Training Department

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

An asymmetrical rotary Screw compressor coupled

to a NT 495 C Engine runs at 1800 rpm, produces
Compressed air of 300 to 750 cfm at 100 to 200 psig pr.

* 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, for
operation of air tools and may be for laying cables etc.
* The major systems involved in this machines is Starting,
Regulating, Cooling and Lubrication , Shut down and
Blow down system.
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*

The starting System of the Engine consists Battery ,

Starter, alternator fuel shut off solenoid , throttle cylinder
and start and run valve etc.

Cooling system is incorporated in the system for cooling

compressor oil and water cooling of engine body. Major
Parts are Cooler with fan, Temperature by pass valve etc.

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.

Entire unit is covered with a canopy for protection from

dust, dirt and rain.
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CLASSIFICATION
AND
SPECIFICATION
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Classification of Portable Compressors
TYPE
FLOW cfm
PR psig

HP450

300

450

400

600

150

170

150

100

A.E SIZE MM 125.75

ENGINE
FULL RPM
IDLE RPM

ALU6.65
2500
1200

FUL TNK CAP 140 ltr

BHP

109

TRK Wdth mt 1.68

WEIGHT kg

Cbl Layir

P300

2050
Small range

178.5

178.5

NT495C
2100
1100
275 ltr

HP600 HP650 HP750

226

650
150

700
150

226

226

NT495C N743TC NT743C NT855C

2100
1100
275 ltr

2100

1800

1800

1100

1000

1000

340 ltr

340 ltr 340 ltr

180

180

240

253

253

1.62

1.62

1.7

1.7

1.7

3300

3400

4000

4000

Mid range

Large Range

4000

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PARAMETERS AND SPECIFICATION
Small range
P300

P400

BLAST AIR

FLOW cfm

300

400

PR. psig

100

100

TYPE

A.E SIZE MM 125.75

ENGINE

ALU6.65

178.5
ALU402

FULL RPM

2500

2400

IDLE RPM

1200

1200

FUL.TNK CAP 140 ltr

BHP

109

TRK Wdth mt 1.68

WEIGHT kg

2050

140 ltr

Mid range
P500

HP450

400

500

450

170

100

150

178.5

178.5

178.5

P600
600
100
178.5

NT495C NT 495C NT495C NT495C

2100
1100
275 ltr

1800

2100

2100

1100

1100

1100

275 ltr

275 ltr 275 ltr

122

180

180

180

180

1.68

1.62

1.62

1.62

1.62

2050

3400

3300

3300

3300

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GENERAL LAYOUT
PORTABLE
COMPRESSOR
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MPV

S.V

S.R.V

SEP.
TANK

THROTTLE CYL

COF
PR.REG

ABV

TBV

SER VLV

CONTROL
PANEL

U/V
COMPRESSOR

ENGINE

R
O
C

RUNNING GEAR

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MAJOR PARTS AND THEIR

FUNCTIONAL DETAILS

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LIST OF MAJOR PARTS
1. AIR END
2. ENGINE
3. UNLOADER
4. TEMPRATURE BYPASS VALVE
5. SEPERATOR TANK
6. AUTO BLOWDOWN VALVE
7. RADIATOR OIL COOLER
8. PRESSURE REGULATOR
9. START AND RUN VALVE
10 . MINIMUM PRESSURE VALVE
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1. SCREW COMPRESSOR
Air Discharge end
Housing front brg

Air intake Point

seal
Female rotor
Housing
rear bearing

Drive
shaft
Bellow
housing

Male rotor

Gear
Set
Bearing

Bearing

Rotor housing

226 mm air end

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BELLHOUSING
REAR BEARING
HOUSING

ROTOR HOUSING
AIR OUT

AIR INTAKE
POINT

FMALE
ROTOR

DRIVE
SHAFT

BEARING

OIL
SEAL
DRIVEN SHAFT
MALE ROTOR

GEAR SET

178.5 MM AIR END INTERNAL CONSTRUCTION

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BLADE VANES

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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

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Turbo charger
Exhaust

Fan

Engine Crank case body

Starter
Oil tray

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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

ENGINE RPM

1800

2000

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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
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UNLOADER VALVE

Controls amount of air

entry to air end.

When the Engine is in

Full Load air entry in
the Unloader valve.

In Load position
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In Start
run condition
Condition

To Thrtle cyl.
& UL 99

Separator tank

START AND RUN VALVE

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Only air

Only oil

Air and oil

Mixture

SEPERATOR RECEIVER

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AUTO BLOWDOWN VALVE LOCATION

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AUTO BLOWDOWN VALVE

X
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

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Compressor
oil filter
Cooler Fan

Engine
air filter

Separator
Tank

ROC
Fuel pump

MPV

Fuel filter

Main Parts in the power pack

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LOCATION OF TEMPRATURE BY PASS VALVE

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INITIAL START POSITION

FULL LOAD POSITION

TEMPRATURE
BY PASS VALVE

FROM
TANK

TO FILTER
DIRECTLY

WHEN OIL IS
IN HEAT UP
OILDIVERTED TO
COOLER & THEN
TO OIL FILTERS.

PRESSURE
BY-PASS
VALVE HANDY
WHEN COOLER
IS CHOCKED

WHEN OIL IS
BELOW 65 deg.C
OIL PASSES
THRU TBV TO
OILFILTERS

OIL TEMPRATURE BY PASS VALVE

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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

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Minimum Pr. Valve
Pressure Regulator

Safety Valve

PARTS MOUNTED
ONSEPARATOR.TANK
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BREATAHER

LOOK AT THE WAY THE THROTTLE CYLINDER IS MOUNTED TO ENGINE

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Working Principle

MPV Open

1. Air oil mist entry in to tank

MPV

2. Most of the oil falls down

3 Next Oil Filtration
4. Dry air at service line
5. Oil thru scavenger
line to air end.

Scavenger line

From Air end

To oil cooler

SEPERATION SYSTEM

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Blow down valve

6. Diaphragm
activation

8. Air blown out

1. Air intake is cut off

7.Ball
Shift

Question
What happens
when the
engine is off

5. Pilot line
2.High pressure
in separator
Air end

3.Low pressure
in air end

Separator tank
Discharge line

4. Air gushing in to air end

AUTO BLOW DOWN CIRCUIT

Question
What happens
when Engine
is in load ?

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AIR AND OIL CIRCUIT

OF A MID RANGE
PORTABLE
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MPV
50 PSI

THROTTLE CYL

S.V

S.R.V

SEP.
TANK

P.R

COF

UV
AIR END

B
TBV

ABV

SER VLV

CONTROL
PANEL

C
OUT

R
down O
system
4.Full
load
Run5.Shut
Position
2.3.Warming
upcondition
1.Air
entry
toSRV
Auto Blow
1.1.SRV
open.
1.Cylinder
Stroking
ENGINE
1.
Air
cut
off
Say
50
PSI
isthru
reached
C down valve
2.passes
Pilot
operation
from
2.2.Throttle
Air
Passes
thru
SRV
& TC
2.Engine
Run
atP.R
full
load air end.
2.Air
thru
cylinder
retracts.
IN
3.Diaphragm
ABV activation.
3.System
warm
up
3.Set
ADPout
increase
3. Air
Supply
to.of
ULof
99
3.Air
bleeding
orifice
4.4.Spring
Pressure
buildsSpeed
up
slowly
Venting
of
air
from air end
4. air 4.
toaction/
Throttle
Cylinder
drop

1 Start position

RUNNING GEAR

SERVICE
COOLING
DISCHARGE
COOLING
LINE
ANDFROM
AND
LUBRICATION
LINELUBRICATION
FROM
SEPARATOR
AIR
SYSTEM
END
BEFORE
TO
TO
SERVICE
AFTER
SEPARATOR
WARMING
WARMING
VALVE
TANK

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REGULATION SYSTEM
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REGULATION SYSTEM

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TROUBLE SHOOTING

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AIR END OVER HEATING
Low oil
level

OK

Fill to the center

of the sight glass

Is air re circulation
takes place

OK

Adjust
reg. system

Clean

OK

Is the correct
oil being used

Oil filters
blocked
Replace

Faulty oil
TBV?

OK

Remove thermostat
and test

Replace

OK

OK

Oil cooler exterior

matrix blocked

Replace

Reposition
unit & close door

Is the unit operate at

wrong Pr and Del.

OK

Fan belt broken

or slipping

OK

Is the air end Temperature

shut down switch is faulty
Replace

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INSUFFICIENT AIR PRESSURE
Air demand too
high

OK

System leakage

Match demand to
rated out put

Rectify

Is Start and Run

valve faulty?

Is Pressure reg .
Valve faulty /
wrong setting

OK

Adjust or
Replace

Replace

Is the Sep. element

Blocked or restricted
Replace the
element

OK

Is UL 99not OK
opening fully
Repair /Replace

OK

OK

Air end air filter

blocked

Clean

OK

Is the main
Pr. Valve
defective

OK

Repair or Replace

Is there a fault inside air end

Check air end
for leaks

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Is the engine
speed is too low

Is the speed contol

cylinder sticky or
defective

Replace

OK

Is regulation valve
OK
orifice/ silencer
blocked, Frozen or
wrong size

Rectify

Is air intake filter

is blocked or
restricted

Air filters
blocked

OK

Replace

Replace

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Oil carry over problem

High oil
level

OK

Drain oil and ensure

correct Level

Check discharge
Pressure (75 PSI)
Replace min. Pr.
Valve if not

Check shut down

procedure

Abrupt stoppage at full

load may saturate the
separator filter element

OK

Is the Scavenger
line blocked

OK

Opening manual blow down

valve on shut down May
saturate filter element

OK

Clear line
blockage
Level unit

OK

Check blow down

Procedure

Is the separator
element is ruptured

Replace
Is unit at angle
> 15 Deg .

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EXCESSIVE AIR PRESSURE
Is Pressure regulating
Valve faulty?/wrong set
Adjust or replace
parts

OK

Is UL 99 not
closing properly

OK

Is the Diaphragm
ruptured?

OK

Is the valve
sticking

Free off or replace the

damaged parts

Replace

Are there any leak

in Regulator piping
Replace min. Pr.
Valve if not

OK

Is separator
element blocked
Clear
blockage

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MAINTENANCE
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INTRODUCTION

To Prevent major failures

To avoid repairs and to avoid cost involvement

Preventive maintenance is less expensive

Facilitates easy servicing

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CAUTION
* No warranty for any unauthorized modifications.
* 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
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COMPRESSOR OIL LEVEL
* Oil level should be mid way of the sight glass
* Do not over fill, 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.
Replace filter once Red indication is seen
Short of new element used cleaned old element
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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.
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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.
Safety element must not be cleaned and re used
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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 . 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.
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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
Periodically
* Use clean fuel
* Use non- metallic funnel for fuel filling

BATTERY

* Keep terminals free of corrosion

* Keep correct Electrolyte level in cells
* Secure hold clamps

Disconnect cabl
while mnt.

BELTS

* No tight or no lose
* Replace in a set
* Belt adjustment as per procedure

Loose tight belt

effects Bearing

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SAFETY SHUT DOWN SYSTEM

Maintain the three switches

EOT

---

EOP

----

Calibrate switches periodically.

Engine oil pressure avoid damage due to starvation.

Check the shut down system once in a month.

ADT

CAUTION
Never operate the unit with a defective
safety shut down switch or by shorting
over a switch.
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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

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REQUIRED MAINTENANCE SCHEDULE
ITEM
TYPE
Comp oil lvl
Engine oil

Daily

week

12 MO
6 MO
1000 hrs 1500 hrs

C
C

ENGINE
Air
filter clog

Gauges
FULL RPM

Fuel tank lvl

FUL
FanTNK
BeltsCAP

BHP Elect
Battery

Cooler external

3 MO
500 hrs

A.E
SIZE
MM
ROC
coolent

Shut down

month

C
C
C Check and Replace

R Replace

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ITEM
TYPE

Daily

week

month

Hoses

3 MO
500 hrs

12 MO
6 MO
1000 hrs 1500 hrs

Comp oil filter

Fasteners

ENGINE
Wheel
Bearing

Sep.
FULLelement
RPM

Safety switch

FUL
TNK
CAP
Scav.
line

BHP
C Check and Replace

R Replace

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SAFETY
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SAFETY

TO OPERATOR

TO THE MACHINE

TO OTHERS

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SAFETY TO THE OPERATOR

Use Safety Appliances like shoes, Goggles, Helmet and Ear Plugs

Do not expose yourself to the pressure air.

Ensure all the air hose clamps are secured properly

Do not use compressed air for blowing out chips. Dust etc.

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

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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, 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.

Ensure proper oil level in all units and top up if required

Ensure periodic replacement of filters and dust caps etc

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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

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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, Engine, Separator tank, ROC, Temp. By pass Valve, SRV
Auto Blow down valve, Minimum pressure valve Filter elements
What are the grade of oil used in the different units
Separator tank, Engine oil, Cooler.
What are the Pressure settings done in the compressor
ADP, Safety valve, Pressure switch Tyre pressure etc.
What should be the safe EWT, EOP, COP, COT, ADT etc
EWT < 95degC. EOP 4kg/cm2, COP 4 kg/cm2, COTor ADT 105degC

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

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ENGINE DOES NOT CRANK

BATTERY DOWN
STARTER STUCK.
STARTER/FLYWHE
EL-GEAR TEETH
FAILURE.
ENGINE JAMMED.
A/E SEIZED.

CHARGE BATTERY.
SERVICE STARTER.
CHANGE PARTS.

CHECK & RECTIFY.

CHECK & RECTIFY.

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ENGINE DOES NOT START

BATTERY DOWN.
CLOGGED
FILTER/LINES.
AIR LOCK IN FUEL
SYSTEM.
INJECTORS BLOCKED.
Pump solinioid electrical
not ok.

CHARGE BATTERY.
CLEAN/CHANGE.
REMOVE AIRLOCK.
CLEAN &
CALIBERATE.

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ENGINE DOES NOT PICK UP

SPEED
FUEL LINE
BLOCKAGE.
FUEL FILTER
CHOCKED.
STICKY THROTTLE
CYLINDER.

CLEAN FUEL LINE.

REPLACE FILTER.
RECTIFY.

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ENGINE DYING ON LOAD

CLOGGED FUEL
SYSTEM.
INJECTORS
BLOCKED.
HIGH
A.D.P.SETTING.
CLOGGED
SEP.ELEMENT.
LOW E.O.P.

CLEAN THE FUEL

SYSTEM.
CLEAN &
CALIBERATE.
ADJUST PRESSURE.
CHANGE ELEMENT.
CHECK& RECTIFY.
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HIGH ENGINE WATER

TEMPERATURE
LESS WATER IN
RADIATOR.
AIR LOCK IN THE
WATER LINE.
LOW FAN SPEED.
WRONG FAN
ALLIGNMENT.
AIR LEAK THRO
COWL.

FILL WATER
CORRECTLY.
RECTIFY.
CORRECT BELT
TENSION.
CORRECT
ALLIGNMENT.
RECTIFY.

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HIGH E.W.T
RADIATOR
BLOCKAGE
EXTERNALLY AND
INTERNALLY.

CLEAN THE
RADIATOR
EXTERNALLY AND
INTERNALLY.

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HIGH AIR DISCHARGE

TEMPERATURE.
LOW COMP. OIL
LEVEL.
GRADE OF OIL USED.
OIL COOLER
BLOCKED
EXTERNALLY.
OIL COOLER
BLOCKED INTERN.

FILL TO CORRECT
LEVEL.
USE RECOMMEND.
OIL.
CLEAN.

CLEAN.

CONT.
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HIGH A.D.T.
LOW FAN SPEED.
COMP.OIL FILTER
BLOCKED.
A/E DISCHARGE
CLEARENCE MORE
DEFFECT. TEMP.
BYPASS VALVE.
RECIRCULATION
OF COOLING AIR.

RECTIFY.
CHANGE OIL
FILTER.
O/HAUL THE A/E.
CHANGE.
RECTIFY.

CONT.
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HIGH A.D.T.
FAULTY
TEMP.SHUT DOWN.

CHECK &
CORRECT.

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OIL CARRY OVER

OIL FILLED MORE
THAN MAX.LEVEL.
BLOCKED SCAVEGE
LINE.
SHORTER SCAVENGE
TUBE.
DAMAGED SEP.
ELEMENT.
LOW SYSTEM PRES.

DRAIN EXCESS OIL.

CLEAN,CHECK
ORIFICE ADPT. ON
A/E.
CHANGE & ADJUST
CHANGE.
CHECK M.P.C.V.SET.
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OIL BLOWS BACK THROUGH

AIR FILTER
U.L.PISTON STUCK.
U.L.PISTON SPRING
LOST ITS TENSION.
U.L. DIAPHRAM
PUNCTURE.
PISTON SEATING
DAMAGED.
PISTON/ BUSHING
WORN OUT.

RECTIFY.
CHANGE THE
SPRING.
CHANGE THE
DIAPHRAM.
CHANGE THE U.L.
ASSY.
CHANGE THE
REPAIR KIT.
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EXCESSIVE VIBRATION /
RUMBLING NOISE
LESS ,ENGINE LOW
IDLE SPEED.
ANTIVIBRATION
PAD DAMAGE.
STUCK
ANTIRUMBLE
VALVE.

SET ENGINE LOW

IDLE SPEED.
REPLACE.
RECTIFY.

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AIR END OIL SEAL LEAKING

SEAL DAMAGED.
IMPROPER
FITMENT OF SEAL.
DUST ENTRY.

REPLACE OIL
SEAL.
RECTIFY/REPLACE.
CLEAN THE
SYSTEM
CHANGE AIR & OIL
FILTER IN TIME.
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LOW AIR DISCHARGE

CAPACITY.
STUCK MIN. PR.
VALVE.
LINE LEAKAGE.

RECTIFY.
RECTIFY

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ENGINE SHUTS DOWN

PREMATURELY.
LESS FUEL SUPPLY.
SAFETY
SHUTDOWNS
MALFUNCTIONS.
ELECTRICAL FAULT.
LOW ENGINE OIL
PRESSURE.

CHECK FUEL
SUPPLY.
CHECK ALL SAFETY
SYSTEMS.
RECT. ELECTRICAL
FAULT.
CHECK OIL LEVEL
& PRESSURE.
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SAFETY VALVE BLOWS

OP. PR. TOO HIGH.
FAULTY
REGULATOR.
U.L. DIAPHRAM
FAILED.
LOW SAFETY
VLV.SETTING.
SAFTY VALVE
FAILURE.

ADJUST PR. REGUL.

REPLACE SEAL KIT.
REPLACE.
SET CORRECTLY.
CHANGE SEAL
KIT /VALVE.
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MOISTURE COMES WITH AIR

AUTO DRAIN TRAP
NOT WORKING OK

RELEASE
MOISTURE
MANUALLY .
OPEN A.D.T & DO
SERVICE.

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COMPRESSOR OIL BECOMES

MILKY
HIGH HUMIDITY.
MOIST WHETHER
MOISTURE IN OIL

DRAIN WATER
DAILY BEFORE
STARTING,TILL
LITTLE OIL COMES
OUT.
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D+
G
B+

Fuel
solenoid
valve

Ignition switch

Ammeter

Alternator

MCB 20 A
B

2
2

EOP safety switch

Fuse

No charge lamp

No
Nc

Start bush button

Toggle switch

No
No Nc
Nc
H. ADT Switch

EWT safety switch

24V - ve ground

Starter Motor

Batteries

Engine Electrical circuit

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k
n
a
h

u
o
Y

99