PROCUREMENT OF SPARES FOR AIR COMPRESSOR FROM OEM AUTHORISED DEALER

Kirloskar Pneumatic Company Limited

A Kirloskar Group Company

MAINTENANCE AND SERVICE PROCEDURE

This section explains the service procedures and precautions to be taken before doing the service. It is

necessary to follow the procedure given for safe working. The PLC controller has inbuilt hour counter,

which helps you to plan your schedule maintenance in time for consumables like air filter, oil filter,

separator element and oil. The service requirement of oil injected screw compressors are very minimal

compared to other compressors. It is always recommended to have stock of spares needed for

minimum of 1 year of operation and replenish them in FIFO basis. This will help to increase the

breakdown time of machine due to unavailability of spares.

10.1 Daily operation

Record all parameters for all shifts in the given tabular form.

Compressor Model:

Compressor Sl. No.:

No Parameter 1 2 3 4 5 6

4 Cleaning of Control Panel

5 Cleaning of Compressor from Inside

6 Check oil level (Running)

7 Check & drain moisture from AOS tank

8 Check for working of auto drain

9 Drain moisture from moisture separator.

10 Discharge Pressure (PT1)

11 Air Oil Temperature

12 Total Run Hours

13 Total Load Hours

19 Energy meter reading

20 Alarms (If any)

21 Check for oil leakage

22 Check for air leakage

23 Drain moisture from receiver tank

24 Cleaning of dryer from inside

25 Ambient Temperature

26 Cleaning of cooler (Every 200 Hrs)

10.2 1000 Hour service (Initial) / 3 months (Whichever is earlier)

 Clean scavenge line orifice (DO NOT use Loctite / Teflon tape in scavenge line, it will block the

orifice, affect the performance of the separator element)

Kirloskar Pneumatic Company Limited

A Kirloskar Group Company

 Replace oil filter element

 Check contactors, motor terminals and all electrical connections and tighten.

 Clean choked coolers for better performance.

Record all parameters for all shifts in the given tabular form.

10.3 2000 Hour service (Use 2000 hour service kit) / 6 months (Whichever is earlier)

 Replace air filter element kit

 Replace oil filter element

 Clean scavenge line orifice (DO NOT use Loctite / Teflon tape in scavenge line, it will block the

orifice, affect the performance of the separator element)

 Check contactors, motor terminals and all electrical connections and tighten.

 Clean choked coolers for better performance.

10.4 4000 Hour service (Use 4000 hour service kit) / 1 year (Whichever is earlier)

 Replace air filter element kit

 Replace oil filter element

 Change K-SMART oil

Remove old oil completely from AOS tank, cooler, Airend, hoses and oil filter. If old oil mixed with new

oil life of new oil will be reduced quickly.

 Change air oil separator kit

Use new O ring supplied along with separator element

 Clean scavenge line orifice (DO NOT use Loctite / Teflon tape in scavenge line, it will block the

orifice, affect the performance of the separator element)

 Check contactors, motor terminals and all electrical connections and tighten.

 Clean choked coolers for better performance.

10.5 8000 Hour service (Use 8000 hour service kit) / 2 years (Whichever is earlier)

 Replace air filter element kit

 Replace oil filter element

 Change K-SMART oil

Remove old oil completely from AOS tank, cooler, Airend, hoses and oil filter. If old oil mixed with new

oil life of new oil will be reduced quickly.

 Change air oil separator kit

Use new O ring supplied along with separator element.

 Clean scavenge line orifice (DO NOT use Loctite / Teflon tape in scavenge line, it will block the

orifice, affect the performance of the separator element)

 Check contactors, motor terminals and all electrical connections and tighten.

 Clean choked coolers for better performance.

 Minimum pressure valve service kit

 Intake valve service kit

The above recommendation is valid for General Engineering industry only. Life of consumables will vary

depending on the operating environment.

Kirloskar Pneumatic Company Limited

A Kirloskar Group Company

Note: DO NOT mix different brands / grades of oil.

10.6 To Do before starting service

 SWITCH OFF machine in PLC controller

 Isolate machine from power supply

 Close the delivery valve of the machine

 Release the pressure in the air line after minimum pressure valve to delivery valve.

 Wait for 5mins for the air oil separator tank to vent completely.

 Allow the compressor parts hot surfaces to cool, so that no injury while touching them during