MAINTENANCE MANUAL AND

PART LIST

AIR COMPRESSOR RECIPROCATING

MODEL ATT200/300

AIRTEK MACHINERY LIMITED

COIMBATORE - 641028
 MAINTANENCE
MANUAL AND
PARTLIST

AIR COMPRESSOR RECPROCATING

MODEL ATT 200/300

AIRTEK MACHINERY LIMITED

COIMBATORE - 28.
FOREWORD

The AIRTEK Compressor, which you have purchased, has been designed and constructed with the utmost skill
and care. The. compressore is manufactured under stringent quality conditions by experienced and dedicated workmen.
Due to design innovations you can expect higher reliability and better performance from dare AIRTEK Compressor. The
materials that go into the make of the Compressor are carefully chosen keeping in mind their end uses.

The manual which accompanies the compressor explains in detail all the salient features of the compressor.A
detailed description and drawing of all the major systems and parts are incorporated into the book. A detailed
maintenance and trouble-shooting section is also enclosed.the book has been put together with much effort and care
and the user should go through the book in detail and follow the instructions to get the best of his compressor.

A hassle free operation for several years can be guranteed under normal working conditions and with regular
maintence.The perfomance of the AIRTEK compressor will match and even exceed your expectations and thank
you on your purchase of an AIRTEK product.

NOTE:

COMPRESSOR
MODEL..:—
SL.NO..:—
MED.YEAR..:—
MOTOR
MAKE..:—
HP..:—
SL,NO..:—..
AIR RECEIVER
CAPCITY..:—
MED.YEAR..:—
TESTED PRE..:—
SOARE PARTS
SL.NO..:—
DESCRIPTION..:— ..

REQD.QTY..:—
DRG.NO..:—
 INDEX

FOREWORD

INDEX

1. IMPORTANT NOTICE

2. SAFETY PRECAUTIONS

3. UNIT SPECIFICATIONS

4. KNOW YOUR COMPRESSOR

5. KNOWYOURCONTROLS

6. COMPRESSOR THEORY AND OPERATIONS

7. INSTALLATION

8. MA1NTENCE

9. TROUBLE SHOOTING

10.REPA1RS

11.APPENDIX

12.PART LIST
 1.IMPORTANT NOTICE

1.1) Read the manual thoroughly and follow theinstructions.

1.2) Clean thecompressor unit and air filter regularly.

1.3) In case of replacement use only genuine certified spares.

1.4) The condensate collectiflg in the air receiver must be

drainedon aday-to-day basis.

1.5) Use only recommended lubricants (See appendix —1) and

maintain the correct oil level in the crankcase.

1.6) Attend maintenance & repai works only by experienced

servicemen.

1.7) Errectthecompressorn a well ventilated area.

1.8) Do not alter the factory settings or the pressure

adjustments.

1.9) liie compressor must not be operated with belt guard

removed.

1.10) Do not use cleaning agents whils servicing the compressor.

1.11) Repair work should not be carried out when the

compressor is in operation.

1.12) The compressor must be overloaded on a continuo basis.

 2. SAFETY PRECAUTIONS

2.1) The air compressor must be operated only by those who we

have been trained to do so and those who have read and understood the operation manual meant for the compressor.

2.2) Any alteration or modification made to the compressor is very dangerous and may cause it to become unstable
and shold be avoided at all costs

2.3) The safety valve should be checked manually (popped) to make sure it is not clogged or blocked on a
fortnightly basis.

2.4) The rated pressure of the compressor should not be exceeded during operation.

2.5) Care should be taken to ensure that the air holes or discharge pipes are not operated by inexperienced personall
or misused in any other way.

2.6) Discharge all air from the air receiver before opening the line fitting or any other compressor connections.

2.7) The hose connections & other fittings should be connected securely to prevent accidental disconnections.

2.8) Do not use fiamable solvents for cleaning the compresso.

2.9) Do not attempt to operate the compressor in a hazardous environment unless the compressor has been
specifically designed for the application.

2.10) Do not attempt to operate the compressor without the fan or the belt guard.

2.11) Keep all parts of the body and clothing away from all points of air discharge and from all moving compressor
parts such as belts fans etc.

2.12) The air from the compressor should no to be used for the purpose respiration (breathing).

2.13) The compressor should be operated only in a well ventilated open area.Do not operate the compressor in
closed confined areas where there is no free flow of air.

2.14) Do not start or operate the compressor unless it is safe to do so.The compressor must not be operated in
known unsafe conditions.
 3.UNIT SPECIFICATION

VERIABLE ATT-200 ATT-300

Reciprocating Air Cooled Reciprocating Air Cooled

1. TYPE
Splash Lubricated Splash Lubricated

2. FAD 5 cfm.
8 cfm.
3 DISPLACEMENT 6.5 cfm. 10.5 cfm.

4 WORKING PRESSURE 12kg/Cm² 12kg/Cm²

NO. OF STAGES 2 Nos, 2 Nos.

5

6 NO. OF CYLINDERS 2 Nos, 2 Nos.

7 CYLINDER BORE I STROKE 70mm X 50 mm X 85 mm 70mm X 50mm X 25 mm

8 TYPE OF VALVE Stainless Steel Finger Type Stainless Steel Finger Type

9 BELT SIZE & QUANTITY A 62 X 2Nos. A 72 X 2 Nos.

10 COMPRESSOR SPEED 600 RPM 920 RPM

11 VOLUMETRIC EFFICIENCY 76.5 % 76.5 %
12 AIR RECEIVER CAPACITY 160/250 Ltrs 160/250/300Ltrs
PRESSURE SWITCH 12kg/Cm² 12kg/Cm²
13 (a). CUTOFF 9 kg/Cm² 9 kg/Cm²
(b). CUT IN

SAFETY VALVE SET PSSURE 5 kg / Cm² 5 kg / Cm²

(a). INTER COOLER 13kg/Cm² 13kg/Cm²
14
(b). AFTER COOLER PIPE 14kg/Cm² 14kg/Cm²
(c).A1RRECEIVER
15 CRANKCASE OIL CAPACITY 550 ml Mini. 550 ml Mini.

16 MOTOR RATING 2 HP 3 HP

17 CLASS OF INSULATION Class ‘F’ Class ‘F’

18 MOTOR SPEED 1400RPM 1400RPM
19 TYPE OF STARTER DOL DOL
20 OUTLET AIR TEMPRATURE 10° C Above Ambient 10° C Above Ambient
 4: KNOWY YOUR COMPRFSSOR

The new Airtek reciprocating corn presser is a two stage, two cylinder compressor,
It has been specially designed to suit industry requirements, and is widely used in
applications such as service station, foundries, mining; Textile machines and in
newer applications such as food processing, packaging machines and automation
systems.

4.1 RECIPROCATINCAIR COMPRESSOR UNIT:

4.1.1 Configuration:
The reciprocating air compressor is an two stage, two cylinder unit arranged in a
“V” type configuration. The compressor is splash and is air-cooled. An intercooler
made of high-grade aluminum casting connects the two cylinder heads. An air filter
connected to the low-pressure cylinder head. The discharged air tied trough the after
cooler, from the high pressure cylinder to a non-return valve. A dynamically balanced
pulley cum fans which performance as a flywheel is fitted to the crankshaft end for
driving the compressor and for cooling it. The motor is fitted on a pivoted motor plate
with provisions for belt tension adjustment.

4.1.2 CWANK CASE:

The crankcase houses the crankshaft assembly and is made up of high-grade cast iron.The
two cylinders are fitted on to it iu a ‘V’ form. The crankcase acts as a sump for the
lubricating oil anti is provided with an oil level indicator. Drain plug and a breather valve
The breather valve maintains a partial vacuum inside the crank case facilitating
optimum lubrication.
4.1.3 CRANKSHAF AND CONNECTING ROD ASSEMBLY:
The connecting rod and the crank shaft assembly are precision machined and are
dynamically balanced. A single row heavy duty ball bearings are provided at both ends of
the connecting rod assembly. The connecting rod big end is provided with a cylindrical
steel roller the small and is provided with a phosphorbrozne bush bearing. The crank webs
are forged out of carbon steel and are hardened and precision ground.The crankshaft
assembly is provided with an oil splasher for lubricating all moving parts by spalshing the
oil in the crank case.
4.1.4 PISTON & PISTON RINGS:
The pistons are of automotive type and are made of low expansion aluminium alloy. The
pistons are provided with plain, stepped and slotted oil control rings. The piston rings are
made of close grained pearlitie cast iron and are designed for controlling wear and excessive
oil consumption. The gudgeon pins made of chromium steel are case hardened, and
precision ground
4.1.5 CYLINDER AND CYLINDER HEAD:
The cylinder and cylinder heads are provided with deepfine for effective cooling and are
made of high grade cast iron to ensure high wear resistance. The cylinder bores are precision
honed. All air passages in the cylinder heads are generously curved for easy air flow. Valve
flates are provided with stainless steel finger type valve plates between the cylinder and
Cylinder heads.

4.1.6 AIR FILTER:

An efficient dry type air fitted to the Suction side of the Compressor to separate the dust
mixed the suction air. This and prevent excessive wear and ensure maximum life for the
cylinders and pistons.
Alternatively an oil filter can also be provided in conditions where the air is dusty for
example in foundries textile mills etc. The oil filter effectively cleans the air of dust
particles even below in microns size.

4.1.7 INTER COOLER AND AFTER COOLER:

The intercooler connects the first stage discharge and the second stage suction and is made
of aluminium casting provided with deep fins for effective cooling. it is provided with a
safety valve set to open if the pressure in the intercooler exceeds the safety limit. The
spindle of the safety valve can be lifted manually.
The after cooler is a deeply finned aluminium pipe connecting the second stage delivery to
the non return valve, it is Provided with a safety valve of similar design to that of the
intercooler and is set to open if the maximum working pressure is exceeds. Both the inter
and after cooler are placed in the air stream provided by the fan for effective cooling.

4.1.8 NON RETURN VALVE:

An automatic non-return valve is provided at the end of the after cooler pipe to set as an
automatic air shut off valve. The Valves Is equipped with an oil and heat resistant valve seat
and is spring loaded. The valve alloes air to into the air receiver and prevents reverse flow
of air.
4.1.9 SAFETY VALVES:
There are three safety valves incorporated into the unit. they are machined out of copper
and are spring loaded. They are set to open if the pressure exceeds the safety limits
prescribed for the particular part to which the safety vaves are provided. The inter cooler
after cooler and the air receiver are provided with safety valves.

4.1.10 PRESSURE SWITCH:

A pressure switch is provided to automatically switch on and switch off the compressor at
predetermined pressures. The pressure switch is diaphragm operated. The diaphragm is
made of flexible nitride rubber to ensure enhanced response to pressure fluctuations.
Since the pressure switch has to with stand high pressure during the course of operation
of the compressor. Bakelite is used to impart strength to the pressure switch. The main
spring tension is easily adjusted by the knob present at the top, the differential can also be
adjusted by turning the knob(diagram gives directions on using the pressure switch).

4.1.11 UNLOADER VALVE:

An unloader valve to realease the compressed air after the compressor off is incorporated
into the pressure switch the valve is present at the bottom part of the pressure switch and is
Operated by a link rod operates by the contact bridge of the pressure switch. A nut
provision at top is given to adjust the operation of the valve.
The valve does not operate in case of power failure or when the machine is shutdown. The
air can is then released by operating the safety valve present in the after cooler.

4.1.12 PRIME MOVER (MOTOR):

A suitable power rated electric motor is provided as the prime mover for the compressor it
is a squirrel cage TEFC 4 pole induction motor it is suitable for operation at a supply
voltage of 4lSvolt 3 phase supply. The power supply for single phase motor is 240v, 50HZ
and for 3 phase motor is 415V, 50HZ.
Airtek motors functions satisfactorly at low voltage up to 160V for single phase and up to
350V for 3 phase motors. The fitted on a motor plate of provided type on which belt
tension adjustments are easily made.
4.1.13 AIR RECEIVER / BASE:
The air receiver base is fabricated out of quality structural stell. A shut off valve is provided
at the outlet of the air receiver/base to control the flow of air. The air receiver (tank) is
provided with a drain valve to release the condensed water collecting in the. tank. A safety
valve set to open if the operating pressure is more than the working pressure is also provided
along with the tank. Saddle supports are provided to station the tank on level ground.
The base mounted compressor package is equipped with a safety valve set to open if the
operating pressure exceeds the working pressure in the delivery pipe.
 5 KNOW YOUR CONTROLS

5.1 PURPOSE OF CONTROLS

Your compressor has a wide range of controls, safety devices and instruments to
ensure that it is functioning at its best. Each has its own domain of operation.It is
essential to interpret its reading and act accordingly.Given below is a short summary
of the various controls and instruments.Please go through them and familiarize your-
self with their uses.

CONTROL OR INDICATOR PURPOSE

5.1 On/Off Button It turns the compressor (Starter) on and and it also doubles as
an direct on line (DOL) starter (optional).

5.2 Pressure gauge lt contant1ynionftorsthe pressure hit receiver or delivery pipe

dunng load / unload condtions.

It allows you to see and monitor if the level is correct. Fill

5.3 Oil level indicator the oil only when the compressor is switched off.The
minimum and maximum oil levels are indicated y red
lines on the plastic outer body.

It opens to the atmosphere if the intercooler air pressure is

5.4 Safety Valve - Center cooler over 130% of the intermediate pressure of the compressor.
It comes into operation if the inter cooler becomes cIogged
or blocked.

5.5 Safety valve Aftercooler It opens to th atmospliere if the pressure in the aftercooler
exceeds 130% of the working pressure du to mal-function or
failure of the non return valve.
 5 KNOW YOUR CONTROLS

It opens if the pressure in the air receiver / delivery pipe exceeds

5.6 Safety Valve - air receiver
130% of the working pressure of the compressor due to
Delivery pipe
malfunction or failure of the pressure switch.

It allows the discharge air into the air receiver or delivery pipe
5.7 Non-return valve and prevents the air from returning back (reverse flow) into the
Aftercooler

It maintains the correct air pressure-in the air receiver or delivery

5.8 Pressure switch pipe and accordingly switches on (pressure cut in) or off (pressure
cut off) the compressor motor depending on the load conditions
and discharged air off take

It is used to drain the condensed water collecting in the air receiver

5.9 Drain valve in the course of operation of the compressor.

It is used to isolate the compressor unit from the servicing

5.10 Shut off valve connections

The valve maintains a partial vacuum inside the crankcase

5.11 Breather valve facilitating optimum lubrication. The valve is connected to the
crank case body.

The valve releases the air left in the Aftercooler when the pressure
5.12 Unloader valve cut of point is reached this prevents excessive load on the motor
when the compressor cuts in again (restarts).
 6. COMPRESSOR THEORY AND OPERATION

6.1 THEORY BEHIND OPERATION:

Compressors are called positive displacement units.ie those in which successive volumes
of air trapprd. Their volume reduced thereby increasing, their Pressure. The compressed
air is then forced out of the enclosure and a fresh volume forced in. Reciprocating
compressors are these in which the moving element is a piston having a reciprocating
motion within a cylinder.

6.2 OPERATION OF THE SYSTEM:

The air from the atmosphere is sucked into the compressor through the air filter during
the suction stroke (downward) of the piston. During ‘the upward stroke (compression
stroke) of the compressor.The original volume is reduced, Increasing the pressure inside
the cylinder. The discharge valve then opens and the air is released into the after cooler.
This is known as the discharge valve closes and the air present in the clearance region
(at discharge pressure) expands as the piston moves downwards in the expansion stroke,
both the valves are closed and when the pressure inside fails below the inlet pressure the
inlet valve opens and air flows into the cylinder repeating the whole process again.

6.3 WORKING OF THE SYSTEM

The temperature of the discharged air at the end of the single stage compression stroke is
around 65c to 75c, the air is subsequently cooled by passing it through a center cooler
after the first stage compression. A safety valve is present at the end of the after cooler. It
opens to the atmosphere if pressure exceeds the safe limit.The air enters the air receiver /
delivery pipe after passing through a non return valve.The pressure gets built up due to
the presistent flow of air into the air receiver 1 delivers pipe.
The pressure in the air receiver is controlled by a pressure switch which cuts off supply to
the motor when the set pressure is reached. The motor is reactived when the pressure fails
below a predetermined level. The pressure switch is operated with the help of a rubber
diapharm.A safety valve is fitted to the air receiver which operates when the pressure.
Switch malufunctions or fails.
When the pressure switch cuts off supply to the motor. The air in the after cooler pipe is
released through the unloaded vave.This prevents load on the motor when it restarts again.
The unloaded valve is fitted to the lower portion of the pressure switch.
The air reciver is fitted with a shut off valve which controls the air being fed into the
service lines.
 7. INSTALLATION

7.1.LOCATION OF THE COMPRESSOR:

7.1.1 The compressor must be placed on level surface of suitable strength.Due to vibration or
other. externel forces. It is necessary to fix the compressor to the floor by means of foundation
bolts.
7.1.2 The compressor must be installed in a cool well-ventilated area. The compressor must
never be installed near a boiler,furnance or any other place where the atmosphere is hot and
dirty.
7.1.3 The machine must be installed at a distance of minimum three feet away from the
surrounding walls. The location must permit sufficient ftree air flow to and away from the
compressor location.

7.2.EQIPMENT CHECK:
7.2.1 Oil check : Pour correct graded oil (refer appendix) to (he optimum level as seen through
the oil level indicator.
7.2.2 Belt tension : Proper belt tension between the motor pulley and fanpulley must be
maintained. There must be a plat of 100mm for the bell tension to be correct.The belt tension
is altered b the tension adjusting boll provided on the motor plate. Tighten the lock nut after
the adjustment.
7.2.3 Roiation heck : The shaft should turn counter clockwise.Vhen seeing from the oil level
indicator side of the crank, if not so, then exchange two of the three power input teds, after
disconnecting power to the starter. Repeat the check after the alterration. See that there is free
rotation of the fan blades and there is no mechanical obstruction.

7.3 ELECTRICAL CONNECTION:

7.3.1 Check if the incoming voltage is the same for which the machine is rated.
7.3.2 Connect the electrical supply as show in diagram.
7.3.3 The compressor must be properly earthen by a copper wire running from the compressor
body to the ground.
7.4.4 Check the starter on / off controls.
 8. MAINTENANCE

8.1 DAILY ROUTINE MA1NTENANACE :

8.1.1 Check the oil level in the crankcase and refill if necessary.
8.1.2 Check for the free rotation. of. the fit wheel and feel for a abnormal sounds.
8.1.3 Check for Air and Oil leafages, if any.
8.1.4 Drain the water from the Air Receiver
8.1.5 Check the Belt tension and belt guard moving.

8.2 AFTER INITIAL 150 HOURS OF OPERATION:

8.2.1 The Drain valve must be removed from the air receiver and cleaned. The compressor must be operated for
some time valve to blow out all the mositure and direct from the drain valve on the Air receiver.
8.2.2 The first oil change should be done. It should be the oil is warm (run the compressor force for a short while if
necessary) carried out when

8.3 AFTER EVERY 250 HOURS OF OPERATION:

8.3.1 Observe for operational noise and vibration.

8.3.2 Check the tightness of the mounting bolts and the hell tension.
8.3.3 Check for air leaks in the coolers, Pressure lines, Safety valves, Drain valves etc.
8.3.4 Check the pressure switch operation.
8.3.5 Dismantle the suction filter and clean it with compressed air and after through cleaning, reassemble it on the
compressor. (Refer Repairs— 10).

8.4 EVERY 500 HOURS OF OPERATION:

8.4.1 The breather valve should be dismantled cleaned and checked for perfect seating of the valve.
8.4.2 The oil should be changed with that of correct grade and quantity.
8.5 EVERY 1000 HOURS OF OPERATION:

8.5.1 Remove the cylinder leads and inspect the valve plates. Replace the wornout parts with spares..
8.5.2 All pipe lines should be checked for leaks at joints and the pickings are to be renewed if necessary.-

8.5.3 Dismantle the non return valve and examine the spring for stiffness and check its valve seat. Replace the
spring and valve seat if required..
8.5.4Decarhonize the after cooler pipe and inter cooler. Refer repairs 10 for the approprate method of
—

decarhonizing.
8.5.5 Check and clean the pressure valves ( Refer Repairs 10).
-

Motor bearing should be lubricated using the appropriate grease.

8.6 EVERY 2000 HOURS OF OPERATION:

8.6.1 General overhaul : The compressor should be completely dismantled and all parts have to be thoroughly
cleaned, exarnined and repaired or replaced it necessary. Replace the suction air filter elements. The crank shaft
assembly should be removed, cleaned in kerosene and dried. The coolers, piston and the piston rings have to be
decarbonized (Refer Repair 10) check the bearings and replace if necessary. Care should be taken to see that
—

packing do not get damaged during the general overhaul. The maintenance should be carried out by experienced
workmen and in a clean surrounding.

8.7 EVERY TWO YEARS:

Check and clean the inside surface of the air receiver

8.7.1 Check the hand hole packing on the air receiver and replace if necessary.
8.7.2 The air receiver should be tested hydraulically to a pressure of 175% of the working pressure.
NOTE:
The oil change should be carried out after 150 hours of operation and then afteF every 500 hours of use of the
compressor.. Drawing of oil should only he done when the oil is warm..
 9. TROUBLE SHOOTING

DEFECTS LIKELY CASULAS REMEDIES

9.1 COMPRESSOR After cooler pipe or. NRV is clogged. Dismantle and clean the parts.
OVERHEATS Inadequate dirty oil. Change the oil.
Oil leel is low Refill the oil.
Breather valve is not working. Cylinder Clean the breather valve.
or intercooler fins dirty.
Blow with Compressed air and
clean witha a cloth.

9.2 COMPRESSOR Blocked unloader pipes. Open and Clean the Pipe.
DOES NOT Defective unloading. Open the pressure switch and
UNLOAD adjust the nylon nut.

Chocked air filter. Clean or remove the air filter.

9.3 OIL
Drain to the correct level.
DETECTED IN Oil level is high.
COMPRESSED Change to recommented grade
AIR Oil viscosity is too low.
Open, clean and refit after checking
Breather not working
Remove the pistons rings if broken.
Piston rings stuck in groves or broken. Change the rings as a set. Check
all related parts for wear before
Piston to cylinder clearance excessive. fittng

9.4 OVER Increase frequency of cleaning

Inadenate air filter maintenance.
WEARING OF Increase frequency with more
CYLINDER periodic checks of oil change to
Oil change not done regularly.
PISTON AND correct commanded grade.
PISTON RINGS.
Incorrect of oil
 9. TROUBLE SHOOTING

9.5 WATER OR Faulty Breather Check and replace the breather valve if
RUST necessary.
FORMATION IN
CRANK CASE.

9.6 OIL LEAK Breather valve not working Dismantle the breather valve and refit.
THROUGH Loosen the piston rings,if broken, change the
BREATHER Piston rings broken. rings as a set
VALVE
Piston to cylinder clearance Check and change as required.
excessive.

9.7 COMPRESSOR Loose compressor fan pulley. Remove fan pulley and examinc keyway for
KNOCKING wear
Worn out piston cylinder crank
shaft and connecting rod Overhaul the compressor unit and replace the
bearings. related Components

Belts loose and slipping. Adust or replace if elongated.

9.8 DISCHARGE
PRESSURE LOW / Open and retighten with teflon tape or shellac.
PRESSURE BUILT Leaky joints in pressure lines.
UP TIME Check and replace the cylinder.
EXCESSiVE Cylinder worn out
Open, clean and refit after careful check.
Defective seating of inlet and
delivery vanive plates. Check and replace the gauge.
Gauge defectives. Replace after checking the related components.
Suction filter clogged.
 Incorrect belt tension. Check the belt adjusment frequently.
9.9 EXCESSIVE
BELT WEAR Incorrect motor pulley and Check and adjust using straight edge or string
(Refer repairs) compressor pulley alignment across the diameter of both the pulleys

9.10 Unloader defective (dirt between Clean the cone seat and ressemble.
COMPRESSOR the cone and valve seat of the
Replace the valve seat with new one.
FAILS TO LOAD / pressure switch)
AIR LEAK IN
CROSS HOLE OF Defective valve seat.
UNLOADER.

9.11 FAULTY This may be due to over Re-adjust

WORKING adjusting.
PRESSU RE
DIFFERENTIAL
FROM THOSE OF
SETTING IN
PRESSURE
SWITCH

9.12 PRESSURE Sparking of mailed contact points. Replace the contact assemblies.
SWITCH MAL -
FUNCTION

The pressure switch diapharm could Replace the diaphram and reset the differential
9.13 PRESSURE
SWITCH DOES be punctured due to frequent
NOT WORK. operations on low differintial for a
long periods.

9.14 Grout properly.

Grounting not proper.
COMPRESSOR
VIBRATION Increase length of foundation bolts.
Foundation bolts too small.
EXCESSIVE.
Bolts and nuts may be loose. Tight bolts and nuts.

Belts loose and slipping leakage Adjust the belts and check the belt
9.15 CAPACITY may be therein the system. tension.
LESS
Check the valves and replace if necessary.
Valves leaking
Remove and clean the suction filter.
In take filter clogged
Check and if faulty replace the piston rings
as a set only.
Piston rings worn/broken
Check & replace the gauge if necessary.
Gauge defective

9.16 UNLOADER Valve seat clogged or Adjust the unloader nut, if necessary
VALVE LEAKY. damaged. replace valve seat
 10. REPAIRS

MAINTENANCE DETAILS:

Before the compressor is dismantled the air inside the compressor is removed and the
power supply is disconnected. Drain the condensate by opening the drain cock. Replace
safety valves to remove all stagrnent air and drain the oil in the crankcase

10.1 SAFETY VALVE CLEANING:

The safety valves are to be removed after the air receiver / delivery pipes and the coolers
have been cleared of all stagment air pressure.
Remove the locknut and unscrew the pressure adjustment from the valve housing. Then
remove the actuating rod, valve cone, valve seat along with rest of the parts.
Clean the safety valve thoroughly using compressed air.Check the valve spring for
sufficient tension, the seat in the housing is careful! checked prior to reassembling. To
reset the safety valve, tighten the pressure adjuster nut to the correct level of pressure
setting. Tighten the locknut after the correct setting has been obtained. The ne setting
must be checked a few times to ensure the correct pressure setting has been obtained

10.2 AFTER COOLER ASSEMBLY:

The two ermeto nuts are simultaneously loosened from both the ends.The after cooler
pipe is pulled removed from the ermeto. Decarbonize the pipe following any one of the
procedures given below. While refixing the pipe , both the ends arc to be tightened at the
same time.

10.3 CENTER COOLER ASSEMBLY:

The two ermeto nuts are simultaneously loosened from both the ends. Remove the
central cooler pipe from the ermeto and inspect the ertmeto cone seatings. Check the
packing and renew if found necessary. Decarbonize the pipe using any one of the
procedure given below and clean with compressed air, while refixing the pipe, both the
ends are to be tightened at the same time.
 10. REPAIRS

10.4 DECARBONIZING OPERATlONS:

Decarbonizing of the centercooler and after cooler pipes should be carried out after 1000
hours of operation of the compressor. The carbonparticles clog the compressor, hence
decorbonizing should be carried out regularly. There are three way of carriying it out.
10.4.1 The cooler is heated to a suitable temperature (around l00c — l00c) at which the
carbon seating starts to disintegrate from the inside walls. Then the cooler is hammered
with help of mallet to release the carbon particles off the cooler.

10.4.2 The cooler is immersed in a solution of carbon tetra chloride for a substaintial
period of time. Then the cooler is cleaned with compressed air

10.4.3The cooler is immersed in benzene or tolene solutions for a sustained period of

time and then cleaned with compressor air care should be taken not to immerse for a long
time period as the coolers may get damaged.

10.5 AIR FILTER CLEANING:

The air filter is cleaned using compressed etc, this may be done for a maximum of six
times. However the filter must be replaced after ever’ year or ever 2500 hours of
operation.Cleaning of the air filter must be done with compressed air of pressure not
exceeding 3kg/cin2. Reverse flush the element by directing air up and down the pleats of
the lifter from the core side Repeat till all the dust is removed. Even after cleaning if oil
or grease particles are found then the filter elements should be changed.

10.6 CYLINDER AND VALVE ASSEMBLY:

The cylinder head is removed first and then the valve flats are removed, taking care not to
damage the mating faces and the packing material. if the plate grooves are found
damaged then lap the mating faces and refit. Reassembling should be done using proper
seating agents. To remove the cylinder, loosen all the cylinder holding nuts and pull the
cylinder out.(It can be easily removed by rotating the fan, the cylinder then eases up).
Check the cylinder for scratches and gently clean the inside of the cylinder and then refit.
If the bore size is different from the actual, the cylinder should be renewed and refitted.
 10. REPAIRS

10.7 PISTON ASSEMBLY:

The circlip is removed using the circlip plier. Then the gudegon is removed gently.
Inspect the surface of the piston for scratches and marks.
The piston rings are then removed using the ring expander. The piston and the rings are
decarbonized using one of the procedure given above. Check the ring for clearances and
replace them only as a set even if only one has worn out or has been broken.

10.8 CONNECTING ROD AND CRANKSHAFT ASSEMBLY:

Inspect the crankshaft and connecting rod to see if there is any shake in the shaft and if the
bearings are worn out. The crankshaft assembly has to be removed only if repairs are
necessary.
The pulley is removed from the shaft using a puller. Remove the breather assembly and
see to that there is no oil in the crankcase.. Then remove the cover bolts from both the
ends. The free end cover is removed first and then the crankshaft assembly along with the
fly end covers at the fly end opening. Inspect the oil seal and the bearings. If the
connecting rod and crankshaft assembly are found to be worn out they have to be sent to
the factory for repairs since special fixtures are needed for dismantling and assembling.

10:9 BEARINGS:
The bearings are removed using a bearing puller. Clean them throughly using disel and
check them. If they are in good condition, oil and assemble them. The bearings are heated
in a oil bath to about 100c to 120c. then insert them on the shaft so that will slide in and fit
tightly on cooling.

10.10 FAN BELT CHANGE:

Inspect the fan belt for any signs of wear and tear . the belts must be replaced only as a set
( in a pair) even if only one belt is found to be woim out o cut. Replacing only one belt at
a time wil lead to excessive load and strain on the freshly replaced belt due to difference
in tension between the new and the old belts.
 APPENDIX

I. RECOMMENDED LUBRICANTS

LUIRICANT MANUFACTURES

Ambient I.S.O Bharat Hindustan Indian oil Castrol

temp c V.G.NO. petroleum petroleum

-30 to -15 I.S.O.32 Bharat Enklo 32 Servo Press 32 Perfect 32

Hydrol 32 Perfect T-32

-15 to +10 I.S.O.68 Bharat Enklo 68 Servo Press 68 Perfect 68

Hydrol 32 Perfect T-68

10 to 25 I.S.O.100 Bharat Enklo 100 Servo Press 100 Perfect 100

Hydrol 100
Perfect T-100

26 to 80 I.S.O.150 Bharat Enklo 150 Servo Press 150 Perfect 150

Hydrol 150 Perfect T-150

2. RECOMMENDED BEARING GREASE

GREASE MANUFACTURES

TYPE Bharat Wheel Bearing Servo Grease Castro ball Bearing Grease
Univex ‘A’ Grease MP Ap-3

IDENTIFICATION PART LIST

 AIR COMPRESSOR RECIPROCATING MODEL ATT
200/ATT 300 TANK MOUNTED
DRG .NO - 02 0262

44 29 .30 .31
28 27
11
5

1
2,
3,
4,
17, 6,
18, 7,
20 19, 8,
9,
16 34
15

36
24
25
35

14 26
32 12 33
23 21 13
22
 AIR COMPRESSOR RECIPROCATING MODEL ATT200 / ATT 300
TANK MOUNTED DRG, NO- 02 0 0262

S.NO DESCRIPTION QTY DRG.NO

1 AIR COMPRESSOR ATT200 / ATT300 1 02 0 0262

2 HEX BOLT M 10 x 50 4 90 0 1050
3 SPRING WASHER Ø 10 4 97 0 50 10
4 HEX NUT M10 4 96 0 9010
5 MOTOR 2 Hp 1 --- --- ---
MOTOR 3 Hp 1 --- --- ---
6 HEX BOLT M 10x50 4 90 0 1050
7 PLATE WASHER Ø 10 4 97 0 6010
8 SPRING WASHER Ø 4 97 0 5010
9 HEX NUT M10 4 96 0 9010
10* MOTOR PULLEY ATT 200/ 1 04 0 1923
MOTOR PULLEY ATT 300 1 04 0 1930

11 V’BELT A68 ATT 200 2 --- --- ---

V’BELT A72 ATT 300 2 --- --- ---
12 TENSION ADJUSTER M 12 2 90 0 1280

13 HEX NUT M12 2 96 0 9012

14 AIR RECEIVER 120 Ltrs 1 02 0 0258
AIR RECEIVER 160 Ltrs 1 02 0 0259
AIR RECEIVER 220 / 250 Ltrs 1 02 0 0256
AIR RECEIVER 300 Ltrs 1 02 0 0272
15 HEX NIPPLE 3/4” BSP x 40 1 04 0 1206

16 NRV ASSEMBLY 3/4” BSP 1 04 0 1907

17 HEX NIPPLE 3/4” BSPx4O 1 04 0 1206
18 T’PIECE (GI) 3/4”BSP 1 04 0 1584
19 ERMETO UNION 3/4” x 7/8”BSP 1 04 0 1901
20** SAFETY VALVE ASSEMBLY 3/4”BSP 1 04 0 0666
21 PRE LINE PIPE 1 04 0 1910
22 ERMETO UNION 1/8” x 1/4”BSP 1 04 0 0491
23 ERMETO NUT 1/4” BSP 1 04 0 1227
24 HEX NIPPILE 1/2” BSP x 40 1 04 0 1212
25 BALL VALVE 1/21”BSP 1 04 0 1884

26 SQ. CONNECTER 1/2”BSP 1 04 0 1474

27** SAFETY VALVE ASSEMBLY 1/2”BSP 1 04 0 0647
28 PRE, SWITCH ASSEMBLY 1 --- --- ---
29 BELD GUARD ASSEMBLY 1 03 0 0463
30* HEX BOLT M8 x 20 2 90 0 0820

31* SPRING WASHER Ø 8 2 97 0 5008

*Not Shown in Drg,
**To be Supplied only asan ASSENBLY
 S.NO DESCRIPTION QTY DRG.NO

32 DRAIN VALVE ASSEMBLY 1/4”BSP 1 04 0 0698

33 STARTER 2HP 1 -- -- -----
STARTER 3 HP 1 -- -- -----
34 SPIRAL HOSE (PVC&WITH WIRE) 1 04 0 2073
35 SPIRAL HOSE ( PVC&WITH WIRE) 1 04 0 2074
36 PLUG MS 1/2”BSP (120,160 Ltrs) 1 04 0 1883
PLUG MS 3/4”BSP (250,300 Ltrs) 1 04 01878
37* HAND HOLE COVER (250,300 Ltrs) 1 03 0 0393
38* PACKING 1 03 0 0392
39* LOCKING PLATE 1 03 0 0391
40* HEX NUT M20 1 04 0 1427
41* NAME PLATE TANK 1 04 0 1546
42* REVIT 4 04 0 1132
43* PLUG MS 11/2”BSP 1 04 0 0665
44 PRE,GAUGE 0 TO 25 KG/CM²x3”DAIL13/8”BSP 1 -- -- -----

* Not Shown In Drg.

AIR COMPRESSOR RECIPROCATING MODEL ATT 200 / ATT 300

BASE MOUNTED DRS. NO 02 0 0263

28
29-30-31
11

-17 -18 -19

20

16

15

24 2-3-4
25 22 21 14 1 26-27 12
23 6-7-8-9
13
 AIR COMPRESSOR RECIPROCATING MODEL ATT200 / ATT 300

BASE MOUNTED DRG, NO- 02 0 0263

S.NO DESCRIPTION QTY DRG.NO

1 AIR COMPRESSOR ATT 200/ATT 300 1 02 0 0204

2 HEX BOLT M10 X 50 4 90 0 1050
3 SPRING WASHER Ø 10 4 97 0 5010
4 HEX BLOT M10 4 96 0 9010
5 MOTOR 2 Hp 1 --- --- ---
6 MOTOR 3 Hp 1 --- --- ---
6 HEX BOLT M 10 x 40 4 90 0 1040
7 PLATE WASHER Ø 10 4 97 0 6010
8 SPRING WASHER Ø 10 4 97 0 5010
9 HEX NUT M10 4 96 0 9010
10* MOTOR PULLEY ATT 200 1 04 0 1923
MOTOR PULLEY ATT 300 1 04 0 1930

11 V’BELT A68 ATT 200 2 --- --- ---

V’BELT A72 ATT 300 2 --- --- ---
12 TENSION ADJUSTER M 12 X 80 2 90 0 1280

13 HEX NUT M12 2 96 0 9012

14 BASE PLATE 1 02 0 0263
15 HEX NIPPLE 3/4 “BSP x 40 1 04 0 1206
16 NRV ASSEBLY 3/4 “BSP 1 04 0 1907
17 HEX NIPPLE 3/4 “BSP x 40 1 04 0 1206
18 T’PIECE (GI) 3/4 “BSP 1 04 0 1584

19 ERMETO UNION 3/4” x 7/8”BSP 1 04 0 1901

20** SAFETY VALVE ASSEMBLY 3/4”BSP 1 04 0 0666
21 PRE, LINE PIPE 1 04 0 1910
22 ERMETO UNION 1/8” x 1/4”BSP 1 04 0 0491
23 ERMETO NUT 1/4”BSP 1 04 0 1227
24 HEX NIPPLE 1/2”BSP x 40 1 04 0 1212
25 BALL VALVE 1/2”BSP 1 04 0 1884
26 SQ, CONNECTER 1/2”BSP 1 04 0 1474
27** SAFETY VALVE ASSEMBLY 1/2”BSP 1 04 0 0647
28 BELD GUARD ASSEMBLY 1 03 0 0465

29 HEX BOLT M8 x 25 4 90 0 0825

30 SPRING WASHER Ø 8 4 97 0 5008

31 HEX NUT M8 4 96 0 9008

32 PRE, SWITCH ASSEMBLY 1 --- --- ---

*Not Shown in Drg,

**To be Supplied asan ASSENBLY
 AIR COMPRESSOR UNIT ASSEMBLY
ATT 200/ATT 300 DRG . NO 02 0 0204

55
37
17 53
18 19 36 48
49
51 54
52
56 50
31 30
33 28
14 15 60
32
10 34 59
35 45 47
29 46
25
44
26 42
13
61
12 40 39
5 2 11 41
62 43
63 20
6
4 19
9
7
10
27 22

3
64 1 24
65 21 8
23
10A
10
 AIR COMPRESSOR UNIT ASSEMBLY ATT 200/ATT300
DRG.NO - 02 0 0204

S.NO DESCRIPTION QTY DRG.NO

1 CRANKCASE 1 02 0 0200
2 CONNECTING ROD & CRANKSHAPT ASSY 1 03 0 0506

3 BALL BEARING SKF 6305 2 04 0 1920

4 SPACER RING 2 04 0 1886
5 BEARING COVER (FLY WHEELEND) 1 03 0 0493

6 GASKET (FLY WHEEL END) 1 04 0 1887

7 BEARING COVER (PREE END) 1 03 0 0494
8 GASKET (FREE END) 1 04 0 1888
9 SEAL B 32x45x7 10 04 0 1889
10 HEX BOLT M8x20 10 90 0 0820
10A SPRING WASHER T 1 97 0 5008

11 DISTANCE BUSH AT 200 1 04 0 1890

12 FAN PULLEY ATT200 1 03 0 0495

13 FAN HOLDER WITH BLADE ASSY ATT200 9 03 0 0496
14 HEX BOLT M8x20 9 90 0 0820

15 SPRING WASHER Ø 8 1 97 0 5008

16 END DISC ATT200 1 04 0 1919
17 HEX BOLT M10x30 1 90 0 1030
18 SPRING WASHER Ø 1 97 0 5010
19 OIL LEVEL INDICATOR 11/4”BSP 1 04 0 1108
20 O’RING 1 04 0 1109
21 DRAIN PLUG 3/8”BSP 1 04 0 1110
22 HEX NIPPLE 1/2”BSPx40 1 04 0 1212
23 REDUCING ELBOW 1/2” x1”BSP GI 1 04 0 1112
24 BREATHER ASSEMBLY 1 04 0 0697
25 CYLINDER Ø 70 (STD) 1 03 0 0497
26 GASKET 0.8 (CR TOCY) 1 04 0 1891
27 STUD M12 x 48 4 04 0 1114
28 HEX NUT M12 4 96 0 9012
29 SPRING WASHER Ø 12 8 97 0 5012
30 PISTON ASSEMBLY Ø 70 1 04 0 1892

31 VALVE FLAT Ø 70 1 03 0 0499

32 VALVE PLATE Ø 70 2 03 0 0502
33 CYLINDER HEAD Ø 70 1 02 0 0185
34 STUD M12 x 54 3 04 01904
35 STUD M12 x 70 1 04 0 1905
36 SPRING WASHER Ø 12 5 97 0 5012
37 HEX NUT 5 96 0 9012
38 CENTRING BUSH 2 04 0 1118

*Not Shown in drg.

 AIR COMPRESSOR UNIT ASSEMBLY ATT 200/ATT300
DRG.NO - 02 0 0204

S.NO DESCRIPTION QTY DRG.NO

39 CYLINDER Ø50 1 02 0 0161

40 GASKET 0.8 1 04 0 1891

41 STUD M12 x 48 4 04 0 1114

42 HEX NUT M12 4 96 0 9012
43 SPRING WASHER Ø 12 4 97 0 5012

44 PISTON ASSEMBLY Ø50 1 04 0 1768

45 VALVE FLAT Ø50 1 03 0 0427
46 VALVE PLATE Ø50 2 03 0 0428
47 CYLINDER HEAD Ø50 1 02 0 0187
48 STUD M12 x 54 4 04 0 1904
49 SPRING WASHER Ø12 4 97 0 5012

50 HEX NUT M12 4 96 0 9012

51 AIR FILTER ASSEMBLY 1 04 0 1897

52 INTER COOLER ATT 200 1 03 0 0464

53 CONNECTING PIECE 3/4”BSP 2 04 0 1898

54 CONNECTING NUT 1”BSP 2 04 0 1899

55 PACKING RING ( COP , ASB ) 2 04 0 1900
56 SAFETY VALVE ASSEMBLY 1/4”BSP 1 04 0 1126
57 CENTRING BUSH 2 04 0 1118
58 ERNETO UNION 3/4” x 7/8”BSP 1 04 0 1901
59 ERMETO CONE Ø22 2 04 0 1902
60 ERMETO NUT 7/8”BSP 2 04 0 1903
61 AFTER COOLER PIPE AT 200 1 03 0 0480
62 DIRECTION INDICATOR 1 04 0 1131
63 RIVET 2 04 01132
64 NAME PLATE COMPRESSOR 1 04 0 0713
65 RIVET 4 04 0 1132

*Not Shown in drg.

** Tobe Supplied Only assan assembly
 4

5
6

Piston Assembly dia 70 Piston Assembly dia 50

Drg, No 04 0 1892 Drg, No 04 0 1768

Non - return Valve Assenbly 3/4” BSP

Drg, No 04 0 1907
S.NO DESCRIPTION QTY DRG.NO

PISTON ASSEMBLY DIA 70 04 0 1892

1 PISTION Ø 70 1 02 2 0195
2 PLAIN RING 1 04 0 1893
3 STEPPED RING 1 04 0 1894

4 OIL RING 2 03 0 0498

5 GUDGEON PIN Ø 18 1 04 0 1895

6 CIRCLIP Ø B18 2 04 0 1896

PISTION ASSEMBLY DIA 50 04 0 1768

1 PISTON Ø50 1 02 0 0194

2 PLAIN RING 1 04 0 1761

3 STEPPED RING 1 04 0 1762

4 OIL CONTROL RING 1 04 0 1763
5 GUDGEON PIN Ø 12 1 04 0 1764

6 CIRCLIP Ø B12 2 04 0 1765

NON RETURN VALVE ASSEMBLY 3/4”BSP 04 0 1907

1 NRV HOUSING 3/4”BSP 1 03 0 0507

2 SPINDLE 1 04 0 1220
3 GUIDE 1 04 0 1221
4 O’RING 1 04 0 1223

5 SPRING 1 04 0 1224

6 CH SCREW M4x10 1 91 0 0410

7 SEAT RUBBER 1 04 0 1222
8 PLATE WASHER 1 97 0 6004
SAFETY VALVE ASSEMBLY 3/4”BSP SAFETY VALVE ASSEMBLY 1/4”BSP
DRG . NO - 04 0 0666 DRG . NO - 04 0 1126

SAFETY VALVE ASSEMBLY 1/2”BSP SAFETY VALVE ASSEMBLY 3/8”BSP

DRG . NO - 04 0 0647 DRG . NO - 04 0 1549
S.No DESCRIPATION QTY DRAWING No.
SAFETY VALVE ASSEMBLY 3/4” BSP 1 No. 04 0 0666

SAFETY VALVE ASSEMBLY 1/2”BSP 1 No. 04 0 0647

1. 3/4” Housing 1 No. 04 0 1233

1/2”Housing 1 No. 04 0 1801

2. Valve Cone 1 No. 04 0 1134

3. Actuating rod 1 No. 04 0 1135

4. Spring 1 No. 04 0 1236

5. Lock nut (Pressure adjuster) 1 No. 04 0 1237

6. Pressure adjuster 1 No. 04 0 1238

7. Distance bush 1 No. 04 0 1239

8. Lock nut 1 No. 04 0 1240

9. Cover 1 No. 04 0 1241

10. Ring 1 No. 04 0 1160

11. Valve seat 1 No. 04 0 1142

12. Spring seat 1 No. 04 0 1276

SAFETY VALVE ASSEMBLY 3/8” BSP 1 No. 04 0 1549

SAFETY VALVE ASSEMBLY 1/4” BSP 1 No. 04 0 1126

1. 3/8”Housing 1 No. 04 0 1218

1/4”Housing 1 No. 04 0 1151

2. Valve seat 1 No. 04 0 1153

3 Valve cone 1 No. 04 0 1152

4 Spring 1 No. 04 0 1156

5. Pressure Adjuster 1 No. 04 0 1157

6. Lock nut 1 No. 04 0 1158

7. Locking pin 1 No. 04 0 1160

8. Acuating rod 1 No. 04 0 1154

9 Knob 1 No. 04 0 1160

10 Split pin 1 No. 88 0 0620

DRAIN VALVE ASSEMBLY 1/4” BSP BREATHER ASSEMBLY
DRG, NO - 04 0 0698 7DRG, NO - 04 0 0697

INLET AIR FITTER ASSEMBLY

7DRG, NO - 04 0 1897
S.NO DESCRIPTION QTY DRG.NO

DRAIN VALVE ASSEMBLY 1/4”BSP 1 04 0 0698

1 HOSING 1 04 0 0710
2 CONE SEAT 1 04 0 1229
3 VALVE SEAT 1 04 0 0798

BREATHER VALVE ASSEMBLY 1 04 0 0697

1 BREATHER BOTTOM 1 04 0 0709

2 BREATHER VALVE 1 04 0 0716

3 BREATHER TOP 1 04 0 0712
4 C.S SCREW M6x10 2 93 0 3610

INLET AIR FILTER ASSEMBLY 1 04 0 1897

1 FILTER BOTTOM HOUSING 1 04 0 1879

2 FILITER ELEMENT ASSEMBY 1 04 0 1880
3 FILTER TOP HOUSING 1 04 0 1914

4 FILTER ELEMENT COVER 1 04 0 1915