ATLIER FRANCOIS (COMPRESSOR)

MAINTENANCE AND CHECKS DAILY CHECKS DAILY CHECKS INSPECT AND NOTE THE OIL LEVEL AND ALL THE PRESSURE AND TEMPERATURE LEVELS(FILLL IN THE DAILY CHECK IMPORTANT FOR PREVENTIVE MAINTENANCE. INSPECT AND NOTE THE OIL LEVEL AND ALL THE PRESSURE AND TEMPERATURE LEVELS(FILLL IN THE DAILY CHECK IMPORTANT FOR PREVENTIVE MAINTENANCE. CLEAN THE OIL FILTER IN THE CRANKCASE BY FULLY ROTATING THE OPERATION LEVEL OF BRUSH –TYPE FILTER. CLEAN THE OIL FILTER IN THE CRANKCASE BY FULLY ROTATING THE OPERATION LEVEL OF BRUSH –TYPE FILTER. THERE SHOULD BE NO ABNORMAL NOISE DURING OPERATION. THERE SHOULD BE NO ABNORMAL NOISE DURING OPERATION.

AFTER THE 50 OPERATION HOURS DRAIN AND CLEAN THE CRANKCASE OIL AND THE OIL FILTER.USE CLEAN NON FIBROUS’LINT- FREE CLOTHS TO CLEAN THE CRANKCASE.TO CLEAN THE OIL FILTER UNSCREW THE MAGNETISED CAP LOCKED ON THE LOWER PART OF THE FILTERDRAIN OFF ALL THE OIL INTO A CONTAINER AND REPLACE IT. DRAIN AND CLEAN THE CRANKCASE OIL AND THE OIL FILTER.USE CLEAN NON FIBROUS’LINT- FREE CLOTHS TO CLEAN THE CRANKCASE.TO CLEAN THE OIL FILTER UNSCREW THE MAGNETISED CAP LOCKED ON THE LOWER PART OF THE FILTERDRAIN OFF ALL THE OIL INTO A CONTAINER AND REPLACE IT.

A LIGHT COVERING OF FILLING IS NORMAL WHEN DRAINING THE MACHINE FOR THE FIRST TIME. THE PRESSURE OF A SIGNIFICANT AMOUNT OF BRONZE FILLING, BABBITT METAL AND IRON AND STEEL FILLINGS MUST BE NOTIFIED AF.

Check and if necessary, Check and if necessary, re-tighten the fastening screws securing the screws securing the cylinder head.

CHECK THE CROSSHEAD ASSEMBLY.ENSURE THAT THE FASTENING SCREWS ARE PROPERLY SECURED TO THE PISTON RODS ON THE CROSSHEAD. CHECK THE CROSSHEAD ASSEMBLY.ENSURE THAT THE FASTENING SCREWS ARE PROPERLY SECURED TO THE PISTON RODS ON THE CROSSHEAD. CHECK THE SURFACE CONDITIONM OF THE PISTON RODS.IT SHOULD NOT BE SCRATCHED. CHECK THE SURFACE CONDITIONM OF THE PISTON RODS.IT SHOULD NOT BE SCRATCHED. LOOK THROUGH THE PLEXIGLASS INSPECTION DOORS TO CHECK THAT HE OIL SCRAPER RINGS ARE OPERATING NORMALLY. LOOK THROUGH THE PLEXIGLASS INSPECTION DOORS TO CHECK THAT HE OIL SCRAPER RINGS ARE OPERATING NORMALLY.

AFTER 250 HOHRS CHECK THE CLEANLINESS OF AIR FILTER WHEN INSPECTION THE LOW PRESSURE GUAGE LOCATED B/W THE FILTER AND THE LOW PRESSURE CYLINDER.CLEAN IF NECESSARY. CHECK THE CLEANLINESS OF AIR FILTER WHEN INSPECTION THE LOW PRESSURE GUAGE LOCATED B/W THE FILTER AND THE LOW PRESSURE CYLINDER.CLEAN IF NECESSARY. Check the cleanliness of the oil bath. Check the cleanliness of the oil bath. Clean the oil filter. Clean the oil filter.

Check that the electro valves are are secured, together with the fastening screws on the cylinder heads. Check that the electro valves are are secured, together with the fastening screws on the cylinder heads.

After 1000 Hours. After 1000 Hours. Repeat the procedure of 250 hours. Repeat the procedure of 250 hours. Remove the inspection doors from the crosshead guides. Checks thjat the friction surface of the guides are in good position. Remove the inspection doors from the crosshead guides. Checks thjat the friction surface of the guides are in good position. check the wear and tear of the piston ring and the cylinder as follows. check the wear and tear of the piston ring and the cylinder as follows.

Stage1 Stage1 Remove an upper and the lower suction and discharge valves. Remove an upper and the lower suction and discharge valves. After removing the valves carry out a visual check of the surface condition of the internal diameter of the cylinder with a flash light. It should be perfectly smooth and show no seizing. After removing the valves carry out a visual check of the surface condition of the internal diameter of the cylinder with a flash light. It should be perfectly smooth and show no seizing. Check the play b/w the cylinder and the piston as follows. Check the play b/w the cylinder and the piston as follows.

Move the piston to the upper position (by moving the belts). Move the piston to the upper position (by moving the belts). check the play b/w the cylinder and the piston with thickness guages. Repeat procedure a and b with the piston In the lower position.

Stage2 and 3 Remove the suction and discharge valves Remove the suction and discharge valves From each cylinder following the procedure of stage 1. From each cylinder following the procedure of stage 1. Check the condition of cylinder by moving the piston of stage 2 and 3 onto the cylinder head side. Check the condition of cylinder by moving the piston of stage 2 and 3 onto the cylinder head side. For measuring purposes, use the same method describe in stage 1. For measuring purposes, use the same method describe in stage 1.

Re assembly of valves in stage 1, 2 and 3rd Re assembly of valves in stage 1, 2 and 3rd Install the valve cage and cover. Install the valve cage and cover. Tight the screw with respect to torque. Tight the screw with respect to torque. Start the compressor for production.

After 2000 hours To separators the water in liquid from the compressed air, each separator has a demister made stainless steel wire mesh.

These should be firmly inspected every 2000 hours. To do this remove the bolted cover which close the separators. Inspect the density and cleanliness of the meshes. These should not be torn or frayed. checking for wear and tear on the piston rings in stage 2 and 3. If any thing found faulty replace it If necessary.

AFTER 4000 HOURS. Disassembly of piston rings. Turn off the supply of cooling water and drain the water circuit completely. detach the cylinder s in stage 2 and 3 from the suction and discharge pipe system. Disassemble all the vales. Remove stge fastening screws from the 3 stage cylinder.

Support stage 3 cylinder with the aid of pulley block. Carefully remove the cylinder. leave the cylinder in a clean place. remove the inspection doors from the horizontal crosshead guide. Make the center mark on the crosshead and the piston rod (non load bearing section), measure the distance with the inspection door (which eliminates the need to memories it for future (procedure)

Remove the locking pin in the crosshead. Remove the hex socket setscrew located on the locknut on the piston rod. Support the crosshead with the aid of the tool provided for this purpose and remove the crosshead screws. Unscrew the piston rod assembly by turning stage 3 cylinder manually.

Unscrew the locknut from the crosshead rod. Unscrew the locknut from the crosshead rod. Place the cap supplied with the machine onto the end of the piston rod. Place the cap supplied with the machine onto the end of the piston rod. Remove the packing from the oil scraper ring. Remove the packing from the oil scraper ring. Remove the oil cap. Remove the oil cap. Remove the packing on the air side. Remove the packing on the air side. carefully remove the piston rod assembly in the stage 2 and 3 and leave it in a clean place. carefully remove the piston rod assembly in the stage 2 and 3 and leave it in a clean place.

Check the surface condition of the cylinder bores in stage 2 and 3. Check the surface condition of the cylinder bores in stage 2 and 3. it should not show any evidence of seizing or wear and tear, and should have a polished condition brownish appearance. it should not show any evidence of seizing or wear and tear, and should have a polished condition brownish appearance. check the surface condition of the piston. The latter should also show no sign of siezing. check the surface condition of the piston. The latter should also show no sign of siezing. remove the sealing rings from the piston as the supporting rings. remove the sealing rings from the piston as the supporting rings. Clean the rings grooves with the aid of clean cloth. Clean the rings grooves with the aid of clean cloth.

Re assembly of rings Re assembly of rings PROCEDURE FOR SEALING AND SUPPORTING RINGS STAGE 2. PROCEDURE FOR SEALING AND SUPPORTING RINGS STAGE 2. NOTENOTE The supporting rings are recognizable by their greater width and found at the end of the piston. The supporting rings are recognizable by their greater width and found at the end of the piston. Replace the supporting ring by opening Replace the supporting ring by opening it so that it slides onto the piston and into the grooves. it so that it slides onto the piston and into the grooves. repeat the same procedure for the sealing rings. repeat the same procedure for the sealing rings.

Procedure for the sealing and supporting rings stage 3: proceed as for stage 2. Procedure for the sealing and supporting rings stage 3: proceed as for stage 2. NOTE NOTE Onto the certain machines the supporting rings of the piston in stage 3 is a monobloc type. It also wider than the sealing rings. For monobloc rings proceed as follows, first securing that part of the piston rod b/w stages 2 and 3 in vice fitted with a soft clamp.

Discharge valve

Suction valve

Discharge valve

Inter Cooler