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USER GUIDE FOR CE & MC "EXPORT"

Congratulations on having made the decision to purchase a FRANCOIS compressor.

The instructions for installation, operation, periodic inspection and maintenance instructions for your
compressor are described below.

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1. INTRODUCTION

FRANCOIS high-pressure, oil-free air piston compressors are designed for PET blow moulding.
This specific type of compressor requires more careful maintenance than that of a conventional
compressor.

The aim of this guide is to explain the best operating conditions for your machine so that you can
obtain the best results.

Please specify the compressor model and serial number whenever you contact us.

Operating principle

The compressor is a volumetric machine with 2 or 3 compression stages.

The oil-free multi-stage compression system means that high pressures can be achieved and the air
kept at a reasonable temperature. After each stage the air is cooled to a temperature of approx.
60 EC.

Each cylinder has an equal number of suction valves and discharge valves.

When the final service pressure has been reached an electropneumatic device keeps the suction
valves open. The machine stops compressing and the air in the intermediate coolers is discharged
to the outside by means of solenoid bleed valves.

When the pressure drops in the system the pressure controller starts the suction valves up again
and the machine starts compressing again.

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COMPRESSOR TYPE MC 244S SG

1. CRANKCASE

2. LUBE OIL FILLING BOX WITH LEVEL SIGHTGLASS

3. CRANKSHAFT

4. CONNECTING ROD

5. CONNECTING ROD BIG END BOLT

6. CROSSHEAD

7. CROSSHEAD GUIDE

8. SCRAPER BOX

9. PACKING

10. PISTON ROD

11. DISTANCE PIECE

12. CYLINDER 1st & 2nd STAGE

13. PISTON 1st, 2nd, 3th STAGE

14. CYLINDER 3th STAGE

15. SUCTION VALVE 3th STAGE

16. DISCHARGE VALVE 3th STAGE

17. INTERCOOLER 1st STAGE

18. SEPARATOR 1st STAGE

19. INTERCOOLER 2nd STAGE

20. SEPARATOR 2nd STAGE

21. FLYWHEEL

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COMPRESSOR TYPE CE.46.B.S.SG.40

1. CRANKCASE
2. CRANKCASE INSPECTION DOOR
3. CROSSHEAD INSPECTION DOORS
4. CROSSEHEAD GUIDE
5. OIL TEMPERATURE
6. OIL FILTER
7. OIL GEAR PUMP
8. LUBE OIL FILLING BOX WITH LEVEL SIGHTGLASS
9. BREATHER
10. FLYWHEEL
11. CROSSHEAD TEMPERATURE SENSOR
12. DISTANCE PIECE
13. PISTON ROD 1st STAGE
14. OIL DEFLECTOR
15. WATER INLET TEMPERATURE
16. CYLINDER 1st STAGE
17. 1st STAGE CYLINDER HEAD
18. SUCTION VALVE WITH RELEASER 1st STAGE
19. DISCHARGE VALVE 1st STAGE
20. DISCHARGE TEMPERATURE 1st STAGE
21. INTERCOOLER 1st STAGE
22. SEPARATOR 1st STAGE
23. SAFETY VALVE 1st STAGE
24. SUCTION TEMPERATURE 2nd STAGE
25. CYLINDER 2nd STAGE
26. SUCTION VALVE WITH RELEASER 2nd STAGE
27. PISTON ROD 2nd & 3th STAGE
28. DISCHARGE TEMPERATURE 2nd STAGE
29. SEPARATOR 2nd STAGE
30. SUCTION TEMPERATURE 3th STAGE
31. CYLINDER 3th STAGE
32. SUCTION VALVE WITH RELEASER 3th STAGE
33. DISCHARGE VALVE 3th STAGE
34. PULSATION DAMPENER

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COMPRESSOR TYPE CE.68.B.S.SG40

1. CRANKCASE
2. CRANKACASE INSPECTION DOOR
3. CROSSEHEAD INSPECTION DOOR
4. OIL TEMPERATURE
5. OIL FILTER
6. OIL GEAR PUMP
7. LUBE OIL FILLING BOX WITH LEVEL SIGHTGLASS
8. BREATHER
9. FLYWHEEL
10. CROSSEHEAD TEMPERATURE SENSOR
11. DISTANCE PIECE
12. PISTON ROD 1st STAGE
13. OIL DEFLECTOR
14. 1st STAGE CYLINDER BOTTOM
15. CYLINDER 1st STAGE
16. 1st STAGE CYLINDER HEAD
17. SUCTION VALVE WITH RELEASER 1st STAGE
18. DISCHARGE VALVE 1st STAGE
19. DISCHARGE TEMPERATURE 1st STAGE
20. INTERCOOLER 1st STAGE
21. SEPARATOR 1st STAGE
22. SAFETY VALVE 1st STAGE
23. SUCTION TEMPERATURE 2nd STAGE
24. 2nd STAGE CYLINDER BOTTOM
25. CYLINDER 2nd STAGE
26. SUCTION VALVE WITH RELEASER 2nd STAGE
27. DISCHARGE VALVE 2nd STAGE
28. PISTON ROD 2nd AND 3th STAGE
29. INTERCOOLER 2nd STAGE
30. SEPARATOR 2nd STAGE
31. SAFETY VALVE 2nd STAGE
32. DISCHARGE TEMPERATURE 3th STAGE
33. CYLINNDER 3th STAGE
34. DISCHARGE VALVE WITH RELEASER 3th STAGE
35. DISCHARGE VALVE 3th STAGE

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Safety precautions

- Read this leaflet carefully before commissioning the motor/compressor unit.

- Follow the instructions on the labels posted on the machine's components. We provide a list and
an explanation of what they mean (see page 10).

- Most of the physical injuries which occur during operation or maintenance are caused by failure
to follow basic safety regulations.

- The recommendations in this manual are not restrictive.

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2. LOCATION OF COMPRESSOR

The area in which the compressor is installed must satisfy the following requirements:

2.1. Easy access for maintenance staff.

2.2. Lifting facilities such as travelling gantry or a rail with pulley block to disassemble heavy
components (cylinders, pistons, electric motors).

2.3. Adequate ventilation provided naturally through louvred windows or by means of a hot air
extractor (see para. 3.1).

2.4. The air drawn into the machine must be as fresh as possible. However if the
temperature of these premises is likely to lower than 5° C/ 41° F, the crankcase must be
heated.

2.5. The ground must be even and horizontal and sufficiently strong to support the weight of the
compressor mounted on its spring suspension (machine rests on anti-vibration blocks), or
capable of anchoring the machine (check the size of the slab).

2.6. Do not stock dangerous or volatile substances in the machine room which are likely to
explode.

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3. INSTALLATION

ATTENTION: Lift the unit only by the anchoring points provided. The handling of
motor-compressor sets must be carried out by skilled staff.

General:

3.1. (2.3. contd). An ambient temperature higher than 35 - 40EC will cause the compressor to
overheat which is detrimental to the service life of the piston rings.

3.2. The compressor must be easily accessible to facilitate proper and convenient maintenance. It
is essential to provide sufficient surrounding space as well as space above the machine
(see plan 71/.... in appendix) so that large components such as the piston rod and cylinder
assemblies can be dismantled.

3.3. The compressor and its fittings are mounted on a frame supported by springs.
The compressor is positioned directly on to an even, horizontal floor capable of supporting
the weight of the equipment. A flexible tube at the assembly discharge (final coolant or
reservoir according to model type) provides the link to the compressed air system. The
springs are to be fixed to the floor by anchor bolts (one bolt per spring).

3.4. The compressor and its fittings are assembled on a fixed frame (to be mounted on a
concrete foundation).

3.4.1. Compliance with civil engineering plans is obligatory. The depth dimensions
should be checked according to the characteristics of the floor and the reaction
of the compressor.

3.4.2. During assembly, first of all insert the anchor bolts in the holes provided in the
frame. Position the unit on the base and make it level with the aid of metal
blocks.

3.4.3. Fill the empty space between the frame and the slab floor with sealing concrete
and leave to dry for the required time. The anchor bolts should be permanently
sealed after the drying process is complete (8 days for normal sealing concrete
and a few hours for synthetic resin).

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4. ELECTRICAL CONNECTIONS

4.1. The wiring section should be adapted according to the output of the motor, the mains
voltage, the method of installation and the regulations of the country concerned.

4.2. When carrying out electrical connections, follow the circuit diagram on the control panel.

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5. PNEUMATIC CONNECTIONS

5.1. The pipework section for the distribution of compressed air must be adapted to the
output of the compressor(s). Its diameter should be at least equal to that of the discharge
tube. Please contact us to discuss details of your system.
The pipework must be protected against internal and external corrosion.

5.2. If several compressors supply the same installation, it is advisable to install a nonreturn
valve between the compressor and the system, together with an isolation valve.

5.3. It is essential to provide a sufficient number of anchoring points for the compressed air
pipe system to avoid any vibration in the direction of other equipment and users. The first
anchoring support directly after the discharge tube should have a highly rigid structure
and be fixed very solidly to the floor.

5.4. The metal discharge pipe is fitted in perfect alignment with the fixed pipework. It may
not be subjected to tensile stress or compression, nor may it be bent.

Protection against bursting is provided and may not be removed.

5.5 The pipework connecting the compressor and the blow moulder must be fitted by
approved personnel. A test at 1.5 times the service pressure must be carried out prior to
commissioning.

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6. CONNECTIONS TO THE COOLING CIRCUIT

6.1. General

The purity, and the temperature level of the cooling water are essential to ensure the
reliable operation of the compressor.

6.2. The water quality shall comply with the following requirements:

- pH 7 to 9
- hardness in CaCO3 30 to 500 ppm
- alkaline standard in CaCO3 500 ppm max.
- dissolved solids 1000 mg/l max.
- chlorides 125 ppm max.
- sulphates 125 ppm max.

A pressure gauge should be provided at the water inlet.

The temperature at the compressor inlet should be between 10 and 30 EC (50 and 86 EF
inclusive). Max. 45 EC. Recommended pressure: 3 bars eff. Max. 4.5 bars eff.

6.3. The internal circuit of the compressor (in green) is manufactured by us in the factory. It is
connected by means of the flexible tubes supplied with the compressor in accordance with
the inlet and outlet instructions. Any change to the internal circuit of the compressor unit
(cooling of cylinders, inter- and after-coolers) requires the approval of ATELIERS
FRANCOIS.

6.4. Provide a pressure gauge at the circuit inlet.

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6.5 Cooling schema.

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7. SAFETY PRECAUTIONS

The thermostats and pressure switches installed in the compressor unit are set to our test
bench. The values are quoted on the test sheet.

ANY INOPPORTUNE MODIFICATION TO THE SAFETY EQUIPMENT=S SETTINS MAY

DAMAGE THE EQUIPMENT.

In the absence of our written approval, ATELIERS FRANCOIS accepts no responsibility for any
modification made to safety recommendations.

On no account may a safety device be bridged.

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8. COMMISSIONING THE COMPRESSOR

8.1. Preliminary checks.

8.1 .1. Check the quality and the circulation of the cooling water in the entire unit. If
the compressor is fitted with a thermostatic or electromagnetic valve, the air
output level will be established automatically on starting. The pressure of the
water circuit should be 3 bar eff. (4.5 bars max.)
ATTENTION: If, by accident, the compressor is turned on before the water
circulation is established, switch off the machine immediately and leave to cool
down before letting in the cooling water as this might otherwise lead to serious
damage (thermal shock in the cast iron of the cylinders).

8.1.2. Pour clean oil into the crankcase (see table of recommended oils )
until it reaches the upper blade in the filler casing.

BRAND CE - MC

BP RC 150

CASTROL AIRCOL PD 150

CHEVRON GP OIL 150

ESSO TERESSO 150

FINA EOLAN AC 150

Q8 Q8 SCHUBERT 150

MOBIL RARUS 429

RENAULT ELF DACNIS P 150

SHELL CORENA OIL P 150

TEXACO OMNIS 150

TOTAL CORTUSA 150

UNIL CRP 150

ARAL VCL 150

8.1.3. Before starting the compressor make a full revolution of the compressor
flywheel by moving the belts manually. The machine should rotate freely.
In addition, check the surface condition of the cylinder bores by lifting the
discharge valve on each cylinder. Humidity during transport and/or prolonged
storage may lead to corrosion. If evidence of corrosion is discovered, contact
ATELIERS FRANCOIS for advice.
For belt tension please see 9.1.4.6.

8.1.4. Set the switch on the switch cabinet to the "NO-LOAD@ position.

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8.2. Starting.

8.2.1. When starting the machine for the first time check that the compressor is
running in an anti-clockwise direction when facing the flywheel. If the
direction of rotation is incorrect, reverse the electrical connection of the
motor.

8.2.2. When starting for the first time, set the change-over switch (BS) located on
the switch cabinet door to the "no-load" position and let the compressor
operate at zero pressure for about two hours. Check the oil pressure during
this time to ensure that it does not fall below 2 bars eff. (See the test sheet-
IT102).

8.2.3. If operation is normal (no abnormal noise, no fall in oil pressure or water
leaks), set the change-over switch to the AON-LOAD@ position.
The compressor will then be able to start the compression process.

8.2.4. ATTENTION: It is advisable to carrry out the loading operation in stages as

follows:

- Bring the compressor up to an output pressure of 10 bar (see pressure gauge

stage 3). Once this pressure is reached, set the change-over switch on the
control cabinet to ANO-LOAD@ position. Let the machine run idle for
approximately 5 minutes.

- Repeat this procedure at pressure levels of 20, 30 and 40 bar respectively.

Do not change from one pressure to another if temperatures have not
stabilised.

- Working at its maximum pressure, the pressure switch must disengage and
engage (no load/on load) at pre-set pressure levels.

8.2.5. Check pressure and temperature levels (see IT 102: test sheet for the machine).
Check the timing of the opening of the solenoid bleed valves (see values
shown on enclosed wiring diagram SE....)
If any of the recorded values deviates from the values in the test sheet by more
than 10%, and the parameters are identical, stop the machine and contact
ATELIERS FRANCOIS.

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9. RUNNING-IN PERIOD (the first 1000 hours)

MAINTENANCE AND CHECKS

9.1. Important preliminary remarks.

BEFORE CARRYING OUT ANY WORK ON THE MACHINE, PLEASE ENSURE

THAT THE COMPRESSOR IS DISCONNECTED FROM THE POWER SUPPLY.

CLOSE THE COMPRESSOR'S SLIDE VALVE AND DECOMPRESS THE

FORCING PIPE SYSTEM (using the air bleed valve).

ONLY USE ORIGINAL A.F. PARTS

Place a sign stating "Out of service - do not switch on" on the switch cabinet when
carrying out any work on the compressor.

9.1.1. Daily checks.

9.1.1.1. Inspect and note the oil level and all the pressure and temperature
levels (fill in the daily check list), very important for preventive
maintenance.

9.1.1.2. Clean the oil filter in the crankcase by fully rotating the operating
lever of the brush-type filter.

9.1.1.3. There should be no abnormal noise during operation.

9.1.2. After the first 50 operating hours.

9.1.2.1 Drain and clean the crankcase and the oil filter. Use clean,
non-fibrous, lint-free cloths to clean the crankcase. To clean the oil
filter, unscrew the magnetised cap located on the lower part of the
filter. Drain off all the oil into a container and replace it.
Replace the magnetised cap after cleaning, together with a new
gasket.

A light covering of filings (essentially iron) is normal when draining

the machine for the first time. The presence of a significant amount
of bronze filings, babbitt metal and iron and steel filings must be
notified to ATELIERS FRANCOIS.

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9.1.2.2. Check and, if necessary, re-tighten the locking screws securing the
valves as well as the fastening screws for the valve covers (see table of
tightening torques ) .

DIAMETER TORQUE (NM) WRENCH OPEN

mm Min. max. Mm
4 2,0 2,3 7
5 4,1 4,6 8
6 7,0 7,9 10
8 17,0 19,0 13
10 33,0 37,0 17
12 57,0 64,0 19
14 90,0 100,0 22
16 135,0 150,0 24
20 265,0 295,0 30
22 370,0 415,0 32
24 450,0 510,0 36
27 580,0 650,0 41
30 825,0 920,0 46
33 1130,0 1270,0 50
36 1400,0 1550,0 55

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9.1.2.3. Check and, if necessary, re-tighten the fastening screws securing the
cylinder heads to the cylinders themselves, together with those on
the cylinder assembly in the 2nd and 3rd stages respectively.

9.1.2.4. Remove the inspection doors from the crosshead guide. Ensure that
the fastening screws are properly secured to the piston rods on the
crossheads.

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9.1.2.5. Check the surface condition of the piston rods. It should not be
scratched.

9.1.2.6. Look through the Plexiglass inspection doors to check that the oil-
scraper rings are operating normally.

If significant oil leakage is detected, notify ATELIERS

FRANCOIS.

9.1.2.7. Fill the crankcase with fresh oil until it reaches the upper blade in the
filler casing.

Note: Never let the oil level in the crankcase fall below the lower blade
in the feed box.

9.1.3. After 250 hours.

9.1.3.1. Check the cleanliness of the air-suction filter when inspecting the
low-pressure gauge located between the filter and the low-pressure
cylinder. Clean if necessary (see IT 148).

9.1.3.2. Check the cleanliness of the oil bath.

9.1.3.3. Clean the oil filter.
Unscrew the magnetised cap located on the lower part of the filter.
Drain off all the oil into a container. Unscrew the four fixing screws
on the filter cartridge, dismantle, clean and replace it.
Replace the magnetised cap after cleaning, together with a new gasket.
A light covering of filings (essentially iron) is normal when draining the
machine for the first time.
The presence of a significant amount of bronze filings, babbitt metal
and iron and steel filings must be notified to ATELIERS FRANCOIS.

9.1.3.4. Check that the electrovalves are operating normally by ensuring that
condensation is completely drained off at regular intervals.

9.1.3.5. Check that the covers and valves are secured, together with the
fastening screws on the cylinder heads and the cylinders themselves
(see 9.1.2.2),by checking the value of the tightening torques.

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9.1.4. After 1,000 hours.

9.1.4.1. Repeat the procedures described in 9.1.3 "250 hours".

9.1.4.2. Remove the inspection doors from the crosshead guides. Check that
the friction surfaces of the guides are in good condition.

9.1.4.3. Check the wear and tear of the piston ring and the cylinders as follows :

9.1.4.3.1. Stage 1 (cylindervertical).

9.1.4.3.1.1 Remove an upper and a lower discharge valves. Unlike the

suction valves the discharge valves are not inter-connected by
an 8 mm diameter copper pipe. Proceed as follows :
- Unscrew the fastening screws on the cover.
- Remove the valve cover cage assembly by levering with a
screwdriver inserted between the cover and the cylinder or the
cylinder head.

After removing the valves, carry out a visual check of the surface
condition of the internal diameter of the cylinder with the aid of a
flashlight.
The surface should be perfectly smooth and show no signs of seizing.

9.1.4.3.1.2 - Check the play between the cylinder and the piston as follows:
- Move the piston to the upper position (by moving the belts).
- Check the play between the cylinder and the piston with
thickness gauges, (see IT 93).
- Repeat procedures a and b with the piston in the lower position.

9.1.4.3.2. Stages 2 and 3 (cylinders horizontal)

- Remove the discharge valve from each cylinder following the

procedure for stage 1.
- Check the condition of the cylinders by moving the pistons of
stages 2 and 3 onto the crankcase side.
- Check the wear and tear of the rings by bringing the pistons of
stages 2 and 3 to the base of the cylinder onto the cylinder head side.
- For measuring purposes, use the same method described in stage 1
(see IT 93).

CLEARANCES RECORDEDAFTER 1000 HOURS MUST BE INCLUDED IN THE DAILY

CHECK LIST AND FORWARDEDWITHOUT DELAY TO ATELIERS FRANCOIS.

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9.1.4.4 Re-assembly of valves in stages 1, 2 and 3:

- Insert a new valve gasket in its seating.
- Install the valve cage and cover.
- Spray a film of Teflon on the O-ring of the cover.
- Re-tighten the fastening screws of the tightening torque (see page 21).

9.1.4.5. Restarting the compressor.

- Check that the compressor rotates freely by moving the belts manually
(complete a full revolution).
TAKE CARE NOT TO TRAP YOURFINGERS
(Do not use the motor fan).
- Re-start the machine.
- After 24 hours' operation, check and re-tighten the screw and nuts of
the valve assemblies.

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9.1.4.6. Check the belt tension.

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10. AFTER 2000 HOURS

10.1. Separators at the suction end of the stage 2 and 3 cylinders

To separate the water in liquid phase from the compressed air, each separator
has a demister made of stainless steel wire mesh.
These should be inspected every 2000 hours. To do this, remove the bolted
covers which close the separators. Inspect the density and cleanliness of the
meshes. They should be firmly seated between the central tube and the inside
of the separators' bush. It should not be possible to move them with ease and
they should not be torn or frayed. If either of these applies, they must be
replaced. If they are still firmly seated but are dirty they should be cleaned.
Remove them from the separator body by inserting two steel pins with hooked
ends through the pad (150 mm thick) and withdraw them by pulling on the pins.
Once removed the pads may be cleaned with a spray lance. Clean the body of
the separators which has been exposed in this way. When the pads are dry,
replace them and check their fit in their housing.

10.2 Checking for wear and tear on the piston rings in stages 2 and 3.

Replace if necessary (see the minimum clearances on sheet IT 93).

10.3 If replacement is necessary, proceed as follows:

10.3.1. Disassembly of piston rinqs

- Turn off the supply of cooling water and drain the water circuit completely.
- Detach the cylinders in stages 2 and 3 from the suction and discharge pipe systems.
- Disassemble all the valves (see 9.1.4.3).
- Remove the fastening screws from the stage 3 cylinder.
- Support stage 3 cylinder with the aid of a pulley block.
- Carefully remove the cylinder (without forcing it up or down to avoid bending the
piston rod).
- Leave the cylinder in a clean place (protected from dust).
- Remove the inspection doors from the horizontal crosshead guide.
- Make a centre mark on the crosshead and the piston rod (non-loadbearing
section), measure the distance with the aid of a compass and record the
measurement on the inside of the inspection door (which eliminates the need to
memorise it for future procedures).
- Remove the locking pin in the crosshead.
- Remove the hex socket setscrew located on the locknut on the piston rod.
- Support the crosshead with the aid of the tool provided for this purpose
(supplied by ATELIERS FRANCOIS, see page 25) and remove the crosshead screw.
- Unscrew the piston rod assembly by turning stage 3 cylinder manually.
- Unscrew the locknut from the crosshead rod.
- Place the cap supplied with the machine onto the end of the piston rod.
- Remove the packing from the oil-scraper ring.

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- Remove the oil cap.

- Remove the packing on the air side.
- Carefully remove the piston/rod assembly in stages 2 and 3 and leave it in a clean
place (protected from dust).
- Check the surface condition of the cylinder bores in stages 2 and 3. These must
not show any evidence of seizing or wear and tear, and should have a polished,
brownish appearance.
- Check the surface condition of the pistons.The latter should also show no sign of
seizing.
- Remove the sealing rings from the pistons as well as the supporting rings
(assuming they are not monoblocs).
- Clean the ring grooves with the aid of a clean cloth.

10.3.2. Re-assembly of rings.

10.3.2.1. Procedure for the sealing and supporting rings stage 2:

Note:the supporting rings are recognisable by their greater width and are
found at the end of the piston.
- Replace the supporting ring by opening it so that it slides
onto the piston and into the groove.
- Repeat the same procedure for the sealing rings.
10.3.2.2. Procedure for the sealing and supporting rings stage 3: proceed as
for stage 2.
Note: on certain machines the supporting ring of the piston in
stage 3 is a "monobloc" type. It is also wider than the sealing rings.
For monobloc rings, proceed as follows, first securing that part
of the piston rod between stages 2 and 3 in a vice fitted with a soft
clamp:

10.3.3. Re-assembly of supporting rings.

- Piston nut: if this is an ordinary nut, fixed with LOCTITE, it must be
heated to 180 EC with a blowtorch before being unscrewed, or dismantle
the Superbolts nut, see IT.199.
- Unscrew and remove the nut by supporting the piston rod assembly in a vice.
- Remove the half-piston (external part) manually.
- Cut and remove the old supporting ring.
- Heat the half-piston and the new supporting ring in a oil bath at a temperature
of 160 EC (320 EF) or in a stream of hot air.
- When they have reached this temperature, remove from the oil and slide
the hot ring onto the piston.
- Let the supporting ring and the half piston cool down.
- If, after cooling down, the supporting ring has not shrunk back into the
groove, reheat with the aid of a thermal scraper so that the plastic insert
on the ring shrink-fits into the groove.
- Allow the unit to return to the ambient temperature.
- Degrease the unit with care.

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10.3.4. Re-assembly of sealing rings

- These rings are in two parts. Maintain these as a pair and position in the groove
during the re-assembly of stage 3 cylinder.
- CAUTlON: When re-assembling piston rings in stages 2 and 3, ensure that
consecutive rings are opened opposite one another to avoid any internal leakages.

10.3.5. Re-assembly of the unit.

Re-assembly requires the replacement of ALL gaskets.

10.3.5.1. Piston stage 3.

- Replace both parts of the piston manually in stage 3 and attach to the rod (which
should be clamped in a vice between stages 2 and 3).
- Screw a new rod/piston locknut up at a torque of xx kgm after first coating them
with LOCTITE No.
- If a superbolt is involved, please refer IT199.

10.3.5.2. Packing material and oil-scraper.

- Remove all sealing rings from their seating (see figure 1 - page 33) and clean with a
clean cloth.
- Check for any signs of seizing and/or wear and tear.
- Replace all the sealing rings in their seating, ensuring that they do not bind (see
IT 83 and IT 83CAS).

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Figure 1.

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10.3.5.3. Piston rod assembly.

- Place the cap supplied by ATELIERS FRANCOIS on the fastening thread
of the rod/crosshead.
- Place the piston rod in the packing material.
- Replace the "oil cap" when the piston rod enters the distance-piece.
- Continue to push the rod until it passes through the oilscraper ring packing.
- Grasp the rings manually and insert them one by one in the stage 2 cylinder.
- Remove the protective cap on the fastening thread of the rod/crosshead.
- Tighten the rod/crosshead locknut on the piston rod thread.
- Turn the piston assembly in stages 2 and 3 manually to the crosshead in a
clockwise direction until the reference points
(centre marks made previously on inspection door) return to their initial
value (check with the aid of a compass).
- Insert a new crosshead/rod split pin and open after insertion.
- Re-tighten the locknut for the rod/crosshead with the aid of a special
tool provided by ATELIERS FRANCOIS.
- Re-tighten the rod/crosshead locknut locking screw (hex socket setscrew).

10.3.5.4. Cylinder stage 3.

- Level the cylinder carefully.
- Lift it to the height of the stage 3 piston.
- Insert the cylinder into the stage 3 piston, taking care to tighten the packing
rings manually so that they can be positioned without forcing.
CAUTION: To avoid bending the piston rod, the cylinder must not, under any
circumstances, exert any upwards or downwards pressure on the piston.
- Replace and tighten the fastening screws of the stage 3 cylinder to the stage 2
cylinder tightening torque: see para.9.1.2.2.
- Reassemble suction and discharge tubing.

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10.3.5.5. Reassembling second and third stage suction and discharge valves (see
description maintenance after 1000 hours 9.1.4.4.).

10.3.5.6. Changing oil and cleaning housing (see 9.1.2.1.).

NOTE: Before refilling oil into housing, check the following:

- Check tightness of screws, bolts and nuts

on connecting rod big end (tightening torque-IT 80).
- Check tightness of piston rods adjusting bolts on crossheads (see 9.1.2.4.).
- Check tightness of mounting plates of crosshead pin (see para. 9.1.2.2).

10.3.5.7. Re-starting the compressor

- CHECK THE FREE ROTATION OF THE COMPRESSOR

(one complete revolution) BY MANUALLY MOVING
THE BELTS. REFIT THE SAFETY GUARD.
- Establish water cooling circuit.
- Open the insulating valve of air discharge tubing.
- Replace protection fuses in the electric control box.
- Switch commutator to "off-load".
- Start the compressor.
- Allow the machine to turn off-load for a minimum of 2 hours.
- Before loading it, check the following items: oil pressure; abnormal noises;
oil temperature (see the test sheet).
- Load the machine. As the piston rings are new, it is essential that the
machine be loaded progressively. Increase the pressure in 5-bar steps.
Move to higher pressure only after the temperature has been stable for 30
minutes.
- Use daily report sheets to monitor pressure and temperature.
- After 24 operating hours, re-tighten screws, bolts and nuts of the valve
assemblies (see 9.1.2.2.).

10.4. Control the belt tension (see chapter TRANSMISSION)

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11. AFTER 4000 HOURS

11.1. Separators placed at suction of 2nd and 3rd stages cylinders (see 10.1.).

11.2. Make sure that valves are clean by taking them out of the cylinders. After they have
been reassembled, check tightness of all valves (see 9.1.4.4.).

11.3. Check wear on 2nd and 3rd stage piston rings. Replace if necessary (see minimum
clearances on sheet IT93).

11.4. Check belt tension (see TRANSMISSION chapter).

If the belts are re-tightened, the machine MUST be rotated several times by hand, and
the tension then checked again.

11.5. Before starting up again after maintenance work, check that the compressor rotates
freely by turning it through one revolution by hand.

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12. AFTER 6000 HOURS

12.1. Separators placed at suction of 2nd and 3rd stage cylinders (see 10.1.).

12.2. Check first, second and third stage piston rings (see 9.1.4.3.).

12.3. If necessary, replace worn piston rings.

For first stage, see description on 8000 hours.
For second and third stages (see 10.3.).

12.4. After valves have been removed, check cleanliness and sealing.

NOTE: the tightness of a discharge valve is examined by pouring water onto the part
facing the cylinder. The tightness of a suction valve is controlled by pouring water onto
opposite side of the cylinder. If thightness is poor, replace valves and follow procedure
for overhauling defective valves.
Check that the suction valves=opening fork is working properly: press on the fork=s cap
with your hand and ensure that the valve flap opens completely (approx. 2 mm of
travel).

12.5. Before starting up again after maintenance work, check that the compressor rotates
freely by turning it through one revolution by hand.

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13. AFTER 8000 HOURS

13.1. Separators placed at suction end of second and third stage cylinders (see 10.1.).

13.2. Replacing valves, diaphragms, in first stage piston rings and cleaning water circuit.

- Shut off cooling water supply.

- Remove fuses from electric control box and place a sign saying "do not start".
- Remove suction valves (see 9.1.4.3.) and replace them with new or overhauled
valves. Unload devices for suction valves are to be equipped qith new diaphragms.
- Unscrew adjusting bolts and nuts on cylinder heads.
- Carefully turn the compressor flywheel (manually) by moving the belts so that
the piston is placed in the Aupper@ position. The filler block that was inserted
earlier will then lift the cylinder head slightly.
- Fasten the lifting collar provided for this purpose onto the cylinder head.
- Place a sling (500 kg load) into the collar.
- Carefully place the cylinder head onto a clean wood slab.
- Remove inspection doors from the crosshead guide.
- Place a centre mark on crosshead and piston rod (non-load-bearing part),
Measure the distance with a caliber and record it on the inside of the
inspection door (so that this value can be stored for future operations).
- Remove the safety pin from the crosshead.
- Unscrew the hexagonal socket bolt placed on the lock nut of the piston rod.
- Using tools furnished by ATELIERS FRANCOIS (page 25), hold the crosshead and
remove the nut from it.
- Unscrew the lock nut of the rod on the crosshead.
- Insert the protective hood provided with the machine onto the end of the
piston rod.
- Remove the oil scraper ring packing.
- Remove the oil retain cover.
- Withdraw packing on the air side.
- Carefully withdraw second and third stage rod/piston assemblies. Put these in a clean
place (protected from dust).
- Check the surface of the cylinder bore. It should be polished and slightly brownish and
should show no trace of seizing or wear.
- Check the surface of the piston. It should show no trace of seizing.
- Remove the piston sealings rings and the supporting rings (if they are not monobloc).
- Clean the ring grooves with a clean cloth.
- Unscrew piston rod/piston assembly by manually turning the third piston.
- Screw the piston rod on crosshead nut.

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13.2.1. Cleaning the internal water cooling circuit of the compressor. When
temperature difference between inlet and outgoing air is higher than normal.

13.2.1.1. Clean cylinders and cylinder heads

- Remove inspection doors (square or round) in order to gain access to
water chambers of cylinders in first, second and third stages (or first and
third stages depending on type of machine).
- Protect cylinder bores from water projection (risk of corrosion).
- Clean water chambers. Remove mud and deposit manually and rinse under
pressure (for example, Kärcher).

13.2.1.2. Cleaning coolers

- Release water and air pipes.
- Remove coolers and clamp them in a vice.
- Disassemble the 2 control gaskets located at each end.
- Withdraw tubular bundles.
- Clean the tubes on the inside and outside at high pressure.
- Make sure that the inside of tubes is free.
- Check outer appearance of tybes. They must be in perfect condition.

NOTE: If mechanical cleaning is insufficient, chemical treatment is also possible.

For this purpose, please contact ATELIERS FRANCOIS.

13.2.1.3 Reassembling coolers and inspection doors on cylinders, follow disassembling

steps in opposite direction. Do not forget to replace all gaskets and sealing rings
of the tubing.

13.2.2. Re-assembly

DURING REASSEMBLING OPERATIONS ALL GASKETS MUST BE

REPLACED.
Preliminary remarks: never operate new packing or new rings or scrapers on a piston
rod that is slightly seized or worn by more than 0.08 to 0.2 mm from nominal diameter
even if there are no signs of seizing. In the case of rods up to diameters of 42 mm, do
not exceed regular wear of more than 0.12 mm.

13.2.2.1. Reassembling rings and oil scrapers of piston rods

Remove all elements from their bedding (see figure 2 - page 40)
and clean them with a clean cloth.
Ensure that there are no signs of seizing or wear.
Place all elements back into their housing (control the axial
clearance according to the values in Table IT 83).

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Figure 2.

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13.2.2.2. Reassembling piston/piston rod unit with new sealing rings

(see 10.2)

- Place the protection (sleeve supplied by ATELIERS FRANCOIS) onto the

rod/crosshead mounting thread.
- Insert piston rod into the packing material.
- Insert the "oil retainer" when the piston rod penetrates into the distance sleeve.
- Continue to push the rod until it penetrates the oil scraper ring packing.
- Manually squeeze compression rings (one by one) to introduce them into the cylinder.
- Remove the protection (sleeve) located on the piston/crosshead mounting thread.
- Tighten rod/crosshead lock nut onto the piston rod thread.
- Manually screw the piston rod assembly into the crosshead clockwise until the reference
points (hammer marks already made on the inspection doors) have returned to their
initial value (check with a caliper).
- Insert the "split" crosshead/rod safety pin and open it.
- Re-tighten the rod/crosshead fixing bolt using the tools furnished by
ATELIERS FRANCOIS.
- Re-tighten the hexagonal socket safety bolt of the rod/crosshead mounting unit.

13.2.2.3. Reassembling cylinder heads

NOTES:
13.2.2.3.1. Thoroughly clean upper part of the cylinder and bottom of cylinder
head (remove all trace of old gaskets).

13.2.2.3.2 - Insert a new cylinder head gasket.

- Place cylinder head back onto the cylinder.
- Insert and re-tighten fixing nuts to the specified tightening torque.
- Reassemble new or overhauled valves according to 9.1.4.4.

13.2.2.3.3. Re-start the compressor according to the procedure described under

"re-assembling of unit" 10.3.5.7.
- Check water circuit sealing (before starting).
- Check air and oil sealing.
- Check connecting rod safety according to the following procedure;
- Remove the inspection door from the oil housing.
- Check tightness of the four safety adjusting bolts .

13.2.2.3.4. Before starting up again after maintenance work, check that the
compressor rotates freely by turning it through one revolution by
hand.

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14. AFTER 20000 HOURS (FOR WELL INFORMED AND EQUIPPED TECHNICIAN)

CHECKING MOTION

14.1. Disassembling

- Remove inspection doors of frame and crosshead guide.

- Change housing oil and clean housing.
- Remove and clean oil filter.
- After placing the piston at bottom dead centre, remove the safety plates from the
crosshead pins.
- Remove the crosshead pins.
- Unscrew connecting rod big end safety bolts.
- Unscrew connecting rod big end bolts.
- Remove connecting rod covers.
- Remove the two connecting rods.

14.2. Checking condition of surface and clearance

- Using a micrometer, check the diameter of the crosshead pins. The following
roundness or seizing is allowed:
- 0.10 mm for a diameter of 42 mm is allowed
- 0.10 mm for a diameter of 52 mm is allowed
- 0.15 mm for a diameter of 60 mm is allowed
- 0.15 mm for a diameter of 75 mm is allowed
- Check the clearance between crosshead pins and bushes of connecting rod
small ends, using thickness gauges.
- Check to see whether bushes of small ends of connecting rod sit well in their
bedding and that there is no seizing.
- Manually pivot the crosshead into their crosshead guides and check surface conditioner.
There should be no signs of seizing.
- Using a tickness gauge, check the clearance between roller bearings and the
bearings= external cage bore.

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COMPRESSOR ITEM BEARING SPIEL (mm) BEARING

TYPE SIDE MIN. MAX.

MC244 PUMP 20 R610 A3838 0.050 0.080

FLYWHEEL 20 R610 A3887 0.050 0.080

CE2 PUMP 20 R610 A4470 0.050 0.080

FLYWHEEL 20 R610 A4444/1 0.050 0.080

CE24 PUMP 20 R610 A4470 0.050 0.080

FLYWHEEL 20 R610 A4444/1 0.050 0.080

CE4 PUMP 20 R610 A3801 0.060 0.100

FLYWHEEL 20 R610 A2996 0.060 0.100

CE46 PUMP 20 R610 A7959 0.075 0.120

FLYWHEEL 20 R610 A7958 0.095 0.145

CE68 PUMP 20 R610 A7958 0.095 0.145

FLYWHEEL 20 R610 A880011 0.110 0.170

14.3. Reassembling

- Replace connecting rod bearings in their housings.

- Reset connecting rods onto crankshaft according to the following procedure:
- introduce the first connecting rod into the housing and adjust half bearing onto the crank
pin.
- Replace the adjusting shims (except for CE2, CE24, MC1 and MC2);
- Re-insert connecting rod cover.
- Check surface condition of crankshaft. There should be no signs of seizing.
- Refit the new connecting rod bolts.
- Tighten bolts with tightening torque (see table IT 80).
- Using tickness gauges, check the clearance between the bearing and the crank pin of the
first re-assembled connecting rod (clearance of x mm).

MINIMUM MAXIMUM

MC2-CE2-CE24 0.056 0.133

CE4-CE46 0.036 0.106

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CE68 0.043 0.123

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- Check surface condition of connecting rod big end bearings. There should be
no seizing.
- If the clearance between bearing and crank pin does not correspond to the
value indicated above, change regulating thickness (difficulty ***):
- follow the same procedure to reassemble the second connecting rod except
for measurement of the clearance between bearing and crank pin;
- measure clearance by placing a plumb wire between the connecting rod cover
and crank pin;
- tighten assembly with locking torque (Table IT 80);
- remove connecting rod cover;
- using a micrometer, measure the thickness of the flattened lead wire.
- If the clearance is incorrect, change regulating thickness (difficutlty ***):
- reinsert connecting rod cover and tighten with initial tightening torque;
- re-insert the locking devices of connecting rod big end bolts;
- insert the connecting rods back into the crosshead;
- re-install crosshead pins;
- re-install safety plates of crosshead pins;
ATTENTION: Observe the tightening torque for the fixing bolts for the safety plates.
- refit inspection doors of the crosshead guides and the frame with new gaskets.
- re-fill the housing with fresh oil.

14.4. Starting the compressor

- see operation mode and precautions "re-assembling the unit" (10.3.5.7.).

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15. SUMMARY OF PREVENTIVE MAINTENANCE MEASURES

15.1. Every day

Check pressure, temperature and other parameters according to daily sheet to be filled in.

15.2. Every 2000 hours

- Change housing oil and clean oil filter.

- Ensure that drain is operating correctly.
- Disassemble and clean air filter by blowing in the cartridge from the inside
towards the outside (see IT 148).
- Check demisters.
- Check belt tension.
- Check the clearance between the pistons and stage 2 and 3 cylinders.

15.3. Every 4000 hours

Same operations as for every 2000 hours and plus the following :
- Make sure that valves are clean.
- Check clearance between rider rings of first, second and third stage cylinders.
If there is pronounced wear, replace worn rings.

15.4. Every 8000 hours

Same operation as for 2000 and 4000 hours and plus following :
- Disassemble and overhaul the valves (fit new gaskets) and replace them with
new or overhauled valves.
- Replace the off-load diaphragms.
- Make sure that safety valves function correctly.
- Completely clean water circuit (insert new gaskets).
- If necessary, replace first, second and third stage rings.
- Check oil scraper packings on the air aide. Replace them if necessary.

15.5. Every 20000 hours

- Replace connecting rod big end bolts.

- Check motion.
- Replace V-belts.
- Replace demisters.

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16. INSTRUCTIONS TO BE OBSERVED WHEN COMPRESSOR OPERATES

ABNORMALLY

In the event of temperature rise, abnormal noise vibration or deficient flow, stop the machine
and check the following.

16.1. Abnormal rise in temperature, air discharge, first stage

- Make sure that air filter is clean (see vacuum tester).

- Check cooling water inlet temperature (45 °C max., apart from exceptional climatic
conditions).
- Check sealing of first stage discharge valves.
- Check sealing of second stage valve rings.
- Check contamination of coolers, 1st stage, water side (very rare).

16.2. Abnormal rise in temperature, air discharge, second and third stages

- Same as above, except air filter.

- Check sealing on second stage suction and discharge valves.
- Check sealing on third stage suction and discharge valves.
- Check contamination of cooler, 1st and 2nd stage, water side.

16.3. Rise in pressures on first and second stage

- Check tightness of suction and discharge valves.

- Make sure that unloading systems on suction valve function correctly by manually applying
pressure on the central bolt of the valve.
- Make sure that air passes through inter-cooler(s).
- Check wear on piston rings.

16.4. Oil pressure is too low

- Make sure that oil filter is clean.

- Check connecting rod assembly clearance.
- Check oil viscosity.

16.5. Abnormal noise

- Check tightness of piston rod bolts on crossheads.

- Check valve tightness.
- Make sure that piston lock nuts are correctly tightened to piston rod.
- Check tightness of connecting rod big end bolts.
- Check clearance between crosshead pins and the bushes of small ends of connecting rods.
- Check fixing of cylinders on distance-pieces.

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16.6. Presence of water in oil housing or in internal compressed air circuit

- Determine whether condensate drain functions correctly.

- Check sealing on first stage cylinder head gasket by removing a discharge valve to see if
there is water in the cylinder.
- Check sealing on inter-cooler coolers by putting the cooling water circuit under pressure
and disassembling drain tubing. If considerable quantities of water are found, disassemble
defective cooler(s) and perform a hydraulic test.

16.7. Presence of considerable quantity of water in the air distribution circuit after the aftercooler

- Make sure that condensate drain of after-cooler functions correctly.

- Check the goof fonctionning of the filter drain (eventually installed at the dryer inlet).
- Check the dryer dew point and the good fonctionning of its drain.
- Remove a second and third stage discharge valve.
Check the surface of cylinders. If water is found, check the gasket between the second
and third stage.
- If the drain functions correctly, disassemble the after-cooler and perform a
hydraulic test.

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