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DLT0408 C35-10, C38, C42, C50: Original Operating Manual
DLT0408 C35-10, C38, C42, C50: Original Operating Manual
DLT0408
C35-10, C38, C42, C50
Yanmar 4TNV88BKCP
Powered Compressor
●
GB Id. No. ZS1069423 / 02 - May 2011
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Maintenance and Inspection
Manual for CompAir Compressors
Attention
When starting up your compressor for
the first time, observe the operating
instructions under all circumstances.
Proper operation, care and continuous
supervision of the compressor system are
decisive for the operating reliability,
performance and service life.
We cannot assume any liability for
damage resulting from failure to observe
the operating instructions, improper
repairs or use of other than genuine parts.
Questions/Parts orders
Always indicate:
- Machine number (rating plate)
- Machine model.
Danger
Machine model:________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Remarks:
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Total operating hours
Time required for service work
Hours
Start
End
Oil change (date/hours)
Mechanic's signature
Original Operating Manual
DLT0408
C35-10, C38, C42, C50
Yanmar 4TNV88BKCP
Powered Compressor
1. Index
1 Index
1 Index................................................................................................................................................................................................... 2
2 Foreword............................................................................................................................................................................................ 4
2.1 Information on the compressor ................................................................................................................................................... 4
2.2 Normal use ................................................................................................................................................................................. 4
2.3 Specifications type DLT 0408 ..................................................................................................................................................... 4
2.4 Maintenance and care ................................................................................................................................................................ 8
2.5 General information .................................................................................................................................................................... 8
3 Security Regulations......................................................................................................................................................................... 9
3.1 Identification of safety instructions .............................................................................................................................................. 9
3.2 General safety instructions ......................................................................................................................................................... 9
3.3 Modifications and alterations to the machine .............................................................................................................................. 9
3.4 Loading/Relocation/Transport................................................................................................................................................... 10
3.5 Installation on site / Starting / Normal operation........................................................................................................................ 10
3.6 Special jobs / Maintenance....................................................................................................................................................... 12
3.7 Instructions concerning particular hazards................................................................................................................................ 14
3.8 Symbols and definitions............................................................................................................................................................ 15
4 Construction and functional description....................................................................................................................................... 17
4.1 Construction ............................................................................................................................................................................. 18
4.2 Functional description (see fig. 6 and fig. 7) ............................................................................................................................. 18
4.3 System description ................................................................................................................................................................... 19
4.4 Wiring diagram ......................................................................................................................................................................... 20
4.5 Vehicle Socket Connection Plan 13-pin 12 Volt ........................................................................................................................ 21
5 Transport and installation on site .................................................................................................................................................. 22
5.1 Transport .................................................................................................................................................................................. 22
5.2 Attachment of the contact-breaker cable on braked chassis..................................................................................................... 22
5.3 Loading/Relocation ................................................................................................................................................................... 23
5.4 Installation on site..................................................................................................................................................................... 23
6 Preparing the compressor for operation....................................................................................................................................... 25
6.1 Checking levels ........................................................................................................................................................................ 25
6.1.1 Checking the oil level in the pressure tank.................................................................................................................... 25
6.1.2 Checking the oil level in the engine............................................................................................................................... 25
6.1.3 Checking coolant level .................................................................................................................................................. 25
6.2 Battery...................................................................................................................................................................................... 26
6.3 Filling up the fuel tank............................................................................................................................................................... 26
6.4 Fuel water separator................................................................................................................................................................. 26
6.5 Draining the fuel tank................................................................................................................................................................ 26
6.6 Checking the air filter maintenance display............................................................................................................................... 27
7 Putting the compressor into operation ......................................................................................................................................... 28
7.1 Initial operation ......................................................................................................................................................................... 28
7.2 Operating elements .................................................................................................................................................................. 28
7.3 Start-up..................................................................................................................................................................................... 28
7.4 Setting the operating pressure.................................................................................................................................................. 29
7.5 Monitoring / fault ....................................................................................................................................................................... 30
7.6 Operation.................................................................................................................................................................................. 30
7.7 Shutdown ................................................................................................................................................................................. 31
7.8 Decommissioning ..................................................................................................................................................................... 31
8 Fuels................................................................................................................................................................................................. 32
8.1 Recommended lubricant for compressor .................................................................................................................................. 32
8.2 Recommended engine oil ......................................................................................................................................................... 32
8.3 Tool lubricants .......................................................................................................................................................................... 32
8.4 Diesel fuel................................................................................................................................................................................. 32
8.5 Coolant ..................................................................................................................................................................................... 32
8.6 Recommended lubricants for the bogies................................................................................................................................... 33
2
1. Index
9 Maintenance .................................................................................................................................................................................... 34
9.1 General maintenance ............................................................................................................................................................... 34
9.2 Engine maintenance ................................................................................................................................................................. 34
9.3 Maintenance of the fuel system ................................................................................................................................................ 34
9.4 Maintenance of chassis and brakes.......................................................................................................................................... 35
9.5 Compressor maintenance / Maintenance schedule .................................................................................................................. 36
9.5.1 Oil filter replacement (compressor) ............................................................................................................................... 37
9.5.2 Oil change (compressor) .............................................................................................................................................. 37
9.5.3 Checking the automatic monitoring system.................................................................................................................. 37
9.5.4 Inspecting / Replacing the fine separator ...................................................................................................................... 38
9.5.5 Air filter replacement (compressor / engine) ................................................................................................................. 38
9.5.6 Checking the safety valve ............................................................................................................................................. 38
9.5.7 Control .......................................................................................................................................................................... 39
9.5.8 Battery maintenance..................................................................................................................................................... 39
9.5.9 Torque specifications .................................................................................................................................................... 39
9.6 Spare parts for maintenance purposes ..................................................................................................................................... 39
10 Troubleshooting .............................................................................................................................................................................. 40
11 Generator option ............................................................................................................................................................................. 42
11.1 Introduction............................................................................................................................................................................... 42
11.2 Generator safety precautions ................................................................................................................................................... 42
11.3 Operating principle ................................................................................................................................................................... 42
11.4 Operating the generator (Working safely with electrical equipment) ......................................................................................... 43
11.5 Testing insulation monitoring/startup/device connection ........................................................................................................... 44
11.6 Technical characteristics of 9 kVA 400/230 V generator........................................................................................................... 45
11.7 Technical characteristics of 15 kVA 400/230 V generator......................................................................................................... 45
11.8 Technical characteristics of 7 kVA 110 V generator.................................................................................................................. 46
11.9 Generator switchbox wiring diagram 9 kVA 400/230 V ............................................................................................................. 47
11.10 Generator switchbox wiring diagram 15 KVA 400/230 V ......................................................................................................... 47
11.11 Generator switchbox wiring diagram 7 KVA 110 V .................................................................................................................. 48
11.12 Troubleshooting....................................................................................................................................................................... 48
12 Heat exchanger option.................................................................................................................................................................... 50
12.1 Safety regulations for the use of the heat exchanger ................................................................................................................ 50
12.2 Design and operation ............................................................................................................................................................... 50
12.3 Maintenance/Care .................................................................................................................................................................... 50
13 Compressed air processing option (after cooler / heat exchanger / filter)................................................................................. 51
13.1 Safety regulations for alternate compressed air processing...................................................................................................... 51
13.2 Design and operation ............................................................................................................................................................... 51
13.3 Maintenance instructions .......................................................................................................................................................... 51
13.4 Troubleshooting........................................................................................................................................................................ 51
14 Oil temperature controller .............................................................................................................................................................. 52
14.1 Safety regulations for the use of an oil temperature controller .................................................................................................. 52
14.2 Design and function .................................................................................................................................................................. 52
14.3 Maintenance / care ................................................................................................................................................................... 52
14.4 Troubleshooting........................................................................................................................................................................ 52
15 Undercarriage .................................................................................................................................................................................. 53
15.1 Introduction............................................................................................................................................................................... 53
15.2 Safety ....................................................................................................................................................................................... 53
15.3 Height-adjustable towing system .............................................................................................................................................. 53
15.4 Braking system ......................................................................................................................................................................... 53
15.5 Adjusting the braking system.................................................................................................................................................... 54
15.5.1 Preparations ................................................................................................................................................................. 54
15.5.2 Preliminary requirements: ............................................................................................................................................. 54
15.5.3 Adjusting the brake ....................................................................................................................................................... 54
15.5.4 Adjusting the brake compensating system.................................................................................................................... 54
15.5.5 Adjusting the brake linkage [6] ...................................................................................................................................... 55
15.6 Readjusting the braking system................................................................................................................................................ 55
15.7 Maintenance and care .............................................................................................................................................................. 55
15.8 Malfunctions and remedies ....................................................................................................................................................... 56
16 Tool oiler option .............................................................................................................................................................................. 58
3
2. Foreword
2 Foreword
max. installation
Delivery volume
Type of cooling
Pressure range
Engine coolant
Engine rating
(compressor)
Trade name
Fuel tank
capacity
Ambient Engine
height
Oil fill
C35-10 3.5 10.0 4.75-10.0 -10 50 1500 9.0 water 35.0 1600 2800 6.5 7.4 60.0
C35-10G 3.5 10.0 4.75-10.0 -10 45 1500 9.0 water 35.0 1600 2800 6.5 7.4 60.0
4TNV88 BKCP
C38 3.8 7.0 4.75-7.0 -10 50 1500 9.0 water 35.0 1600 2800 6.5 7.4 60.0
C38-G 3.8 7.0 4.75-7.0 -10 45 1500 9.0 water 35.0 1600 2800 6.5 7.4 60.0
C42 4.2 7.0 4.75-7.0 -10 50 1500 9.0 water 35.0 1600 2800 6.5 7.4 60.0
C42-G 4.2 7.0 4.75-7.0 -10 45 1500 9.0 water 35.0 1600 2800 6.5 7.4 60.0
C50 5.0 7.0 4.75-7.0 -10 50 1500 9.0 water 35.0 1600 2800 6.5 7.4 60.0
C50-G 5.0 7.0 4.75-7.0 -10 45 1500 9.0 water 35.0 1600 2800 6.5 7.4 60.0
4
2. Foreword
location,distance 1m
Width with mudgard
Tyre pressure
to 2000/14/EC
2) Chassis rigid, braked
Total height
Trade name
adjustable, braked
Tyres
4) Chassis „off road“
Rim
1) Chassis height-
unbraked
[kg] [kg] [kg] [kg] [kg] [mm] [mm] [mm] [barg] [dB/1pW] [dB(A)] [dB(A)]
C35-10 1025 810 3797 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 775 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
750 745 3215 1490 1315 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 740 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
C35-10G 1025 895 3797 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 860 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 825 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
C38 1025 810 3797 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 775 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
750 745 3215 1490 1315 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 740 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
C38-G 1025 895 3797 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 860 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 825 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
C42 1025 810 3797 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 775 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
750 745 3215 1490 1315 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 740 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
C42-G 1025 895 3797 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 860 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 825 3065 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
C50 1025 866 3797** 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 835 3065** 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 800 3065** 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
C50-G 1025 955 3797** 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 920 3065** 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
1025 885 3065** 1490 1327 4 1/2 J x 13 155 SR 13 2.5 2 x 3/4" 98 82 69
** plus 100mm with aftercooler option G 7kVA single-phase 110V AC, 50Hz or
9kVA 400V/230V AC, 50Hz or
15kVA 400V/230V AC, 50Hz
5
2. Foreword
Fig. 1
Fig. 2
Fig. 3
6
2. Foreword
Fig. 4
7
2. Foreword
2.4 Maintenance and care 2.5 General information This fact results in the termination/
expiration of the guarantee and warranty
Care and maintenance are all-important This operating manual is to help you to claims against the manufacturer.
if the screw compressor is to meet the get to know the compressor and to use it
demands placed upon it. Compliance with for its intended applications. It contains
the prescribed maintenance intervals and important information about how to Safety regulations
careful execution of care and maintenance operate the compressor safely, cost-
work are therefore essential, especially effectively and with due care. Compliance Danger
under difficult working conditions. with the instructions in this manual will
help to avoid danger, reduce repair costs It is important that you follow the
and downtime, and increase the reliability safety regulations in Chapter 3 of the
Service and service life of the compressor. operating manual.
Warranty
Only use this compressor with accurate
knowledge of and in compliance with this
manual.
Gardner Denver do not accept
responsibility for safe functioning of the
compressor for actions that do not
correspond to normal use or for purposes
not mentioned in the manual.
Warranty claims cannot be entertained for:
Fig. 5 * Operating errors
Please enter the data from the identifi- * Inadequate maintenance
cation plate for your compressor, in the
spaces above. In case of questions or * Incorrect fuels
orders for spare parts, please give us the * Damage caused by non-use of original
compressor type, compressor number and CompAir parts
the year of construction as given on the
identification plate. * Modification of the system.
If you give us this data you can be sure The Guarantee and Liability terms of
that you will be given the correct Gardner Denvers's General Terms and
information or sent the spare parts you Conditions are not extended through the
require. above instructions.
Any unauthorized modification of the
compressor system/station or the
installation of components (e.g. fine
separators) not released by the
manufacturer result in the loss of the
CE symbol.
8
3. Security Regulations
3 Security Regulations
9
3. Security Regulations
3.4 Loading/Relocation/Transport Parts to be removed for transport that it cannot roll away or be used without
purposes must be carefully refitted and authorization!
Loading / Relocation fixed again before putting the machine /
Avoid all operations that adversely affect
installation back into operation.
All loose parts that could fall down when the stability of the unit.
the machine is lifted must first be removed When putting the machine / installation
or secured; pivoting parts like doors, etc. back into operation again, only proceed in
must be immobilized. accordance with the operating manual. 3.5 Installation on site / Starting /
For lifting heavy parts, hoisting gear and Normal operation
heavy-lift facilities with the appropriate Transporting the complete unit
capacities, which have been checked and Installation on site
Make sure that the air vessel is not
approved in accordance with local safety Besides the general technical operation
under pressure.
regulations, must be used. in accordance with the regulations of the
Lift and secure supporting gear. local authorities, it is essential that the
For lifting machines or parts of machines
with one or more lifting eyes, only hooks Make sure that the drawbar eye can following guidelines be observed.
or shackles complying with local safety move freely in the tow bar. Before switching on the machine /
regulations may be used. Never fasten installation, or starting it up, make sure
cables, chains or ropes to or through lifting Check to make sure that the drawbar is
adjusted to the bar height of the towing that nobody can be injured by the
eyes. machine / installation as it starts up.
vehicle.
Lifting hooks, lifting eyes, shackles etc. The installation is to be set up in such a
must never be bent and must always be Check to make sure that the body is
closed and locked, and that the cable for way that it is adequately accessible and
stressed in alignment with the load- that the necessary cooling is ensured.
carrying axis. The load capacity of the the rapid-emergency brake is connected
to the towing vehicle. Never block the admission of air.
hoisting gear is reduced if the lifting force
is applied at an angle to the axis. Join up the connections of the air brake, The air intake is to be designed in such
if present. a way that no dangerous admixtures
All bearing parts must be stressed (inflammable solvent vapors etc., but also
vertically, as far as possible, for maximum Check to make sure that the wheels are dust and other dangerous or toxic
safety and optimum performance of the properly tightened, that the tyres are in a substances) can be taken in. This also
hoisting gear. If required, a support is to roadworthy condition, that the tyre applies to flying sparks.
be installed between the hoisting gear and pressure is correct and that the brakes
the load. Secure the load properly. function properly. The air intake is to be designed in such
a way that no loose personal clothing can
When heavy loads are being conveyed Connect the cable for the signalling be drawn in.
by means of hoisting gear, it is imperative and lighting fittings. Check the proper
to keep well clear of the load in order to functioning of the lighting. Make sure that the compressed air line
avoid accidents. from the compressor to the air network
Release the handbrake. can expand as a result of heat and cannot
Never leave the load suspended on the come into contact with inflammable
hoisting gear. Before transporting the unit, always
materials.
check to make sure that the accessories
Acceleration or braking of the means of are firmly attached so that they can cause The compressed air line connected at
transport must remain within the approved no accidents! the air exit of the unit must not be under
limits. strain.
When using public roads, tracks and
The hoisting gear is to be set up in such spaces, observe the current traffic Compressed-air lines have to be marked
a way that the object is lifted vertically. regulations, and if necessary make the distinctly according to local regulations.
Should this not be possible, precautions unit roadworthy first!
must be taken to prevent the load from If several compressors are arranged in a
swinging. Thus it is possible to use two Never exceed the maximum towing system, manually operated valves have to
sets of hoisting gear, both with an angle of speed. Observe national regulations! be installed so that each machine may be
inclination of not more than 30° to the shut off individually. For the purpose of
Always switch on lights if visibility is poor
vertical. shutting off pressurized systems, you
and during lighting-up time!
should never rely on the effectiveness of
Nominate experienced supervisors for When going through underpasses, return valves alone.
the lifting process. bridges, tunnels, overhead power lines,
Safety devices, protective covers, or
Machines may only be hoisted correctly etc., always make sure that you have
insulations mounted on the system must
using hoisting gear in accordance with the enough clearance!
not be removed or modified in any way.
information in the operating manual (limit Always keep a safe distance from the
stop points for heavy-lift facilities etc.) All pressure tanks located outside the
edges of foundation ditches and
unit with an approved operating pressure
Only use a suitable transport vehicle embankments!
higher than atmospheric pressure and
with sufficient carrying capacity. Do not travel across slopes transversely: fitted with two or more pressure feed lines
Before or immediately after completion always keep equipment and loads near must be equipped with an additional safety
of loading, secure the machine / ground level (for example, do not place device to automatically prevent the
installation to prevent accidental shifting. them on the bodywork). approved operating pressure from being
Display an appropriate warning. Before exceeded by more than 10%.
On descents, always adapt speed to the
putting the machine / installation back into circumstances! Never change into low Pipes and other parts with a surface
operation, the securing devices must be gear during the descent, but always temperature of more than 80 °C must be
duly removed. beforehand. When leaving the driver's suitably secured against contact and
seat, always secure the unit to make sure suitably marked.
10
3. Security Regulations
Electrical connections must comply with Normal operation The compressed air produced by these
local regulations. compressors must not be used as breath-
Before starting work, make yourself
able air, unless it has been processed
With compressors fitted with generators, familiar with the working environment at
specially for such an application in
use equipotential bonding systems for the the installation site. The working
accordance with the “Safety requirements
protection of persons. environment includes, for example,
for breathable air.”
obstacles in the working and transport
Install the machine so that it is as
areas, the carrying capacity of the ground, When breathing apparatus with
horizontal as possible; a slight inclination
and any necessary cordoning off of the cartridges is used, make sure that the
is permissible (see information in Chapter
building site from public traffic areas. correct cartridge has been inserted and
"Installation").
that its service life has not expired.
Take the necessary precautions to make
Set up the machine in such a way that
sure that the machine / installation is only Never use the machine in environments
no inlets, outlets or gates are blocked,
operated in a safe, functional condition. where the possibility cannot be ruled out
even when the doors are open.
that inflammable or toxic vapors may be
Only operate the machine when all
Before disconnecting the machine from taken in.
protective devices, shutdown devices,
the towing vehicle, apply the handbrake.
sound-insulating equipment and extraction Never operate the system at
Disconnect the rapid-emergency brake
equipment is in place and working. temperatures and/or pressures below or
cable and lighting cable, disconnect the
above the values indicated in the technical
lines of the air brakes, use chocks to Be careful: loose articles of clothing, hair
data sheet.
ensure that the machine does not roll or limbs can still be drawn in by revolving
away. parts. Persons working in environments or
rooms in which the acoustic pressure is
If a machine with a combustion engine Verify regularly that:
85 dB(A) or higher must wear ear muffs.
has to work in a fire-risk environment, the
* All protective equipment is properly Caution: this may impair communication
unit must be fitted with a spark catcher.
positioned and fixed in place between persons. Warnings may not be
In dusty environments, set up the heard. Inform supervisor.
* All hoses and/or pipes within the
machine in such a way that the wind does
system are in good condition, are Shieldings and doors must be closed
not blow dust in its direction. During
properly fixed in place and do not chafe during operation so that the flow of cool air
operation in clean environments, the
within the housing is not deflected and the
intervals for cleaning the air intake filter * There are no leaks (fuel, oil or coolant efficiency of the sound-insulating is not
and the cooler elements are much longer. leaks) reduced. Doors and hoods may only be
Do not install the machine directly in * All bolted connections have been opened briefly.
front of walls. Make sure that the warm air tightened With water-cooled combustion engines
coming from the engine and cooling
* All electrical wiring is properly with a closed cooling circuit, the cap of the
systems is not drawn into the air intake
connected and is in perfect condition coolant recovery bottle must not be
under any circumstances. Drawing this
removed before the system has cooled
warm air in through the engine or cooler * Safety valves and other pressure-relief down to ambient temperature.
fan could lead to overheating; if it is drawn devices are in perfect condition and are
into the combustion chamber, this will not blocked, for example by dirt or paint Never fill up with fuel while the engine is
result in a loss of power. running. Make sure that fuel does not
* The safety devices all work properly come into contact with hot machine parts.
Never relocate the machine if external
lines or hoses are connected to the All connected components must be of Do not smoke while filling up with fuel.
discharge valves, in order to avoid the correct size and be suitable for the
specified operating pressure and Filling up at a pump can cause static
damage to the valves and/or collecting
temperature. electricity and possibly sparks. In order to
pipe and hoses.
avoid this, a ground cable must be
No force may be exerted on the Only use the correct type and size of connected to the system while it is being
discharge valves, for example by pulling hose coupling and connection. filled up.
the hoses or fitting additional equipment Before blowing through a hose or air The exhaust from the system contains
(e.g. a water separator, compressed air line, it is essential to hold the open end carbon monoxide, a lethal gas.
oiler, etc.) directly to the discharge valve. firmly. If the open end is not held firmly, it
can whiplash and cause damage or injury. The exhaust must be routed to the
Make sure that:
outside via a pipe or a hose with an
* All bolted connections have been Avoid any working methods that could internal diameter of not less than 100 mm
tightened be considered risky! if the compressor is used indoors.
* All electrical wiring has been connected Never play about with compressed air. Adequate ventilation must be assured.
correctly and is in good condition Never direct compressed air onto the The use of an exhauster system is
* The engine exhaust system is skin or towards another person. urgently recommended.
operationally safe and that no Never use compressed air for cleaning Before connecting or disconnecting
inflammable material is in the vicinity clothing. When using compressed air to hoses, always close the compressor air
* The wheel nuts are properly tightened; clean equipment, work with extreme outlet valves. Before disconnecting a
never exceed the specified torque. caution and always wear suitable eye hose, always make sure that it is not
protection. under pressure.
11
3. Security Regulations
A hose connected to an air valve must and shutdown procedures and the Maintenance
be fitted with a safety wire for operating instructions for maintenance work.
During maintenance and repair work, the
pressures above 7 bars; it is in fact
All maintenance and repair work may contractor has to inform the personnel
recommended that this safety device
only be carried out when the system is about the dangers that can occur during
should be used for pressures above
shut down, or, with electrical systems, their work and about measures to avert
4 bars. The steel wire has a diameter of
when the mains power supply is switched such dangers.
8 mm and is firmly clamped to the hose at
off. Make sure that the equipment cannot
least every 500 mm. Both ends are fitted The personnel have to support all
be switched on by accident.
with cable lugs. measures to improve safety at work.
Whenever the machine/system is com-
Check the machine / installation for Safety devices for preventing or
pletely powered down for maintenance
external damage and faults at least once eliminating dangers must be serviced
and repair procedures, it has to be
per shift. Any changes noticed (including regularly and their functioning tested at
secured against unintentional power-on or
changes in operating performance) must least once per year. Faults discovered
the mains supply has to be cut off with
be reported immediately to the authority or must be corrected at once or reported to
electrical systems.
person in charge. If necessary, shut down the supervisor.
and secure the machine immediately. * Switch off battery master switch and/or
Only use the correct tools for
detach connector.
In case of malfunction, shut down and maintenance and repair work.
secure the machine / installation * Put up a warning sign on the main
immediately. Have malfunctions corrected Only use original spare parts.
switch “Attention! Maintenance work.”
immediately. Close off the complete maintenance All maintenance and repair work may
area, if required. only be carried out when the system is
Observe the operating manual for start-
up and shutdown procedures as well as shut down, or, with electrical systems,
* Disconnect the starter battery.
inspection displays. when the mains power supply is switched
Individual parts and larger subassem- off. Make sure that the aggregate cannot
blies must be carefully attached to the be switched on by accident.
hoisting gear and secured in case of
3.6 Special jobs / Maintenance Whenever the machine/system is com-
replacement.
pletely powered down for maintenance
Care Only use suitable, technically perfect and repair procedures, it has to be
hoisting gear and load suspension devices secured against unintentional power-on or
Observe the setting, maintenance, and
with adequate carrying capacity. Keep the mains supply has to be cut off with
inspection work and intervals stipulated
clear of suspended loads. electrical systems.
in the operating manual, including
information about the replacement of parts Before removing any part under * Switch off battery master switch and/or
/ partial sections. This work may only be pressure, separate the aggregate detach connector.
carried out by specialists. effectively from all sources of pressure
* Put up a warning sign on the main
and release the pressure from the
Maintenance work, tests and repairs switch “Attention! Maintenance work.”
complete system.
should be carried out in a well ventilated Close off the complete maintenance
room, away from heat, open flames, or Never use inflammable solvents or area, if required.
sparks. Appropriate prohibition signs (fire, carbon tetrachloride to clean parts.
open flames, no smoking) must be put up. * Disconnect the starter battery.
Take precautions to avoid toxic vapors
Loss of oil leads to a very slippery floor. Before removing or opening any part
from cleaning fluids.
Statistics have shown that many accidents under pressure, separate the equipment
can be attributed to the installation or Absolute cleanliness is essential during effectively from all sources of pressure
maintenance of machines on oily floors or maintenance and when carrying out and release the pressure from the
machine components. For this reason, repairs. complete system.
always start maintenance work by Only carry out maintenance and repair For moveable machines support the
cleaning the floor and the machine work when the machine is located on an towing mechanism and axle with
exterior. even, stable base and is secured against appropriate means if work is to be carried
Inform operating personnel before running away and against buckling. out underneath the units (a jack is not
beginning to carry out special work or sufficient).
Only carry out inspection, maintenance,
maintenance. Nominate a supervisor. and repair work when the screw com- Observe the safety precautions for work
After completing repair work, always pressor system is at a standstill and is not on batteries.
check to see whether any tools, loose under pressure.
Pay attention to cleanliness. Prevent dirt
parts or cloths have been left in or on the Protective devices, i. e. protective grids, from entering by sealing the parts and
machine, driving engine or driving may not be removed during operation. exposed openings with a clean cloth,
equipment. paper, or tape.
Caution while the screw compressor is
Maintenance and repair work is only to in operation. Before the aggregate is approved for
be carried out under the supervision of or operation after maintenance or an
by a person qualified for this work. After the work has been completed,
overhaul, make sure that operating
replace any protective devices that have
For all work concerning the operation, pressures, temperatures, and time
been removed. Operation without
production adjustment, conversion, or settings are correct and that the control
protective devices is not permissible.
settings of the machine / installation and and shutdown devices are working
its safety-relevant equipment, as well as Working clothing should be close-fitting properly.
servicing, maintenance, and repair, during work on running screw compressor
observe the operating manual for startup systems.
12
3. Security Regulations
The electric motor, generator, air filter, Never carry out welding work or any Ensure safe, environment-friendly
electrical components and control other work that produces heat in the disposal of process materials as well as
equipment are to be protected against the vicinity of fuel or oil systems. Systems, replaced parts. Oil containing
penetration of dampness - for example which could contain fuel or oil, have to be components, such as fine separators and
when cleaning with a steam jet - by completely drained and cleaned, e.g. by oils, must be disposed of in accordance
covering or sealing them. means of a steam jet, before proceeding with the relevant legal provisions. Oil must
with the work to be carried out. not enter the soil!
Under no circumstances should the
sound-insulating material be removed or Never carry out any welding work on any
modified. pressure tank or components under
Safety precautions for work with
pressure, or modify them in any way.
Never use solvents with dangerous batteries
properties for cleaning parts. If work causing heat, flames, or sparks
The fluid contained in batteries is diluted
has to be carried out on a machine, the
Maintenance work, tests, and repairs sulfuric acid which can cause blindness if
surrounding components must be
should be carried out in a well ventilated brought into contact with the eyes, or
protected with nonflammable material.
room, away from heat, open flames, or serious burns if brought into contact with
sparks. Appropriate prohibition signs (fire, Before dismantling or overhauling a the skin. For this reason it is essential to
open flames, no smoking) must be put up. compressor, engine, or any other work with the greatest of care when
machine, make sure that no movable part servicing batteries, e.g. when checking
Wear suitable eye protection when
with a weight of more than 15 kg can battery charge, and to take all necessary
inspecting the system. Make sure that the
move or roll away. safety precautions.
openings of spray containers, valves,
pipes, or atomizers are never directed at Machines whose main movement is Always wear long-sleeved overalls, acid-
yourself or at any other person during the back and forth must be moved at least resistant gloves and safety goggles.
inspection. once, rotating machines several times, in
On charging a battery, an explosive gas
order to make sure that there is no
The fuel used in these systems is highly mixture is formed in the cells, which can
mechanical malfunction in the machine or
inflammable, toxic and poisonous. Avoid escape through the vent holes in the
in the driving part.
contact with eyes and skin, and never sealing caps. If ventilation is poor, a highly
inhale vapors. Should you accidentally Only experienced persons may be explosive atmosphere can form around
swallow fuel, do not induce vomiting, but charged with slinging loads and instructing the battery, and can persist for several
seek medical attention. crane drivers. These instructors must hours after charging.
remain within sight of the operator or be in
Should fuel come into contact with the Thus:
touch with him via walkie-talkie or similar
eyes, or in case of eye irritation by vapors,
device. * Never smoke in the vicinity of batteries
flush eyes with plenty of clean water and
that are being charged or have just
seek medical attention. During assembly work above body
been charged.
height, use appropriate or otherwise
Every time a message is displayed or
safety-relevant climbing aids and working * Put up prohibition signs for fire, open
there is a suspicion that an internal part of
platforms. Do not use machine parts as flames and smoking in workshops
the machine has overheated, the machine
climbing aids! Wear safety belts when where batteries are charged.
must be shut down. Never open the
carrying out maintenance work at greater
inspection cover, however, before the * Never interrupt a current-carrying
heights.
machine has cooled down sufficiently to circuit at battery terminals because of
rule out the possibility of the oil vapors Keep all steps, handles, railings, the danger of spark formation.
igniting spontaneously when mixed with platforms, scaffolds, and ladders free of
air. dirt, snow, and ice. * Proceed particularly cautiously when
connecting or disconnecting rein-
In order to avoid an increase in Before beginning maintenance and forcement cables or quick-charge cable
operating temperature, inspect and clean repair, clean the machine, particularly clamps.
the heat transfer surfaces (cooling ribs couplings and bolted connections, of oil,
etc.) regularly. Draw up a schedule for the fuel, and special care products. Do not When starting up using jumper cables or
most suitable cleaning intervals for each use aggressive detergents. Use lint free auxiliary batteries, first connect the
machine. cloths for cleaning. positive terminals and then the negative
terminals. After starting the engine, first
Avoid damaging the safety valves and After cleaning, remove all covers and disconnect the negative terminal (ground
other pressure-reducing devices. In seals. cable) and only then the positive terminal.
particular, make sure that they are not Disconnect the auxiliary battery after the
After cleaning, check all fuel, engine oil,
blocked through paint, oil carbon, or dust starting procedure in order to avoid the
and hydraulic fluid lines for leaks, loose
accumulation, which could impair the risk of the release of gas (explosion
connections, chafing and damage. Correct
effect of these devices. hazard).
any faults immediately.
The insulation or protective shielding of
Always tighten bolted connections
parts whose temperature may exceed
loosened during maintenance and repair
80 °C and which may accidentally be
work.
touched by personnel may not be re-
moved before these parts have cooled If it is necessary to dismantle safety
down to room temperature. devices during machine set-up, mainte-
nance, and repair work, the safety devices
Check the accuracy of the pressure and
must be reassembled and checked imme-
temperature displays regularly. If the
diately after completing the maintenance
permissible tolerance limits have been
and repair work.
exceeded, then they must be replaced.
13
3. Security Regulations
14
3. Security Regulations
Master switch
100009377
Do not operate
with the hood
open
Do not step on
pressure- Check filling Observe the
conducting parts level operating
instructions
Caution: Hot
surfaces
A93630300
Caution: Hot and Caution: Hot surfaces
dangerous
exhaust fumes Caution: Do not move with the
transport safety locking
Caution: Under
pressure
A13222974
Caution: Hot and dangerous exhaust
fumes
Only operate with
protective grating
100003144
Caution: Do not use ether spray
2,4 BAR
A13145774
Note tyre pressure
Shut down
98
A93634780
15
3. Security Regulations
Options
Condensation drain
from after-cooler or
from after-cooler with
subsequent filtering
16
4. Construction and functional description
17
4. Construction and functional description
4.1 Construction 4.2 Functional description When the preset operating pressure is
(see fig. 6 and fig. 7) exceeded the P controller (23) of the
Compressor and engine control unit feeds control air to the
Oil circuit adjusting cylinder (4) of the engine speed
The DLT0408 series is a sound proofed adjustment system and the intake suction
mobile compressor system. The core is The oil required for sealing and cooling controller (11) in order to modify the
a single-stage, oil-flooded screw the rotors as well as for lubricating the comnpressor's intake volume.
compressor. The CompAir screw profile roller bearings is injected into the
represents the state-of-the-art. The air is compressor (10) from the pressure tank This causes a change in engine speed
delivered pulsation-free. (17), which is under system pressure. The and in compressor intake volume until the
difference in pressure between the preset operating pressure is maintained
The drive assembly is a medium-cooled constant.
pressure tank and the oil injection position
diesel engine, which drives the screw
is approx. 1 bar. The oil hereby passes The system is kept in equilibrium and
rotors of the compressor by a flexible
the oil cooler (16) and the oil filter (13). any condensate occurring in the control
coupling.
The suction controller (11) is fitted with a line is blown off by means of the nozzle (5)
non-return function, so that when the of the engine management system (4) and
system is switched off, flooding of the air the nozzle (12) of the suction controller
Fairing (Body)
filter (9) is prevented. (11).
The fairing consists of a subbox, which
is mounted on a base frame, and to The speed/intake regulation system
which a folding cover for servicing and Air circuit steplessly matches the volumetric flow to
maintenance access is attached. The air take-off between 0 and 100 %.
The intake air flows through the air filter
opening of the cover is effectively If air tale-off drops to zero, the intake
(9) and the suction controller (10) into the
supported by pneumatic springs. The hook controller (11) is closed and the diesel
compressor (10). During compression, oil
inside is for hanging up a load suspension engine (2) is run down to idling speed by
is injected in order to lubricate, cool and
device. The machine rests on rubber the engine control cylinder (4).
seal the screw rotors. The compressed
elements to prevent vibrations and noise.
air-oil mixture flows into the pressure tank If operating pressure drops below the
For convenient assembly, all individual (17). Centrifugal preseparation of the oil is preset value, the control air pressure of
parts of the cover are screwed together ensured through tangential entry into the the P controller (23) of the control unit; the
with machine screws. For the prevention tank. Any remaining oil is separated from intake controller (11) opens and engine
of corrosion, the compressor body is fully the air in the fine separator (18). speed in increased by the engine control
galvanised, electrostatically powder cylinder (4).
The compressed air is fed via the
coated and burnt at °C 220. The sound
pressure retention valve (20) to the When turning off the engine the
absorbing mats are inserted and easy to
compressed air discharge (21). The backlash flap inside the suction controller
be cleaned.
pressure retention valve effectively (11) will be closed through the system
prevents the system pressure from falling pressure. The release valve (25), which
below the minimum operating pressure closes parallel to the engine lifting magnet,
Frame and chassis
required for the system to work properly. looses power and opens. The container
The complete compressor unit is A temperature monitoring device (14) as pressure drops down to zero.
mounted on an easy-to-transport single- well as an operational pressure
axle chassis. The chassis is equipped manometer (22) are integral parts of the
with automatic overrun brakes and air circuit.
parking brakes, as well as a jockey wheel
adjustable in height.
Regulation
Airflow Note
Fresh air is sucked in through the In the event of an error, it is not possible to
admission opening at the back of the start the compressor.
compressor. The air intake volume is
Starting procedure: The control system
air for the engine and for the compressor
is out of operation when the system is
too, as well as cooling air for the engine
started, i.e., motor speed is reduced to
and for the oil cooler of the compressor.
idling speed as system pressure increases
and the suction controller (11) is closed.
Once the unit has warmed up, the load
switching valve (24) is changed over from
off-load to full operation by pressing the
on-load switch (G).
The compressor then starts to deliver
(10) and system pressure in the vessel
(17) increases.
18
4. Construction and functional description
Fig. 7 A13568774
19
4. Construction and functional description
FUEL/WATER SENSOR
FUEL SHORTAGE
S7 COOLANT LEVEL
S4 MOTOR TEMPERATURE
S5 COMPRESSOR TEMPERATURE
OIL PRESSURE
PREHEAT RELAY
GENERATOR OPTION
FUEL PUMP
LIFTING MAGNET
GENERATOR
STARTER
PRE-HEATING
Fig. 8 A13568874
20
4. Construction and functional description
Not assigned
Not assigned
Socket plug
21
5. Transport and installation on site
* Coupling ring 2" dia. (only for UK) * Check the lights (tail lights, brake
lights, indicator lights, and rear fog
* Coupling ring 68 x 25 dia. (only for lamp) (option).
France)
Transport safety locking * Check to make sure that the wheels
A different coupling unit in the form of a are properly tightened, the tyres are
complete kit may be ordered, if necessary. in a roadworthy condition and the tyre
Replacing the trailer coupling ring is pressure is correct (danger of
permitted only if proper fitting is carried out accidents).
by an inspectorate for the sector covered
by the Regulations Authorizing the Use of * When parking the compressor prior to
Vehicles for Road Traffic (e.G. the TÜV - uncoupling from the towing vehicle
Fig. 10 Technical Inspectorate, DEKRA - German actuate the handbrake, detach the
Motor Vehicle Monitoring Association, contact-breaker cable and the lighting
Before moving the compressor for the
etc.). The inspection station provides a cable, and secure the compressor
first time slacken the ratchet on height-
fitting certificate to be kept with the vehicle against rolling using chocks. Then
adjustable towing gear and remove the
documents. adjust to the horizontal position by
transport securement. Then adjust the
means of a support or support wheel.
towing gear from the vertical transport
Danger
position to the required attachment height
Attention
for the towing vehicle and lock it in place The screw compressor may only be
in the toothing using the ratchet (see transported on public roads if Always keep a safe distance from the
Section 15. Undercarriage, height- edges of foundation ditches and
adjustable towing gear). * The machine group (engine) is not embankments! Do not travel across
running, slopes transversely.
* The pressure tank is not under
pressure,
* The shielding is closed,
* The blocks are firmly hooked in 5.2 Attachment of the contact-
place, breaker cable on braked
chassis
* Hoisted and secured tail wheel,
* The tyres and brakes are If the towing connection becomes
operationally safe and roadworthy, uncoupled, the trailer is braked by the
breakaway cable. Put the breakaway
* The lighting is fully functional. cable in the eye provided or wind it around
Never exceed the maximum towing the towing collar and hitch it up to the
speed! Danger! Observe national cable with the snap link.
Fig. 11
regulations! The breakaway cable must be attached
Danger Please also observe the safety in a way that ensures that even on
instructions in Chapter 3 on the extremely sharp bends there is no danger
Make sure to check the torque after of activating the locking brake.
50 kilometers following wheel subject of transporting.
mounting and at regular intervals. Before transporting the compressor,
check to make sure that the draw gear of
Tighten wheel nuts or screws evenly in
the towing vehicle and the drawbar eye or
a diagonal sequence to the specified
trailer hitch ball connection are aligned
torque using a torque wrench.
exactly to each other.
When transporting the screw compressor
with a vehicle, the following points must be
observed:
* The shielding is closed.
* The blocks are firmly hooked in place.
* The support(s) is(are) retracted and Fig. 12
locked in position (jockey wheel).
* Drawbar is connected to the towing
vehicle.
* The drawbar is adjusted to the height of
the towing vehicle (option).
22
5. Transport and installation on site
5.3 Loading/Relocation Never relocate the machine if external 5.4 Installation on site
lines or hoses are connected to the
discharge valves, in order to avoid
damage to the valves and/or collecting
pipe and hoses.
When loading, the following points must
be observed:
* Secure the load suspension device or
the hoisting gear in the lifting device of
the screw compressor.
* When hoisting the compressor, set up
the hoisting gear in such a way that the
compressor, which must be set up
Fig. 13 Fig. 14
horizontally, is lifted vertically.
Danger * Only relocate the compressor by itself. Danger
Only use hoisting gear (e.g. crane) with * Raise and lower the compressor The air intake must be positioned in
appropriate lifting capacity for the carefully. such a way that loose personal
loads occurring! clothing cannot be drawn in.
* After relocating, remove the load
Only use the correct suspension gear! suspension device or the hoisting gear Make sure that the pressure pipe from
from the lifting device. the compressor to the aftercooler or
Keep clear of the swiveling range of the air system can expand as a result
the hoisting gear! * Tie down the compressor on the cargo
of heat, and that it does not come into
area of the means of transport.
Keep clear of suspended loads! contact with inflammable materials.
* Lash only on the tow pipe of the
All loose parts that could fall down The air intake is to be designed in such
chassis and on the rear fixing point.
during hoisting must first be removed a way that no dangerous admixtures
or secured; pivoting parts, like doors, * When dismantling the chassis, the (inflammable solvent vapors etc., but
towbars, etc. must be secured in such fairing and the machine set may be also other dangerous or toxic
a way that they cannot move. supported only under the longitudinal substances) can be taken in. This also
stringers of the subframe box. New applies to flying sparks.
Never leave the load suspended on the self-locking nuts must be used for
hoisting gear. Acceleration or braking Pipes and other parts with a surface
installation. See section 9.5.9 for
of the means of transport must remain temperature of more than 80 °C must
tightening torques.
within the approved limits. be suitably secured against contact
and suitably marked.
Please also observe the safety
instructions in Chapter 3 on the The operation of the compressor in
subject of loading. areas where there is a risk of explosion
is strictly forbidden! (Exception:
Attention specially-made compressors with the
necessary technical modifications for
Do not attempt to use a crane hook or use in such areas)
similar load suspension devices direct
on the lifting device to avoid damages Please also note the safety
to the lifting device! instructions in Chapter 3 on the
subject of installation on site.
Use proper hoisting gears only such as
hoisting straps in compliance with
DIN standard 61360 with proper lifting Location
capacity for connecting the load
suspension device (e.g. crane) and the The complete system is to be set up in
lifting device. such a way that it is easily accessible and
that the required cooling is guaranteed.
Only deploy load bearing equipment Never block the air intake. Ensure that the
which corresponds to the safety entering of moisture and dirt together with
instructions for lifting gear. the intake air is kept to a minimum.
Use a transport harness compliant with The compressor is to be set up away
local regulations for transporting by from walls.
helicopter. The eyes provided may not
be used for this purpose (max.
acceleration if the eyes are used =
2 x g)
Never lift up or lash down the unit
using the shieldings!
23
5. Transport and installation on site
Attention Attention
The screw compressor is to be set up No force may be exerted on the dis-
in such a way that no air reflection can charge valves, for example by pulling
take place, i.e. neither waste air nor the hoses or fitting additional
exhaust emissions may be drawn in; equipment (e.g. a water separator,
the same applies to dangerous compressed air oiler, etc.) directly at
admixtures to the air. Drawing this the discharge valve.
waste air in could lead to overheating
and a loss of power.
Temperatures/air humidity
The compressor must be set up in as
horizontal a position as possible. Install the compressor in a location with
Maximum permissible inclination during maximum possible frost protection. The
operation: suction air temperature must be within the
range specified on the data
* In direction of pull: 15 degrees
* Backwards: 15 degrees
* To the right and to the left: 15 degrees
Altitude
For operation at an altitude above
1.500 m, the compressor and engine must
be adapted (modified design).
Note
Particularly in case of installation out of
doors and at night, observe fuel tempera-
ture. At temperatures below 0 °C, summer
diesel fuel tends to precipitate and block
the fuel filter. In this case use winter diesel
fuel.
Fig. 15
Attention
Note
In dusty environments, set up the machine
in such a way that the wind does not blow
the dust in the direction of the machine.
During operation in clean environments,
the intervals for cleaning the air intake
filter and the cooler elements are much
longer.
24
6. Preparing the compressor for operation
6.1 Checking levels 6.1.2 Checking the oil level in the 6.1.3 Checking coolant level
engine
6.1.1 Checking the oil level in the
pressure tank
Fig. 17
Danger
25
6. Preparing the compressor for operation
6.2 Battery 6.3 Filling up the fuel tank For outside temperatures below 0 °C,
observe the operating manual of the
engine manufacturer for winter operation.
You can reduce the occurrence of
condensation in the fuel tank considerably
by filling it up in good time. This also
prevents downtimes and starting problems
that can occur when the fuel tank is run
dry.
Fig. 19 Fig. 20
Proceed as follows:
* Fill up with battery acid as far as the Bleeding
base of the control insert
Danger
* Leave the battery to stand for some
time To avoid accidents, never bleed the Fig. 22
fuel system with the engine in hot Contaminants must be drained from the
* Then shake it gently condition. Danger of fire! fuel tank every 250 operating hours (see
* If required, top up with acid Bleeding of the fuel system is described chapter entitled "Maintenance" and the
in the operating manual for the engine. It motor operating manual).
* Tighten sealing caps
is necessary in the following cases:
* Leave for 1 hour Maintenance work on the fuel system
* The battery is ready for use (priming pump, filter, water separator,
piping), failure of the engine due to lack of
fuel, before restarting after prolonged
periods of non-use.
Note
The fuel tank should always be filled up in
good time. For outside temperatures
below 0 °C, use only winter diesel fuel.
More information on fuel quality, see
engine operating manual.
26
6. Preparing the compressor for operation
Fig. 23
The air filter element must be replaced
when the red section of the servicing
indicator (2) is fully visible (see
Section 9.5.5, "Air filter replacement")
Empty the dust emission valve by
pressing together the emission slot (1) in
the direction of the arrow.
Note
Clean the emission slot from time to time.
27
7. Putting the compressor into operation
Attention
Opening the covering interferes with
the flow of cool air in the compressor
section.
Full sound-insulating is only achieved
when the covering is closed.
Check the oil levels in the pressure
tank and in the engine of the
compressor each time before start-up.
Do not start the compressor unless the
Fig. 26 Main switch air tapping cocks are closed.
28
7. Putting the compressor into operation
Note Start-up using jumper cables / auxiliary 7.4 Setting the operating pressure
batteries
It is not possible to start up the
compressor in case of a fuel shortage.
* Engine can be started immediately if Danger The setting of the operating pressure
ambient temperature is ≥ 10° C: Turn may only be carried out by a specialist.
ignition switch further to ,
Longer operation with an auxiliary
battery or jumper cables connected The operating overpressure of the screw
At ambient temperatures < 10° C wait can lead to sudden emissions of gas. compressor is set by the manufacturer
until the Preheat indicator lamp goes An inflammable air / gas mixture is (see the identification plate on each
out and then turn the ignition switch formed. Explosion hazard! compressor).
further to . Pressure values can be set between
Attention
5 bar and the operating overpressure
* Hold the ignition switch in position
Serious damage can be caused to the stated on the rating plate. Pressure values
until the engine starts running and the higher than this are not permitted.
electrical system if wrongly connected.
“Battery charge” and “motor oil
pressure” indicator lamps go off. * Ignition switch in position (Off-Aus) Operating pressure is set by a specialist
at the controller.
* Release the ignition switch. * First connect positive terminal then
negative terminal (ground). * Remove counternut below the control
* If the engine has not started after knob of the regulator.
15 seconds at the latest, turn the * Start as described in section “Starting
up the compressor.” * Raise pressure by turning the adjusting
ignition key back to position (Off-
knob of the regulator clockwise
Aus). As soon as the starter has
Note (towards +).
reached a standstill and the pressure
tank is no longer under pressure, the After the engine has started, first * Lower the pressure by turning the
engine can be started again. disconnect the negative cable (ground) adjusting knob of the regulator
and then the positive cable. anticlockwise (towards –).
* After the start, the engine runs at the
idling speed and the compressor at * In order to lower the pressure, open an
reduced pressure. air discharge valve.
* If the engine was started cold, let it * After altering the pressure, lock the
warm up for approximately 2 minutes adjusting knob using the locknut.
and then press the load button (Fig. 24, This readjusted operating pressure is to
Pos. 2). If the engine is warm, the load be checked using the pressure gauge on
button can be pressed immediately. the instrument panel at 100% air
* The installation is now ready to discharge and maximum engine speed.
operate. Check that all the hoses and
tools have been connected correctly
and open the desired air outlet valves.
29
7. Putting the compressor into operation
30
7. Putting the compressor into operation
Attention
Allow the screw compressor to idle
for a few minutes.
* Return the ignition switch (1) to the Fig. 30
position (Off-Aus).
If the system is to be closed down for a
Note longer period of time (approx. 3 months
or longer) the following preservation
This switch can also be used as an measures must be taken:
emergency stop switch. No other
switching off method is provided. * Engine preservation (see separate
engine operating manual).
* Turn off power to the system using the
main switch. * Disconnect battery cables.
After the installation has come to a * No special measures are required at
standstill all the air is automatically blown the compressor.
out of the pressure tank via the blow-off
* Relieve the strain on tyres by jacking
valve.
up the vehicle.
Danger * Check tyre pressure every 2 months.
It is important that you ensure that the * Release the handbrake.
pressure is completely blown off via
the blow-off valve. Attention
Should this not be the case, open the When putting back into operation,
air outlet valves, identify the fault and carry out the maintenance work
correct it. in accordance with Chapter 9
“Maintenance.”
31
8. Fuels
8 Fuels
When using oils with the “Brief De- 8.4 Diesel fuel
8.1 Recommended lubricant for
scription HYD 10/HYD 20" in accordance
compressor
with the ‘Standard Lubricants for Building Refuel only with diesel fuel that is
Machinery and Vehicles’ published by the approved for the motor in accordance with
Note ‘Hauptverband der Deutschen Bauin- the enclosed motor operating manual.
In these screw compressors, circulating oil dustrie e.V.’ (Principal Association of the
has not only a lubricating function, but in German Building Industry), only the Note
particular it also has cooling and sealing given hydraulic fluids may be used in
accordance with ISO VG 32 and
See engine instruction manual.
functions. It is therefore exposed to more
difficult conditions. In particular the ISO VG 46. At low temperatures,paraffin
temperature conditions at the installation precipitation can cause blocks in the fuel
If other lubricants are to be used, please
site and the consistency of the air (dust, system and disruptions in operation.
contact:
dirt, and humidity content, as well as Below outside temperatures of 0 °C use
chemical influences) must be taken into Gardner Denver Deutschland GmbH winter diesel fuel (to -15 °C). (This is
account when selecting a suitable Argenthaler Straße 11 usually available at gas stations in good
lubricant. D-55469 Simmern/Hunsrück time before the winter season begins.)
Telephone 06761 / 832-339 Diesel fuel with additives is frequently
Attention Telefax 06761 / 832-421 offered for use at temperatures as low as
-20 °C („Superdiesel“).
Do not mix oils of different or your authorized dealer or your local
specifications. branch. Attention
The maintenance intervals and the The compressor must not be fuelled
maximum and minimum operating with bio-diesel (DIN 51606) or
temperatures given in this operating 8.2 Recommended engine oil
vegetable oil.
manual only apply when high-quality
Detailed lubricant specifications for the
multi-grade oils are used.
driving engine can be found in the
Use of the wrong oil leads to enclosed engine operating manual. 8.5 Coolant
impairment of function.
For normal service conditions:
Change the compressor oil more Attention
15W40 API CH-415J (ACEA E-3,
frequently than specified if the ACEA E 5) Only operate the engine with coolant
equipment is operated under abnormal (water with corrosion protection/
conditions, i.e. at a high ambient antifreeze fluid)!
temperature, high air humidity or in a
dusty environment. If necessary, 8.3 Tool lubricants Pure water may cause damage to the
analyse the oil. cooler and the engine.
Attention
Out of consideration for the high loads Only use corrosion inhibitors and
imposed on the lubricant in screw Do not run the machine with an empty antifreezes recommended and
compressors with oil injection cooling, we oiler tank! The tank must always approved by the engine manufacturer!
recommend the use of suitable, non contain a minimum of 0.2 l of tool oil. Products of differing product groups
ageing, non foaming, corrosion-protective must not be mixed!
The wrong tool lubricants lead to
oils. They must meet the following
deposits that cause malfunctions in the Recommendation:
requirements for hydraulic fluids: H-LP 32
appliances connected! CompAir ID-Nr. A92131840
and H-LP 46 in accordance with
DIN 51524, Part 2, June 1985. For the perfect lubrication of concrete Texaco: Havoline AFC
breakers and pneumatic spades, we The coolant consists of 50% water and
At normal operating temperatures, the
recommend the use of CompAir oilers or 50% corrosion protection/antifreeze fluid.
viscosity of the lubricating oils used
automatic pipe oilers, using the special
should conform with Viscosity Class
synthetic CompAir oil AES 82. Use drinking water only.
ISO VG 32 DIN 51519, July 1976, viz.
28-35 mm2/s(cSt)/40 °C (obtainable in 20 l The special advantages of CompAir oil are Do not use sea, brackish, industrial, rain
canisters under CompAir ID No.: as follows: or distilled water.
SACO32-20).
* Biodegradable, The coolant should be changed not less
At ambient temperatures continuously frequently than every two years.
above +25 °C, the viscosity of the * Ice guard down to -50 °C, for use with
lubricating oils sued should conform with sound absorbers,
Viscosity Class ISO VG 46 DIN 51519, * Very good lubricity, thus wear-reducing,
July 1976, viz. 41-50 mm2/s(cSt)/40 °C
(obtainable in 25 l canisters under * No irritating exhaust gases, work in
CompAir ID No.: SACO46-25). enclosed rooms possible,
* Good cleaning effect, no residue
Attention
formation
Conventional engine oils marked HD * Excellent preservation properties,
must not be used. protects from corrosion.
When using compressed air consumers
made by other manufacturers, then their
regulations must be observed.
32
8. Fuels
33
9. Maintenance
9 Maintenance
34
9. Maintenance
Danger
35
9. Maintenance
50 h
250 h
500 h
750 h
1000 h
1250 h
1500 h
1750 h
2000 h
1250 h
2500 h
2750 h
3000 h
3250 h
3500 h
3750 h
4000 h
4250 h
4500 h
4750 h
5000 h
5250 h
5500 h
5750 h
6000 h
6250 h
6500 h
6750 h
7000 h
7250 h
7500 h
7750 h
8000 h
Operating hours
Danger
1. year
2. year
3. year
4. year
5. year
6. year
7. year
8. year
workplace before starting any work.
Daily:
Visual checking for external damage, defects and leaks
Check the oil level in the diesel engine
Check the coolant level
Check the oil level in the compressor
Empty fuel water separator
Check air intake line
Check and, if necessary, clean cooling ribs
Check radiator
Clean air filter (screw compressor/engine)
Note the maintenance indicator
between times or renew if the red field appears
Engine maintenance See the engine operating instructions and chapter 9.2!
Every 250 h, although at least every 3 months:
Change lubricant and oil filter (motor) ■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■
Check and adjust the fan's V-belt ■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■
Drain fuel tank ■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■■
Every 500 h, although at least every 6 months:
Check tyre pressure and wheeluts, retighten ifecessary ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Adjust brake system (option) or have checked ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Lubricate chassis / draw gear ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Inspect safety valve ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Lubricate hood hinges ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Replace fuel filter and clean fuel prefilter ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Clean cooler (more frequently if used in a dusty
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
environment)
Check antifreeze ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Every 1000 h, although at least each year:
Check cylinder-head group, adjust if necessary ■ ■ ■ ■ ■ ■ ■ ■ ■
Drain coolant, flush system through and refill ■ ■ ■ ■ ■ ■ ■ ■
Change air filters (screw compressor/motor) ■ ■ ■ ■ ■ ■ ■ ■
Change oil filter in the screw compressor ■ ■ ■ ■ ■ ■ ■ ■
Oil change (screw compressor) ■ ■ ■ ■ ■ ■ ■ ■
Inspect automatic operational monitoring ■ ■ ■ ■ ■ ■ ■ ■
Change fine separator every year or if differential
■ ■ ■ ■ ■ ■ ■ ■
pressure > 1bar
Check hose lines for damage (leaks, formation of cracks)
■ ■ ■ ■ ■ ■ ■ ■
and replace, if damaged
Clean screen of the suction-off line ■ ■ ■ ■ ■ ■ ■ ■
Inspect control (adjustment/function) ■ ■ ■ ■ ■ ■ ■ ■
Inspect solenoid valves ■ ■ ■ ■ ■ ■ ■ ■
Check the battery acid level ■ ■ ■ ■ ■ ■ ■ ■
Check clamping bolts anduts and retighten, if necessary
■ ■ ■ ■ ■ ■ ■ ■
(chassis, frame and bodywork)
Check suspension components ■ ■ ■ ■ ■ ■ ■ ■
Unscrew the optional vessel for tool oil and check inside
for any corrosion. If rust is found, replace the vessel with ■ ■ ■ ■ ■ ■ ■ ■
aew, original spare part.
■
X For your own benefit, put a cross on the servicing schedule against maintenance work when performed.
36
9. Maintenance
9.5.1 Oil filter replacement 9.5.2 Oil change (compressor) * Check sealing ring on dipstick, replace
(compressor) if necessary
* Screw in and tighten dipstick
* Start screw compressor, run for approx.
two minutes, check for leaks
* Switch off screw compressor
* Check oil level, add oil if necessary
Fig. 32 Danger
37
9. Maintenance
Attention * Remove the old seals from the * Remove filter hood.
pressure vessel, clean the sealing
* Remove filter cartridge from the filter
Correct functioning of the engine surface and fit a new seal.
hood.
monitoring system must be restored
* Insert a new fine separator into the
after completion of the check! * Remove safety cartridge from the
pressure vessel and fit a new seal.
housing.
* Fit the lid. Insert the hexagon screws * Replace filter cartridge.
9.5.4 Inspecting / Replacing the and tighten them across the diagonal
fine separator (tightening torque see Chapter 9.5.9 Danger
"Torque specifications").
Never clean the air filter cartridge with
* Check for leakage.
inflammable liquids.
* Dispose of the old fine separator
cartridge in the specified manner.
Reassembling the air filter:
* Clean the sealing surface in the filter
9.5.5 Air filter replacement housing.
(compressor / engine) * Insert safety cartridge and ensure
correct seating.
Danger
* Insert the filter cartridge and make sure
All inspections and servicing work that the seal is properly seated.
Fig. 34
must be carried out when the engine is * Replace filter hood and fasten using
1 Connection for P controller at a standstill and the screw the tensioning brackets (the tensioning
2 Connection for compressor suction line compressor is not under pressure. brackets can only be closed if the filter
3 Oiler connection (option) cartridge with seal is seated properly
on the sealing surface of the filter
Danger
housing).
Pressure tank is under pressure. Only * Reset the maintenance indicator by
work when the motor is at a standstill pressing the reset lever.
and the screw compressor is not under
pressure.
Caution with hot oil: risk of scalding! 9.5.6 Checking the safety valve
Spill no oil!
Note
Dispose of fine separator in accordance
with the relevant regulations - hazardous Fig. 35
waste!
Check for leaks. Note
38
9. Maintenance
If the valve is not working properly, 9.5.8 Battery maintenance 9.6 Spare parts for maintenance
replace it immediately with a new one purposes
designed for the system. This type of
operation may only be carried out by Designation Identification No.
trained personnel.
Service Package A19053474
500 operating hours (engine)
Service Package A19053574
9.5.7 Control
1000 operating hours
C35-10, C38, C42
(fine separator )
Service Package A19052974
1000 operating hours
C50 (fine separator)
Fig. 38
Service Package A19051874
Danger 1000 operating hours
(air filter)
The gases released by the battery are
explosive. Spare parts list ZS1069421
39
10. Troubleshooting
10 Troubleshooting
Screw compressor will not start No power on instrument panel Switch on fuse F1
(starter motor not turning)
Operating voltage low Charge battery or replace
Water in fuel/water separator Drain water
No fuel Fill up with fuel
Cooling water level too low Refill cooling water
Electrical connection loose, corroded, Replace
or broken
Compressor or motor temperature too high Allow unit to cool down, clean cooler
Starter defective Replace
Switch defective Replace
No control system test (LEDs flashing) after Check and switch on main fuse F1
activation of S1
Screw compressor will not start Fuel filter clogged Replace fuel filter cartridge and vent fuel
(starter motor turning) system (see engine operating manual)
Fuel line loose, broken, or jammed Repair line
Air in system Vent fuel system (see engine operating
manual)
Lifter magnet not working Replace
Other engine problems See engine operating manual
40
10. Troubleshooting
41
11. Generator option
11 Generator op tion
42
11. Generator option
11.4 Operating the generator additional insulation monitors to the To cope with the greater mechanical
(Working safely with electrical generator with its built-in equivalent. strains and stresses on the generator’s
distribution system, use rubber-sheathed
equipment) During insulation and voltage tests
cables to the minimum standard of
carried out on the generator by trained
This state-of-the-art synchronous H07RN-F or A07RN-F in accordance with
electricians, disconnect the insulation
generator has been designed and built DIN/VDE 0282 Part 810, or equivalent
monitor.
with maximum safety in mind. It will help designs, as moveable (extension) cables.
you get the most out of your work or Because the generator is not earthed, Where the cables may be under severe
leisure activities. However, like all fault current circuit breakers used in stress, lay them in mechanical protection
electrical equipment, it can represent a distribution systems and equipment systems, or with strong covers, or
source of danger (e.g. risk of electric cannot be relied upon to operate correctly use NSSHöü cables in accordance with
shock) if the operating instructions in this when such units are connected to the VDE 0250.
section are not followed exactly. Please generator, and, due to the Electrical
The lengths and conductor cross
observe the instructions and the notes on isolation with insulation monitoring and
sections of the extension cables must
dangers affixed to your generator. circuit breaking protective measure, are
match the type of equipment and the duty.
not actually required.
Before starting the generator, all devices It is essential to ensure supply cables do
must be unplugged and switched off. Only The insulation monitor and circuit
not exceed the maximum lengths
plug the devices in (one after the other) breaker should be checked daily when the
specified! When using extension cables or
and switch them on after the engine generator is in use, following the quick
moveable distribution systems, the sum of
driving the generator has reached its reference instructions for Testing/
the lengths of all extension cables
nominal operating speed. insulation monitoring/starting/connecting
connected to a generator must not exceed
equipment which are affixed to the
Do not open the generator or the 250 metres (for a copper conductor cross
generator.
switchbox. The brushless synchronous section of 2.5 mm2 - for all sockets). The
design does not require maintenance. total length of the extension cable, or the
Attention
moveable distribution system, connected
Do not modify the internal wiring. Devices connected the generator to any particular socket must not exceed
Repairs to electrical components and to which cause the circuit breaker to 60 m for a copper conductor cross section
electrical operating equipment (supply release, and the red indicator lamp for of 1.5 mm2, or 100 metres for one of
cables, loads) may only be carried out by Insulation fault to light up, must not be 2.5 mm2.
suitably trained electricians. connected to other generators (without
insulation monitoring), or to the public Note
The circuit breakers, control, alarm and mains. Have equipment with insulation For defined releasing of the circuit
release devices and the insulation faults immediately replaced or repaired breaker, a loop resistance of 1.5 Ω per
monitors are specially designed for the by the manufacturer or a suitable socket must not be exceeded.
generator and its sockets. Only use electrical specialist.
original spare parts if replacements are The circuit breaker must not be used for
needed. When working in restricted conductive routine switching on of the 3-phase
areas, i.e. as defined in DIN/VDE 0100 generator. If several devices, particularly
The generator meets the requirements 706 (e.g. in boilers), only one power tool those with different power consumption
of the Protective isolation with equi- or mobile measuring instrument may levels, are connected to the AC sockets,
potential bonding conductor and insulation be connected to the generator, or for different voltage drops can arise, depend-
monitoring with circuit breakers regulation each such load an additional isolating ing on the turn-on time of the neutral.
in IEC 60364-5-551 and the German Gas transformer, or one isolating transformer
Installation and Plumbing Association with several secondary windings, should Avoid overloading the generator. In
(DVGW) regulation GW 308. The system be used. Handheld lights may only ever particular, to ensure user safety and
is an IT type, with neutral and PE be used in restricted conductive areas optimum performance, it is essential to
(equipotential bonding conductor). when operated off a SELV (safe extra low observe the following rules:
voltage) isolating transformer. 1. Only devices whose voltage and fre-
The generator does not have to be
earthed (with a ground rod for example) to Many portable power tools conform to quency data on the load identification
ensure adequate safety protection. German protection class II (i.e. they are plate conform to those on the generator
However, if desired or required, defined double insulated, symbol ■ ■ ). These identification plate may be connected.
earthing of the generator can also be devices should be used if possible. Use a 2. Only devices whose power
provided. cable and plug to connect any protection consumption does not exceed the
Earthing of the neutral (N), or connecting class I device (i.e. with metal housing output specified on the generator
of the neutral to the equipotential bonding parts that are not double insulated) to be identification plate may be used. The
conductor (PE), is prohibited on the used to the PE (equipotential bonding) total power consumption of all of the
generator, the distribution system and all conductor. loads connected to the generator must
other devices. The use of so-called Only connect devices and distribution not exceed its output.
neutralised devices is not permitted, and systems which are in good condition to the 3. Note that the starting consumption of
would lead to insulation monitoring being generator. The insulation, and plug and devices driven by electric engines is
enabled automatically. socket combinations, must be in good generally a multiple of the specified
The generator must not be used to inject condition to ensure user safety. Do not rating. If in doubt, it is advisable to
power into a construction site distribution use any damp or dirty connectors. contact the equipment manufacturer
system. directly.
The distribution systems (e.g. extension
To avoid unwanted interaction, do not cables, device leads) must be carefully The maximum current specified for each
connect distribution systems with chosen, laid and maintained. Check the socket must not be exceeded.
electrical cables regularly, replacing rather
than repairing any that are faulty.
43
11. Generator option
The generator may only be used if the * Ensure that all the devices on the
circuit breaker released during the test generator output sockets have been
and the red indicator lamps came on. disconnected.
Note
All device switches must be in the
AUS / 0 / OFF position.
44
11. Generator option
45
11. Generator option
Efficiency at nominal output (All resistances measured using the 4-wire Generator regulator
at 0.8 ind 0.85 R method) Model DCB
at 1.0 0.88 Connector assignment
8 pole Pin Colour Function
Distortion factor < 5% 1 red F1
Weight 75 kg 11.8 Technical characteristics of 2 grey F2
Overall size BG132 7 kVA 110 V generator 3 yellow ZU
Overall length 508 mm 4 yellow ZV
Generator model WG 7/5-2 5 yellow ZW
Generator regulator Generator type Synchronous, internal 6 brown L1
Model DCB pole, brushless, with
Connector assignment 7 blue N
exciter, electronically 3 pole 1 not assigned
Pin Colour Function controlled
1 red F1 2 N
Generator frame B3/two bearings 3 L1
2 grey F2 Degree of protection IP 54
3 violet 1/2 U 4 pole 1 black switch contact
2 black switch contact
4 violet 1/2 V Generator characteristics:
5 violet 1/2 W 3 not assigned
Extremely low dynamic internal resistance, 4 not assigned
6 blue N same output voltage whether hot or cold,
Switchbox no dangerous overvoltage during dynamic Switchbox
Degree of protection IP 54 overspeed, small reactive effect from non-
Dimensions 206x236x133 mm Degree of protection IP 54
linear or very inductive equipment, trouble- Dimensions 206x256x133 mm
Design Front panel type free operation of equipment with phase
All-pole shutdown in event of ISO error Design Front panel type
control, no dangerous overvoltage of the Fusing All poles
Fuse protection All-pole 32A socket unloaded phases, load current may have
L1 C20A U1 AS32A
significant DC components U2 2 x AS16A
L2 C20A
L3 C20A Power system Insulation monitoring
N leading N (IEC 38/50Hz) 1-phase AC
Fuse protection 16A sockets Model KWG-ISO_001
2 x 115V Controls Red test button
L1 C16A
Green reset button
Amplified phases 3
Insulation monitoring
Model KWG-ISO_001 Areas of application
Nominal output engines difficult to get running, welding
Controls Red test button
(0.8 cap/ind) 7000VA devices (incl. inverters), pumps,
Green reset button
Nominal current 32A + 2 x 16A compressors, tools, construction
Electronic evaluation system Startup current 4.1 times Irated machinery, illumination
Integrated on the generator controller Operating mode S1, continuous
Speed reduction Activation < 75W Protective measure Electrical isolation, Generator data
Time to speed with equipotential Winding Colour Ins. class Resistance
reduction 100 seconds bonding conductor (at 20°C)/Ω)
in accordance with U1-N brown-blue F 0.195
Outputs VDE 0100.728 U2-N black-blue F 0.195
Output for speed reduction Coolant Air/externally ZU-ZN yellow-yellow F 1.25
Potential-free make contact ventilated with own ZV-ZN yellow-yellow F 1.25
Switch voltage: max. 250V AC fan, independent of ZW-ZN yellow-yellow F 1.25
max. 40V DC/1A direction of rotation 1F1-1F2 red-grey H 25.4
Current: max. 6A Nominal speed for
Make-break capacity max. 1500V AC nominal frequency 3000 rpm (All resistances measured using the 4-wire
Min. speed for R method)
Admissible load current
nominal output 3000 rpm
5A/AC1 at 1x105
Efficiency at nominal output
switching cycles
at 0.8 ind 0.81
1A/24V DC L-R at 1.0 0.84
load at 2x105
switching cycles Distortion factor < 5%
Mode switch Weight 53 kg
Type 1 key switch Overall size BG132
Display yellow LED ”1“ Overall length 357 mm
yellow LED ”2“
Generator data
Winding Colour Ins. class Resistance
(at 20°C)/Ω)
U-N brown-blue F 0.29
V-N white-blue F 0.29
W-N black-blue F 0.29
1/2 U-N yellow-blue 0.15
1/2 V-N yellow-blue 0.15
1/2 W-N yellow-blue 0.15
1F1-1F2 red-grey H 25.4
46
11. Generator option
RESET
TEST
RED 1
GREY 2
ORANGE 8
YELLOW 3
YELLOW 4
YELLOW 5
BROWN 1
BLUE 4
BLUE 5
WHITE 2
BLACK 3
GREEN/YELLOW 6
FUSE 5A
braun
blau
Fig. 42
Fig. 43
47
11. Generator option
Fig. 44
11.12 Troubleshooting
Sockets dead
no no
Connected
devices are faulty
Unplug
Does fuse
Has fuse blown? yes connected yes
still blow?
devices
no no
Connected
devices are faulty
Contact customer
service or
take device in for
checking.
48
11. Generator option
Attention
Use genuine spare parts only!
49
12. Heat exchanger option
Danger
12.3 Maintenance/Care
This system is maintenance-free.
50
13. Compressed air processing option (after cooler / heat exchanger / filter)
In an air cooler (on the cooling air intake 13.3 Maintenance instructions
13.1 Safety regulations for
side), the compressed air is cooled down
alternate compressed air
to a temperature close to the prevailing Danger
processing ambient air temperature downstream of
the pressure vessel. A condensate Prior to and when carrying out
Danger separator with continuous condensate maintenance and repair procedures,
discharge is installed downstream the air- please do observe the general safety
When operating the compressor, cooler.
please observe the general safety regulations in chapter 3 of the
regulations laid forth in the compressor operating manual.
Attention
compressor operating manual.
Attention
When there is a danger of freezing or
when the machine is switched off for a The filters have to be disposed of.
prolonged period, any remaining
13.2 Design and operation The post cooling systems is mainte-
condensation must be drained from the
secondary cooler. For doing this the nance-free. For cleaning procedures,
System function diagram:
bottom cover of the secondary cooler see 9.1 ”General maintenance“ in the
see page 19, Fig. 7
must be opened and it must be compressor operating manual.
emptied utilising the pressure
After cooler option remaining in the machine.
Post option
The oil-containing condensate has to
be collected. Do not allow to enter into Filter change is required at latest when
the soil or into the drains! a differential pressure of 400 mbar has
been reached or after approximately
500 operating hours - depending on the
Filter option (ZTV-ING Part 3 Sec. 4) degree of contamination.
13.4 Troubleshooting
51
14. Oil temperature controller
Danger
TO COOLER
FROM
PRESSURE
VESSEL
FROM
COOLER
TO COMPRESSOR
Fig. 46
14.4 Troubleshooting
Compressed air temperature too low
Oil temperature controller in the oil line
is defective -> replace it.
52
15. Undercarriage
15 Undercarriage
Fig. 47
53
15. Undercarriage
Over-run hitches 15.5.2 Preliminary requirements: When the brake is correctly adjusted,
the actuating travel of the control cable
KNOTT over-run hitches are available * When carrying out adjustments, always [11] will be 5-8 mm.
for both hydraulic and mechanical brakes. start with the wheel brakes.
Carry out the adjustment procedure,
Handbrake lever with power reservoir, * When carrying out adjustments, turn as described, on all the wheel brakes
code „KH“ the wheel only in the direction of in succession.
forward travel.
With the type “KH” the spring reservoir is
under torsion at the centre point. If the * Insert the security bolt [15] (see
handbrake is applied, then it works warning plate)! 15.5.4 Adjusting the brake
automatically and requires almost no compensating system
force. The system is designed so that * Do not pre-tension the expanding
when the handbrake is applied, sufficient locking mechanism in the brake. If
energy is stored within the spring. When necessary, loosen the brake linkage [6]
transmitted through the brake rods this at the brake compensator [8].
prevents the brake shoes from slipping * Check the expanding locking
away from the brake drum. mechanism and control cable [11]
for ease of movement.
54
15. Undercarriage
* If necessary, adjust the position of the 15.6 Readjusting the braking 15.7 Maintenance and care
balance [10] and control cables [11]; in system
the case of tandem trailers, also adjust KNOTT – overrun systems
the master compensator [9] on the In general, readjusting the wheel brakes
linkage [6]. * The overrun system must be lubricated
adequately serves to readjust the braking
with lithium-soap grease by way of the
* The compression spring [7] may only system, i.e. to compensate for brake lining
grease nipples and at all the moving
be lightly pre-tensioned and must not wear. To readjust the wheel brakes,
parts.
become fully compressed when proceed as described under 'Adjusting the
activated! braking system'. Check the play in the a) every 5000 km (3000 miles)
linkage [6] and readjust if necessary. b) or every 6 months
c) or if they become stiff
Attention
15.5.5 Adjusting the brake linkage [6] * Inspect the bellows for damage,
* Check the expanding locking replace if necessary
Adjust the brake linkage [6] so that it is mechanism and control cable [11]
free of play longitudinally, without initial * Replace the overrun shock absorber
tension (reversing lever [4] free of play). * The expanding lock compensator every 20,000 km (12,500 miles) or
must not be pre-tensioned in the every 3 years at the latest.
brake.
Readjustment * Check the play at the coupling point
* Do not attempt to compensate for every 20,000 km (12,500 miles). If the
* Operate the handbrake lever [3] ease of movement caused by brake play exceeds 3 mm, replace the guide
powerfully several times in order to lining wear by readjusting (shorten- bearing or drawbar.
settle the braking system. ing) the brake linkage [6], e.g. by
* Check the tightening torques of the
* Check the position of the brake way of the linkage screw fastenings
fastening screws at the guide bearing
compensating balances [9 and 10] every 5000 km (3000 miles);
which should be at right angles to the Readjustment
direction of towing Screws with grease nipple
* Operate the handbrake lever [3] 50 +5 Nm
* Check the play in the linkage [6]; if powerfully several times in order to Screws without grease nipple
necessary, adjust the linkage [6] again settle the braking system 80 +5 Nm
so that it is free of play, but without
initial tension * Check the position of the brake * Check the tightening torques at the
compensating balances [9 and 10] clamping block of the drawbar and
Slight play in the bowden cable [14] (which should be at right angles to the clamping socket (drawbar tube - axle
must persist. direction of towing). joint) every 5000 km (3000 miles);
* Check the position of the handbrake * Recheck the play in the linkage [6]; M12 screws 80 +5 Nm
lever [3]; M14 screws 90 +10 Nm
if necessary, adjust the linkage [6]
when checking the dead centre of the again so that it is free of play, but * Check that the braking system is
lever, resistance starts 10-15 mm without initial tension. correctly adjusted every 5000 km
above dead centre (3000 miles).
* Check the positions of the handbrake
* Check that the wheels rotate freely with lever [3], the play in the bowden cable
the brake released. and compression spring [7] (only light Vertically adjustable drawbars
initial tension);
Clean the faces of the tooth systems
Final check * when checking the dead centre of the free of fretting rust or other contamination
* Check fastenings for security (secure lever, resistance starts 10-15 mm at least once a year in order to maintain a
the hexagon locking nuts of the screw above dead centre good fit.
fastenings for the transmission system, Lubricate the threaded bolts and joints
control cables, brake compensators, Final check once a year or at any time if they become
turnbuckle, linkage, etc.). stiff.
* Check the screw fastenings for the
* Check the bowden cable for slight play transmission system (control cables,
[14]; if neccessary, adjust the cable. Attention
brake compensators, linkage, etc.).
* Check the compression spring [7] for Do not grease the tooth system!
* during operating braking with empty
initial tension. trailer should be used maximally 1/2 of If desired, a lifting and adjusting system
the overrun travel can be installed between the drawbar
Test run and the overrun system. The control arms
* Check tthe bowden cable for slight play
of the adjusting system permit swivelling
* If necessary, carry out 2-3 brake tests [14]; if neccessary, adjust the cable.
about an angle of -10° to +49° in six
* Check the tension of the compression positions. In every case, the overrun
Brake test spring [7] system or drawgear always remains
horizontal.
* Recheck the play in the brake linkage
[6] and, if necessary, readjust the An integral gas-filled strut automatically
linkage [6] for length free of play generates lifting force which reduces the
(during operating braking with empty force required by the user. If the strut
trailer should be used maximally 1/2 of becomes damaged or develops a leak, it
the overrun travel) must be replaced.
55
15. Undercarriage
56
15. Undercarriage
57
16. Tool oiler option
Fig. 53
Attention
Fig. 54
Do not run the machine with an empty * Shut down the screw compressor and
oiler tank! The tank must always wait until the compressor is
contain a minimum of 0.2 l of tool oil. depressurized.
Danger * Unscrew the screw plug.
Only refill the tool oiler, when the * The oil must be visible in the oiler
screw compressor is out of operation reservoir; refill, if necessary (oil to be
and depressurized! used: CompAir AES 82).
Only screw off the oiler reservoir, when * Check the seal of the screw plug,
the screw compressor is out of replace if required.
operation and depressurized! * Screw in the screw plug with the seal
Do not spill any oil! and tighten.
Watch out for leakage! * Check for leaks after start-up of the
screw compressor.
The oil dosage is continuously variable
at the adjusting knob.
* Turning the adjusting knob clockwise
(symbol »–«) will reduce the oil flow up
to 0-quantity (i.e. no oil for tool
lubrication in the compressed air).
* Turning the adjusting knob
counterclockwise (symbol »+«) will
increase the oil flow.
58
Gardner Denver Deutschland GmbH
Argenthaler Str. 11
55469 Simmern
Deutschland
w w w.compair.com
e-mail: sales@compair.com