USER MAINTENANCE

1. USER MAINTENANCE

2. Presentation Overview 1. Compressor function 2. Maintenance Routine 3. Problem solving

3. 1. Compressor Function i. Pumping group description • The air compression process • Safety Valves • Pressure maintaining valve

4. i. Pumping Group Description The main parts of a pumping unit are: • Cylinders / heads • Pistons / con-rods • Crankcase / shaft

5. 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 .

6. 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.

7. 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

8. 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

9. i. Pumping Group Description • Filtration Path • Intake Filter • Water Separator • Main Filtration Tower • .

10. ii. The Air Compression Process

11. iii. Safety Valves • First Stage safety valve: 8 Bar • Second Stage safety valve: 50 Bar • Third Stage safety valve: 225/330 Bar

12. 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 @ 120 - 150 bar • Check valve setting weekly

13. 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 + • .

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

15. 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

16. ii. Filter Cartridge • Replace before air starts • to smell: MCH 6 50 Hrs* MCH 13 50 Hrs* MCH 16 40 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.

17. 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

18. iii. Oil Changes &Type • Synthetic oils Coltri Oil CE 750

19. 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

20. 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.

21. Problem Solving • Air Odor • Compressor overheats • Decreasing air output • Electric motor fails to start • Electric motor runs slowly

22. 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

23. 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

24. ii. Compressor Overheats • Problem: Insufficient ventilation or ambient temperature above 40 Celsius • Solution:Re-site compressor or use additional forced ventilation

25. 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

26. 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

27. 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

28. 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