director general border roads generals maintenance instruction no ...

Introduction :-DIRECTOR GENERAL BORDER ROADSGENERALS MAINTENANCE INSTRUCTION NO. 92ONCARE AND MAINTENANCEOFAIR COMPRESSOR MAW INDIA 160 CFM1. Regular servicing and preventive maintenance are essential to prolong its life ofthe equipment, ensure timely repairs to arrest defects from developing into major ones,work the equipment effectively at all times, minimize inopportune breakdowns anddowntime losses.Aim :-2. (a) To enumerate the details of periodic and preventive maintenance andlubrication fo AIR COMPRESSOR MAW INDIA 160 CFM.(b)Issue CHECK CARD for use by Mobile Maintenance Team.Action By :-3. (a) User Units :- To carry out periodic inspection, regular servicing andpreventive maintenance tasks as laid down.(b) Field Workshops (GREF) :-(i) To check the 'Record of Maintenance and Lubrication' in the logbook of the eqpt during its inspection and repairs, if carried out as perMaintenance and Lubrication schedules given in this instruction.(ii)Advise user units in respect of any discrepancy noticed.Details :-4. Details of Maintenance and Lubrication alongwith the periodicity have beentabulated in Appendix 'A' to this instruction.

Appendix- 'A' to HQ DGBR GMINo. 92 Dated 10 Apr 73PREVENTIVE MAINTENANCE – AIR COMPRESSOR MAW INDIA 160 CFMS/No. Item/Assys Maintenance Instruction Lubrication No of points1 2 3 4 508 HOURS TASK1 General(a) Check oil, water or gas forleaks(b) Check for exhaust smokecolour, noise or vibration(c) Read all gauges & meters(d) Check all bolts and nuts ifloose or deficientEngine2 Oil level Check oil level in oil sump, topup to level if necessary andcheck oil pressureEngine oil 13 Cooling system (a) Check water level, top up ifnecessary(b) Check radiator for leak(c) Check radiator cap forproper tightening4 Fuel Tank Fill fuel tank after finishingwork in order to reducecondensation, Drain sedimentsand water from sediment trapif provided5 Fuel filter Drain sediment and water fromfuel filter drain plug6 Air cleaner Check air filter in dirtycondition daily.7 Dynamo Check fan belt for correcttension and dynamo for correctfunction.8 Electrical system (a) Check wiring fordiscontinuity, short circuit,loose terminals etc.(b) Check battery for securityin its place, check electrolytelevel and if necessary tip upwith distilled waterCompressor side9 Crank shaft Check the level of oil and topup if necessary to requiredlevel10 Air filter Clean air filter in dustyconditions daily, in normalconditions air cleaner must becleaned on alternative day.11 Air storage tank (a) Open the air out let valvewhen the equipment isstopped.(b) Check the leakage if any.12 Moisture trap Drain off daily.13 Safety valve Check the safety valve forfunction, blowing off manuallyonce or twice111CompleteEngine oil 1

14 Pressure machinerunning(a) Check for exhaust smokecolour, noise or vibration(b) Read all gauges for properreadings after every hour.(i) Engine oil pressure(II) Temperature gauge(III) Compressor low pressuregauge(IV) Compressor high pressuregauge50 to 60 Psi (3.5to 4.2 Kg/cm2)190 F (88 C)25/30 Psi (1.7 to2.1 Kg/Cm2)100 Psi (7.00Kg/cm2)Note :-1. Engine and oil compressor – Oil Grades2. Grease :-(a) Above 90 Degree - Use SAE 40 HD(b) 90 Degree to 60 Degree - Use SAE 30 HD(c) Below 60 Degree F - Use SAE 20 HD(a) Above 60 Degree F - Use Grease No. 2(b) Below 60 Degree F - Use Grease No. 13. When the compressor is running idle i.e, without load the low pressure gaugeshould indicate 'ZERO' pressure.4. Safety valve will open at 10% higher pressure than the maximum fixed for thenormal operation of the compressor.5. Never user PETROL or KEROSENE to clean or flush out the compressor crankcaseas its use is dangerous and should be absolutely PROHIBITED. Use flushing oil only.6. Before stopping the plant open all air delivery cocks and drains cocks on the airstorage tank.EVERY 50 HOURS MAINTENANCE TASKS1 - Carry out 8 hours maintenance tasks.2 Engine sump Change engine oil after first 50 hoursof run (Running in period). Secondchange after every 100 hours ofoperation, Subsequent change after250 hours.Engine oil 13 Fan belt Check fan belt adjustment 14 Fuel feed pump Clean pre-filter with diesel 15 Battery Clean battery terminal, apply mineraljelly, check for any leak, top upelectrolyte level6 Grease points(a) water pump(b) Wheel bearingGrease the bearing of water pumpAdd greaseCompressor side7. Crank case Change engine oil after first 50 hours(Running in period). Second engine oilchange after 100 hrs operationsubsequent change after 150) hoursof operation.Grease No. 1Grease No. 211Engine oil 1

8 Compressor oil Clean the oil strainer at every oilchange9 Air suction filter Remove and clean air suction filter bybrushing11Note :-1. Engine and oil compressor – Oil Grades(a) Above 90 Degree - Use SAE 40 HD(b) 90 Degree to 60 Degree - Use SAE 30 HD(c) Below 60 Degree F - Use SAE 20 HD2. Grease :-(a) Above 60 Degree F - Use Grease No. 2(b) Below 60 Degree F - Use Grease No. 1EVERY 100 HOURS MAINTENANCE TASKS1 General Carry out 8 hours and 50 hoursmaintenance tasks.2 Engine oil Change engine oil Engine oil 13 Clutch Twiflex automatic clutch couplingrequire very little attention, Examineto ascertain the state of the wear ofshoe linings and bushes, at periodicintervalsNote :-1. Engine and oil compressor – Oil Grades(a) Above 90 Degree - Use SAE 40 HD(b) 90 Degree to 60 Degree - Use SAE 30 HD(c) Below 60 Degree F - Use SAE 20 HD2. Grease :-(a) Above 60 Degree F - Use Grease No. 2(b) Below 60 Degree F - Use Grease No. 13. Change engine oil early under adverse working conditions.4. Inspect drained engine oil for metal particles. If any found report to fieldWorkshop. DO NOT RUN THE ENGINE TILL RECTIFIED.EVERY 150 HOURS MAINTENANCE TASKS1 General Carry out 8 hours, 50 hours and 100hours maintenance tasks.2 Oil filter Clear the lub oil filter element with1diesel.3 Fuel filters Clean fuel oil coarse filter element 14 Fuel InjectionspumpFill fuel injection pump housing withengine oil if requiredEngine oil 1

5 Cooling system Flush out radiator and water jackets,cleanCompressor side6 Compressor crank Change oil after every 150 hrs ofcaseoperation7 Moisture trap Clean the felt packing, if compressorworking in humid climates1Engine oil 11Note :-1. Engine and oil compressor – Oil Grades2. Grease :-(a) Above 90 Degree - Use SAE 40 HD(b) 90 Degree to 60 Degree - Use SAE 30 HD(c) Below 60 Degree F - Use SAE 20 HD(a) Above 60 Degree F - Use Grease No. 2(b) Below 60 Degree F - Use Grease No. 13. Change engine oil early under adverse working conditions.4. Inspect drained engine oil for metal particles. If any found report to fieldWorkshop. DO NOT RUN THE ENGINE TILL RECTIFIED.5EVERY 200 HOURS MAINTENANCE TASKS1 General Carry out 8 hours, 50 hours and 100hours maintenance tasks.2 Battery Check electrolyte level and specificgravity and if required send forrecharging check the battery forcorroded fittings, remove batteryconnections and clean terminal posts.Apply petroleum jelly. Vent plugsshould be kept clean and tight.3 Dynamo and self Lubricate with one drop of oil in oilstarterholesCompressor side4 Air storages tank Inspect and clean the air storage tank5 Air filter storage Replace felt packing of air filter for airtankstorage link1Engine oil 11Note :-1. Engine and oil compressor – Oil Grades(a) Above 90 Degree - Use SAE 40 HD(b) 90 Degree to 60 Degree - Use SAE 30 HD(c) Below 60 Degree F - Use SAE 20 HD2. Grease :-(a) Above 60 Degree F - Use Grease No. 2(b) Below 60 Degree F - Use Grease No. 1

3. Never keep your battery idle for periods exceeding 2 weeks. If this cannot beavoided, arrange that battery is removed and recharged every 2-3 weeks. Alwaysmaintain batteries in a charged date and do not allow the batteries to stand indischarged condition.EVERY 500 HOURS MAINTENANCE TASKS51 General Carry out 8 hours, 50 hours, 100hours and 200 hrs maintenance tasks.2 Oil sump Flush the system. Remove oil sump,1clean the sump and strainer and refit.3 Fuel injection Change oil and refil upto level Engine oil 1pump4 Tappet clearance Check valve clearance and adjust if12required.Valve clearance inlet 0.010" hot andexhaust 0.012" cold5 Injection Remove injectors and test. Testinjector pressure if necessary.Compressor side6 Concentric valve Check and clean7 Suction air filter Change the element8 Blow off valve Check and clean blow off valve on theinter cooler9 Pressure Regulator Check and clean10 Main and big andbearings11 Connectionsfittings andcontrolsNote :-Check bearing for lift and side play,Examine the big end and bolt mainbearings, check nuts and split pins forsecurityTighten all loose nuts, bolts andscrews1. Engine and oil compressor – Oil Grades(a) Above 90 Degree - Use SAE 40 HD(b) 90 Degree to 60 Degree - Use SAE 30 HD(c) Below 60 Degree F - Use SAE 20 HD2. Grease :-(a) Above 60 Degree F - Use Grease No. 2(b) Below 60 Degree F - Use Grease No. 13. Before removing cylinder head cover, the air receiver should be released to avoidan accident due to pressure remaining in the cylinder head.EVERY 1000 HOURS MAINTENANCE TASKS51 General Carry out 8 hours, 50 hours, 100hours 200 hrs and 500 hrsmaintenance tasks.2 Engine (a) Carry out decarburising,(b) Inspect main and big end bearingfor wear and tear and replace ifnecessary

3 Fuel tank Remove and clean4 Gauges Check all gauges for properfunctioning, Replace if required5 Air cooler Clean the air coolerNote :-1. Engine and oil compressor – Oil Grades(a) Above 90 Degree - Use SAE 40 HD(b) 90 Degree to 60 Degree - Use SAE 30 HD(c) Below 60 Degree F - Use SAE 20 HD2. Grease :-(a) Above 60 Degree F - Use Grease No. 2(b) Below 60 Degree F - Use Grease No. 1EVERY 2000 HOURS MAINTENANCE TASKS51 General Carry out 8 hours, 50 hours, 100hours 200 hrs, 500 hrs and 1000 hrsmaintenance tasks.2 Fuel pump Check fuel pump and calibrate FIP ifrequired.Note :-1. Engine and oil compressor – Oil Grades(a) Above 90 Degree - Use SAE 40 HD(b) 90 Degree to 60 Degree - Use SAE 30 HD(c) Below 60 Degree F - Use SAE 20 HD2. Grease :-(a) Above 60 Degree F - Use Grease No. 2(b) Below 60 Degree F - Use Grease No. 1

CHECK CARD : PREVENTIVE MAINTENANCE(ORIGINAL/DUPLICATE)1. Project ................ 4. Make & Type Air Compressor ActionMAW INDIA 160 CFMAfter carrying outthe preventative2. Task Force............ 5. BA/EM NO. ....................... maintenanceTask, IC3. Unit ..................... 6. Location .......................... Mobilemaintenance team will enter its date in the month's column below and initial.Srl Tasks J F M A M J J A S O N DNo.1 08 Hours(a)(b)(c)(d)(e)(f)2 50 Hours(a)(b)(c)3 100 Hours(a)(b)(c)4 150 Hours5 200 Hours6 500 Hours7 1000 Hours8 2000 HoursSignature of SO1/SO2 EME Project ...........................................................Date ..........................................Remarks ....................................................................................................Note : Column 'J' to 'D' stands for months of the year.