Compressors, 

Generator Sets, 
Elevators & Escalators, Conveyors & 
Hoists 

Basic Mechanical Engineering

Compressors 
Compressors are machine designed to deliver gas at 
pressure higher than that originally existing   
Methods employed to achieve 
Compression: 
y Reduce the volume 
y Overcoming back flow and push the compressed gas 
out of the enclosure 
y By the action of rotating impelers or bladed rotors  
y Entrain the gas in high velocity jet of another 
compatible gas  
 Reciprocating or Piston‐type compressors 

‐ a positive‐displacement compressor that uses pistons with constant motion to pump 
air into the  air chamber. 

1.Pistons 
2.Compression chamber 
3.Cylinder 
4.Suction  
5. Discharge  
 Straight Lobe  Compressor 
  ‐ a positive displacement lobe pump which operates by pumping a fluid with a 
pair of meshing lobes not unlike a set of stretched gears. Fluid is trapped in 
pockets surrounding the lobes and carried from the intake side to the exhaust. 
Sliding  Vane Compressor 
  consist of a rotor having slots mounted eccentrically in the body and 
vanes mounted on the rotor. During the rotation or rotor, the air from the inlet 
passage is drawn into the space between the rotor, cylinder and two adjacent 
vanes. 
Liquid Ring Compressor 
  utilize a squirrel cage fan type impeller which is placed eccentric inside a 
tube. A compatible liquid is introduced into the chamber along with the gas to be 
compress. Because of centrifugal force and the shape of the internal cavity, the liquid 
forms a eccentric shape producing regions of changing volume.  
Helical or Spiral lobe Compressor 
  the gas id trapped in the rotor pockets at one end; it is compressed between 
the intersecting rotors and discharged at the opposite end. 
Centrifugal Compressors 
  a dynamic machines in which the rapidly rotating impeller accelerates the 
gas. The process flow propagates from axial to radial into a stationary diffuser 
converting velocity to pressure . 
Axial Compressor 
  Dynamic machines in which the gas flow is accelerated in an axial and 
peripheral direction by the rotation of specially shaped blades. The process flow is 
parallel to shaft centerline. Stator blades allow the recovery of velocity to pressure.  
Application: 
 
   •Vents 
   •Flares 
   •Oxidizers 
   •Overhead Recompression 
   •Process Recompression 
   •Transmission 
   
Maintenance 
● Changing Compressor Pump Oil 
1. Ensure unit is off and disconnect from the power source 
2. Ensure compressor is on a flat and level surface 
3. Remove fill cap / plug 
4. Place collection container underneath the oil drain cap. 
5. Remove the oil drain cap, and let the oil drain out. 
6. Replace the oil cap and be sure to tighten this nut securely. Fill 
crankcase with appropriate oil, be sure it does not exceed the 
halfway point. 
Maintenance 
● Checking the Air Filter Element 
1. Ensure unit is off and disconnect from the power source 
2. Allow compressor pump to cool off. 
3. Unscrew the filter top from the filter base by turning counter‐
clockwise. 
4. Separate the filter top cover from the base. 
5. Remove the element from the filter base 
6. Blow out dust and debris from the filter element. 
7. Replace element if needed. 
8. Reconnect filter top to the base and secure filter. 
Safety 
● Always read your owners manual before running your 
compressor, there is important information in there. Improper 
use is the number one cause for repairs and personal injury. 
● Remember to use eye protection and hearing protection when 
operating your air compressor. 
● Try and avoid using air compressors in a wet area. If the 
compressor is exposed to water for long periods of time, it can 
cause rust to the tank, damage to the tools, and also cause 
problems with the electrical circuits. 
Safety 
● Ensure that all hose fittings are tight. Loose fittings can not 
only damper you compressors performance, but also cause 
personal and equipment damage. 
● Keep all hoses clean of dirt and debris. This will not only 
lengthen the life of your hose, but your air compressor as well. 
● Never add or change the oil or refuel when the compressor is 
running or has just recently been used. This will help avoid 
smoke, fire, and other concerns 
Safety 
● Ensure that the machine is plugged into a properly grounded 
outlet. If your machine is plugged into an outlet without the 
properly grounded electrical circuits, there may be damage to 
the electrical panel of the compressor as well as the possibility 
of a fire. 
● Consult the owners manual for the recommended extension 
cord use. Using a longer extension cord than recommended can 
result in a loss of power, and can cause damage to the 
compressors electrical panel and/or motor. 
a machine that converts on
e form of energy into anothe
r, especially
mechanical energy into
electrical energy
PARTS OF GENERATOR
 ENGINE
The engine is the source of the input
mechanical energy to the generator.
The size of the engine is directly
proportional to the maximum power
output the generator can supply.

a) Type of Fuel Used – Generator engines operate on a variety of fuels

such as diesel, gasoline, propane (in liquefied or gaseous form), or natural
gas.
b) Overhead Valve (OHV) Engines versus non-OHV Engines –intake and
exhaust valves of the engine are located in the head of the engine’s
cylinder as opposed to being mounted on the engine block.

c) Cast Iron Sleeve (CIS) in Engine Cylinder – The CIS is a lining in the
cylinder of the engine. It reduces wear and tear, and ensures durability
of the engine.
Alternator
The alternator, also known as the ‘genhead’, is the part of the
generator that produces the electrical output from the
mechanical input supplied by the engine. It contains an assembly
of stationary and moving parts encased in a housing.
Fuel System
The fuel tank usually has sufficient capacity to keep the generator
operational for 6 to 8 hours on an average.
Voltage Regulator
This component regulates the output voltage of the generator.

(1) Voltage Regulator:

Conversion of AC Voltage to
DC Current – The voltage
regulator feeds this DC current
to a set of secondary windings
in the stator, known as exciter
windings.
(2) Exciter Windings:
Conversion of DC Current to
AC Current – The exciter
windings now function similar
to the primary stator windings
and generate a small AC
current.
(3) Rotating Rectifiers:
Conversion of AC Current to DC
Current –This DC current is fed to
the rotor / armature to create
an electromagnetic field in
addition to the rotating
magnetic field of the rotor /
armature.

(4) Rotor / Armature: Conversion

of DC Current to AC Voltage –
The rotor / armature now
induces a larger AC voltage
across the windings of the stator,
which the generator now
produces as a larger output AC
voltage.
Lubricating System
The generator’s engine is lubricated by oil stored in a pump. You
should check the level of lubricating oil every 8 hours of generator
operation.
Battery Charger
The battery charger keeps the generator battery charged by
supplying it with a precise ‘float’ voltage.
 Control Panel
This is the user interface of the
generator and contains provisions
for electrical outlets and controls.

Main Assembly / Frame

The frame also allows for the
generated to be earthed for
safety.
TYPES AND APPLICATION
OF GENERATOR
 Portable RV/Recreational Generat
ors: The inverter technology
makes them super quiet for
recreational use and also
provides the cleanest power for
sensitive electronics like
computers. These generators run
on gasoline.

Portable Residential Generators: A

good choice to power essential
items in your home when the power
goes out (refrigerators, freezers,
pumps, sump pumps, furnaces,
lights, etc.) and for use around your
yard (electrical tools, etc.). Most
residential portable generators run
on gasoline, but some models run on
L.P., Natural Gas, or all three.
 PTO Generators:Pair these
generators with tractors for
portable power
around yards or farms.

Standby Generators: These

stationary generators are
designed to run most or all of
business when the power goes
out. These generators are often
used with an automatic transfer
switch and starting
system. Standby generators
are also used for industrial and
agricultural applications.
 Two Bearing Generators:
These generators are
powered by a variety of
independent power
sources using a pulley
system – often used on
service trucks.

Welder
Generators: Combines a
generator with welding
capabilities in one
unit. Available in portable
gasoline models and mobile
diesel units.
Maintenance
Start by checking the overall
condition of the generator. Look for
corroded elements, loose wires, stuck
buttons, etc. Check for any loose
connections and frayed wiring. Make
sure the area around the generator is
clean, and if the generator has
sucked in any dirt or leaves make
sure to clean out the area. Debris
getting into an alternator is the #1
way of destroying a perfectly good
generator!
Check the distilled water
in the battery; top up if
needed. Also check the
battery's voltage. It is
generally best to replace
your battery every 2-3
years.
Change the lubricant oil and filters
(super, by-pass, etc.) following the
manufacturer's instructions. This
doesn't need to be done each 6
months; rather this is an annual task
whether or not the generator has
been operated. Record the yearly
change in the record book so that
you are reminded each time when it
is due. Make sure that the oil level is
adequate and top up if needed. Air
cooled machines should have their
oil replaced every 30-40 hours of run
time. Liquid cooled machines should
have their oil replaced every 100
hours of run time. MAKE SURE TO USE
SYNTHETIC OIL IN AIR COOLED
MACHINES!
Check the bolts. Note that
bolts on the generator will
tend to loosen after
reasonable usage; this is
usual wear and tear caused
by the vibrations. Check the
gasket head and piston for
solid condition; replace if
worn or cracked.
Check that the following items are
properly calibrated annually or
biannually, depending on usage
patterns. It is best if a certified
generator technician makes
these checks:
Fuel pump
Turbocharger
Injectors
Automatic voltage regulator
Check the fuel. Gasoline that is
simply sitting in the generator loses
its effectiveness after half a year
when not used. You have several
alternatives here:Bleed the fuel
and replace it; dispose of properly
Keep regularly used fuel for general
farm/household use in fuel suitable
containers and top up when
needed
Add fuel stabilizer available from
gas stations or hardware stores;
follow manufacturer's instructions
If you are using a generator as a
home standby solution, you should
really consider a natural gas or
liquid propane generator. These
generators do not have any fuel
maintenance, other than to make
sure your LP tank has fuel in it!
Start up the generator regularly. If a generator is not
used on a regular basis, it is recommended that you fire
it up at quarterly intervals to ensure that its workings run
smoothly. At the very least, start it after each six monthly
maintenance, twice. First check is to see that it is starting
OK, second check is to ensure that it will keep starting
OK.
Safety of the
Generator
THE PRIMARY HAZARDS TO AVOID
WHEN USING A GENERATOR ARE
CARBON MONOXIDE (CO)
POISONING FROM THE TOXIC
ENGINE EXHAUST, ELECTRIC SHOCK
OR ELECTROCUTION, AND FIRE.
FOLLOW THE DIRECTIONS SUPPLIED
WITH THE GENERATOR. EVERY YEAR,
PEOPLE DIE IN INCIDENTS RELATED
TO PORTABLE GENERATOR USE.
BE SURE TO TURN THE GENERATOR OFF
AND LET IT COOL DOWN BEFORE
REFUELING.
FOR POWER OUTAGES, PERMANENTLY
INSTALLED STATIONARY GENERATORS ARE
BETTER SUITED FOR PROVIDING BACKUP
POWER TO THE HOME. EVEN A PROPERLY
CONNECTED PORTABLE GENERATOR CAN
BECOME OVERLOADED. THIS MAY RESULT IN
OVERHEATING OR STRESSING THE GENERATOR
COMPONENTS, POSSIBLY LEADING TO A
GENERATOR FAILURE. BE SURE TO READ
INSTRUCTIONS THAT COME WITH THE
GENERATOR TO MAKE SURE YOU OPERATE IT
WITHIN ITS LIMITATIONS FOR POWER OUTPUT.