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PT. ANEKA MAKMUR TEKNIK NUSAJAYA

- Ps Hayam Wuruk Indah (Lindeteves) Blok A No.19-21, Jakarta - 11180
Tlp.(021) 6248828, 6248829 (Hunting) Fax.(021) 6242405, 6243759
- Glodok Makmur No 32, Jakarta – 11180
Tlp.(021) 6262971, 6262975 (Hunting) Fax.(021) 6262972
- Jl. P. Jayakarta 141 Blok III / F5, Jakarta 10730
Tlp.(021) 6290106, 6282005 (Hunting) Fax.(021) 6295455, 6282002
 CONTENTS

I . Introduction

II. Main TechnicalSpecification.

III. Stmctureand Working Principle.

[V. Cooling and Lubricating.

V. Autocontrol and SafetyDevice.

VI. Lutallation and Maintenance.

V[. Appearanceand Installation Dimension,

1[.'Common Breakdownand RemovalMethod.

 I . Introductiop

The company specializes in the manufacture of marine auxiliary machin-

ery. Air compressoris one of the main products.
W.ith long history, the company's products are advanced in technology and
superb in quality. Model 2zF-0.3413-B air compressor won the " High
Quality
Certificates"from the Ministry in 1984. and won the certificates in adopting in-
ternational standardsform JiangSu Province in 1986. Model 2ZF-0.3413-B and
2ZS-0.3413-B air compressors have always been approved by China Classifi-
cation Society Nanjing Branch. The technical functions of products reach to
the domestic advanced level and sale all 6u". the country. The necessary ac-
cessories export abroad, are good in reputation.
The products mainly are used for the start of marine diesel, the start and
stop of hydropower equipment and gas resource in pressure can also be used as
gas resource in pressure vessel check, instrument check, pneumatic device,
building, petrochemical area and plastic area,etc.
The product can install air-powered control apparatus, electric control
apparatus or autocontrol apparatus. We can supply single machine, motor-
drived horizontal machine unit, vertical machine unit,and also supply horizon-
tal machine unit which is drived by diesel and gas bottle machine unit and so
on.

II. Main TechnicalSpecification.

N
Exhaust Rated Cylinder
Piston Rotationa Shaft The
capacity Pressure diameter
(suctlon (Meter necessary
travel speed power Motor
state) pressure) I I
m3lmin Mp" mm mm r/min kw

zZF-0.34t3-B 0.34 a
108 48 Yt32S-4
J 95 600 <5 5.5kW
2ZS-0.34t3-B 0.34 3 108 48 95 Yl32S-4
600 <5 5.5kW
nF-0.34t3-Bn 0.34 3 108 48 95 600 <) YT32S_4
5.5kW
wF-0.6/3 0.6 2-100 60 Yl32S-4
J 67 800 <7 7.5kW
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 III. Structuryand WorkingPrinciple-
Air compressor is structured as two stages, single actingo Piston type. F
'
stands for wind cooling. S stands for water cooling. The structures of air com-
pressors are shown in diagram one and diagram two.
The running'mechanism of the crank and connecting rod is used for the air
compressor. The crankshaft is installed in two rolling bearings in the crankcase.
The belt pulley is installed on the left of the crankshaft. The first and second
stage cylinders are positioned by flanges and installed side by side on the
"HaFu"
crankcase. The bottom end of the connecting rod is in form. The con-
necting rods are tightly fixed together. with the connecting rod screw. The con-
necting rods are connected by piston and piston pin. On each stage piston, a
different number of the piston rings are fitted for sealing, and at the same time,
oil rings and the scraper rings are dso fitted for collecting the spare lubricating
oil on the cylinder wall, sending it back to the crankcase. Each stage valves
are all the ring valves or combination valves which can open automatically with
the change of pressure. The safety valves and conEol valves are spring con-
trolled.
The crankshaft of the air compressor is driven by motor or diesel engine
through belt pulley, and the rotation of crankshaft is transformed to reciprocating
motion of piston in the cylinder by means of connecting rod. The compressed air
in the first stage cools through cooler, then pressed by the seconed stage to rated
presswe, entering the gas bottle.
Gas bottle machine unit is composed by moveable gas bottle, compressor.
Type is B V-belt and motor or diesel engine. The compressed air enters gas bot-
tle through one-way valve. The pressure in the cylinder is show through pres-
sure gauge.
When the pressure of the compressed air exceeds the adusted pressure.
Control valve and safety valve or pressure controlling device begin to work in or-
der.
lV. Cooling and Lubricaling.

1. Colling
The cooling type of air compressor is wind-cooling or watercooling. For
wind-cooling type compressor many radiating fins are installed on the cylinder

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and cylinder head castingsoat the sametime, rldiating pipe units are installed
betweenthe stages. When the compressedair Ts pressedout of the first stage
cylinder into the radiating tubes, cylinders and cylinder head ect. So a
lot of compressedheat is carried away.Thus, the compressoris colled.
The cooling water jackets are installed betweenthe cylinder and cylinder
head of water-cooling type compressor. The cooled water which runs con-
tinuiously into the compressorcarries aivaya great deal of compressedheat. In
the meanwhile compressed air goesthroughthe first and the sebondstagecool-
er. Therefor, the cooledeffect is more effective. For W' type wind-cooling com-
pressor, the drain nuts are installed under radiating fins betweenthe stages,
which can drain condensationoil and water in time.
2. Lubricating
The lubrication of the bearingand the machineparts in motion is done with
the oil cup hung on the crankshaftor the frothing oil made by the splashingoil
which is producedas the giving-oil shaft on the connectingrod runs.
No.13 compressoroil is used as the lubricating oil in winter and No.19

Diagram1 Structurefigurer of Model 2ZF-0.3413-Bair compressor

-3-
compressoroil is used in summer.

V. Autocontrol and SafetYDevice

1. Pneumaticapparatus
When air compressor equips with pneumatic system. The discharge valves
are controlled by control valve. That it is, when the pressure reaches to rate
pressure, control valve opens automatically, compressor runs without loading.
When the pressure decreases to a certain pressure' the control valve closes

Figure 2 : Assembly diagram of control valve

automatically, compressor returms to its normal work state.

The assemble method is shown in figure 2.
The adjusting nut in the control vale should be in a loose state. Once it
twists tightly, that means forcing compressor to run without load, the pressure in
the gas bottle can't rise.
2. Electric control apparatus
The electric control apparatus has functions, stopping automatically as the
compressor exceeds its loading, starting automatically. When unloading or low
the adjusting pressure. The electric control devices are composed by the
controller, magnetic valve, one-way valve and electric control case.
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 Tum on the switch in the electrical control cne, magnetic valve electrifies
and in the state of colsed position. The compressor fills gas to gas bottle, the
pressure of controller adjusts within the range of Max. Pressure and Min. Pres-
sure. When the pressure in gas bottle reaches to the Max. Pressure, the singnal
travels to electric control case sent by pressure controller. The compressor stops
running, magnetic valve is cut off. Air compressorunloads. As one-way valve is
installed at the enhance of gas bottle. The pressure in the bottle doesn't drop.
When the pressure in gas bottle lows the Min. Pressure. The signal travels to
elechic conhol case, sent by pressure controller. The compressor begins to start.
(Notes: If supply with autocontrol device, Its working principle, Service and
"seryice
Electric-pneumatic principle detail in manual of air compressor auto-
control device").
3. Security protection device
To ensure air compressor run safely. The first stage safety valve and the
second stage valve has the function of unloading by hand. The first pressure of
safety valve has been adjusted during the assembling. The second stage safety
valve is covered by lead. The start pressure of safety valve is as follows. First
stage is 0.6-0.8Mpa. Secondstage is 3.1-3.3Mpa.
Safety film is installed in the first stage cooler of water-cool air eompres-
sor. When the pressure of cooled water exceeds the rated value Safety fiIm will
explore automatically.
If air compressor supplied with electric control device. Over-loading pro-
tection device is installed in electric control case. When over loading caused un-
der the unnormal stage, lead to the supply current of motor e*ceeds the adjusted
current of heat Relay in control line. The heat Relay will be cut off automatical-
ly, and the gas source is cut off. Force the motor and compressor to stop work-
irg.

YI. Installation and Maintenance.

1. Requirement of Installation.
(1) The compressorshouldbe installed in the ventilation,dry area with less
dust.
(2) When install the compressoro
keep certain room around it so as to as-
sembleand disassembleand maitain.
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 (3) The basementscrewof compressorshould be load and reliable, in case
of causingpipe leakageof parts loosenby over vibration.
(4) Each of the first-installed pipe should blow cleanly, avoiding other
things enteringthe system.
2. Check before in rotation
(lj Check if the each pulley belt is properly slackened.
(2) Check if the filtered lubricating oil in the crankcaseis reachedbetween
the two scales.
(3) Check if the compnessor is all right by rotatingthe pulley.
3. Check when in rotation
(1) Before regular starting, the electric switch is switched on and off to see
if the turn direction of pulley is right or not.
(2) Pay attention to the cooling water supply of the water-cooling air com-
pressor. The supply water pressure is 0.15Mpa, The dischange is about 0.5tlh.
(3) Open the first stage safety valve, let the compressorrun without load for
about half an hour, close the valve, then increase pressure step by step.
(4) During the rotation, should not have oil leakage, water leakage or gas
leakage.
(5) Check each stage safety valve, pneumatic control device or
electric control device to see they are in the normal work itate.
4. Check after stopping
(1) Stop the air compressor without Ioading as soon as possible.
(2) Cut off electricity.
(3) If the compressor is water-cooling, should cut off water resource,
drain off the cooled water in the cooler.
(4\ Open the valve under gas bottle to drain off water after operation
every 16 hours.
5. Requirement of maintenance
(1) Clean the inner of muffler, dirt and Seasy dirt regularly.
(2) Replace lubricating oil regularly, clean the greasy dirt in the
crankshaft box.
(3) Check the wear allowance of each motion parts regularly.
(4) Check the function of safety valve, pneumatic control device or electric
control device regularly.
(5) It is necessary to remove the excessive carbon deposits on the gas

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valve, clean it in the ?-UVo
kawtic sodasolution * 70t-80t, then washit in
warm water.
(6) Check the gas bottle according to the provision of regulation of safety
and Technologyof PressureVessel.

YII. Appearanceand InstallatioD Dimension.

1. Appearancediagramand installation dimensionof model 2ZF-0.3413-B

air compressoris shownin Figure4.
2. Appearancediagrarnand installation dimensionof model 2ZF-0.3413-B
air compressoris shownon Figure 5.
3. Appearancediagramand installationdimensionof model 2ZF-0.3413-B
air compressorhorizontal machineunit is shownin Figure 6.
4. Appearancediagramand installationdimensionof model 2ZF-0.3413-B
air compressorgas bottle machineunit is shownin Figure 7.
5. Appearancediragrarnsnd irstallation dimensionof model 2ZF-0.3413-B
air compressordiesel engine unit is shownin Figue 8.
6. Appearancediagram and installation dimension of model WTB-0.6/3 air
compressoris showin Figure 9.
7. Appearancediagram and installation dimension of molde WTB-0.6/3 air
compressorhorizontal machine unit is shownin Figure 10.
8. Appearancediagramand installationdimensionof model WFB-0.6/3 air
cinoressorgas bottle machineunit is showin Figure 11.

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 VIII.CommonBreakdownand RemovalMethod.
Characterof Removalmethod
Possibleeause
breakdown

Thecompressor 1.Theelecnicityis breakdorm

or the 1. 0verhaulto removalbreakdown
I volrageis toolow 2. Checkpressurecontroldeviceand
can'tstart
2. Notstartwithoutloading one-wayvalveto removalbreakdown

1. The screwand nut of the 1. Screwtightly the connectingrod

connectingrod becomeloosen screw.
Unusualsoundin 2. The rop end of piston beatsthe 2. Repair and maintain spacer
2 the crankcase
and cylinder spacer 3. Replace the valve disk or the
3. The valve disks are bmken,the 0ther damagedparts and remove
cylinder.
broken fall into the cylinder the broken piceces
4. The pistonpin hole is muchworn 4. Check and replace the piston
5. The connectingrod bearing 5. Adjust the spaceror replacethe
bushing is mlch worn connectingrod

1. The runningspeedis reduced l. Ensure a nonnal running speed

2. The spring of the inlet valve is 2. Replacethe spring,repair and
bmken or the valve disks are maintain the valve.
seized. 3. Replaceor clean the filter.
Insufficientair 3. The filter is clogged 4. Replacethe pistonring and
J
4. The piston ring is worn by friction clean the ring groove.
dischange
or seizedby the ring groove 5. Cleanthe valve system.
5. T'heu.rnnectionof the inlei valve 5. CLeckairri rernovalihc
seat and chamberis not sealed breakdown.
well
6. The air feed systemis leakage

1. The valve disk or the springis 1. Repairand maintainor replace

Thefischargeair
4 broken 2. Cleanand removeit
temperature
2. Carbondepositsheavily on the 3. Cleancooler
suddenlyrises
dischargevalve
3. The cool ellect is nit effective

The temperatureof 1. The piston and cylinder are seized l. Replaceor repair and maintain
2. The piston ring and piston are 2. Check and replace the piston
) the lubricating oil
seriouslyworn ring or piston
is too high. the 3. The oil in crankshaftcaseis too
3. Checkoil position
supply oil increases much

L The pistonring and cylinder are 1. Replaceor repair and maintain

Increaseof power seized 2. Replaceor repair and maintain
consumption 2. The connectingrod bearing 3. Checkand clean it
6
bushing holds the crankshaft
3. The air passageof the inlet and
dischargevalve is not free

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