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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* and pump * * feed system The main drive wheel provides air flow to cool the machine via fan blades * MCH 6, 8,13 & 16 * * TROPICAL RANGE
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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 Tropical plus range incorporate pump and 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 First Stage safety valve: 8 Bar
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 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 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 hrs MCH hrs MCH hrs
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ii. Filter Cartridge Replace before air starts to smell: MCH 6 50 Hrs*
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 MCH 36 * 250 hrs synthetic oil * Coltri Synthetic Oil only recommended. Mineral and synthetic oils must not be mixed
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iii. Oil Changes &Type Synthetic oils Coltri Oil CE 750
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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 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
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