MAINTENANCE TRAINING

Screw Type Compressors

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Periodical Maintenance Schedule

Periodical maintenance and inspection are essential for continued optimum performance and long
service life of the compressor and its components.

The following are general requirements and schedules for periodical maintenance:

Maintenance Interval: 3000 hours or 6 months(whichever comes first) / 6000 hours or 12 months (whichever comes first)
When high operating temperatures occur or in dusty and dirty environments or where there are gaseous pollutants; the
maintenance must be done at shorter intervals than that recommended under clean condition.
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Preventive Maintenance

COMPRESSOR START-UP IN COLD AND AFTER LONG SHUTDOWNS

Our compressors are designed to operate in ambient temperatures between about 2°C and 43°C. As the
ambient temperature starts to fall below about 5°C problems can start to occur. The critical issue is to keep
the temperature of the compressor above 5°C. This can be achieved by fitting special heaters for oil tank
(Hertz cold start option) inside the compressor or by heating the compressor house (10-15°C). Ambient
temperature is also important for the operation of the dryers to avoid freezing and damage drain line, heat
exchanger etc.

After each long shutdowns compressors must be started up according to long shutdown start up procedure.
As a minimum requirement; condens water must be drained from oil tank, motor & airend must be turned a
few tours by hand.

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Periodical Maintenance

Perform daily or weekly inspections for the following items:

Daily Basis Checks Weekly Basis Checks

Compressor
Clean Panel Filters
Display (Alarms, Warnings)

Air Pressure Unusual Noise, Vibration, etc

Oil Temperature Main Electric Motor Current

Condensate Drain (Water Separator,

Condition of Panel Filters
Air Tanks, Dryers)

Oil Level

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Preventive Maintenance

If the period between the production date and start-up date is longer than 6 months, a preventive maintenance is
required

Preventive maintenance includes the:

Preventive
Stock Period ≥ 6 months Stock Period ≥ 12 months Stock Period ≥ 24 months
Maintenance Item
Oil Filter Replace Replace Replace

Oil Change Change Change

Check the deformity condition visually,

Belts check tension and check any abnormal Check / Replace if required Replace
noise and vibration while turning
Fill oil from airend (0,5 to 2 liters Fill oil from airend (0,5 to 2 liters Fill oil from airend (0,5 to 2 liters
Add oil to Air End
depends on size) depends on size) depends on size)

Motor Bearing
Re-grease (Open type) Re-grease (Open and ZZ type) Re-grease / Replace if necessary
Lubrication

Check oil carryover and pressure drop Check oil carryover and pressure drop
Separator Replace the separator
after start-up; replace if necessary after start-up; replace if necessary

Check the condition; replace if

Air Filter Check the condition; replace if necessary Replace the air filter
necessary

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 Compressor Maintenance

Panel Filter - Replacement

*Shut off the Compressor *Replace the panel filter
Action: * Loosen the screws *Remove the retaining grill
*Reinstall the retaining grill
Time: 3000 hours or Period:6 months
Maintenance Cycle:
(whichever comes first)

If the ambient is very dusty, clean panel filters using low pressurized, compressed air once a week.
However filter will lose its filtering property after it has washed a few times. Dry the filter with air
after you wash it with water.
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 Compressor Maintenance

Air Filter - Replacement

*Stop the compressor *Remove nuts and filter cover
Action:
*Wipe out large particles/oil strains with clean cloth *Replace filter element
Time: 3000hours or Period: 6 months
Maintenance Cycle:
(whichever comes first)

Filters elements can not be cleaned, need to be replaced only.

While replacing the filter element take care that no debris or dirt enter the throat of inlet hose . 7
 Compressor Maintenance

Compressor Oil - Replacement

*Shut off the compressor *Wait for the internal pressure to be discharged
*Remove oil filter *Drain the oil
Action: *Open oil filler plug *Install the new oil filter after filling the new oil
*Operate compressor a few minutes and check any possible leaks
*Shut off the compressor and wait for the oil to settle *Check oil level and complete if necessary
Smart Oil 3000 - Time: 3000hours or Period:6 months (whichever comes first)
Maintenance Cycle:
Smart Oil 6000 - Time: 6000hours or Period:1 year (whichever comes first)

When high operating temperatures occur or in dusty and dirty environments or where there are gaseous
pollutants; the oil must be changed at shorter intervals than that recommended under clean condition.

After long stock periods (≥6

months) fill the 0,5 to 2 liters
(depends on size) of new oil
from air intake valve to
lubricate the air end and
rotate the airend by hand a
few tour.
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 Compressor Maintenance

Oil Filter - Replacement

*Shut off compressor *Wait for the internal pressure to be released *Loosen the filter and
Procedure
remove old filter *Remove any drips with a clean cloth *Place the new filter and tighten it.
Time: 3000hours or Period: 6 months
Maintenance Cycle:
(whichever comes first)

Never use filter wrench to tighten filters to avoid damaging filter cartridge. Tighten oil filter by hand ONLY.

Slightly lubricate the new oil filter gasket before installing.

Before mounting fill some oil into the inversed positioned oil filters.

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 Compressor Maintenance

Separator - Replacement
*Shut off compressor *Wait for the internal pressure to be released *Loosen the filter and
Procedure (Spin On Type) remove old filter(use Filter Wrench) *Remove any drips with a clean cloth *Place the new
filter and tighten it ( by Hand Only)
Procedure (Tank Type) *Shut off compressor *Loosen the bolts and slide tank lid off *Remove old separator and
install the new one *Reinsert the scavenge line *Re-fasten the tank lid
Time: 6000hours or Period: 1 year
Maintenance Cycle:
(whichever comes first)

Lubricate the gasket before mounting

the separator

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 Compressor Maintenance

Scavenge Line

Action: Replace the pneumatic hoses

Time: 6000hours or Period: 2 years

Maintenance Cycle:
(whichever comes first)

For the maintenance, change the pneumatic hose of the

scavenge line because the color of the hose becomes darker
over the time and oil flow inside can not be observed.
Check scavenge line in case of too much oil reduction Hose can break down when it became hard.
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 Compressor Maintenance

Belt Tension Check

Action: *Shut off the compressor *Adjust the tensioning bolts-Hand Check

Maintenance Cycle: Time: 3000hours / 6 months (whichever comes first)

Please see belt tension tables for correct tensioning.

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 Compressor Maintenance

Belt Replacement

*Shut off the compressor

* Loosen holder’s bolts to release the holder.
*Loosen the tensioning bolts to release the belt
*Remove the belts by turning the the pulleys
Action:
*Replace the new belts
*Tighten Tensioning Bolts in balanced manner to get the belts tensioned
*Use ‘’ruler’’ to check pulley allignment
*Tighten Holder bolts

Time: 6000 hours or Period: 1 year

Maintenance Cycle:
(whichever comes first)

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 Compressor Maintenance

Minimum Pressure Valve Repair Kit

Action: Old kit parts need to be changed with new ones as indicated on drawing(K)

Maintenance Cycle: Time: 6000 hours

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 Compressor Maintenance

Intake Valve Repair Kit

Action: Old kit parts need to be changed with new ones as indicated on drawings

Maintenance Cycle: Time: 6000 hours

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 Compressor Maintenance

Intake Valve Repair Kit

Action: Old kit parts need to be changed with new ones as indicated on drawings

Maintenance Cycle: Time: 6000 hours

Clean parts with thinner if necessary Replace all parts inside the repair kit even if some parts seems serviceable 16
 Compressor Maintenance

Combination Valve Block Repair Kit

Action: Kit parts need to be changed with new ones as indicated on drawing (K1+K2+K3)

Maintenance Cycle: Time: 6000 hours

37kW ≤ Compressors have combination valve blocks which contains the MPV and
thermostatic valve blocks.

Replace all parts inside the repair kit even if some parts seems serviceable

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 Compressor Maintenance

Thermostatic Valve Repair Kit

Action: Just replace the thermic element as indicated on drawing(K1)

Maintenance Cycle: Time: 6000 hours

45kW ≥ Compressors have thermostatic valves installed.

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 Compressor Maintenance

Radiator Cleaning
Action: Use low pressurized, compressed air to blow off dust
Time: 3000hours or Period: 6 years
Maintenance Cycle:
(whichever comes first)

Use Compressed Air

Never use a brush as this may damage fins.

If the dust between fins meets the oil, it may be caught and hardened; in such cases, spray a non-
flammable industrial cleaner between the radiator fins for cleaning.

Do not use solvents with a strong acid or alkaline base to clean the radiator.
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 Compressor Maintenance

Air End Repair

Action: Check the Air End , Revision(Full Repair of Air End)
Control: Time: After 18.000 hours
Maintenance Cycle:
Revision:Time: 24.000/30.000 hours
How to repair the Air End?
o Clean the air end components
o Race replacement
o Bearing replacement
o Seal kit replacement
o Check the clearances

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 Compressor Maintenance

Electrical Panel Checks

Check loose power connections, inspect relays, switches etc., and blow clean with
Action:
low pressurized compressed air
Time: 3000 hours or Period: 6 months
Maintenance Cycle:
(whichever comes first)

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 Compressor Maintenance

Motor Bearing Lubrication

Action: Replace the grease cartridge

Time: The greasing time of each machine varies according to the motor sizes of the machines
Maintenance Cycle:
(contact your Hertz Service for more information)

≥55kW VSD Compressors (Frecon+ 55 and up) have Automatic Greasing System

≥55kW Fixed Speed Compressors (HSC 55 and up) need to have manual re-greasing.
We recommend to use only manual (hand) greasing pumps.
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 Compressor Maintenance

Coupling Pad Replacement

*Remove the Belhousing guard cover

Action: *Loosen the mounting screws of two rubber pad pieces
*Replace the rubber pads with new ones

Maintenance Cycle: 18000 - 24000 hours

Belhausing Guard Cover

Coupling Pad

The coupling pad consists of two semi-circular rubber pieces.

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 Compressor Maintenance

Pneumatic And Hydraulic Hoses Replacement

*Shut off the compressor

Action: *Wait for the internal pressure to be released
*Replace the hoses
For Hydraulic Hoses: Time: 15000 hours
Maintenance Cycle:
For Pneumatic Hoses: Time: 6000 hours

Hydraulic hose replacement can go up to 24.000 in good ambient conditions

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 Compressor Maintenance

Dryer Maintenance

Air dryers improve the quality of compressed air.

If you do not conduct dryer maintenance on schedule:

o Water running in your compressed air pipes poses a corrosion

o May damage the production machines

o Freezing Risk

Refrigerated dryers only work effectively in ambient temperatures down to 5°C. If your refrigerated
dryer is in an unheated compressor room the dryer could fail to operate correctly.
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 Compressor Maintenance

Refrigerant Air Dryer Maintenance

*Shut down the dryer *Disconnect the pressure sources and depressurize the
Action:
system. *Perform the maintenance procedure as explained below
Time: 3000hours or Period: 6 months
Maintenance Cycle:
(whichever comes first)
o Check condensate drain tap
o Clean the drain strainer
o For aircooled dryers, clean the air condenser with low pressurized air
o Check operating pressures, temperatures and leaks

Float valve

The automatic condensate

water discharge unit (dryer
with controllers)

≤HRD170 dryers have two interlnal line filters(MX+MY) inside. You will get external MX+MY filters with HRD180 and bigger sizes.
New dryers have a controller unit. The condensate drain is controlled via PLC. For this reason, float type drains no longer used.
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 Compressor Maintenance

Desiccant Dryer Maintenance

Replace the Active Alumina Granuls
Action: Note: The line filters sent with the dryers must change every 6000 hours or at least
once a year
Time: 20000hours or Period: 3 years
Maintenance Cycle:
(whichever comes first)

Tank 1 Filling Plug Tank 2 Filling Plug

For deciding the granul replacement,
check the dew point value rise; that is
the decrease in dryer performance.
Please follow the attached procedure
for the replacement
Tank 1 Drain Plug Tank 2 Drain Plug

Example: HDA 440 Total Active Alumina Granul Quantity: 130kg

1) Remove existing active alumina granuls (65kg from Tank 1 , 65kg from Tank 2)
2) Drain the granul from both tanks

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 Compressor Maintenance

Desiccant Dryer Maintenance

Replace the active alumina granuls
Action:
Note: The line filters sent with the dryers must change every year
Time: 20000hours or Period: 3 years
Maintenance Cycle:
(whichever comes first)
3) Remove the top gland and fill the tank with actived alumina granuls (65kg for each tank)

4) After filling process is finished, hit the tank with

a plastic hammer several times so that the
granules in the tanks are better placed. The
granuls is added to the upper part of the tank
while hitting the tank.

Use a Funnel

5)Install the top gland.

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 Compressor Maintenance

Line Filters
Action: Replace filter element

Maintenance Cycle: Time: 6000hours or Period: 1 years (whichever comes first)

o Most customers are simply are unaware that they need new line filter elements each year
o Make sure that the filters are installed in the correct sequence
Old Type Filters

HG MODEL HGO MODELS

HG MODEL DRYAIR HRD MODEL

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 Compressor Maintenance

Line Filters
Action: Replace filter element

Maintenance Cycle: Time: 6000hours or Period: 1 years (whichever comes first)

HF MODELS HHG MODELS

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Thank You...

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 MAINTENANCE TRAINING

Reciprocating Type Compressors

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Periodical Maintenance Schedule - Reciprocating Type Compressors
Periodical maintenance and inspection are essential for continued optimum performance and long service life of the
compressor and its components.
The following are general requirements and schedules for periodical maintenance:

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Periodical Maintenance Schedule - Reciprocating Type Compressors

HPC Booster Series

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Periodical Maintenance Schedule - Reciprocating Type Compressors

HPC Booster Series

When elevated operating temperatures occur or in dusty and dirty environments or where there are
gaseous pollutants; the maintenance must be done at shorter intervals than recommended periods 36
Periodical Maintenance Schedule - Reciprocating Type Compressors

HPC Pet Plus Series

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Periodical Maintenance Schedule - Reciprocating Type Compressors

HPC Pet Plus Series

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Preventive Maintenance

If the period between the production date and start-up date is longer than 6 months, a preventive maintenance is
required.

Preventive maintenance includes the:

Preventive
Stock Period ≥ 6 months Stock Period ≥ 12 months Stock Period ≥ 24 months
Maintenance Item

Oil Filter * Replace Replace Replace

Oil Change Change Change
Check the deformity condition
visually, check tension and
Belts * Check / Replace if required Replace
check any abnormal noise and
vibration while turning
Motor Bearing Re-grease Re-grease Re-grease / Replace if
Lubrication (Open typebearings) (Open type bearings) necessary

Check the condition; clean if Check the condition; replace if

Air Filter Replace the air filter
necessary necessary

* If applicable

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Periodical Checks

Oil Level Check Interval: Daily

Check the oil level every day. Fill up to 2/3 of the oil level indicator.

Do not overfill

Check Condensate Drain Interval: Daily

Drain moisture accumulation from the air receiver

Check Air Filter and Clean(if required) Interval: Weekly

Use low pressurized, compressed air to clean
air filters.

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Replacement Parts

Interval: 250hours (Booster series)

Breathing Air Separator Filter Replacement

Oil Change Interval: 250hours for HPC Series, 500 hours for Pet Plus and Wave Series
• After commissioning first oil replacement time must be 50 working hours. This is
necessary for discharging compressor production dusts together with oil change.

• Then periodical oil replacement period is 150 to 250 hours (maximum), depends
on working and ambient conditions.

• Our compressor are using Smartoil1000 which is produced specially for the
reciprocating compressors.

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Replacement Parts

Belt Replacement Interval: 3000hours(HPC Series)

Check belt condition every week

Piston Rings and Piston Pins Replacement Interval: 3000hours(HPC Series)

Be careful about the positioning of the
piston rings. Each piston ring’s open
side must be positioned on opposite
side of the following one

If the pistons and pins have deep scratches or cracks, replace the pistons.
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Replacement Parts

Check Cylinders and Replace if required Interval: 3000hours(HPC Series)

Cylinders must be replaced only if there are deep
scratches occured

Check Connecting Rod Bearings and Replace (if required) Interval: 3000hours (HPC Series)

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Replacement Parts

Radiator Cleaning Interval: 3000 hours

Check Actuator and Solenoid Valves and Replace if required Interval: 1000hours (Boosters)
In order for the machine to operate at
maximum efficiency, the input pressure
must be at least 9 bars and a maximum of
10 bars. If the inlet pressure is too low, it
will not be possible to adjust the
pneumatic regulator which controls the
actuators. Control pressure for actuators
must be 5-7 bar, we recommend it as 6 bar.
Please ensure the control pressure is not
reducing under 5 bar and it is not more
than 7 bar.
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Replacement Parts

Check Valves and Replace(if required) Interval: 3000hours (Booster Series)

Valves can be blocked from dust or
particles, remove cylinder cover and check
condition
Use P-type Line filters before inlet of the
compressor to protect the compressor from
foreign particles which may damage the
valves.

Check Non Return Valve and Replace(if required) Interval: 1000hours (Booster Series)
It is recommended to move the non-return valve from
booster outlet to air tank inlet. Because the booster outlet is
too hot, moving this non-return valve to air tank inlet will
decrease the possibility of non-return valve failures.

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Thank You...

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