DIRECTORATE GENERAL BORDER ROADS
GENERAL MAINTENANCE INSTRUCTION NO: 216
ON PERIODICAL MAINTERNACE OF
CHICAGO PNEUMATIC
DIESEL SCREW COMPRESSOR
INTRODUCTION
1. This General Maintenance
Instruction covers the periodical maintenance of Chicago Pneumatic Diesel Screw
Compressors. The rotary screw air compressor is a single stage oil flooded,
rotary compressor driven by an engine through a coupling. The compressor casing
accommodates a pair of male and female helical rotors, machined with the
highest precision and mounted on rolling element bearings. The male rotor has
four helical lobes, which mesh with six flutes of the female rotor. The male
rotor revolves at 1.5 times the speed of the female rotor. The male rotor is
driven by a coupling through step-up gears. The male rotor lobes mesh with
female rotor flutes and the air trapped in the interiobal spaces is smoothly
compressed until it reaches the outlet port. As continuous compression takes
place in all the pockets, pulsation free air is delivered.
2. The oil injected through
the lower gusset of the comp0ressor casing mixes with the indrawn air and
ensures an efficient sealing between the rotors and the casing, and at the same
time, there is an intensive cooling during the compression process.
3. Inter cooling is not
necessary because huge quantity or lubricating oil cools the air as it is being
compressed. The oil which lubricates the compressor and seals the clearance
spaces, is cooled in a oil cooler mounted in front of the radiator by an engine
fan.
4. Regular pre-checks and
periodic maintenance are essential to prolong the life of the equipment. Also
it should be ensured that preventative maint
task are carried out timely, repairs to arrest defects from developing
into major ones are done expeditiously and that the equipments is operated
efficiently at all times, thereby minimizing inopportune breakdowns and down
time losses.
5. To enumerate the details
or periodic preventive maintenance of Chicago Pneumatic diesel Screw
Compressor.
ACTION BY
a)
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USER UNIT:
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To carry out maintenance schedule and oil changes etc as per
periodicity laid down by this maintenance instruction and also follow safety
precautions for optimum utilization.
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b)
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FIELD WORKSHOP:
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i)
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To carry out and monitor, maintenance schedule and oil changes etc as
per periodicity laid down vide these instructions.
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ii)
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To advise user unit in respect of any lapses noticed.
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DETAILS
The details of maintenance, fuel, lubricants and safety precautions are
as under:-
a)
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Operation & Periodical Maintenance Schedule
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Appx ’A’
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b)
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General Specification
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Appx ‘B’
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c)
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Do’s and Dont’s
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Appx ‘C’
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Please ack receipt.
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Sd/xxx
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EE(E&M)
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Offg Director (Tech)
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Distribution:-
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For Dir Gen Border Roads
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Normal
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Appx- ‘A’
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OPERATION AND PERIODICAL MAINT SCHEDULE ON DIESEL
SCHEW AIR COMPRESSOR
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1. CHECK THE FOLLOWING
BEFORE
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a) Ensure
that chassis and wheel bearing are correctly lubricated and tyres inflated.
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b) Set
the compressor in a location which is as leveled as possible and free from
dust or dirt.
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c) Remove R ¾” plug, located on
top of inlet casing and fill approx 10 Ltrs of clean compressor oil and refit
plug.
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d) Drain water and dirty oil from air- oil
receiver and fill compressor oil in air oil receiver. The oil level indicator
glass should show ½ of the indicator or up to the black band.
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e) Drain water and dirty diesel from diesel
tank and fill with suitable good quality engine fuel. Prime fuel system.
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f) Drain
old dirty oil from engine oil sump and fill correct grade engine oil.
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g) Blow and clean the radiator and oil cooler
assemble to remove the dust and dirt collected on it. Flush radiator with
clean water and refill to correct level. In winter a good permanent
antifreeze should be used. Ensure that there are no leakages.
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h) Check and connect the batteries to the
system. Check that all the electrical connections are correctly made.
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j) Tighten the fan belt, if necessary, and
ensure that the fan is not touching the fan cowl.
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k) Blow
and clean suction air cleaner elements for compressor and engine.
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l) Open
choke in the oil return line and check for blockage. Clean the strainers.
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m) Clean “Y” type strainers. Clean oil
injection nozzle for gears.
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n) Check
the oil filter elements and if found in bad condition, replace it with new
one.
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o) Ensure
that P2P type capacity controller and control lever connections are in order.
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p) Check that the fiber glass elements are in
good condition. It these are deteriorated, replace them with new ones. This
can only be established after the compressor has been started and the oil
throw noticed.
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q) Tighten all hoses and flexible nylon tube
connections and fittings etc and check that they are free from damages.
Repair or replace any damaged parts.
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2. ROUTINE PRE START
INSPECTION
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a) Check engine oil, water and fuel lines for
leakages.
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b) Drain water and dirty oil from air receiver,
till clean oil appears.
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c) Check oil for contamination.
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d) Maintain oil level to ½ in oil level
indicator glass.
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e) Check oil cooler and radiator for external
cleanliness.
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f) Check cooling water for contamination and
fill water in radiator to correct level.
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g) Check air cleaner condition.
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h) Drain water from engine diesel filter and
tank. Check fuel level and fill if required.
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j) Check battery electrolyte level.
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k) Check safety valve for operation/
activation, after first starting.
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l) Check wiring and piping for loose
connections.
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m) Check cooling fan belt
tension.
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3. STARTING
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a) Relieve any air pressure in the air/ oil
receiver by opening one or the air service valves. Close all air service
valves. This is important.
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b) Loosen the wing nut on the ‘L’ Slotted
plate, so that it is pulled to ‘IDLE position. This will ensure that start of
engine at idle speed.
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c) Operate starter.
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d) Relieve air pressure if
engine shown sign of stalling. Never run the compressor with less than 4 Kg
/cm2 receiver pressure.
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e) Run the engine at idle speed for five
minutes to warm up.
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f) Set the nut ‘L’ slotted in ‘RUN’ position
and tighten the wing nut.
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g) Open air service valve to load the
compressor.
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4. COLD WEATHER
STARTING
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a) When starting, run engine at idle speed till
it is well warmed up. Run the compressor with the radiator air flow closed
and open them only as required to prevent the water temperature exceeding 85 0C.
The front radiator closing has a considerable
effect on the cooling so regulate their position carefully.
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b) The service valve should
only be opened after the compressor has been started and air receiver
pressure quickly brought to about 4 Kg/cm2 or more. The pressure
should then be raised gradually to the full working pressure.
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5. STOPPING
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a) Close all the air service valves causing
plant to unload.
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b) Run the plant in unload condition for about
15 Minutes to cool down.
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c) Set the wing nut on ‘L’ slotted plate to
‘IDLE’ position.
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6. WARNING
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a) The compressor must NEVER be
operated with a compressor air discharge temperature higher than 1100C
(2200 F).
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b) Do not restart the compressor until the air
pressure in the receiver has fallen to Zero.
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c) Release all air pressure before removing the
oil filling cap of air /oil receiver.
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7. ROUTINE/PERIODICAL
MAINTENACE TASK
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a) Daily Before starting.
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i)
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Drain water from Air/Oil receiver.
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ii)
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Check and maintain correct lub oil level in compressor air oil
receiver and engine crankcase.
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iii)
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Check and maintain correct coolant level in radiator.
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8. DAILY MAINTENANCE
TASK
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a) Drain water from control filter frequently
and before shutting down. ‘Service Indicator’
on suction air cleaner (Dry Type only)
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9. FIRST 50 HOURS
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a) Change engine oil.
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b) Change engine oil filters.
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c) Change battery electrolyte specific
gravity.
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d) Clean /replace engine air cleaner elements.
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e) Replace cooling water, fill clean water and
fit new corrosion resistance/coolant.
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f) Change fuel filter elements.
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g) Clean internal and externals of radiator
cooling systems.
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h) Clean fuel tank terminals.
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j) Change compressor oil filter element.
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k) Clean ‘Y’ strainers.
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l) Clean all chokes of compressors.
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m) Clean /replace compressor in take air
cleaner element.
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n) Apply grease to Trailer spring pins and
wheel hub bearing.
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10. EVERY
50 HRS RUN
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a) Drain water and dirty diesel from fuel
filter.
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11. FIRST
100 HOURS
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a) Chicago Compressor lub oil and refill with
Chicago pneumatic super Oil/IOC HLP 68.
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12. EVERY
100 HOURS PERIODICAL CHANGE
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a) Check battery electrolyte specific gravity.
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b) Clean/replace engine air cleaner elements.
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c) Clean/replace compressor intake air
cleaner elements.
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13. EVERY 250 HOURS PERIODICAL CHANGE
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a) Change engine oil.
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b) Change engine oil filters.
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c) Replace cooling water, fill clean water
and fit new corrosion resistance/coolant.
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d) Check fuel filter element.
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14. EVERY 500 HOURS PERIODICAL CHANGE
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a) Replace Lub oil filter.
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b) Clean internal and external of radiator
cooling system.
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c) Change compressor oil filter element.
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d) Clean ‘Y’ strainers.
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e) Clean all chokes of compressor.
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f) Inspect, replace oil check valve ‘O’ rings.
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g) Apply grease to trailer spring pins and
wheel bearing.
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15. EVERY 1000 HOURS PERIODICAL CHECK
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a) Clean fuel tank terminals.
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b) Clean engine oil pan and strainers.
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c) Check and replace rubber and nylon
hoses.(At every overhauling)
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d) Clean oil cooler tubes internally.
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e) Check and change compressor lub oil if
found dirty.
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f) Clean/replace compressor intake air
cleaner elements.
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16. EVERY 1500 HOURS
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a) Change compressor lub oil.
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b) Clean radiator and oil coolers.
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c) Clean air / oil receiver.
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NOTE: Under adverse condition servicing period should be suitably
reduced.
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17. COMPRESSOR
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Recommended lubricating
oil is shown below:-
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Ambient Temperature (oC)
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Brand
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Source
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Remarks
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+ 11 to + 50
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Super Oil
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Chicago Pneumatic
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-21 to + 50
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HLP-68
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Indian Oil
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+11 to +45
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ENKLO-68
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Hindustan Petroleum
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+11 to +45
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Bharat Turbo
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Bharat Petroleum
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Appx
-‘B’
GENERAL SPECIFICATION
MODELS
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CPS 180
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CPS 260
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FAD at normal working
Condition
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CFM M3/MIN
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180/ 5.1
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260/7.4
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Normal working Pressure
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PSIG
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100
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100
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Kg/cm2g
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7.03
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7.03
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Max. Unloading
Pressure
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PSIG
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115
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115
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Kg/cm2g
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8.09
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8.09
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Air/oil receiver Volume
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Liters
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32
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60
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Oil to be filled in Receiver
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Liters
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12
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18
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Fuel tank capacity
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Liters
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110
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140
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Length without Draw bar
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Meters
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2.8
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3.1
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Width
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Meters
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1.2
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1.3
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Height with silencer
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Meters
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1.6
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1.9
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Weight
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Kgs
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1580
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2000
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Engine Model
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P6(I)
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ALU 6.65
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Appx - ‘C’
Do’s and DONT’s
Do’s
1. Follow the instructions
given in Appx-‘A’.
DONT’S
1. Do
not tow compressor more than 25 Km/Hour speed.
2. Do
not locate compressor on uneven ground for filling oil and operation.
3. Do
not disturb unloader/ capacity controller setting unless it fails to operate.
4. Do
not disturb safety valve setting
5. Do
not start compressor until the pressure in receiver has fallen to Zero.
6. Do
not operate compressor beyond 1100 C Air discharge Temperature.
Investigate cause of high discharge air temperature.
7. Do
not open oil filter cap of oil receiver before relieving completing pressure
from receiver.
8. Do
not operate starter motor for starting engine for more than 30 seconds
continuously as it may overheat and burn.
9. Do
not run alternator without the battery as regulator plate will burn.
10. Do
not disconnect any lead of alternator when the engine is running.
11. Do
not flash alternator output leads to check for current flow.
TO OBTAIN THE BEST RESULTS FROM THE COMPRESSOR
1. Ensure
that the compressor plant is placed on a firm level surface.
2. Use
only the recommended oils for the compressor and engine.
3. Maintain
the lubricating oil level between the low level and high level marks on the oil
indicator or dip stick, preferably near the high level, never allow it to fall
too low.
4. If
the oil pressure gauge fails to register, stop the compressor immediately,
check for correctness or replace.
5. Check
the tightness of all bolts and nuts at regular intervals.
6. Maintain
the general cleanliness of the compressor.
7. Cleaning
of the air cleaners at regular intervals is of great importance for prolonging
the life of both the compressor and the engine.
8. Never
run the compressor or engine without air cleaners.
9. Do
not adjust the unloader/ capacity controller unless it fails to operate.
10. Change
lubricating oil and oil filters at recommended intervals.
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