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
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 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 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 hrs
MCH hrs
MCH hrs

16. 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.

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 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