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