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CAP-600XMAY, 2005WARNINGBefore installing and operating this compressor, readand understand the safety precautions contained inLV-474 supplement to and part of CAP-600IMPORTANTMake a permanent record of theModel and Serial number ofyour machine here. You’ll savetime and expense by includingthis reference identification onreplacement part orders.CURTIS-TOLEDO, INC.1905 Kienlen AvenueSt. Louis, MO 63133REFER TO MODEL & SERIAL NUMBER.READ INSTAL. & OPERATION INSTR.DO NOT OPERATE LOWER THAN 500R.P.M. OR ABOVE MAX. AS STIPULATEDBY PERFORMANCE DATA SHEET.MODEL NO.SERIAL NO.*CONSULT FACTORY FOR SPECIAL APPLICATIONSCURTIS-TOLEDO, INC.1905 Kienlen Avenue, St. Louis, Missouri 63133phone: 314-383-1300fax: 314-381-1439Sales representatives in principal citiesinfo@curtistoledo.com

CAP-600INSTALLATIONOn basic or base mounted compressors run adischarge pipe to the receiver or optionalaftercooler and bush up or down as necessary.The pipe should enter near the top of the receiver.Keep in mind that condensate may form in thedischarge line; therefore, the lines should alwaysbe pitched to drain condensate away from thecompressor. Always provide a safety relief valve inthe discharge line between the compressor and inline shutoff valves. If more than one compressorpumps into a common system, a check valve in thedischarge line of each compressor is recommendedto prevent moisture from entering the cylinder headwhen one compressor is idle. A globe or gate valveinstalled in the discharge line will allow compressorisolation from plant air system for compressormaintenance. (Note: A safety relief valve should belocated between the compressor and theglobe/gate valve.)CONGRATULATIONS on your new CurtisChallenge Air Compressor. Please examine thecompressor for shipping damage(s) and if any arefound report it immediately to the carrier.Select a clean dry location with a rigid floor strongenough to support the compressor. If thecompressor is to be located in an area wherevibration is critical, properly engineered vibrationmounts and flexible piping should be used.Remove the skid. NOTE: The compressor shouldnever be operated on the shipping skid. Levelthe compressor so it can be bolted down securely.Before tightening the bolts, check to see that allfour feet are resting on the foundation. Shim asnecessary to eliminate stress on the receiver orbase when the bolts are tightened. We suggestusing a level for proper alignment.Maximum ambient temperature in which thecompressor and motor should be operated is104 F. Therefore, adequate ventilation must beprovided.Check the electrical supply for voltage, phase, andfrequency to see that they match the nameplatestampings on the motor, magnetic starter,solenoids, and other controls. Use electrical wiresof adequate size to carry the full load current of themotor without excessive voltage drop. Charts areavailable from Curtis (upon request) to provideinformation on this. The motor must always beprotected by a starter with properly sized thermaloverload(s). The starter should protect the motorfrom overheating and burnout due to an overload,low voltage or single phasing of a 3-phase circuit.Failure to install the proper starter andoverloads will void the motor manufacturerswarranty. Follow the National Electric Code orlocal electric code in providing wiring, fusing anddisconnect switches. NOTE: Do not close thedisconnect switch to start the compressor untilthe procedures outlined under "StartupProcedures" have been completed.The suction openings of the compressor areequipped with a combination air filter-muffler toprotect the compressor from normal dust and otherharmful substances. If the air around thecompressor is excessively hot, dusty, humid orcontaminated with foreign gases (such as ammoniaor acid fumes) move the filter-muffler to a remotepoint where the air is clean, cool and dry. Run apipe to the compressor suction opening. If the runis over 50 feet in length, use a larger pipe to avoidexcessive pressure drop. In order to fit the filter tothe compressor, bush down the connections. Besure piping and fittings are clean and free from dirtand chips. If the filter is installed outside, check toinsure that it is located above the normal outsidedust level, and that rain cannot enter the filterelement. Where the relocation of the filter-muffleris not possible or feasible, an oil bath filter isrecommended and is available from Curtis.LIMITED SAFETY PRECAUTIONS(Also see supplement LV-474)The following safety precautions are recommendedin the use of this compressor:1. Use a totally enclosed OSHA-approved beltguard to cover the drive assembly. Wherepossible, place the flywheel toward the wall, andmount the unit a minimum distance of 2 feet fromthe wall for maintenance convenience.2. Turn off & lock out the electrical disconnectswitch before working on the unit to prevent theunit from starting unexpectedly3. Release all air pressure from the system beforeworking on the unit and red tag all electricalcontrol switches, for safety precaution.4. Do not by-pass motor over-current protection.5. Do not change the setting or in any way affectthe operation of the safety valve.6. Keep unit securely anchored so that movementwill not put a strain on piping, wiring, or airreceiver.WARNING: Read and understand supplement LV-474 before installing and operating the compressor.2

CAP-600START-UP PROCEDURESOIL RECOMMENDATIONUse a good grade of industrial compressor oil (nondetergent) with foam, rust and oxidation inhibitors and aminimum life of 1500 hours in the ASTM D 943 test foroxidation stability.Ambient Temperatures:0 - 32º F -Viscosity 180 to 240 SUS at 100º F.Minimum pour point of - 20º F.Grade ISO 4Approved listing:Chevron-Turban GST Oil 46.Amoco-Amokon Oil 46.Conoco-Turban Oil 46.Shell-Turbo Oil T-46.Texaco-Regal R & O Oil 46.Exxon- Teresstic Oil 4632 - 100º F Viscosity 300 to 350 SUS at 100º F.Grade ISOApproved listing:Chevron-Turban GST Oil 68.Amoco-Amokon Oil 68.Conoco-Turban Oil 68.Shell-Turbo Oil T-68.Texaco-Regal R & O Oil 68.Exxon- Teresstic Oil 68100 - 110º F Viscosity 450 to 550 SUS at 100º F.Grade ISO 100.Approved listing:Chevron-Turban GST Oil 100.Amoco-Amokon Oil 100.Conoco-Turban Oil 100.Shell-Turbo Oil T-100.Texaco-Regal R & O Oil 100.Exxon- Teresstic Oil 100If the compressor is equipped with an automatic start-stopcontrol (with pressure switch unloading), it is automaticallyunloaded upon starting, and will automatically load afterattaining running speed. If the compressor is equipped witha constant speed control (pilot valve unloading), it isnecessary to manually unload the compressor, if there ispressure in the discharge line, in order to achieve anunloaded start. The compressor must be manually loadedafter the compressor has attained full running speed,thereafter, it functions automatically to maintain operatingpressure until the unit is shut off.Close the disconnect switch and start the compressor.Observe the direction of rotation, which should becounterclockwise when viewed from the flywheel side of thecompressor on all models. For single-phase units, thedirection of rotation is determined by the motor nameplateinstructions, and is adjusted at the factory. For three-phaseunits, if the rotation is incorrect, stop the unit andinterchange any two of the three wires to the motor at thedisconnect switch. This will reverse the direction of rotationof the motor and compressor.PREVENTIVE MAINTENANCEA good maintenance program will add years of service toyour air compressor. The following is recommended as aminimum maintenance program. (TURN OFF POWERBEFORE SERVICING.)3. Check for unusual noise or vibration (See "Trouble Shooting".)WEEKLY MAINTENANCE1. Clean the air filters. A clogged air filter can seriously affect theefficiency of the compressor and cause overheating and oilusage.2. Clean all external parts of the compressor and driver. Be sureto clean the intercooler-finned surface on two-stagecompressors. A dirty compressor will cause abnormally highdischarge temperature and resulting oil carbonization oninternal valve components3. Check the safety valve manually (by pulling ring or lever) tosee that it is not stuck.LUBRICATION1. For proper lubrication the compressor shall not beoperated below the minimum or above the maximum R. P.M.recommended for the various models.2. Maintain oil level mid-way between the upper and lower linesof the crankcase sight gage. NOTE ILLUSTRATION:MONTHLY MAINTENANCE1. Inspect the entire air system for leaks.2. lnspect condition of oil and change if necessary.3. Check drive belt tension and tighten if needed.EVERY 3 MOS. OR 1,000 HRS. OF OPERATION1. Change oil.2. lnspect valves. Clean the carbon from valves and head ifnecessary.3. Check and tighten if necessary all bolts, nuts, etc.4. Check unloader operation.3. Stop compressor to add and gauge oil.4. Do not fill above the upper line and do not operate compressorwith oil level below the lower line.DO NOT OVER FILL5. Change oil at the first 100 hours of operation and 1000 hoursthereafter, or as required. It may be necessary to change oilmore frequent due to abnormal humid and contaminatedconditions.*CHECKING BELT TENSIONThe v-belt(s) should be adjusted so that a declination of about 3/8– 1/2 inch will be obtained when it is pushed by a finger at themiddle point as shown in Figure 1.CAUTION: Over tightening the v-belt(s) will result inoverloading of the motor and belt failure, while a loose beltwill be slipping and resulting in an unstable speed,overheating the belt and high amp draw.DAILY MAINTENANCE1. Check and maintain oil level at centerline of sight glass andadd oil as necessary.2. Drain condensate from receiver unless it is equipped with anautomatic tank drain, in which case the drain should bechecked weekly to see that it is operating. See automatic tankdrain instructions.WARNING: Read and understand supplement LV-474 before installing and operating the compressor.3

CAP-600To change tension, loosen the motor hold-down bolts andslide the motor on the base, using a lever if necessary, orby turning the adjusting bolt at the end of the base.Retighten motor hold-down bolts.NOTE: Do not over tighten belts.ELECTRIC MOTORGrease once a year with a good grade of lithium ballbearing grease, or as directed by the motor manufacturer.Figure 1VALVE INSPECTION AND MAINTENANCEValves should be inspected at regular intervals asrecommended under "Maintenance" and cleaned orreplaced when necessary. The valve can be servicedwithout disconnecting air piping or removing the head.(Be sure the power to the motor is disconnected andall pressure released before starting to work on thecompressor.)5. Check the valves to see if they can move freely in theirguides.6. Turn over the cylinder head (70112-11010).7. Place the inlet valve plate (70112-31030) in position.8. Insert the small end of inlet valve spring (7011231070) into position of valve receiver (70112- 31020).9. Screw inlet valve receiver in position.10. Check the valves to see if they can move freely in theirguides and do not pinch or bind between the seat andguard legs.On constant run models, it is necessary to remove theunloader piping before the valve plugs can be removed.MODELS E-11 AND E-23 (Figures 2 and 3)A. Disassembly:1. Unbolt the outlet valve push cover (70112- 11450).2. Remove the outlet valve push cover packing (7011211650), spring (70112-41070) and valve plate (7011231030). CAUTION: Steps 1 and 2 are for outletvalve.3. Remove the unloading connecting tube for ModelsE-11 and E-23.4. Untighten four cylinder head fixed bolts.5. Remove cylinder head carefully and turn it over.6. Unbolt inlet valve receiver (70112-31020).7. Remove valve spring (70112-31070) and valve plate(70112-31030).Figure 2Valves should be inspected approximately every 1,000hours of operation. Inspect the valve seats oncylinder head for dents, cracks or wear. Replace alldefective parts. Remove carbon deposits and wash allvalve components in a suitable non-flammablecleaning fluid.B. Assembly:1. Place outlet valve plate (70112-31030) in position.2. Place the outlet valve push cover packing (7011211650) in position.3. Insert the spring (70112-41070) into outlet valve pushcover (70112-11450).4. Turn outlet valve push cover (70112-11450) in positioncarefully.Figure 3WARNING: Read and understand supplement LV-474 before installing and operating the compressor.4

CAP-600MODELS E-50, E-71 AND E-15 (Figures 4 and 5)D. Reassembly of Outlet Valve Assembly1. Place valve spring (70123-41070) in valve receiver70123-41020).2. Place valve plate (70123-31030) in valve receiver.(70123-41020).3. Insert the sub-assembled part (assembled instep I and 2) into valve seat (70123-41010).4. Tighten the hex nuts.5. Check the valves to see if they can move freely in theirguides and do not pinch or bind between the seat andguard legs.A. Disassembly of Inlet Valve Assembly (Figure 4).1. Untighten the hex nut.2. Remove unloading fork (70123-31080), unloading forkguide (70123-31090), unloading spring (70123-11230)and valve seat (70123-31010).CAUTION:1. If a vise is used to hold the valve assembly, becareful not to clamp the assembly too tight.2. Valve assembly should be inspected approximatelyevery 1,000 hours of operation.3. Inspect the valve seat for dents, cracks or wear.4. Replace all defective parts.5. Valve seats that might be worn after years ofoperation can be re-lapped or re-ground, in thiscase the recess in which the valve guard legs fitmust also be cut down accordingly to ensure asame valve lift.6. Remove carbon deposits and wash all valvecomponents in a suitable non-flammable cleaningfluid.B. Reassembly of Inlet Valve Assembly1. Place valve spring (70123-31070) and valve plate(70123-31030) on valve receiver (70123-31020).2. Place valve seat (70123-31010), unloading fork guide70123-31090), unloading spring (70123- 11230) andunloading fork (70123-31080) respectively.3. Tighten the valve assembly by tightening the hex nut.4. Check the valves to see if they can move freely in theirguides and do not pinch or bind between the seat andguard legs.C. Disassembly of Outlet Valve Assembly (Figure 5)1. Untighten the hex nuts.2. Remove valve receiver (70123-41020), valve spring(70123-41070) and valve plate (70123-31030).FIGURE 4(EXAMPLE SHOWN E-50)CAUTION: Refer to disassembly of inlet valve assembly(paragraph B).FIGURE 5(EXAMPLE SHOWN E-50)WARNING: Read and understand supplement LV-474 before installing and operating the compressor.5

CAP-600VALVE ASSEMBLY INSTALLATION - E-50 MODELPISTON RINGS (Rebuild Kit)To inspect or replace piston rings as follows:1. Remove cylinder head.2. Remove cylinder.3. Loosen the connecting rod bolts.4. Push out the piston with piston rings and connectingrod.5. To remove the old rings, pry them out of their groovesand slide them over the piston. Care should be takennot to damage the piston.6. Inspect the ring grooves for nicks and carbon deposits.Clean the ring grooves and remove the obstructions,which might prevent the rings from moving freely.(Figures 6 and 7)1. Install valve assembly gasket (70123-11110)2. Install valve assembly (70123-31000).3. Install valve push cover (70123-11150).4. Install head bolt and tighten evenly and securely.It is strongly recommended that a PreventativeMaintenance Kit & Valve/Gasket Maintenance Kit be kepton hand. In this manner, the valves can be used in turn tokeep the compressor always in good condition and aminimum downtime.To install new rings on the piston as follows: (Becareful not to damage the piston and rings).1. Install the oil control ring (70123-61050) first. Rotatering in groove to make sure it is free.2. Install the Compression ring (70123-61030). Make surethe "top" or "R" mark is exactly on top. If not, it mightcause excessive oil consumption.3. Repeat the process with other rings, if any.4. Assemble connecting rod into the crankshaft. Be surethat the connecting rod and its cap are in original pairand position, since the connecting rod cap andcrankshaft pin bushing are selected fitted and are notinterchangeable.5. Check if the ring gaps are in proper positions (Figure 8).FIGURE 6FIGURE 8WARNING: Read and understand supplement LV-474 before installing and operating the compressor.6

CAP-600 REBUILD KITSAIR COOLED SINGLE STAGE MODELSES03PARTNO.ES05PARTNO.CONSISTS 5796092521-190600Filter ElementValve DiscSpringSpringGasketHead GasketComp. RingOil RingBottom Cover GasketFront bearing cover gasketFront Oil SealRear Cover GasketCopper 5797092521-190600Filter ElementValve DiscSpringSpringGasketHead GasketCrankcase GasketComp. RingOil RingFront Cover GasketRear Cover GasketBottom Cover GasketCopper WasherES-30PARTNO.CONSISTS OF:CF1246REBUILD KIT 12-5796070112-5708092521-19080070112-11461Filter ElementValve DiscSpringSpringComp. RingOil RingHead GasketCrankcase GasketFront Cover GasketRear Cover GasketOil SealCopper WasherCopper GasketES10, ES10PPARTNO.CONSISTS OF:24222224211124CF1237CONSISTS OF:12112111111121Filter KitDiscSpringSpringCompression RingOil RingSeat GasketHead GasketCrankcase GasketFront Cover GasketRear Cover GasketFront Oil SealBushingSet, Rod BearingCopper 21-19080070112-11461ES-50PARTNO.CONSISTS OF:CF12523CF124563363CF1244PREVENTATIVE MAINTENANCEKIT INCLUDES70123-66140Filter ElementVALVE / GASKET MAINT. KIT 1070123-11612DiscSpringSpringSeat GasketHead GasketREBUILD KIT -57960Front Oil SealCompr.RingOil RingBushingSet, Rod BearingCrankcase Gasket3492521-191000Copper WasherFrt. Brg. Cvr. GasketRear Brg. Cvr. GasketES20PARTNO.CONSISTS OF:Filter ElementDiscSpringSpringCompression RingOil RingHead GasketCrankcase GasketFront Cover GasketRear Cover GasketFront Oil SealCopper WasherCopper GasketCF1239ES-100PARTNO.CONSISTS OF:PREVENTATIVE MAINTENANCEKIT INCLUDESCF1252370123-66140Filter ElementCF1252363363639633**CF12421663631134REBUILD KIT pr.RingOil RingBushingSet, Rod BearingCrankcase GasketFront Oil Seal92521-191000Copper WasherFrt. Brg. Cvr. GasketRear Brg. Cvr. GasketPREVENTATIVE MAINTENANCEKIT INCLUDESFilter ElementVALVE / GASKET MAINT. KIT 1124CONSISTS OF:70123-66140CF1241DiscSpringSpringSeat GasketHead Filter ElementDiscSpringSpringCompression RingOil RingHead GasketCrankcase GasketFront Cover GasketRear Cover GasketFront Oil SealCopper WasherCopper GasketES-150PARTNO.CF1243 VALVE / GASKET MAINT. KIT 11070124-11612CONSISTS OF:36336333111263DiscSpringSpringSeat GasketManifold GasketHead GasketHead GasketREBUILD KIT 21-191000Front Oil SealCompression RingOil RingBushingSet, BearingCrankcase GasketFrt. Brg.Cvr GasketRear Brg.Cvr GasketCopper WasherES-150APARTNO.CONSISTS OF:CF1

Chevron-Turban GST Oil 46. Amoco-Amokon Oil 46. Conoco-Turban Oil 46. Shell-Turbo Oil T-46. Texaco-Regal R & O Oil 46. Exxon- Teresstic Oil 46 32 - 100º F - Viscosity 300 to 350 SUS at 100º F. Grade ISO Approved listing: Chevron-Turban GST Oil 68. Amoco-Amokon Oil 68. Conoco-Turban Oil 68. Shell-Turbo Oil T-68. Texaco-Regal R & O Oil 68.

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