Portable Compressor 7/20
9---3
SEPTEMBER 2003
9.2.
ROUTINE MAINTENANCE
This section refers to the various components which require
periodic maintenance and replacement.
The
Table 9---1. MAINTENANCE SCHEDULE
indicates the
various components’ descriptions and the intervals when
maintenance has to take place. Oil capacities, etc., can be found
in the
7.GENERAL INFORMATION
section of this manual.
For any specification or specific requirement on service or
preventative maintenance for the engine, refer to the
13. KUBOTA D1005 EGINE.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented
from the system and that the machine cannot be started
accidentally.
If the automatic blowdown fails to operate, then pressure must
be gradually relieved by operating the manual blowdown valve.
Suitable personal protective equipment should be worn.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
A. Prior to attempting any maintenance work, ensure that:
---
all air pressure is fully discharged and isolated from
the system. If the automatic blowdown valve is used
for this purpose, then allow enough time for it to
complete the operation,
---
the discharge pipe
I
manifold area must be kept
depressurised by opening the discharge valve, whilst
keeping clear of any airfiow from it,
---
the machine cannot be started accidently or
otherwise, by posting warning signs and/or fitting
appropriate anti---start devices,
---
all residual electrical power sources (mains and
battery) are isolated.
B. Prior to opening or removing panels or covers to work
inside a machine, ensure that:
---
anyone entering the machine is aware of the reduced
level of protection and the additional hazards,
including hot surfaces and intermittently moving
parts,
---
the machine cannot be started accidently or
otherwise, by posting warning signs and/or fitting
appropriate anti---start devices.
C. Prior to attempting any maintenance work on a running
machine, ensure that:
---
the work carried out is limited to only those tasks
which require the machine to run,
---
the work carried out with safety protection devices
disabled or removed is limited to only those tasks
which require the machine to be running with safety
protection devices disabled or removed,
---
all hazards present are known (e.g. pressurised
components, electrically live components, removed
panels, covers and guards, extreme temperatures,
inflow and outflow of air, intermittently moving parts,
safety valve discharge etc.),
---
appropriate personal protective equipment is worn,
---
loose clothing, jewellery, long hair etc. is made safe,
---
warning signs indicating that maintenance work is in
progress are posted in a position that can be clearly
seen.
D. Upon completion of maintenance tasks and prior to
returning the machine into service, ensure that:
---
the machine is suitably tested,
---
all guards and safety protection devices are refitted,
---
all panels are replaced, canopy and doors closed,
---
hazardous materials are effectively contained and
disposed of.
9.3.
PROTECTIVE SHUTDOWN SYSTEM
Comprises:
---
low engine oil pressure switch,
---
high discharge air temperature switch,
---
high engine water temperature switch.
A. Low Engine Oil Pressure Switch
At three month intervals, test the engine oil pressure switch
circuit as follows:
---
start the machine,
---
remove a wire from one terminal of the switch. The
machine should shutdown.
At twelve month intervals, test the engine oil pressure switch as
follows:
---
remove the switch from the machine,
---
connect it to an independent low pressure supply
(either air or oil). The switch should operate at 1.0 bar
(14.5 psi),
---
refit the switch.
B. Temperature Switch(es)
At three month intervals, test the temperature switch circuit(s) as
follows:
---
start the machine,
---
disconnect each switch in turn. The machine should
shutdown,
---
re---connect the switch.
C. High Discharge Air Temperature Switch(es)
At twelve month intervals, test the air discharge temperature
switch(es) by removing it from the machine and immersing in a
bath of heated oil. The switch should operate at 120
˚
C (248
˚
F).
Refit the switch.
D. High Water Temperature Switch
At twelve month intervals, test the water temperature switch by
re---moving it from the machine and immersing in a bath of
heated oil. The switch should operate at 115
˚
C (239
˚
F). Refit the
switch.
CAUTION
NEVER REMOVE OR REPLACE SWITCHES WHEN THE
MACHINE IS RUNNING.
9.4.
SCAVENGE LINE
The scavenge line runs from the combined orifice/drop tube in
the separator tank, to the orifice fitting located in the airend.
Examine the orifice, check valve and hoses at every service or
in the event of oil carryover into the discharge air.
It is good preventative maintenance to check that the scavenge
line and tube are clear of any obstruction each time the
compressor lubricant is changed as any blockage will result in
oil carryover into the discharge air.
