USER MAINTENANCE

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USER MAINTENANCE
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Presentation Overview

• 1. Compressor function
• 2. Maintenance Routine
• 3. Problem solving

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1. Compressor Function

• i. Pumping group description
• The air compression process
• Safety Valves
• Pressure maintaining valve

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i. Pumping Group Description

• The main parts of a pumping unit are
• Cylinders / heads
• Pistons / con-rods
• Crankcase / shaft

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i. Pumping Group Description

• Cylinders are connected
• with Stainless Steel pipes
• The pipes move
• pressurized air
• between the first,
• Second and third
• Cylinders cooling it at the same time .

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i. Pumping Group Description
Each cylinder has two valves Suction
valve Allows air into cylinder to be compressed
by the piston. Release valve Allows pressurized
air out after the piston has compressed it
further.
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i. Pumping Group Description

• Lubrication is
• achieved via a splash
• feed system
• The main drive
• wheel provides air flow to
• cool the machine via fan blades
• MCH 6, 8,13
  16

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i. Pumping Group Description

• The Coltri Sub range uses 3 types of pumping
  unit
• MCH 6
• 4 cylinders, splash feed
• MCH 8,13,16 32
• 3 cylinders, splash feed
• MCH 36
• 4 cylinders, oil pump

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i. Pumping Group Description

• Filtration Path
• Intake Filter
• Water Separator
• Main Filtration Tower
• .

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ii. The Air Compression Process
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iii. Safety Valves

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• First Stage safety valve
• 8 Bar
• Second Stage safety valve
• 50 Bar
• Third Stage safety valve
• 225/330 Bar

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iv. Pressure Maintaining Valve

• The function is to retain a
• 120 150 bar pressure in the
• filter tower to ensure efficient
• filtration
• Filter media functions best with
• air flowing _at_ 100 bar
• Check valve setting weekly

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iv. Pressure Maintaining Valve

• To set valve
• Start compressor open filling valve
• Check gauge on separator
• for internal pressure
• Adjust by turning lower cap
• Anti clockwise
• Clockwise -
• .

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Maintenance routine
Maintenance Routine

• Air Intake filter
• ii. Filter cartridge
• iii. Oil changes and types
• iv. Safety checks
• v. Compresor cleaning

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i. Air Intake Filter

• Gently blow clean every 20 hrs and
• re-insert rotating position.
• Change filter regularly
• MCH 6 100 hrs
• MCH 13 80 hrs
• MCH 16 70 hrs

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ii. Filter Cartridge

• Replace before air starts
• to smell
• MCH 6 50 Hrs
• MCH 13 50 Hrs
• MCH 16 40 Hrs
• _at_ 20 Celsius ambient temp. Filter lifespan
  decrease when ambient temperature and humidity
  increase. Halve the values listed above for
  temperature of 30 degrees and above.

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iii. Oil Changes Type

• After initial 50 operating Hrs and then every
• MCH6 50 hrs synthetic oil
• MCH 13/16 200 hrs synthetic oil 100
  Hrs mineral oil
• Synthetic Oil only recommended.
• Mineral and synthetic oils must not be mixed

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iii. Oil Changes Type

• Synthetic oils
• AItek 751 USA
• Airtek 755 CE
• Airtek 788 CE
• Mineral Oils
• Shell Corena P150
• (not recommended for continuous use)

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iv. Safety Checks

• Check motor-engine and compressor bolts
• Check V belt tightness
• Check electric power supply
• Check compressor oil level
• Check function of safety valve and their
  calibration.
• If valves blow stop machine,
• Call technician

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v. Compressor Cleaning

• A dirty machine overheats, and does not allow
  to see clearly oil or air leaks.
• A weekly rinse with medium/low strength pressure
  pump will avoid this
• Ensure that water does not enter the air intake,
  electric motor or electrical parts of the
  compressor system.

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Problem Solving

• Air Odor
• Compressor overheats
• Decreasing air output
• Electric motor fails to start
• Electric motor runs slowly

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i. Air Odor

• Problem Filter cartridge exhausted
• Solution Replace cartridge
• Problem Piston rings worn out
• Solution Replace piston rings
• Problem Use of wrong oil
• Solution Refer to user manual for
• correct lubricant

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ii. Compressor Overheats

• Problem Compressor running backwards
• Solution Check 3 phase connection
• Problem Dirty intercoolers
• Solution Clean intercoolers
• Problem Suction /Release valve are not
  functioning,
• Solution Clean or replace

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ii. Compressor Overheats

• Problem Insufficient ventilation or
  ambient temperature above
  40 Celsius
• Solution Re-site compressor or use
  additional forced ventilation

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iii. Decreasing air output

• Problem Suction/release valve
  malfunction
• Solution Clean or change valves
• Problem 3rd/4th stage piston worn
• Solution Replace piston and rings
• Problem Loose fitting or leaking gaskets
• Solution Check leaks with soap solution
• tighten fitting or replace
  gaskets

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iii. Decreasing air output

• Problem Intake air filter blocked
• Solution Clean/replace filter
• Problem Air intake extension bent or
  too small
• Solution Use larger section non
  collapsing pipe/hose
• Problem Piston rings worn
• Solution Replace piston rings

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iv. Electric Motor fails to start
Problem Three Phase, no supply or one
phase down Single Phase, No supply Solution
Check supply, phases and condenser,
electronic switches relays
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v. Electric Motor runs slowly
Problem Tight bearings within motor Solution
lubricate/service motor Problem Loose
electrical connection Solution Tighten
connections Problem Insufficient power supply
Solution Check rating of supply Problem Loose
drive belt Solution Tighten belt