERVICE VALVE3/4” FNPT
COMPRESSORAIR FILTER
COALESCER
COMPRESSOROIL FILL
COMPRESSOR OIL DRAIN
OILFILTER
NK100 INTEGRATEDROTARY SCREW
AIR COMPRESSOR
PRESSUREREGULATOR VALVE
BLOW DOWN VALVE
THERMALVALVE
PRESSURERELIEF VALVE
18 P/N: 307049
COMPRESSOR OPERATION
ROTACIDNIROLORTNOC ESOPRUP
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To use air from this compressor, simply connect your airline to the 3/4” FNPT ball valve mountedon the discharge end of the compressor unit. This compressor is running when the engine is and has anautomatic pressure regulating valve that opens and closes the inlet valve depending on air usage.
COMPRESSORAIR PRESSURE GAUGE
19P/N: 307049
COMPRESSOR OPERATION
OPERATING CONDITIONS
The following conditions should exist for maximum performance of the compressor. Thecompressor should be as close to level as possible when operating. The compressor willoperate on a 15-degree sideward lengthwise tilt without any adverse problems. Fluidcarryover and oil starvation may occur if operated beyond this tilt.
NOTE
IF THE COMPRESSOR IS BEING USED TO POWER SANDBLASTING EQUIPMENT ORAN AIR TANK, USE A CHECK VALVE DIRECTLY AFTER THE SERVICE VALVE TOPREVENT BACK-FLOW INTO THE SUMP. THIS CHECK VALVE SHOULD HAVE AMAXIMUM PRESSURE DROP RATING OF 2 PSIG (13.78 kPa) OPERATING AND ACAPACITY RATING EQUAL TO THE MAXIMUM RATING OF THE COMPRESSOR.
20 P/N: 307049
COMPRESSOR INSPECTION, LUBRICATION AND MAINTENANCE
This section contains instructions for performing the inspection, lubrication andmaintenance procedures required to keep the compressor in proper operatingcondition. The importance of performing the maintenance described herein cannot be overemphasized.
Periodic maintenance procedures to be performed on the equipment covered by this manualare listed below. It should be understood that the intervals between inspections specifiedare maximum intervals. More frequent inspections should be made if the unit is operatingin a dusty environment, in high ambient temperature, or in other unusual conditions. Aplanned program of periodic inspection and maintenance will help avoid premature failureand costly repairs. Daily visual inspections should become a routine.
The LUBRICATION AND MAINTENANCE CHART lists serviceable items on thiscompressor package. The items are listed according to their frequency of maintenance,followed by those items which need only “As Required” maintenance. The maintenancetime intervals are expressed in hours. Use the hourmeter readings for determining yourmaintenance schedules. Perform the maintenance at multiple intervals of the hours shown.For example, when the hourmeter shows “100” on the dial, all items listed under “EVERY10 HOURS” should be serviced now for the tenth time, and all items under “EVERY 50HOURS” should be served for the second time. In addition to the followingLUBRICATION AND MAINTENANCE CHART refer to the Engine Operator’s manual forrecommended engine lubrication and maintenance.
DANGER
COMPRESSOR MUST BE SHUT DOWN AND COMPLETELY RELIEVED OF PRESSUREPRIOR TO CHECKING FLUID LEVELS. OPEN SERVICE VALVE TO ASSURE RELIEFOF SYSTEM AIR PRESSURE. FAILURE TO COMPLY WITH THIS WARNING MAY CAUSEDAMAGE TO PROPERTY AND SERIOUS BODILY HARM.
21P/N: 307049
COMPRESSOR INSPECTION, LUBRICATION, AND MAINTENANCECHART
NOTE: See Maintenance Section for clarification on above.
LAVRETNI NOITCA
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FOR ENGINE MAINTENANCE DETAILS,PLEASE REFER TO THE ENGINE MANUAL. **
22 P/N: 307049
COMPRESSOR INSPECTION, LUBRICATION,AND MAINTENANCE
NOTE
DRAINING WATER FROM COMPRESSOR OIL
Prior to initial start-up; it is recommended to drain water from the compressor sump. Compressor must beshut off for at least 4-6 hours. First, verify there is no pressure in the system. Then, slowly crack the oildrain cap. When opening the oil drain port, any water will drain out before the oil if fully separated. Catchall fluids in a container and dispose of properly. When no water is present, retighten the compressor oildrain cap. Check the compressor oil level and add oil if necessary.
OBSERVE ALL GAUGE READINGS. NOTE ANY CHANGE FROM THE NORMALREADING AND DETERMINE THE CAUSE. HAVE NECESSARY REPAIRS MADE.“NORMAL” IS THE USUAL GAUGE READING WHEN OPERATING AT SIMILARCONDITIONS ON A DAY-TO-DAY OPERATION.
FIRST COMPRESSOR OIL AND OIL FILTER CLEANING SHOULD BE DONE AT 50HOURS. ALSO, MORE FREQUENT OIL CHANGES WILL BEREQUIRED UNDER EXTREME OPERATING CONDITIONS OF EXTREMELY HIGH ORLOW TEMPERATURES, AND HIGH HUMIDITY.
CHANGE OIL EVERY SIX MONTHS, EVEN IF THE NORMAL OIL CHANGE PERIOD, INHOURS, HAS NOT YET ELAPSED.
ALWAYS WARM UP THOROUGHLY PRIOR TO CHANGING EITHER THE ENGINE OILOR THE COMPRESSOR OIL.
DO NOT OPEN COMPRESSOR OIL DRAIN; OIL FILTER CAP, OR OIL FILTER UNTILALL PRESSURE HAS BEEN RELIEVED. CHECK BY MANUALLY OPENING THE ASMESUMP PRESSURE RELIEF VALVE.
23P/N: 307049
LUBRICATION
LUBRICANT RECOMMENDATIONS
WARNING
The following general characteristics categorize lubricants that have been found to besatisfactory for use in helical screw type air compressors. Due to the impossibility ofestablishing limits on all physical and chemical properties of lubricants which can affecttheir performance in the compressor over a broad range of environmental influences, theresponsibility for recommending and consistently furnishing a suitable heavy-duty lubricantmust rest with the individual supplier. The lubricant supplier’s recommendation must,therefore, be based upon not only the following general characteristics, but also upon hisown knowledge of the suitability of the recommended lubricant in helical screw type aircompressors operating in the particular environment involved.
CAUTION
IT IS IMPORTANT THAT THE COMPRESSOR FLUID BE OF A RECOMMENDED TYPEAND THAT THIS OIL AS WELL AS THE AIR FILTER, OIL FILTER AND COALESCERELEMENTS BE INSPECTED AND REPLACED AS STATED IN THIS MANUAL.
THE COMBINATION OF A SEPARATOR ELEMENT LOADED WITH DIRT ANDOXIDIZED OIL PRODUCTS TOGETHER WITH INCREASED AIR VELOCITY AS ARESULT OF THIS CLOGGED CONDITION MAY PRODUCE A CRITICAL POINT WHILETHE MACHINE IS IN OPERATION WHERE IGNITION CAN TAKE PLACE AND COULDCAUSE A FIRE IN THE OIL SUMP.
FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TOPROPERTY AND SERIOUS BODILY HARM.
MIXING DIFFERENT TYPES OF BRANDS OF LUBRICANTS IS NOT RECOMMENDEDDUE TO THE POSSIBILITY OF A DILUTION OF THE ADDITIVES OR A REACTIONBETWEEN ADDITIVES OF DIFFERENT TYPES.
24 P/N: 307049
LUBRICATION
APPLICATION GUIDE
Not all lubricating oils are suitable for rotary screw compressor use. The most satisfactoryoils are the non-detergent types that contain high levels of corrosion, oxidation, and foaminhibitors.
Your Morse NK100 compressor is factory filled with Dextron III ATF. Other non-detergentmotor oils, SAE 10W, class SE or CD, and HD32 HYD OIL that meet the requirementsbelow can be used. However, Morse recommends you use Dextron III ATF.
The viscosity of the oil chosen depends largely on the ambient operating temperature range.The oil must provide sufficient lubrication for bearings and rotors at operating temperature,and it must have a pour point low enough to provide fluidity at low starting temperatures. Ingeneral, the viscosity range represented by these SAE grades is satisfactory for thetemperature range shown:
-20 degrees Fahrenheit to 120 degrees Fahrenheit HD 32 HYD OIL(-25 degrees Fahrenheit Pour Point)
-10 degrees Fahrenheit to 75 degrees Fahrenheit SAE 10 W(-20 degrees Fahrenheit Pour Point)
-40 degrees Fahrenheit to 120 degrees Fahrenheit Auto Trans. Fluid(-50 degrees Fahrenheit Pour Point)
PRIME LUBRICANT CHARACTERISTICS
1. Flash point 400°F minimum.2. Pour point -40°F.3. Contains rust and corrosion inhibitors.4. Contains foam suppressors.5. Contains oxidation stabilizer.
SYNTHETIC DIESTER ANDSYNTHESIZED HYDROCARBON LUBRICANTS OIL
All elastomeric components and all metal used in the compressor are fully compatible withsynthetic diester and synthesized hydrocarbon lubricants. The viscosity grade chosen forsynthetic diester base or SHC lubricants should be based upon the suggested viscosityranges listed under prime lubricant characteristics and the lubricant supplier.
25P/N: 307049
LUBRICATION
NOTE
NOTE
ENGINE LUBRICATION
Refer to Engine Operator’s manual for recommended engine lubricating oil.
COMPRESSOR OIL SUMP FILL, LEVEL, AND DRAIN
Before adding or changing compressor oil make sure that the sump is completely relievedof pressure. Oil is added at the fill cap on the side of the compressor. A drain plug isprovided at the bottom of the sump. The proper oil level, when unit is shutdown and has hadtime to settle is at the bottom of the threads in the oil fill port. The package must be levelwhen checking the oil. DO NOT OVERFILL. The oil sump capacity is given in “Compres-sor Specifications”.
DANGER
UNKNOWN INFLUENCES OF ENVIRONMENTAL FACTORS SUCH AS THE INTAKE OFREACTIVE GASES OR VAPORS IN THE AIR MAY LEAD TO CHEMICAL CHANGES INANY OIL. CAUSING PREMATURE FAILURE OF THE LUBRICANT AND THE USEFULLIFE OF ALL “EXTENDED LIFE” LUBRICANTS MAY BE SHORTER THAN QUOTED BYTHE LUBRICANT SUPPLIER. BECAUSE THE NORMAL “DRAIN AND REPLACE”PERIOD MAY BE EXCEEDED USING SYNTHETIC LUBRICANTS, DIFFERING FROMTHOSE SPECIFIED IN THIS MANUAL, MORSE ENCOURAGES THE USER TO CLOSELYMONITOR THE LUBRICANT CONDITION AND TO PARTICIPATE IN AN OIL ANALYSISPROGRAM WITH THE SUPPLIER.
NO LUBRICANT, HOWEVER GOOD AND/OR EXPENSIVE, CAN REPLACE PROPERMAINTENANCE AND ATTENTION. SELECT AND USE IT WISELY.
WHILE COMPRESSOR IS RUNNING DO NOT ATTEMPT TO DRAIN CONDENSATE,REMOVE THE OIL LEVEL FILL PLUG OR BREAK ANY CONNECTION IN THE AIR OROIL SYSTEM WITHOUT SHUTTING OFF COMPRESSOR AND RELIEVING PRESSUREFROM THE SUMP. FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGETO PROPERTY AND SERIOUS BODILY HARM.
26 P/N: 307049
MAINTENANCE
AIR INTAKE FILTER
The air intake filter is a heavy-duty single-stage high efficiency filter designed to protectthe compressor from dust and foreign objects. See compressor mounting system inillustration section.
Frequency of maintenance of the filter depends on dust conditions at the operating site.The filter element must be serviced when clogged.
AIR/OIL COALESCER
The air/oil coalescer employs an element permanently housed within a spin-on canister.This is a single piece unit that requires replacement when it fails to remove the oil from thedischarge air.
To replace element, P/N 304122, proceed as follows:
1. Shutdown compressor and wait for complete blow down (zero pressure).2. Turn element counterclockwise for removal (as viewed from top).3. Install new rubber seal in head and supply a film of fluid directly on the seal.4. Rotate element clockwise by hand until element contact seal (as viewed from top).5. Rotate element at edge of can one more turn clockwise with band wrench.6. Run system and check for leaks.
WARNING
DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE MORSE INDUSTRIALREPLACEMENT ELEMENT. THIS ELEMENT IS RATED AT 200 PSI WORKINGPRESSURE. USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULDIMPAIR THE PERFORMANCE AND RELIABILITY OF THE COMPRESSOR, POSSIBLYVOIDING THE WARRANTY.
27P/N: 307049
OIL FILTER
The compressor oil filter is a cartridge. It is designed with abuilt in by-pass so that if there is a large restriction, due to cold oil orclogged element, the compressor will still be lubricated.
To replace filter (P/N:306854) proceed as follows:
1. Make sure system pressure is relieved.2. Remove filter by unscrewing from filter head (one-fourth turn counterclockwise with bandwrench,
viewing from bottom, continue to remove by hand) and discard.3. Install a new filter by applying a little oil to the seal and then screw the filter on by hand (turning it
clockwise until hand tight, plus one-fourth turn with band wrench viewing from bottom).4. Check for leaks in operation.
MAINTENANCE
Minimum PressureValve
3/4” FNPTService Valve
Coalescer
Regulator Valve
WARNING
DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE MORSE INDUSTRIALREPLACEMENT ELEMENT. THIS ELEMENT IS RATED AT 200 PSI WORKINGPRESSURE. USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULDIMPAIR THE PERFORMANCE AND RELIABILITY OF THE COPRESSOR, POSSIBLYVOIDING THE WARRANTY.
28 P/N: 307049
TROUBLESHOOTING
UNPLANNED SHUTDOWN
When the operation of the machine has been interrupted by an unexplained shutdown, checkthe following:
1. Check to determine if compressor oil is at proper level.2. Check oil cooler for dirt, slush, ice on the fins, or any other obstructions to cooling
airflow.3. Make a thorough external check for any cause of shutdown such as broken hose, broken
oil lines, loose or broken wire, etc.4. Check the engine oil level with the engine stopped and in a level position. If the oil
level is low, remove the oil filler cap, and fill to the upper limit mark on the dipstickwith the recommended oil.
IMPROPER DISCHARGE PRESSURE
1. If discharge pressure is too low, check the following:a. Too much air demand.b. Service valves open blowing to atmosphere.c. Leaks in service line.d. Restricted compressor inlet air filter.e. Faulty control system operation (regulator, inlet valve etc.)f. Low engine speed.
2. If discharge pressure is too high or safety valve blows, check the following:
a. Oil separator plugged up.b. Faulty safety valve.c. Faulty regulator or set to high.d. Inlet valve leaking, or partially open. Loss of pressure signal to inlet valve from
regulator causing inlet valve to stay open.
29P/N: 307049
TROUBLESHOOTING
BLOWDOWN VALVE
If after the compressor is shutdown, pressure does not automatically blow-down, check for:
1. Automatic blowdown valve may be inoperative.2. Blockage in air line from compressor to blow down valve.3. Orifice at blowdown clogged.
ENGINE OVERHEATING
1. Low oil level, refill.2. Air blockage into engine fan.3. Air blockage from fan exhaust side of engine.4. Dirty oil in engine.5. Low engine coolant level.
COMPRESSOR
Abnormal compressor oil consumption or oil in service line, check for the following:
1. Over filling of oil sump.2. Leaking oil lines or oil cooler.3. Defective separator element.4. Compressor shaft seal leakage.5. Discharge pressure below 55 PSI.
SEPARATOR PLUGGING
If the separator element has to be replaced frequently because it is plugging up, it is anindication that foreign material may be entering the compressor inlet or the compressor oilis breaking down or excessive moisture is not being drawn from the unit.
Compressor oil can break down prematurely for a number of reasons.1. Extreme operating temperature2. Negligence in draining condensate from oil sump3. Using the improper type of oil4. Dirty oil.
The complete inlet system should be checked for leaks.
30 P/N: 307049
TROUBLESHOOTING
HIGH COMPRESSOR DISCHARGE TEMPERATURE
1. Check compressor oil level. Add oil if required (see section for oil specifications).2. Check engine fan and fan belt.3. Clean outside of oil cooler.4. Clean oil system (cooler) internally.5. Plugged compressor oil filter. Change element.6. Plugged oil return line, clean orifice and check valve.
INSUFFICIENT AIR DELIVERY
1. Plugged compressor air filter, clean or replace.2. Plugged air/oil separator. Replace separator element and also change compressor oil
and oil filter at this time.3. Defective pressure regulator, adjust or repair.
COMPRESSOR RECOMMENDED SPARE PARTS
Below you will find a list of parts we recommend you keep on hand for your compressor option.
YTINAUQ NOITPIRCSED REBMUNTRAP
1 TNEMELERETLIFRIA 290003
1 TNEMELERETLIFLIO 458603
1 NO-NIPS,RECSELAOC 221403
1 TIKRIAPERLAESTFAHS 358603
1 STLEBEVIRD 999603
1 ERUSSERPMUMINIMEVLAV 558603
1 EVLAVLAMREHT 658603
1 EVLAVTELNI 758603
1 NWODWOLB-ROTALUGERYLBMESSAEVLAV 858603
FOR ENGINE MAINTENANCE DETAILS,PLEASE REFER TO THE ENGINE MANUAL. **
31P/N: 307049
WARRANTY
SECTION
32 P/N: 307049
THIS PAGE WAS INTENTIONALLY LEFT BLANK.
33P/N: 307049
WARRANTY
Morse Industrial Equipment
6990 Cordingley Crescent
Mississauga ONTARIO L5N 4Z4
Phone: 647-393-1212
Fax: 905-824-9406
www.morseindustrial.ca
FOR DIESEL ENGINE WARRANTY REFER TO PERKINS MANUAL
Morse Industrial Equipment warrants that this generator unit conforms to applicable drawings andspecifications approved in writing by Morse. The unit assembly will be free from defects in materialand workmanship for a period of one (1) year from the date of initial operation or thirty (30) monthsfrom the date of shipment, whichever period first expires. All other components and parts of Morsemanufacture, will be free from defects in material and workmanship for a period of one (1) yearfrom the date of initial operation or eighteen (18) months from the date of shipment, whicheverperiod first expires. If within such period Morse receives from the Buyer written notice ofallegeddefect in or nonconformance of the unit, all other components and parts of Morse manufacture andif in the judgment of Morse these items do not conform or are found to be defective in material ofworkmanship, Morse will at its option either, (a) furnish a Service Representative to correct defectiveworkmanship, or (b) upon return of the item F.O.B. Morse original shipping point, repair or replacethe item or issue credit for the replacement item ordered by Buyer, (Defective material must bereturned within thirty (30) days of return shipping instructions from Morse. Failure to do so withinspecified time will result in forfeiture of claim), or (c) refund the full purchase price for the itemwithout interest. Factory installed compressor units will also include warranty on installation for aperiod of one (1) year. This warranty does not cover damage caused by accident, misuse ornegligence. If the generator or compressor unit is disassembled the warranty is void. Morse’s soleresponsibility and Buyer’s exclusive remedy hereunder is limited to such repair, replacement, orrepayment of the purchase price. Parts not of Morse manufacture are warranted only to the extentthat they are warranted by the original manufacture. Morse shall have no responsibility for any costor expense incurred by Buyer from inability of Morse to repair under said warranty when suchinability is beyond the control of Morse or caused solely by Buyer.
There are no other warranties, express, statutory or implied, including those ofmerchantability and of fitness of purpose; nor any affirmation of fact or representationwhich extends beyond the description of the face hereof.
This warranty shall be void and Morse shall have no responsibility to repair, replace, or repay thepurchase price of defective or damaged parts or components resulting directly or indirectly from theuse of repair or replacement parts not of Morse manufacture or approved by Morse or from Buyer’sfailure to store, install, maintain, and operate the equipment according to the recommendationscontained in the Operating and Parts Manual and good engineering practice. The total responsibilityof Morse for claims, losses, liabilities or damages, whether in contract or tort, arising out of orrelated to its products shall not exceed the purchase price. In no event shall Morse be liable for anyspecial, indirect, incidental or consequential damages of any charter, including, but not limited to,loss of use of productive facilities or equipment, loss of profits, property damage, expenses incurredin reliance on the performance of Morse, or lost production, whether suffered by Buyer or any thirdparty.
34 P/N: 307049
SUMMARY OF MAIN WARRANTY PROVISIONS
As claims, policies and procedure are governed by the terms of the Morse Industrial Equipmentwarranty, it is necessary to outline some of the more important provisions.
The Morse warranty applies only to new and unused products which, after shipment from the factory,have not been altered, changed, repaired or mistreated in any manner whatsoever. Normal maintenanceitems such as lubricants and filters are not warrantable items.
Parts not of Morse manufacture are warranted only to the extent they are warranted by the originalmanufacturer.
Damage resulting from abuse, neglect, misapplication or overloading of a machine, accessory or partis not covered under warranty.
Deterioration or wear occasioned by chemical and/or abrasive action or excessive heat shall notconstitute defects.
Parts replacement and/or correction of defective workmanship will normally be handled by Morse ortheir authorized distributor.
Failure to file a detailed warranty claim/service report for each occurrence of material defect ofdefective workmanship will cause warranty claim to be rejected.
Defective material must be returned within 30 days of receipt of shipping instructions. Failure to doso within specified time will result in forfeiture of claim.
The distributor is responsible for the initial investigation and write up of the warranty claim.
Distributor shall be allowed no more than 30 days from date of repair to file a warranty claim/servicereport.
Warranty for failure of Morse relacement parts covers the net cost of the part only, not labor andmileage.
The Morse warranty does not cover diagnostic calls and travel. That is time spent traveling to themachine to analyze the problem and returning with the proper tools and parts to correct the problem.
Morse will deduct from allowable credits for excess freight caused by sender failing to follow returnshipping instructions.
Distributors or end-users automatically deducting the value of a warranty claim from outstandingbalances due and payable to Morse prior to receiving written notification of Morse approval of thewarranty claim may be subject to forfeiture of the entire claim.
35P/N: 307049
The warranty policy and procedures outlined here within are detailed to provide the claimant withthe information necessary when filing a warranty claim, and enabling Morse the ability to best serveit’s customers.
WARRANTY CLAIMS - GENERAL
An approved claim depends on the following provision:
1. A warranty claim/service report # must be issued by Morse. (See filing procedures).2. Failed part must be returned within 30 days, freight prepaid, with receipt of warranty claim/
service report.3. Part is definitely defective.4. Workmanship is definitely defective.5. Machine is within warranty period.6. Machine has been operating within design conditions.
Claims made by customers must be verified by distributor prior to contacting Morse.
WARRANTY CLAIMS - FILING PROCEDURES
1. Initiate through purchase order for warranty part or request for credit.2. Warranty Claims/Service Report will accompany replacement part. When returning failed part
to the factory for warranty credit, fill out all information requested on Warranty Claims/ServiceReport when it is returned to you with replacement part.
3. Morse will confirm disposition of failed part within 30 days, and or request additionalinformation.
4. Claim acceptance or denial will result in release of a credit or confirmation letter of denial.5. Morse will consider each claim on it’s own merit and reserves the right to accept or reject
claim request. In case of air-ends, these will be returned to the manufacturer for their analysis/input.
6. Send Warranty Claim/Service Report request to:
Morse Industrial Equipment6990 Cordingley CrescentMississauga ONTARIO L5N 4Z4
Phone: 647-393-1212Fax: 905-824-9406www.morseindustrial.ca
WARRANTY INTRODUCTION
36 P/N: 307049
Parts returned to the factory must be properly packaged to prevent damage during shipment.Damage to a part as a result of improper handling or packing could be cause for claimsdisallowance of credit. When addressing the package for shipment, the following information mustbe on the outside of or tagged clearly to package.
1. Return Goods Authorization number.2. Distributor or end-users return address.3. Correct factory address.4. Warranty Claim/Service Report number.5. Number of packages pertaining to each claim.
NOTE: Our warranty requires that all defective parts be returned to Morse freightprepaid. Items sent without RGA number will not be accepted.
DAMAGE IN TRANSIT
Do not return damaged merchandise to Morse Industrial, Inc. please follow claim procedure.
1. Loss in transit:All equipment is tested prior to shipping from our facility. Rregardless of the care taken at the
factory, there is a possibility that damage may occur in shipment. For this reason, it isrecommended that the unit be carefully inspected for evidence of possible damage or malfunctionduring the first few hours of operation. Responsibility for the safe delivery of the equipment wasassumed by the carrier at the time of shipment. Therefore, claims for loss or damage to theequipment should be made upon the carrier.
2. Concealed loss or damage:Concealed loss or damage means loss or damage which does not become apparent until theequipment is unpacked or ran by the end-user. The equipment may be damaged due to roughhandling while in route to its destination, even though the unit shows no external damage. Whenthe damage is discovered upon unpacking, make a written request for inspection by the carrieragent within fifteen days of delivery date. Then file a claim with the carrier since such damage isthe carrier’s responsibility.
WARRANTY CLAIMS - PREPARATION OF PART RETURN
By following these instructions carefully, we guarantee our full support of your
claims, to protect you against loss from concealed damage.
3. Visible Loss or Damage
Any external evidence of loss or damage must be noted on the Freight Bill or
Express Receipt, and signed by the carrier’s agent. Failure to adequately describe
such external evidence of loss, or damage may result in the carrier refusing to
honor a damage claim. The carrier will supply the form required to file such a
claim.
37P/N: 307049
Warranty Registration
To: Fax:
From: Date:
Re: Pages:
Name: Phone:
Address:
City: State: Zip:
Contact:
Name:
Address:
City: State: Zip:
Contact:
Date Product in Service:
ONE REGISTRATION FORM PER UNITRegistration form must be mailed or faxed within 15 days of customer installation.
Mail to:
Morse Industrial Equipment
Warranty Department
6990 Cordingley Cresent
Mississauga, Ontario L 5N 4Z4
Date Product Delivered: Compressor Serial No.:*
Product Information: (Required for Warranty Activation)
Model No.:
E-mail Address:
Distributor Information: (Required for Warranty Activation)
Product Registration
E-mail Address:
(Required for Warranty Activation)
MORSE INDUSTRIAL EQUIPMENT WARRANTY REGISTRATION
(905)824-9406Warranty Department
End User Information:
Fax Transmission
* if units equipped with compressor option
Serial No.:
Phone: 647-393-1212
Fax: 905-824-9406
Warranty Registration Rev. 10/ 31/ 06Warranty Registration
38 P/N: 307049
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39P/N: 307049
ILLUSTRATION DRAWINGS
40 P/N: 307049
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41P/N: 307049
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THIS DRAWING AND ALL
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G:\INVENT OR53\
Rev. Num. Rev. Date EN Num.Released For
OPT, NEMA BOX GAUGE BOX - HZ-VOLT-AMP
61118-999
1 1
0D
JPC 1/19/2007
60K
AS NOTED
1=2
Miss issauga OntarioPhone: 647-393-1212
Fax: 905-824-9406
Parts ListITEM QTY PART NUMBER DESCRIPTION
1 1 305696 BOX, NEMA1 W-HZ-VOLT-AMP 40KW
1.1 1 305696A COVER, NEMA1 BOX1.2 1 305696B BASE, NEMA1 BOX1.3 1 305696C GROMMIT, 1"1.4 4 305696D BOLT, 1/4"-20
1.5 4 305696E ISOLATOR, 5/16 X 2 1/2 RUBBER1.6 8 305696F WASHER, LOC GR5 5/161.7 8 305696G NUT, HEX GR5 5/16-182 1 306047 PLATE, MTG 40KW GAUGE BOX TO GEN (REV 1)3 1 306824 DIAGRAM, WIRING GENERATOR 40 & 60KW
GAUGE PANEL
1.4
1.1
1.7
1.6
1.4
1.5
21.6
1.7
1.2
1.3
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MATERIALG:\INVENTOR53\
Rev. Num. Rev. Date EN Num.Released For
DIAGRAM, WIRING GENERATOR 30, 40 & 60 KW
306823
1 1
0A
JPC
300K
NA
NA
Mississauga OntarioPhone: 647-393-1212
Fax: 905-824-9406
(FA
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