Precautions Before Overhauling

Air compressor may be overhauled for planned maintenance or stripping down for
survey purposes. First of all, make sure the spare parts are available on board. This
will include joints, gaskets, major spare parts such as piston, piston rings, bearings,
etc.

Unless the compressor has suffered a major failure, it would be better to leave
overhauling air compressor until the vessel has berthed, especially on a reversible
engine with fixed pitch propeller. This is in case there is a high demand for
compressed air during maneuvering.

For survey purpose, ensure the following papers are readily accessible: copies of
previous survey reports, running hours since last survey, copies of planned
maintenance reports, recorded clearances and manufacturers recommended
tolerances.

Overhauling Air Compressor

The compressor to be isolated both electrically and mechanically and locked out.
MEN AT WORK notices are posted. The oil and cooling water is drained, compressor
is stripped down removing cylinder head and valves, piston and connecting rod. The
circlips, gudgeon pin and top end bearing are removed from the piston using proper
tools. The piston rings are removed. The parts to be cleaned for survey, but no
evidence of wear or damage is removed. The parts are gauged (ring grooves, piston
pin diameter, bearing clearances) and the readings are recorded. Safety devices are
checked. Hydraulic tester can be used to test the opening pressure of relief valves.

Air Compressor Assembly

Major parts such as piston, liner (replaceable type), bearings, etc. to be inspected
and renewed if necessary. Piston rings would also be renewed as would the gudgeon
pin and top end bearing. Before fitting new piston rings, butt and axial clearances to
be checked. Ensure correct tool is used to guide the rings to the cylinder bore. All
nuts to be torque tightened to correct settings and with new locking devices such as
split pins. Suction and discharge valves must be renewed or overhauled. Checking
bumping clearance is necessary after a major overhaul. Normal value of bumping
clearance for a two stage main air compressor is about 0.5 mm. Use modern

squeezable plastic or lead wire ball for measuring bumping clearance. After fitting
cylinder cover, turn flywheel by hand to make sure it is free to turn.

Clean or renew crankcase oil suction filter and refill crankcase with new oil. Renew
lube oil filters and air filter. Open cooling water valves and check for leakages. Turn
the flywheel continuously by hand to prime the lube oil pump. Conduct an initial
running of compressor in unloaded condition and check motor amperes, noise, etc.
Then load the compressor and then check for bearing overheating. Once everything
found satisfactory, test run the compressor and measure time taken to fill the air
bottle from empty to full.

Keep all the records of clearances, spare parts consumed, etc. and sent to the
company. Raise requisitions for necessary spares immediately. Update the work
done and running hour in computer based planned maintenance system (PMS).