. ¤ R ¤ Reciprocating Air Compressors ¤ R Operation and Maintenance Manual R Jenny Products, Inc. ¤ 850 North Pleasant Avenue Somerset, PA 15501-1069 Ph:814-445-3400 ● Fx:814-445-2280 www.jennycompressor.com ● info@jennycompressor.
Table of Contents Section 1 Safety and Health Instructions Safety and Health Instruction for Safe Use.................... 5 Section 2 Introduction and Description Introduction.................................................................... General Description........................................................ Major Components......................................................... Reciprocating Air Compressor Assembly....................... Single Stage and Two Stage Reciprocating Pumps.......
Thank you ! For ordering a JENNY®. Jenny has been a manufacturer of high quality equipment since 1929. Special attention has been given to every detail of engineering design, perfection of manufacturing methods, individual part inspection, and thorough testing upon completion to assure the continuous trouble-free operation of your Jenny. In short, your Jenny was designed and made by customer-minded workers.
Section 1 Safety and Health Instructions 4
Important! SAFETY AND HEALTH INSTRUCTIONS FOR SAFE USE ! DANGER THIS PRODUCT CAN CAUSE SERIOUS INJURY OR DEATH IF NOT USED IN ACCORDANCE WITH THE FOLLOWING SAFETY INSTRUCTIONS. WE CAN NOT ANTICIPATE EVERY POSSIBLE CIRCUMSTANCE THAT MIGHT INVOLVE A POTENTIAL HAZARD. THE WARNINGS, CAUTIONS, DANGERS, AND SAFETY SUGGESTIONS ARE THEREFORE NOT ALL INCLUSIVE. AS THE OWNER YOU ARE RESPONSIBLE FOR THE SAFE OPERATION OF THIS EQUIPMENT.
Do not replace a fuse or circuit breaker with one of a higher rating without being certain the wire size is adequate to handle the increased electrical load. Keep all electrical connections dry and off of the ground. Observe all local and national codes for the installation and use of this type of equipment. Please use the following criteria for wire selection. • • • • 0 to 25 Feet from Main Power Source - At least the same size wire. 25 to 50 Feet from Main Power Source - At least one wire size larger.
6. Do not operate this unit with any components rated less than the maximum operating pressure of the unit. This unit was designed to compress air at a specific operating pressure and volume. Never exceed the pressure rating of air tools, spray guns, air operated accessories, tires, and other inflatables. This can cause them to explode or fly apart and could result in a serious injury. 7. Do not direct air stream at people, animals, or any living thing. Use only OHSA approved air blow guns.
10. Never modify or alter this unit. For your own safety as well as others, never allow this unit to be altered or modified. Modifying or altering equipment to operate in a fashion other than its original design may cause serious injury or death. Never exceed the factory pressure or temperature rating of the system. Be sure that all accessory equipment and system components meets or exceeds the pressures and temperatures developed by the unit. 11.
15. Do not operate near flammable or combustible materials. This product is not intended for use in locations where fire or explosion hazards may exist due to the presence of flammable vapors, liquids or gases, or combustible dusts or fibers. Heat generated by the compression cycle and/or drive system is released into the atmosphere and can cause materials in close proximity to reach their flash temperatures and ignite or explode. Always operate the compressor in a well ventilated area.
Safety Data Sheet (MSDS) for the material being used. Use a NIOSH/MSHA approved respirator designed for use each specific application. Always wear the appropriate approved safety equipment. Always operate the compressor in a well ventilated area. Always store flammable materials in a secure location away from all open flames, sparks, and heat sources. 19. Use this machine only in a well ventilated area. This unit requires adequate ventilation.
22. Do not permit untrained personnel to maintain or make repairs on this unit. Only qualified personnel should be permitted to make any type of repairs to this unit. Improper repairs may cause this unit to malfunction which could result in serious injury or death to the operator, repair person, or bystander. 23. Risk of Asphyxiation. The pressurized spray from this unit can cause particles as well as vapors to become airborne. Keep a safe distance from the vapors and airborne particles.
30. Always release the system pressure prior to service, storage, daily shutdown, and/or disconnecting the hose or from the unit. Always release pressure prior to service, storage, daily shutdown, and/or disconnecting the hose from the unit. Pressure contained within the unit could be released unexpectedly and could cause injury. 31. Never leave an operating machine unattended. Always shut off the machine and relieve the system pressure before leaving the unit. Never leave an operating machine unattended.
35. Do not touch the exhaust system, cylinder head or crankcase when hot. (If gasoline engine equipped) The crankcase, cylinder head, exhaust system, and other components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running - or immediately after it is turned off. Never operate the engine with heat shields or guards removed. 36. Do not inhale engine exhaust gases.
Section 2 Introduction and Description 14
INTRODUCTION This manual contains operation and service instructions for the Jenny Air Compressors.
or gasoline engine V-belt drive sheave assembly. The pumping unit is either a Single Stage or Two Stage Reciprocating Pump. SINGLE STAGE AND TWO STAGE RECIPROCATING PUMPS Reciprocating (Piston) Compressors can be widely found in these two primary configurations; Single Stage and Two Stage. Single stage air compressors work by drawing free air in and subsequently compressing the air to its final pressure in a single piston stroke. Single stage air compressors can attain pressures of up to 150 PSI.
valve directs the flow into the air system or to the atmosphere. Start-Stop Control Units As with constant run units, the air intake is controlled by air pressure demand. Instead of being controlled by a pilot valve, Start-Stop units are controllled by an electrical switching device, called a pressure switch. When the system reaches a designated pressure, or maximum pressure set point, the pressure switch de-energizes the electric motor.
motor. Once the air demand drops the system pressure to a predetermined set point, the pressure switch activates and closes the switch and subsequently starts the electric motor. Many pressure switches also contain a special unloading device which relieves the pressure from the compressor pump when the motor is shut off. PRESSURE REGULATOR The pressure regulator is used to maintain a constant outlet pressure. It allows adjustment to any desired pressure below the maximum outlet pressure of the compressor.
Section 3 Preparation for Use and Initial Installation Instructions 19
PREPARATION FOR USE GENERAL The Jenny Air Compressor unit was thoroughly tested at our factory as part of the manufacturing process. The machine will function as designed if properly assembled, set up, and operated. There are certain steps that must be taken prior to attempting to operate unit to assure it is ready for operation. INSPECTION OF NEW EQUIPMENT 1.) Check the box or crate for possible shipping damage. If extensive damage is apparent to the box, please notify the freight carrier immediately.
9.) Inspect all tubing and piping for loose connections or damage. 10.) Check all accessories for damage and loose mountings. SERVICING NEW EQUIPMENT 1.) Remove the unit from the shipping pallet and place on a level surface. This can be accomplished by removing the shipping bolts or bands located at the four corners of the base weldment or receiver tank. 2.) Check oil level in pump, safety relief valve operation, air filter cleanliness, air receiver condensate as specified in Section 4. 3.
! CAUTION This unit requires adequate ventilation and must be placed in a location which provides at least three feet of clearance to all adjacent construction. Failure to allow adequate ventilation or restrict the air flow may cause the machine to overheat. Damage to the machine, operator, and any other unit, product, and accessory in the air stream may result. Compressors run out of level by over 10 degrees may be permanently damaged.
4.) Ensure the new equipment service was performed prior to operation. 5.) Review all Danger, Warning, and Caution information located on the machine and in the Operator’s Manual. 6.) Check to be certain that all the control switches are in the off position. ! WARNING The unit is capable of starting automatically. 7.) Turn the power on to the machine. 8.) Start the unit.
Section 4 Operating Instructions 24
OPERATING INSTRUCTIONS This section describes the operating controls and indicators, detail theory of operation, and operating procedures. OPERATING CONTROLS AND INDICATORS Jenny compressors are designed to be highly reliable and very simple to operate. Therefore, there are only a few operating control and indicators. They are as follows: On/Off Switch (SW-3, SW-4, Start/Stop Control & Dual Control)- A switch which allows the operator to manually turn the machine on and off.
can be switched from either operating mode by opening and closing a ball valve. The pilot valve is used to control the compressor when operating in the constant run and the pressure switch is used to control the compressor when operating in the stop/start mode. A good rule of thumb in determining which is the best mode of operation is by the amount of time the compressor will be required to supply air.
AIR CLEANER The air cleaner is of the dry, replaceable type. One of the most important service requirements for long term maintenance free operation is to replace or clean the air cleaner element regularly. ! CAUTION Excessive wear, high oil consumption and poor performance will result if the air cleaner is clogged or allows contamination to enter the compressor. Refer to maintenance instructions in Section 5 for service instructions and intervals for cleaning or replacement of element.
Never decouple the quick coupler when the machine is running. ! WARNING Always release the pressure in the system before coupling or decoupling. DRAINING AIR RECEIVER CONDENSATE 1. Ensure that the ON/OFF switch is in the OFF position or disconnect the power from the power source. 2. If the unit is portable, move the compressor into an inclined position so that the drain valve(s) are at the lowest point (this will assist in removing moisture, dirt, etc. from tanks) 3.
3. Replace the safety hitch pin in the guard. 4. Check and/or replace the plug with the UL/CSA listed plug for the rated current and voltage. Follow the cord plug manufacturers installation instructions and procedures or contact a qualified electrician. Ensure that all connections are properly tightened. Improper connections could result, causing damage, injury, or death of the equipment operator.
TRANSPORTING (Portable Compressors) If the unit is a portable type either hand carry or wheeled portable, care must be taken when transporting the compressor. When transporting the compressor in a vehicle, trailer, etc. ensure that the tanks are drained and the unit is secured and placed on a flat horizontal surface. Secure the machine in place by use of a rope or some type of strapping. Use care when driving so to avoid tipping the unit over in the vehicle.
CONDENSATE DISCHARGE PIPING If installing a condensate discharge line, the piping must be at least one size larger than the connection, as short and direct as possible, secured tightly and routed to a suitable drain point. Condensate must be disposed of in accordance with local, state and federal laws and regulations. REFUELING (If gasoline engine equipped) The fuel tank is located on top of the gasoline engine or in an approved red gasoline container. Always refuel with care.
not connect the equipment-grounding conductor to a live terminal. Check with a qualified electrician or service personnel if the grounding instructions are not completely understood or if in doubt as to whether the unit is properly grounded. ! CAUTION Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles.
! CAUTION Do not operate this unit with any components rated less than the maximum operating pressure of the unit. 9.) If machine is electric powered, connect electrical service using a fusible disconnect switch. Ensure that the machine is connected to the proper power supply both amperage and voltage. Ensure that all connections are properly tightened. Improper connections could result, causing damage, injury, or death of the equipment operator.
Start/Stop Control If the unit is Start/Stop equipped and does not have an On/Off switch turn the OFF-AUTO (MAN) switch from the OFF position to either the MAN or AUTO position. If the unit is equipped with an On/ Off switch move the switch to the On position. Dual Control If the unit is Dual Control equipped and does not have an On/Off switch turn the OFF-AUTO (MAN) switch from the OFF position to either the MAN or AUTO position.
switch from either the MAN or AUTO position to the OFF position. If the unit is equipped with an On/ Off switch move the switch to the OFF position. Stopping Gasoline Engine (If so equipped) If so equipped, your air compressor is powered by a gasoline engine. Most accidents with engines can be prevented if you follow all instructions in this manual, the engine owner’s manual and on the engine. Follow the instructions in the owners manual for the proper stopping procedure. A.
Section 5 Maintenance Instructions 36
PREVENTIVE MAINTENANCE CHECKS CHECKING COMPRESSOR PUMP OIL LEVEL ! pump head, and surrounding parts are very hot, do WARNING Aftercooler, not touch. ! Do not operate without lubricant or with inadequate lubricant. Jenny can not be responsible for compressor failure caused by inadequate lubrication. CAUTION 1. Ensure Unit is off and disconnect from the power source 2. Locate unit onto a flat horizontal surface. 3. Remove knurled oil fill plug from crankcase. 4.
CHECKING SAFETY RELIEF VALVE OPERATION ! pump head, and surrounding parts are very hot, do WARNING Aftercooler, not touch. 1. Ensure unit is off and disconnected from the power source. 2. Ensure tanks are empty by looking at tank pressure gauge. Drain tanks if necessary. 3. Grasp wire ring on safety valve. 4. Pull and release ring a few times to ensure plunger moves in and out. CHECKING AIR FILTER ELEMENT ! WARNING Aftercooler, pump head, and surrounding parts are very hot, do not touch. 1.
2. Turn screw “A” clockwise to increase cut-out pressure limit or counter clockwise to decrease cutout pressure. (example: if the cut-out pressure on the tank gauge reads 120 psi. and desired cut out is 130 psi, turn screw “A” clockwise) 3. Drain air from tanks through drain valves until pump begins to charge tanks. B C D 4. Close drain valves. A 5. Monitor cut-out pressure to verify the new setting 6. Once setting is complete hold screw “A” firmly 7.
There is live electrical power on the four contact points on the switch. Use only electrically insulated tools to perform this adjustment in case of accidental contact with the electrical system. Pressure Range Adjustment To increase the pressure range: Turn screw A clockwise to increase the overall system pressure range (both cut-in and cut-out). A To decrease the pressure range: Turn screw A counter clockwise to decrease the overall system pressure range (both cut-in and cut-out).
reference location. 9.) If the deflection of belt too great, then loosen the motor or engine bolts and slide the motor or engine away from the pump. If the deflection of belt too small, then loosen the motor or engine bolts and slide the motor or engine toward the pump. A.) Remove the Belt B.) Scribe a mark approximately 1/8” from the original reference mark. C.) Loosen the 4 screws holding the electric motor or gasoline engine. D.) Slide the motor or engine to the new mark. E.
4.) Tighten or replace any joints, fittings or hose connections that are found to be leaking. ! CAUTION Do not attempt to tighten or repair any joints, fittings or hoses while the unit is pressurized. PREVENTIVE MAINTENANCE SCHEDULE GENERAL Preventive maintenance pays off in many ways. Avoid long serious downtimes, costly delays, and harmful effects to intricate parts of compressor.
! CAUTION In the presence of harsh operating conditions and environments, the oil change and air cleaner change interval should be performed on a more accelerated schedule.
Section 6 Troubleshooting Instructions 44
TROUBLESHOOTING The following chart lists the malfunctions that occur most commonly when operating an industrial air compressor. It gives the symptoms, their causes and the corresponding corrective actions. In some cases, the operator or maintenance personnel can perform the corrective actions, while others may require the assistance of a qualified Jenny compressor technician or dealer.
Troubleshooting Guide Problem Compressor does not start or restart Possible Cause Power cord not plugged in. Motor thermal overload switch has tripped. Possible Solution Plug cord into grounded outlet. Turn air compressor off, wait until motor is cool, if motor is a manual reset type, then press motor thermal overload button firmly until click is heard. (Located on motor) Fuse blown or circuit has tripped. Replace fuse or reset circuit breaker.
Problem Possible Cause Possible Solution Ambient temperature too low. Relocate unit to warmer environment. Ensure Jenny Ultimate Blue Synthetic Oil is in crankcase. Worn cylinder finish. Deglaze cylinder with 180 grit flexhone Defective motor, motor capacitor or Contact Jenny Customer Service pressure switch. at 1-888-4-A-JENNY. Air compressor is not large enough Check the accessory air for air required. requirement.
Problem Possible Cause Connecting rod, piston pin, or crank wrist pin bearings worn or scored. Air compressor is not large enough for air required. Insufficient pressure at air tool or accessory Possible Solution Inspect all. Repair or replace as required. Check the accessory air requirement. If it is higher than the CFM or pressure supply of the air compressor, you need a larger air compressor. Defective gaskets. Replace and torque head bolts to 6 - 7 ft lb. Fittings not tight enough or leaking.
Problem High oil consumption. Unit runs excessively hot. Possible Cause Possible Solution Fittings not tight enough or leaking. Warning drain air before tightening: tighten fittings where air can not be heard escaping. Check joint with soap solution. Do not overtighten. Pressure regulator knob not Adjust pressure regulator knob to turned to high enough pressure or proper setting or replace. defective pressure regulator. Hose or hose connections are to Replace with larger hose or small or long.
Problem Possible Cause Connecting rod, piston pin, or crank wrist pin bearings worn or scored. Crankshaft seal worn or crankshaft scored. Extremely dusty atmosphere. Worn cylinder finish. Wrong gauge wire or length of extension cord. Air compressor on unlevel surface. Excessive starting and stopping Compressor check valve leaky, broken, carbonized or loose. Defective motor, motor capacitor or pressure switch. Air compressor is not large enough for air required. Defective gaskets.
Problem Moisture in discharge air. Moisture in crankcase or “milky” appearance in petroleum lubricant or rusting in cylinders. Possible Cause Possible Solution Piston rings damaged or worn (broken, rough, or scratched). Excessive end gap or side clearance. Piston rings not seated, are stuck in grooves or end gaps not staggered. Cylinder or piston scratched, worn, or scored. Connecting rod, piston pin, or crank wrist pin bearings worn or scored. Crankshaft seal worn or crankshaft scored.
Problem Oil in discharge air (oil pumping) Oil leaking from shaft seal Safety relief valve “pops” or reliefs pressure. Air leaks at pump. Possible Cause Possible Solution Fittings not tight enough or leaking. Warning drain air before tightening: tighten fittings where air can not be heard escaping. Check joint with soap solution. Do not overtighten. Defective or rusted air tank Air tank must be replaced. Do not attempt to repair air tank Water in oil due to condensation. Drain oil.
Problem Air leaks at fittings. Air leaks from tank. Abnormal piston ring or cylinder wear. Possible Cause Possible Solution Fittings not tight enough or leaking. Warning drain air before tightening: tighten fittings where air can not be heard escaping. Check joint with soap solution. Do not overtighten. Defective or rusted air tank. Air tank must be replaced. Do not attempt to repair air tank Lubricant viscosity too low Drain existing lubricant and refill with Jenny Ultimate Blue Synthetic lubricant.
