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Training Department

TRAINING ON
PORTABLE
COMPRESSORS
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Flush . * Man converts air in to energy for some useful work.Cable lay 4 . 3. Combustion in an IC Engine. To blow air in a tube of a vehicle. 1. Our application:. Flushing of Drilled holes. * Compressed air has many use full things to do. * Nature has given this abundantly in atmosphere. 5 For Oxygen in an intensive care unit etc. Training Department Introduction * The most indispensable for human existence is air. * IR is one such industry who knows the value of air. 4.Drill . 2. For a pneumatic tool operation. * We have made research on compressed air for ages.

Training Department
Course contents
A. General Description of Portable compressor.

B . Specification and Parameters of portables.

C. General layout of the machine.

D. Major parts and their functional Description.

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E. Systems Operational details.

1. Regulation system .

2. Cooling and Lubrication system.

3. Blow Down System.

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F. Maintenance.

G. Trouble shooting.

H. Safety aspects.

I. Course Review.

J. Test and Evaluation.

K. Conclusion session .

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8 . * The equipment is fitted on a running gear mechanism in general and at times the same has been mounted on the machine as it is mounted on ICM 260. * Purpose of the unit is to cater air supply need for Drilling and bailing out the cuttings after drilling. Cooling and Lubrication . produces Compressed air of 300 to 750 cfm at 100 to 200 psig pr. Regulating. Training Department General Description * An asymmetrical rotary Screw compressor coupled to a NT 495 C Engine runs at 1800 rpm. for operation of air tools and may be for laying cables etc. * The major systems involved in this machines is Starting. Shut down and Blow down system.

throttle cylinder and start and run valve etc. dirt and rain. * Cooling system is incorporated in the system for cooling compressor oil and water cooling of engine body. * Entire unit is covered with a canopy for protection from dust. Temperature by pass valve etc. Training Department * The starting System of the Engine consists Battery . Starter. 9 . * There Shut down system in the machine which brings the system to a halt and blows out air or empties the separator tank with out any pressure air in the system. Major Parts are Cooler with fan. alternator fuel shut off solenoid .

Training Department CLASSIFICATION AND SPECIFICATION 10 .

68 1.65 NT495C NT495C N743TC NT743C NT855C FULL RPM 2500 2100 2100 2100 1800 1800 1100 IDLE RPM 1200 1100 1100 1000 1000 FUL TNK CAP 140 ltr 275 ltr 275 ltr 340 ltr 340 ltr 340 ltr BHP 109 180 180 240 253 253 TRK Wdth mt 1.62 1.7 1.5 226 226 226 ENGINE ALU6.75 178.E SIZE MM 125. Training Department Classification of Portable Compressors TYPE P300 HP450 Cbl Layir HP600 HP650 HP750 FLOW cfm 300 450 400 600 650 700 PR psig 100 150 170 150 150 150 A.62 1.7 WEIGHT kg 2050 3300 3400 4000 4000 4000 Small range Mid range Large Range 11 .5 178.7 1.

5 178.68 1.E SIZE MM 125.5 ENGINE ALU6.65 ALU402 NT495C NT 495C NT495C NT495C FULL RPM 2500 2400 2100 1800 2100 2100 1100 IDLE RPM 1200 1200 1100 1100 1100 FUL.62 1. psig 100 100 170 100 150 100 A.5 178.62 1.62 WEIGHT kg 2050 2050 3400 3300 3300 3300 12 .62 1.TNK CAP 140 ltr 140 ltr 275 ltr 275 ltr 275 ltr 275 ltr BHP 109 122 180 180 180 180 TRK Wdth mt 1.5 178.5 178.75 178. Training Department PARAMETERS AND SPECIFICATION Small range Mid range TYPE P300 P400 BLAST AIR P500 HP450 P600 FLOW cfm 300 400 400 500 450 600 PR.68 1.

. Training Department . GENERAL LAYOUT PORTABLE COMPRESSOR 13 .

V ABV THROTTLE CYL SEP.R. TANK COF TBV PR.V S. Training Department MPV S.REG SER VLV CONTROL U/V PANEL R O COMPRESSOR ENGINE C RUNNING GEAR 14 .

Training Department MAJOR PARTS AND THEIR FUNCTIONAL DETAILS 15 .

PRESSURE REGULATOR 9. RADIATOR OIL COOLER 8. MINIMUM PRESSURE VALVE 16 . START AND RUN VALVE 10 . SEPERATOR TANK 6. AUTO BLOWDOWN VALVE 7. AIR END 2. UNLOADER 4. Training Department LIST OF MAJOR PARTS 1. ENGINE 3. TEMPRATURE BYPASS VALVE 5.

SCREW COMPRESSOR Air Discharge end Air intake Point Housing front brg seal Drive Female rotor shaft Housing rear bearing Bellow housing Male rotor Gear Set Bearing Bearing Rotor housing 226 mm air end 17 . Training Department 1.

5 MM AIR END INTERNAL CONSTRUCTION 18 . Training Department BELLHOUSING REAR BEARING ROTOR HOUSING HOUSING AIR INTAKE AIR OUT POINT FMALE ROTOR DRIVE SHAFT BEARING OIL SEAL DRIVEN SHAFT GEAR SET MALE ROTOR 178.

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Training Department BLADE VANES 26 .

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Training Department EO Filter Safety valve Air filters and Separator element Fuel filter Start and run Valve PR. Regulator Service valve COF Gauge Temp Switches Gaskets Thermo stat Level Gauge 29 .

Training Department Turbo charger Exhaust Fan Engine Crank case body Starter Oil tray 30 .

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Training Department ENGINE RPM AND COMPRESSOR OUT PUT A % I C R A P A D C E I L T I Y V E C R F Y M 1000 1200 1400 1600 1800 2000 ENGINE RPM 32 .

Training Department UNLOADER VALVE • Controls amount of air entry to air end. • Anti rumble Valve incorporated to avoid vacuum creation. • When the Engine is in idle no air entry in the UV valve In Idle position 33 .

• When the Engine is in Full Load air entry in the Unloader valve. In Load position 34 .Training Department UNLOADER VALVE • Controls amount of air entry to air end.

& UL 99 X Separator tank START AND RUN VALVE 35 . Training Department In Start run condition Condition To Thrtle cyl.

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Training Department Only air Only oil Air and oil Mixture SEPERATOR RECEIVER 37 .

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AUTO BLOWDOWN VALVE LOCATION
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AUTO BLOWDOWN VALVE

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Purpose
To Blow air out of system
to maintain atmospheric
pressure in system

Working principle
* In full load/ Idle no Action on the Diaphragm
* Spring force retain ball in closed position
* In Blow down position Pilot pressure activates diaphragm
* Ball is pressed against the spring pressure
* Exhaust port gets opened and air is relived through this port 40

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Engine
air filter MPV
Compressor
oil filter Cooler Fan

Separator
ROC Tank
Fuel pump
Fuel filter

Main Parts in the power pack 41

Training Department LOCATION OF TEMPRATURE BY PASS VALVE 42 .

Training Department FULL LOAD POSITION INITIAL START POSITION TEMPRATURE BY PASS VALVE FROM TANK TO FILTER DIRECTLY PRESSURE WHEN OIL IS BY-PASS WHEN OIL IS IN HEAT UP VALVE HANDY BELOW 65 deg.C OILDIVERTED TO WHEN COOLER OIL PASSES IS CHOCKED COOLER & THEN THRU TBV TO TO OIL FILTERS. OILFILTERS OIL TEMPRATURE BY PASS VALVE 43 .

Training Department In Idle condition MPV Spring Pressure does not allow air in the the line In Run condition MPV Spring is pushed back and air escapes in to air line MINIMUM PRESSURE VALVE 44 .

Valve Pressure Regulator Safety Valve PARTS MOUNTED ONSEPARATOR.TANK 45 .Training Department Minimum Pr.

Training Department BREATAHER LOOK AT THE WAY THE THROTTLE CYLINDER IS MOUNTED TO ENGINE 46 .

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Oil thru scavenger line to air end. Training Department MPV Open Working Principle 1. Dry air at service line 5. Air oil mist entry in to tank MPV 2. Most of the oil falls down 3 Next Oil Filtration 4. Scavenger line From Air end To oil cooler SEPERATION SYSTEM 48 .

Air intake is cut off 7. Air blown out What happens when the 1.High pressure in separator Air end Separator tank Discharge line 3.Ball engine is off Shift 5. Air gushing in to air end when Engine is in load ? AUTO BLOW DOWN CIRCUIT 49 . Diaphragm Question activation 8. Pilot line 2. Training Department Blow down valve 6.Low pressure Question in air end What happens 4.

Training Department AIR AND OIL CIRCUIT OF A MID RANGE PORTABLE 50 .

buildsSpeed Venting toaction/ Throttle up of slowly air from air end Cylinder drop RUNNING GEAR SERVICE COOLING DISCHARGE COOLING LINE ANDFROM AND LUBRICATION LINELUBRICATION FROM SEPARATOR AIR SYSTEM END BEFORE TOTO SERVICE AFTER SEPARATOR WARMING WARMING VALVE TANK 51 .Warming load down O upcondition Position system AIR END 1.Set warm ADPout Supply bleeding up ULof to.Air operation thru Run SRV thru cylinder atP. SayAir1.SRV 1. orifice IN 4.1.Shut 4.R.Full 2.Air 3.Cylinder 50ENGINE cutPSIentry off isthru toSRV Auto Blow Stroking reached C down valve 2.Diaphragm 3. TANK B A COF C TBV SER VLV ABV OUT CONTROL UV R PANEL 1 Start position Run5.Engine 2. 1.R& TC full retracts.2.R SEP.3.V 50 PSI P.of increase 99ABV activation.from load air end. Air 3.V S.Spring Pressure 4.Air open.4.Throttle Air Passes Pilot 2. air 4.System 3. 3.passes 2. Make an animation to bleed out air in the run positrion Training Department THROTTLE CYL MPV S.

Training Department REGULATION SYSTEM 52 .

Training Department REGULATION SYSTEM 53 .

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Training Department TROUBLE SHOOTING 55 .

system Replace Replace 56 . Training Department AIR END OVER HEATING Low oil OK Fan belt broken OK Oil cooler exterior OK level or slipping matrix blocked Fill to the center of the sight glass Replace Clean Is air re circulation OK OK OK Is the correct Faulty oil takes place oil being used TBV? Reposition Replace Remove thermostat unit & close door and test Is the unit operate at OK Oil filters OK Is the air end Temperature wrong Pr and Del. blocked shut down switch is faulty Adjust reg.

Is the main Is Start and Run OK Valve faulty / OK Pr. Training Department INSUFFICIENT AIR PRESSURE Air demand too OK OK Air end air filter OK high System leakage blocked Match demand to rated out put Rectify Clean Is Pressure reg . Valve OK valve faulty? wrong setting defective Adjust or Repair or Replace Replace Replace Is the Sep. element OK Is UL 99not OK Is there a fault inside air end Blocked or restricted opening fully Replace the Check air end element Repair /Replace for leaks 57 .

Training Department Is the engine speed is too low Is regulation valve Is the speed contol OK orifice/ silencer OK Air filters OK cylinder sticky or blocked. Frozen or blocked defective wrong size Rectify Replace Replace Is air intake filter is blocked or Replace restricted 58 .

59 . Clear line Valve if not blockage Replace Is unit at angle Level unit > 15 Deg . Pr. Training Department Oil carry over problem High oil OK Check shut down OK Check blow down OK level procedure Procedure Drain oil and ensure correct Level Abrupt stoppage at full Opening manual blow down load may saturate the valve on shut down May separator filter element saturate filter element Check discharge OK OK Is the Scavenger Is the separator Pressure (75 PSI) line blocked element is ruptured Replace min.

Pr. Clear Valve if not blockage 60 . Training Department EXCESSIVE AIR PRESSURE Is Pressure regulating OK Is UL 99 not OK Is the valve OK Valve faulty?/wrong set closing properly sticking Adjust or replace parts Is the Diaphragm ruptured? Free off or replace the damaged parts Replace Are there any leak OK Is separator in Regulator piping element blocked Replace min.

Training Department MAINTENANCE 61 .

Training Department INTRODUCTION • To Prevent major failures • To avoid repairs and to avoid cost involvement • Preventive maintenance is less expensive • Facilitates easy servicing 62 .

* While on Service function of any kind * Disconnect Battery cables * Open manual Blow down valve * Ensure no pressure in discharge piping * Avoid coming in contact with the hot surface * Never operate machine in guard open condition * Both Metric and British system is used in design 63 . Training Department CAUTION * No warranty for any unauthorized modifications.

• Replace filter once Red indication is seen • Short of new element used cleaned old element 64 . drain excess oil filled * Add oil only when the level drops down near bottom AIR FILTER ELEMENT • Daily maintenance required • Dust collection box may be allowed only half fill. Training Department COMPRESSOR OIL LEVEL * Oil level should be mid way of the sight glass * Do not over fill.

Training Department CAUTION * Never Remove and Replace element when the compressor is running * Never use compressed air to blow through the element media * Never operate Unit with defective safety shut down switch or by shorting over a switch. 65 .

• Safety element must not be cleaned and re used 66 . Training Department REMOVAL AND CLEANING OF AIR FILTER ELEMENT • Clean exterior of filter housing • Remove end cap and empty dust collector box • Unscrew nut securing main element to housing • Remove element • Clean inside of housing • Clean element with 5 Bar air pressure • Mark number of services in the main element Max 3.

Keep the core clean • Prevent sludge and rust in ROC • Use right coolent oil not Plain water in Radiator • Air cooling is by fan ensure proper mounting of fan • Efficiency reduces when dust accumulates on fins. Training Department Engine Radiator • Engine cooling avoids combustion chamber damage • To maintain operating temperature in the safe limits • To maintain efficiency of the engine • To prevent damage to moving parts Maintenance of Radiator and oil cooler • Clean outside and fins with air . 67 .

Training Department GAUGES * Essential for safety of the system Inspect Gauges * To Maximize Productivity Periodically * Long service life of the machine FUEL TANK * Avoid condensation * Fill daily or after 8 hours of operation Clean Fuel tank * Use clean fuel Periodically * Use non.metallic funnel for fuel filling BATTERY * Keep terminals free of corrosion Disconnect cabl * Keep correct Electrolyte level in cells while mnt. * Secure hold clamps BELTS * No tight or no lose Loose tight belt * Replace in a set * Belt adjustment as per procedure effects Bearing 68 .

ADT • Calibrate switches periodically. EOP ---. Training Department SAFETY SHUT DOWN SYSTEM • Maintain the three switches EOT --. 69 . • Check the shut down system once in a month. • Engine oil pressure avoid damage due to starvation. CAUTION Never operate the unit with a defective safety shut down switch or by shorting over a switch.

Training Department HOSES * Inspect intake line hoses to cooler and filter * Clean brake and fuel line hoses * Ensure no hose leakages * Ensure No contact with rotating parts * Ensure all the hoses are clamped and secured * check for the damage of the hose fittings 70 .

Training Department REQUIRED MAINTENANCE SCHEDULE 3 MO 6 MO 12 MO ITEM TYPE Daily week month 500 hrs 1000 hrs 1500 hrs C Comp oil lvl Engine oil C A.E SIZE MM C ROC coolent ENGINE Air filter clog C Gauges FULL RPM C Fuel tank lvl C FUL FanTNK BeltsCAP C BHP Elect Battery C Shut down C Cooler external C C Check and Replace R Replace 71 .

FULLelement RPM C Safety switch C FUL TNKline Scav. CAP C BHP C Check and Replace R Replace 72 . Training Department 3 MO 6 MO 12 MO ITEM TYPE Daily week month 500 hrs 1000 hrs 1500 hrs Hoses C Comp oil filter R Fasteners C ENGINE Wheel Bearing C Sep.

Training Department SAFETY 73 .

Training Department SAFETY • TO OPERATOR • TO THE MACHINE • TO OTHERS 74 .

• Use compressed air only when necessary • Excise utmost vigil and alertness while on operation on the unit • Compressed air entered to blood stream leads to fatal results • Ear muff is a must while operating the machine to avoid over noise 75 . Goggles. Dust etc. Helmet and Ear Plugs • Do not expose yourself to the pressure air. Training Department SAFETY TO THE OPERATOR • Use Safety Appliances like shoes. • Ensure all the air hose clamps are secured properly • Do not use compressed air for blowing out chips.

• Ensure proper oil level in all units and top up if required • Ensure periodic replacement of filters and dust caps etc 76 . etc are proper • Ensure no air leakage in the air lines and replace damaged parts • Periodically make a walk around test and ensure all bolts/ nuts are secured • Check for the cleanliness of oil in the separator and other areas. Training Department SAFETY TO THE MACHINE • Ensure the machine is fully secured in the running gear mechanism • Ensure the fins of the Radiator and oil cooler is clean and not chocked • Ensure the throttle cylinder orifice is clean air easily bleeds out • Ensure all the air and hydraulic hoses are tightened and secured properly • Ensure all the thermal cut outs like ADT. EOT. EWT.

Training Department SAFETY TO OTHERS • Do not allow other to stand closer to the machine • Close air valve imeadetly after the work is completed • Do not clean others dress/ body with compressed air • Never used compressed for filling Auto tyre with out Aids • Do not encourage horse play while working on compressor 77 .

SRV Auto Blow down valve. Minimum pressure valve Filter elements What are the grade of oil used in the different units Separator tank. COT. What are the Pressure settings done in the compressor ADP. Safety valve. What should be the safe EWT. Separator tank. COP. COP 4 kg/cm2. COTor ADT 105degC 78 . Engine. By pass Valve. Training Department Course Review Selection of compressor depending the CFM and Pressure requirement Mostly 100 to 150 PSI 300 to 700 CFM What are all the parts involved in a portable Air end. EOP. ADT etc EWT < 95degC. Engine oil. ROC. EOP 4kg/cm2. Pressure switch Tyre pressure etc. Cooler. Temp.

Separator element replacement. Regulator etc. Battery electrolyte. Separator tank etc filling. Safety Valve. 79 . Anti freeze solution to engine.TBV. ABV .Condense drain. MPV. Blow down. and cooling system Understand the individual component internal details and their functions Air end. Understand the systems involved in the power pack Regulation. Engine. Pr. SRV. Training Department Understanding Maintenance peoridics Air filter.

L-GEAR TEETH FAILURE. Training Department ENGINE DOES NOT CRANK • BATTERY DOWN • CHARGE BATTERY. • STARTER/FLYWHEE • CHANGE PARTS. 80 . • CHECK & RECTIFY. • SERVICE STARTER. • CHECK & RECTIFY. • A/E SEIZED. • STARTER STUCK. • ENGINE JAMMED.

• CLOGGED • CLEAN/CHANGE. • CHARGE BATTERY. • AIR LOCK IN FUEL SYSTEM. • REMOVE AIRLOCK. • Pump solinioid electrical • CLEAN & not ok. • INJECTORS BLOCKED. Training Department ENGINE DOES NOT START • BATTERY DOWN. 81 . FILTER/LINES. CALIBERATE.

BLOCKAGE. 82 . CHOCKED. • STICKY THROTTLE • RECTIFY. Training Department ENGINE DOES NOT PICK UP SPEED • FUEL LINE • CLEAN FUEL LINE. • FUEL FILTER • REPLACE FILTER. CYLINDER.

Training Department ENGINE DYING ON LOAD • CLOGGED FUEL • CLEAN THE FUEL SYSTEM.P.ELEMENT.P. SEP. • INJECTORS • CLEAN & BLOCKED. • HIGH • ADJUST PRESSURE. • CHECK& RECTIFY. CALIBERATE. • CLOGGED • CHANGE ELEMENT. 83 . SYSTEM.SETTING.O. • LOW E.D. A.

• LOW FAN SPEED. COWL. • CORRECT BELT • WRONG FAN TENSION. • CORRECT • AIR LEAK THRO ALLIGNMENT. 84 . • RECTIFY. WATER LINE. ALLIGNMENT. Training Department HIGH ENGINE WATER TEMPERATURE • LESS WATER IN • FILL WATER RADIATOR. CORRECTLY. • AIR LOCK IN THE • RECTIFY.

T • RADIATOR • CLEAN THE BLOCKAGE RADIATOR EXTERNALLY AND EXTERNALLY AND INTERNALLY. Training Department HIGH E. 85 . INTERNALLY.W.

EXTERNALLY. • GRADE OF OIL USED. CONT. • OIL COOLER BLOCKED INTERN. • CLEAN. Training Department HIGH AIR DISCHARGE TEMPERATURE. LEVEL. BLOCKED • CLEAN. • LOW COMP. • OIL COOLER OIL. 86 . OIL • FILL TO CORRECT LEVEL. • USE RECOMMEND.

Training Department HIGH A. • RECTIFY. • COMP. CONT. OF COOLING AIR.D. • RECIRCULATION • RECTIFY. TEMP. BYPASS VALVE.T. FILTER. 87 . • A/E DISCHARGE • O/HAUL THE A/E. CLEARENCE MORE • DEFFECT.OIL FILTER • CHANGE OIL BLOCKED. • CHANGE. • LOW FAN SPEED.

SHUT DOWN.D. • FAULTY • CHECK & TEMP. Training Department HIGH A.T. CORRECT. 88 .

ORIFICE ADPT.CHECK LINE. 89 . • LOW SYSTEM PRES. • CHANGE & ADJUST • DAMAGED SEP.SET.P. Training Department OIL CARRY OVER • OIL FILLED MORE • DRAIN EXCESS OIL.LEVEL. • CHANGE. ON • SHORTER SCAVENGE A/E. TUBE.V. • BLOCKED SCAVEGE • CLEAN. THAN MAX. • CHECK M.C. ELEMENT.

L. SPRING. • RECTIFY.PISTON SPRING • CHANGE THE LOST ITS TENSION. • U. DAMAGED. • PISTON/ BUSHING • CHANGE THE WORN OUT. • PISTON SEATING • CHANGE THE U. • U.PISTON STUCK.L. 90 . Training Department OIL BLOWS BACK THROUGH AIR FILTER • U. REPAIR KIT. DIAPHRAM • CHANGE THE PUNCTURE. DIAPHRAM.L.L. ASSY.

ENGINE LOW • SET ENGINE LOW IDLE SPEED. • ANTIVIBRATION • REPLACE. Training Department EXCESSIVE VIBRATION / RUMBLING NOISE • LESS . ANTIRUMBLE VALVE. • STUCK • RECTIFY. 91 . IDLE SPEED. PAD DAMAGE.

92 . • DUST ENTRY. Training Department AIR END OIL SEAL LEAKING • SEAL DAMAGED. • CLEAN THE SYSTEM • CHANGE AIR & OIL FILTER IN TIME. • RECTIFY/REPLACE. FITMENT OF SEAL. • REPLACE OIL • IMPROPER SEAL.

• RECTIFY. VALVE. • RECTIFY 93 . • STUCK MIN. • LINE LEAKAGE. Training Department LOW AIR DISCHARGE CAPACITY. PR.

SHUTDOWNS • CHECK ALL SAFETY MALFUNCTIONS. • LOW ENGINE OIL • RECT. SYSTEMS. FAULT. • CHECK OIL LEVEL & PRESSURE. • CHECK FUEL • SAFETY SUPPLY. • LESS FUEL SUPPLY. Training Department ENGINE SHUTS DOWN PREMATURELY. ELECTRICAL PRESSURE. 94 . • ELECTRICAL FAULT.

95 . Training Department SAFETY VALVE BLOWS • OP. TOO HIGH. • FAULTY • REPLACE SEAL KIT.SETTING.L. • ADJUST PR. VLV. • U. • CHANGE SEAL • SAFTY VALVE KIT /VALVE. REGUL. FAILURE. FAILED. • LOW SAFETY • SET CORRECTLY. REGULATOR. PR. DIAPHRAM • REPLACE.

96 . • OPEN A.T & DO SERVICE.D. Training Department MOISTURE COMES WITH AIR • AUTO DRAIN TRAP • RELEASE NOT WORKING OK MOISTURE MANUALLY .

• MOIST WHETHER • MOISTURE IN OIL • DRAIN WATER DAILY BEFORE STARTING. Training Department COMPRESSOR OIL BECOMES MILKY • HIGH HUMIDITY. 97 .TILL LITTLE OIL COMES OUT.

ADT Switch EWT safety switch 7 + + . . Training Department Ammeter Ignition switch Alternator MCB 20 A Fuel D+ 6 L B R solenoid G B+ B 6 valve S 2 Fuse EOP safety switch 2 No charge lamp Start bush button No 2 Nc Toggle switch 2 2 No No Nc Nc H.ve ground Batteries Engine Electrical circuit 98 . 7 Starter Motor 24V .

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