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To extend the life of your air compressors.
In addition to periodic inspections, many of the components in the your compressors require intermittent servicing to provide maximum output and performance. This servicing would typically consist of pre-operational procedures to be performed by maintenance personnel at your workshop. The primary function of such preventative maintenance is to prevent failure, the need for repair and, consequently, unhappy rental customers and idle, inoperative equipment. Preventive maintenance is the easiest and the least expensive type of maintenance . Maintaining the compressors you rent and keeping them clean at all times will facilitate servicing.
Refer to engine operator's manual furnished with the unit for the specific requirements on preventive maintenance for engine and accessory systems.
Schedule Maintenance
Always follow the manufacturer's recommended maintenance practices and frequencies to avoid warranty problems. In the event unusual environmental operating conditions exist, the schedule should be adjusted accordingly.
Compressor Oil Level
The optimum operating level is midway of the oil reservoir sight tube. DO NOT OVERFILL. A totally filled sight tube indicates an over full condition and requires that oil be drained. Add oil only when the level is near the bottom. Then add enough oil to bring the level midway of the sight tube.
Air Cleaner
To assure maximum compressor and engine protection against the ravages of dust, you must keep the air cleaners and inlet properly maintained. Most compressors offer air filter service indicators that should be checked daily.
For specific air cleaners service procedures, refer to your service manual. Basically there are three approaches to air cleaner service: air cleaning, filter washing; and disposal and replacement with a new element. Although the third is not the most economical, it is the safest and can provide the greatest economy over the life of the unit. Before either cleaning or washing, check to be certain these practices do not void your warranty.
A leak in the housing will NEVER be reflected by the service indicator and eventually will result in damage to the engine or compressor.
Make sure that the inlet is free from obstructions, that the air cleaner mounting bolts and clamps are tight and that the air cleaner is mounted securely. Check the air cleaner housing for dents or damage to the cleaner that might lead to a leak. Inspect the air transfers tubing from the air cleaner to the compressor and the engine for holes. Make sure that all clamps and flange joints are tight.
Instruments
The instrument lamps or gauges are essential for safety, maximum productivity and long rental life of the machine. Inspect the instruments prior to startup and during operation to ensure proper functioning. Refer to the operating manual for the normal readings.
Fuel Tank
The fuel tank should be filled daily or every eight hours if necessary. In order to prevent condensation from forming in the fuel tank, it should be filled immediately after the unit has been operated, for example, at the end of each working day. Using clean fuel is vitally important and every precaution should be taken to ensure that only clean fuel is either poured or pumped into the tank.
Every six months the drain plug(s) should be removed from the tank so that any sediment or accumulated condensate may be drained. When replacing a drain plug, make sure it is tightened securely.
Fuel/Water Separator
The fuel/water separator bowl should be inspected for a distinctive fluid-color separation on a weekly basis, or whenever the engine is difficult to start or loses power. Water can be drained by lifting the drain valve or loosening the plastic plug beneath the bowl. Then air must be purged from the system.
Every six months or 500 hours, or more often if fuel is contaminated, replace the element. Follow the procedure outlined in your service manual.
Battery
Keep the battery posts and cable connectors clean and lightly coated with a grease.
Safety Shutdown System
If your compressor is equipped with a shutdown system, it should be checked every month, or whenever it appears not to be operating properly.
Once a year, the temperature actuated switch should be tested by removing it from the unit and placing it in a bath of heated oil. The high discharge-air temperature switch will require approximately 248 F (120 C) to actuate.
Never operate the unit with a defective safety shutdown switch or bypassing it.
Compressor Oil Cooler
The compressor lubricating and cooling oil is cooled by means of the fin and tube-type oil cooler. The oil cooler is so arranged that the lubricating and cooling oil, flowing internally through the core section, is cooled by the air stream from the cooling fan flowing past the core section. When grease, oil and dirt accumulate on the exterior surfaces of the oil cooler, its efficiency is impaired. Each month it is recommended that the oil cooler be cleaned by directing compressed air, which contains a non-flammable safety solvent, through the core of the oil cooler. This procedure should remove the accumulation of grease, oil dirt from the exterior surfaces of the oil cooler core so that the entire cooling area can transmit the heat of the lubricating and cooling oil to the air stream.
In the event foreign deposits, such as sludge and lacquer, accumulate in the oil cooler to the extent that its cooling efficiency is impaired, a resulting high discharge-air temperature is likely to occur, causing shutdown of the unit. To correct this situation, you will need to clean the oil cooler, using a cleaning compound in accordance with the manufacturer's recommendations. Use only a dependable cleaning compound. This is of prime importance because different cleaners vary in concentration and chemical composition. After completing the cleaning procedure, the oil cooler must be flushed before returned to service.
Hoses
Each month it is recommended that all of the intake hoses to and from the air cleaners and all of the flexible lines used for air, oil and fuel be inspected.
To ensure freedom from air leaks all rubber hose joints and the screw-type hose clamps must be absolutely tight. Regular inspection of these connections for wear or deterioration is a definite "must" if regular servicing of the air cleaners is to be effective. Premature wear of both the engine and compressor is a result of dust-laden air entering the engine's combustion chamber or the compressor intake.
All components of the engine cooling system should be checked periodically to keep the engine operating at peak efficiency. Consult the engine operator's manual for instructions and schedule.
The flexible hoses used in the fuel, oil and air lines on these units are primarily used for their ability to accommodate relative movement between components. Secondarily, they reduce vibration problems found with fixed piping and permit much more flexibility in routing. Because hose lines are flexible, it is extremely important that they be periodically inspected for wear and deterioration.
Clamps are used to prevent hose cover abrasion through vibration. This abrasion may occur when two hose lines cross, or when a hose line rubs against a fixed point. Therefore, it is necessary that you replace any missing clamps and add new clamps where required to prevent further wear. It is also important to warn your rental customers not to let the operator use the hoses as convenient handholds or steps. Such use can cause early cover wear and hose failure.
Compressor Oil Filter
Most compressor lubricating and cooling oil systems are equipped with in-line, spin-on type oil filters and bypass values.
The oil filter must be replaced every 500 hours of operation or at the intervals recommended by the manufacturer. On new or overhauled units, replace the element after the first 50 and 150 hours of operation, then every 500 hours.
If there is any indication of formation of varnishes, shellacs or lacquers on the oil filter element, it is a warning the compressor lubricating and cooling oil has improper characteristics and should be immediately changed.
Fasteners
Visually check entire unit in regard to bolts, screws being properly secured. Spot check several cap screws and nuts for proper torque. If any are found loose, a more thorough inspection must be made.
Compressor Oil
The lubricating and cooling oil must be replaced every 500 hours of operation or six months, whichever comes first. Refer to the manufacturer's lubrication recommendations for detailed instructions and specifications.
Running Gear
Every six months the wheel bearings, grease seals and spindles should be inspected for damage and wear (i.e. from corrosion, scratches, metal particles). Replace any damaged worn parts. Repack wheel bearings. Use a wheel bearing grease conforming to specifications MIL-G-10924 and suitable for all ambient temperatures.
Note
Excessive grease in the hub or grease cap serves no purpose due to the fact that there is no way to force the grease into the bearing. The manufacturer's standard procedure is to thoroughly pack the inner and outer bearing with grease and then apply only a very small amount of grease into the grease cap.
Receiver-Separator System
Warning!
Hot pressurized fluid.
Before performing any service on the compressor lubricating system:
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Open service valve at end of machine.
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Ensure pressure is relieved, with BOTH:
- Discharge of air pressure till gauge reads zero.
- No air discharging from the service valve.
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When draining oil, remove and replace (tightly) plug at bottom of separator tank.
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When adding oil, remove and replace (make tight) plug on side of separator tank.
In the compressor lubricating and cooling system, separation of the oil from the compressed air takes place in the receiver-separator tank. As the compressed air enters the tank, the change in velocity and direction drops out most of the oil from the air. Additional separation takes place in the oil separator element which is located in the tip of the tank. Any oil accumulation in this separator element is continuously drained off by means of a scavenger tube which returns the accumulated oil to the system.
The life of the oil separator element is dependent upon the operating environment (soot, dust, etc.) and should be replaced every 12 months or 1,000 hours, whichever comes first.
When replacing the element, the scavenger lines, orifice, filter and check valve should be thoroughly cleaned and the oil changed.
Scavenger Line
The scavenger line originates at the receiver-separator tank cover and terminates at the rear of the air end. Once a year, or every 1,000 hours of operation, whichever comes first, remove this line, orifice, filter (screen) and check valve. Thoroughly clean these parts, making sure the orifice is not clogged, and then reassemble.
Excessive oil carryover may be caused by oil-logged separator element. Do not replace element without first performing the recommended maintenance procedure.
Exterior Finish Care
The external appearance of your compressor is important and requires regular attention. It should be cleaned using automotive-type detergents in mild soaps. A wax job is a good investment in protecting the exterior finish of your compressor. Good looking equipment on the job site is good publicity.
Warning!
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If performing more than visual inspections: (1) disconnect battery cables, (2) open service valve and (3) ensure discharge-air pressure gauge reads zero.
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Use extreme care to avoid contracting hot surfaces (engine exhaust manifold and piping, air receiver and air discharge piping, etc.).
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Never operate this machine with any guards removed.
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