USER MAINTENANCE

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

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

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

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 .

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.

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

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

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

ii. The Air Compression Process

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

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

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 + .

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

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

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.

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

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

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

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.

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

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

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

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

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

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

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

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