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C30-C50 Deutz Operating Manual G-DLT0404 02-1
C30-C50 Deutz Operating Manual G-DLT0404 02-1
Deutz M1011F
Powered Compressor
61
1. Foreword
max. installation
Delivery volume
Type of cooling
Pressure range
Operating
Fuel tank
Ambient Engine
pressure
capacity
Engine
height
Oil fill
temperature speed
[m3/min] [bar] [bar] [°C] [°C] [m] [l] [kW] [rpm] [rpm] [l] [l]
C30 3.0 7 5.0-8.0 -10 +50 1000 9 F2M1011 Oil 22.6 1850 3000 7.5 60
C30G 3.0 7 5.0-8.0 -10 +45 1000 9 F2M1011 Oil 22.6 1850 3000 7.5 60
C38 3.8 7 5.0-8.0 -10 +45 1000 9 F3M1011F Oil 34.0 1650 2800 6.75 60
C42 4.2 7 5.0-8.0 -10 +50 1000 9 F3M1011F Oil 35.6 1850 3000 6.75 60
C42G 3.8 7 5.0-8.0 -10 +45 1000 9 F3M1011F Oil 34.0 1650 2800 6.75 60
C35-10 3.5 10 5.0-10.0 -10 +40 1000 9 F3M1011F Oil 34.0 1650 2800 6.75 60
C50 5.0 7 5.0-8.0 -10 +50 1000 9 F3M1011F Oil 35.6 1850 3000 6.75 60
location,distance 1m
max. sound intensity
Length (max.)
Tyre pressure
to 2000/14/EC
at the operators
weight rating
connections
Trade name
Width with
mudguard
distance 7m
Operating
Height
Tyres
Rim
[kg] [kg] [mm] [mm] [mm] [bar] [dB/1 pW] [dB(A)] [dB(A)]
C 30 1025 760 3447 1490 1336 41/2 J x 13 165SR13 2.5 2 x 3/4" 100 84 71
C 30G 1025 835 3447 1490 1336 41/2 J x 13 165SR13 2.5 2 x 3/4" 100 84 71
C 38 1025 795 3447 1490 1336 41/2 J x 13 165SR13 2.5 2 x 3/4" 100 84 71
C 42 1025 795 3447 1490 1336 41/2 J x 13 165SR13 2.5 2 x 3/4" 100 84 71
C 42 G 1025 870 3447 1490 1336 41/2 J x 13 165SR13 2.5 2 x 3/4" 100 84 71
C 35-10 1025 795 3447 1490 1336 41/2 J x 13 165SR13 2.5 2 x 3/4" 100 84 71
C 50 1025 865 3447 1490 1336 41/2 J x 13 165SR13 2.5 2 x 3/4" 100 84 71
62
1. Foreword
1.4 Maintenance and care 1.5 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 operate Safety regulations
careful execution of care and maintenance the compressor safely, cost-effectively
work are therefore essential, especially and with due care. Compliance with the Danger
under difficult working conditions. instructions in this manual will help to avoid
It is important that you follow the safety
danger, reduce repair costs and downtime,
regulations in Chapter 3 of the operating
and increase the reliability and service life
manual.
Service of the compressor.
In case of faults, or should you require This operating manual is to be
spare parts for the screw compressor, supplemented by instructions concerning Technical modifications
please contact your local CompAir agent. current national regulations for accident
We reserve the right to undertake
prevention and environmental protection. It
In case of damage, the trained technical modifications without notice in the interests
must always be available at the site of the
staff will guarantee a fast, expert repair of technical progress.
compressor. The operating manual is to be
using CompAir spare parts. Original
read and used by all persons in charge of
CompAir spare parts are manufactured
work with the compressor, for example
according to the state of the art and
operation, including setting up, correcting
guarantee continued reliable operation.
faults during operation, disposal of waste
products from production, care, disposal of
If you have important questions, process materials, upkeep (maintenance,
inspection, repair) and transport.
Besides the operating instructions and
CompAir Drucklufttechnik GmbH the current regulations applicable in the
Werk 55469 Simmern
user's country and at the sites of operation
concerning accident prevention, the
recognized technical rules for safe and
proper working are also to be complied
with.
Typ, type, modèle, tipo
1 2
Warranty
Handelsbezeichnung, trade name, dénomination Baujahr, year,
commerciale, denominazione commerciale année, anno
63
2. Index
1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.1 Information on the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.2 Normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.3 Specifications type DLT 0404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.5 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3. Security regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.1 Identification of safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.3 Modifications and alterations to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.4 Loading / Relocation / Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.5 Installation on site / Starting / Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.6 Special jobs / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.7 Instructions concerning particular hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.8 Symbols and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8. Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.1 Recommended lubricant for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.2 Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.3 Tool lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.5 Recommended lubricants for the bogies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
64
2. Index
9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.2 Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.3 Maintenance of chassis and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.4 Compressor maintenance / Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.4.1 Oil filter replacement (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.4.2 Oil change (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.4.3 Checking the automatic monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.4.4 Inspecting / Replacing the fine separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.4.5 Air filter replacement (compressor / engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.4.6 Checking the safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.4.7 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.4.8 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.4.9 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
65
3. Security Regulations
3.1 Identification of safety Personnel delegated to work with the Only trained or specially instructed
machine must have read the operating personnel may be assigned to this work.
instructions
manual before beginning this work, The responsibility of the personnel for
CompAir accepts no responsibility for particularly the chapter on safety operating, setting up, maintaining and
any damage or injury caused by non- instructions. It is too late to do this while repairing the machine / installation must
compliance with these safety measures or working. This applies particularly to be clearly defined.
non-observance of normal care and personnel only using the machine
Make sure that only authorized personnel
caution during the handling, operation, occasionally, e.g. for setting up and
use the machine.
maintenance or repair of this compressor, maintaining the machine.
even if not expressly stated in this Define who is responsible for operating
Safety and danger-conscious working
operating manual. the machine, and authorize him to ignore
by the personnel in compliance with the
instructions from third parties if these
If any of the regulations contained in operating manual should be checked at
instructions could compromise safety.
this manual do not correspond to local least occasionally.
statutory provisions, particularly with Only allow personnel that are training,
The personnel must not have long, loose
reference to safety, then the stricter of that are under instruction or are attending
hair, or wear loose clothing or jewellery,
the two applies. a course of general training to use the
including rings, due to risk of injury through
machine / installation under the constant
These safety instructions are of a general catching. Personal protective equipment
supervision of an experienced person.
nature and are applicable to various types should be worn if necessary or as required
of machine and equipment. For this reason by regulations. Work on the electrical systems of the
it is possible that some information may not machine / installation may only be carried
Pay attention to all safety and danger
apply to the aggregate(s) described in this out by a trained electrician in accordance
warnings on the machine/ installation!
manual. with electrical regulations.
Make sure that all safety and danger
Only persons with special knowledge and
Danger warnings on the machine / installation can
experience of hydraulics may work on
be read.
system elements, for example components
Places thus marked refer to possible
For all safety-relevant modifications to under pressure.
dangers for persons.
the machine / installation or its operating
Attention behavior, stop the machine / installation
immediately and report the fault to the
Places thus marked refer to possible competent authority / person. 3.3 Modifications and alterations
dangers for machines or parts of to the machine
Spare parts must meet the technical
machines. requirements laid down by the No alterations, additions, or modifications
manufacturer. This is always guaranteed to the machine may be carried out without
Note when original spare parts are used. the approval of the manufacturer. This
Places thus marked give general and Replace hydraulic hoses at the given is also true for the installation and the
technical information for optimum, cost- intervals, or at suitable intervals, even if adjustment of safety devices and valves
effective machine use. no safety-relevant defects are visible as well as for welding at supporting
(DIN 20066, Part 5). and pressurized parts. Unauthorized
modifications to the machine are prohibited
Observe the intervals stipulated or those for reasons of safety.
3.2 General safety instructions given in the operating manual for routine
checks and inspections. Original parts are specially designed for
Organizational measures our machines. We must explicitly point out
Workshop equipment suitable for carrying that parts and special accessories not
Please keep this operating manual handy out maintenance work is essential. supplied by us are not approved by us.
at all times on the site of the machine / Installing or using such products may thus
installation, in the bag provided. The location and operation of fire
extinguishers must be made known. adversely affect active and/or passive
Please note and pass on general Observe the instructions concerning fire safety.
statutory and other binding regulations alarm and firefighting. The manufacturer accepts no liability
that may supplement the operating whatsoever for damage resulting from the
manual for the prevention of accidents Limiting values (pressure, temperature,
time settings etc.) must be permanently use of non-original parts or special
and the protection of the environment. accessories. This also applies to the
Such obligations may be for example the marked.
installation and adjustment of safety
handling of hazardous materials, or the devices and valves as well as to welding
provision and/or wearing of personal Personnel selection and qualification; on bearing and pressurized parts.
protective equipment, or traffic regulations. basic tasks
Instructions, including supervisory
Note
Work on or with the machine / installation
responsibility and duty of notification for may only be carried out by reliable The General Type Approval becomes inva-
taking account of special in-plant factors, personnel. Observe the minimum statutory lid in case of modifications or alterations
for example regarding work organization, age. which change or infringe upon the external
sequences of operations, personnel geometry as well as the gross axle weight
assigned to certain tasks, are to be added rating.
to the operating manual.
66
3. Security Regulations
3.4 Loading / Relocation / Transport Before or immediately after completion Do not travel across slopes transversely:
of loading, secure the machine / installation always keep equipment and loads near
Loading / Relocation to prevent accidental shifting. Display an ground level (for example, do not place
appropriate warning. Before putting the them on the bodywork).
All loose parts that could fall down when machine / installation back into operation,
the machine is lifted must first be removed On descents, always adapt speed to the
the securing devices must be duly
or secured; pivoting parts like doors, etc. circumstances! Never change into low gear
removed.
must be immobilized. during the descent, but always beforehand.
Parts to be removed for transport When leaving the driver's seat, always
For lifting heavy parts, hoisting gear and purposes must be carefully refitted and secure the unit to make sure that it cannot
heavy-lift facilities with the appropriate fixed again before putting the machine / roll away or be used without authorization!
capacities, which have been checked and installation back into operation.
approved in accordance with local safety Avoid all operations that adversely affect
regulations, must be used. When putting the machine / installation the stability of the unit.
back into operation again, only proceed in
For lifting machines or parts of machines accordance with the operating manual.
with one or more lifting eyes, only hooks
or shackles complying with local safety 3.5 Installation on site / Starting /
regulations may be used. Never fasten Transporting the complete unit Normal operation
cables, chains or ropes to or through lifting Make sure that the air vessel is not under
eyes. pressure. Installation on site
Lifting hooks, lifting eyes, shackles etc. Lift and secure supporting gear. Besides the general technical operation
must never be bent and must always be in accordance with the regulations of the
stressed in alignment with the load-carrying Make sure that the drawbar eye can local authorities, it is essential that the
axis. The load capacity of the hoisting gear move freely in the tow bar. following guidelines be observed.
is reduced if the lifting force is applied at an Check to make sure that the drawbar is Before switching on the machine /
angle to the axis. adjusted to the bar height of the towing installation, or starting it up, make sure
All bearing parts must be stressed vehicle. that nobody can be injured by the
vertically, as far as possible, for maximum Check to make sure that the body is machine / installation as it starts up.
safety and optimum performance of the closed and locked, and that the cable for The installation is to be set up in such a
hoisting gear. If required, a support is to be the rapid-emergency brake is connected way that it is adequately accessible and
installed between the hoisting gear and the to the towing vehicle. that the necessary cooling is ensured.
load. Secure the load properly.
Join up the connections of the air brake, Never block the admission of air.
When heavy loads are being conveyed if present. The air intake is to be designed in such
by means of hoisting gear, it is imperative
Check to make sure that the wheels are a way that no dangerous admixtures
to keep well clear of the load in order to
properly tightened, that the tyres are in a (inflammable solvent vapors etc., but
avoid accidents.
roadworthy condition, that the tyre pressure also dust and other dangerous or toxic
Never leave the load suspended on the is correct and that the brakes function substances) can be taken in. This also
hoisting gear. properly. applies to flying sparks.
Acceleration or braking of the means of Connect the cable for the signalling The air intake is to be designed in such a
transport must remain within the approved and lighting fittings. Check the proper way that no loose personal clothing can be
limits. functioning of the lighting. drawn in.
The hoisting gear is to be set up in such Release the handbrake. Make sure that the compressed air line
a way that the object is lifted vertically. from the compressor to the air network can
Should this not be possible, precautions Before transporting the unit, always expand as a result of heat and cannot
must be taken to prevent the load from check to make sure that the accessories come into contact with inflammable
swinging. Thus it is possible to use two are firmly attached so that they can cause materials.
sets of hoisting gear, both with an angle of no accidents!
The compressed air line connected at the
inclination of not more than 30° to the When using public roads, tracks and air exit of the unit must not be under strain.
vertical. spaces, observe the current traffic
Compressed-air lines have to be marked
Nominate experienced supervisors for the regulations, and if necessary make the
distinctly according to local regulations.
lifting process. unit roadworthy first!
Never exceed the maximum towing If several compressors are arranged in a
Machines may only be hoisted correctly
speed. Observe national regulations! system, manually operated valves have to
using hoisting gear in accordance with the
be installed so that each machine may be
information in the operating manual (limit Always switch on lights if visibility is poor shut off individually. For the purpose of
stop points for heavy-lift facilities etc.) and during lighting-up time! shutting off pressurized systems, you
Only use a suitable transport vehicle with should never rely on the effectiveness of
When going through underpasses,
sufficient carrying capacity. return valves alone.
bridges, tunnels, overhead power lines,
etc., always make sure that you have Safety devices, protective covers, or
enough clearance! insulations mounted on the system must
not be removed or modified in any way.
Always keep a safe distance from the
edges of foundation ditches and
embankments!
67
3. Security Regulations
All pressure tanks located outside the unit Make sure that: * There are no leaks (fuel, oil or coolant
with an approved operating pressure higher leaks)
* All bolted connections have been
than atmospheric pressure and fitted with
tightened * All bolted connections have been
two or more pressure feed lines must be
tightened
equipped with an additional safety device * All electrical wiring has been connected
to automatically prevent the approved correctly and is in good condition * All electrical wiring is properly connected
operating pressure from being exceeded by and is in perfect condition
* The engine exhaust system is
more than 10%.
operationally safe and that no * Safety valves and other pressure-relief
Pipes and other parts with a surface inflammable material is in the vicinity devices are in perfect condition and are
temperature of more than 80 °C must be not blocked, for example by dirt or paint
* The wheel nuts are properly tightened;
suitably secured against contact and
never exceed the specified torque. * The safety devices all work properly
suitably marked.
All connected components must be of
Electrical connections must comply with
the correct size and be suitable for the
local regulations. Cold-starting diesel engines with ether
specified operating pressure and
fuel systems
With compressors fitted with generators, temperature.
use equipotential bonding systems for the The fuel used in these systems is highly
Only use the correct type and size of
protection of persons. inflammable, toxic and poisonous. Avoid
hose coupling and connection.
contact with eyes and skin, and never
Install the machine so that it is as
inhale vapors. Should you accidentally Before blowing through a hose or air line,
horizontal as possible; a slight inclination is
swallow fuel, do not induce vomiting, but it is essential to hold the open end firmly.
permissible (see information in Chapter
seek medical attention. If the open end is not held firmly, it can
"Installation").
whiplash and cause damage or injury.
Before using the ether cold-starting
Set up the machine in such a way that no
system, please read the instructions Avoid any working methods that could be
inlets, outlets or gates are blocked, even
carefully. considered risky!
when the doors are open.
Never use the ether cold-starting system Never play about with compressed air.
Before disconnecting the machine from
while the engine is running, as this can
the towing vehicle, apply the handbrake. Never direct compressed air onto the skin
lead to serious damage.
Disconnect the rapid-emergency brake or towards another person.
cable and lighting cable, disconnect the Wear suitable eye protection when
lines of the air brakes, use chocks to Never use compressed air for cleaning
inspecting the system. Make sure that the
ensure that the machine does not roll away. clothing. When using compressed air to
openings of containers, valves, or pipes are
clean equipment, work with extreme
never directed at yourself or at any other
If a machine with a combustion engine caution and always wear suitable eye
person during inspection.
has to work in a fire-risk environment, the protection.
unit must be fitted with a spark catcher. Never store ether containers at
The compressed air produced by these
temperatures above 70 °C.
In dusty environments, set up the compressors must not be used as breath-
machine in such a way that the wind does able air, unless it has been processed
not blow dust in its direction. During Normal operation specially for such an application in
operation in clean environments, the accordance with the “Safety requirements
Before starting work, make yourself
intervals for cleaning the air intake filter for breathable air.”
familiar with the working environment at the
and the cooler elements are much longer.
installation site. The working environment When breathing apparatus with cartridges
Do not install the machine directly in includes, for example, obstacles in the is used, make sure that the correct
front of walls. Make sure that the warm air working and transport areas, the carrying cartridge has been inserted and that its
coming from the engine and cooling capacity of the ground, and any necessary service life has not expired.
systems is not drawn into the air intake cordoning off of the building site from public
under any circumstances. Drawing this Never use the machine in environments
traffic areas.
warm air in through the engine or cooler where the possibility cannot be ruled out
Take the necessary precautions to make that inflammable or toxic vapors may be
fan could lead to overheating; if it is
sure that the machine / installation is only taken in.
drawn into the combustion chamber, this
operated in a safe, functional condition.
will result in a loss of power. Never operate the system at temperatures
Only operate the machine when all and/or pressures below or above the values
Never relocate the machine if external
protective devices, shutdown devices, indicated in the technical data sheet.
lines or hoses are connected to the
sound-insulating equipment and extraction
discharge valves, in order to avoid damage Persons working in environments or
equipment is in place and working.
to the valves and/or collecting pipe and rooms in which the acoustic pressure is
hoses. Be careful: loose articles of clothing, hair 85 dB(A) or higher must wear ear muffs.
or limbs can still be drawn in by revolving Caution: this may impair communication
No force may be exerted on the
parts. between persons. Warnings may not be
discharge valves, for example by pulling
the hoses or fitting additional equipment heard. Inform supervisor.
Verify regularly that:
(e.g. a water separator, compressed air Shieldings and doors must be closed
oiler, etc.) directly to the discharge valve. * All protective equipment is properly
during operation so that the flow of cool air
positioned and fixed in place
within the housing is not deflected and the
* All hoses and/or pipes within the system efficiency of the sound-insulating is not
are in good condition, are properly fixed reduced. Doors and hoods may only be
in place and do not chafe opened briefly.
68
3. Security Regulations
With water-cooled combustion engines 3.6 Special jobs / Maintenance Only use suitable, technically perfect
with a closed cooling circuit, the cap of the hoisting gear and load suspension devices
coolant recovery bottle must not be Care with adequate carrying capacity. Keep clear
removed before the system has cooled of suspended loads.
down to ambient temperature. Observe the setting, maintenance, and
inspection work and intervals stipulated in Before removing any part under pressure,
Never fill up with fuel while the engine is the operating manual, including information separate the aggregate effectively from
running. Make sure that fuel does not come about the replacement of parts / partial all sources of pressure and release the
into contact with hot machine parts. sections. This work may only be carried out pressure from the complete system.
Do not smoke while filling up with fuel. by specialists. Never use inflammable solvents or
Maintenance work, tests and repairs carbon tetrachloride to clean parts.
Filling up at a pump can cause static
electricity and possibly sparks. In order to should be carried out in a well ventilated Take precautions to avoid toxic vapors
avoid this, a ground cable must be room, away from heat, open flames, or from cleaning fluids.
connected to the system while it is being sparks. Appropriate prohibition signs (fire,
open flames, no smoking) must be put up. Absolute cleanliness is essential during
filled up.
maintenance and when carrying out
The exhaust emissions of combustion Loss of oil leads to a very slippery floor. repairs.
engines contain carbon monoxide - a lethal Statistics have shown that many accidents
can be attributed to the installation or Only carry out maintenance and repair
gas. If a machine with such an engine has
maintenance of machines on oily floors or work when the machine is located on an
to work in an enclosed room, the exhaust
machine components. For this reason, even, stable base and is secured against
gases must therefore be conducted out
always start maintenance work by cleaning running away and against buckling.
of doors by means of a hose or pipe with
an internal diameter of at least 100 mm. the floor and the machine exterior. Only carry out inspection, maintenance,
The use of extraction systems is highly Inform operating personnel before and repair work when the screw
recommended in test rooms for mobile beginning to carry out special work or compressor system is at a standstill and is
machines. maintenance. Nominate a supervisor. not under pressure.
Before connecting or disconnecting After completing repair work, always Protective devices, i. e. protective grids,
hoses, always close the compressor air check to see whether any tools, loose may not be removed during operation.
outlet valves. Before disconnecting a hose, parts or cloths have been left in or on the Caution while the screw compressor is in
always make sure that it is not under machine, driving engine or driving operation.
pressure. equipment.
After the work has been completed,
A hose connected to an air valve must Maintenance and repair work is only to be replace any protective devices that have
be fitted with a safety wire for operating carried out under the supervision of or by a been removed. Operation without
pressures above 7 bars; it is in fact person qualified for this work. protective devices is not permissible.
recommended that this safety device
should be used for pressures above 4 bars. For all work concerning the operation, Working clothing should be close-fitting
The steel wire has a diameter of 8 mm production adjustment, conversion, or during work on running screw compressor
and is firmly clamped to the hose at least settings of the machine / installation and its systems.
every 500 mm. Both ends are fitted with safety-relevant equipment, as well as
cable lugs. servicing, maintenance, and repair,
observe the operating manual for startup Maintenance
Check the machine / installation for and shutdown procedures and the
external damage and faults at least once During maintenance and repair work, the
instructions for maintenance work. contractor has to inform the personnel
per shift. Any changes noticed (including
changes in operating performance) must All maintenance and repair work may about the dangers that can occur during
be reported immediately to the authority or only be carried out when the system is shut their work and about measures to avert
person in charge. If necessary, shut down down, or, with electrical systems, when the such dangers.
and secure the machine immediately. mains power supply is switched off. Make The personnel have to support all
sure that the equipment cannot be measures to improve safety at work.
In case of malfunction, shut down and switched on by accident.
secure the machine / installation Safety devices for preventing or
immediately. Have malfunctions corrected Whenever the machine/system is eliminating dangers must be serviced
immediately. completely powered down for maintenance regularly and their functioning tested at
and repair procedures, it has to be least once per year. Faults discovered must
Observe the operating manual for start- secured against unintentional power-on
up and shutdown procedures as well as be corrected at once or reported to the
or the mains supply has to be cut off supervisor.
inspection displays. with electrical systems.
Only use the correct tools for
* Remove the ignition key, and / or maintenance and repair work.
* Put up a warning sign on the main Only use original spare parts.
switch “Attention! Maintenance work.”
Close off the complete maintenance All maintenance and repair work may
area, if required. only be carried out when the system is shut
down, or, with electrical systems, when the
* Disconnect the starter battery. mains power supply is switched off. Make
Individual parts and larger subassemblies sure that the aggregate cannot be switched
must be carefully attached to the hoisting on by accident.
gear and secured in case of replacement.
69
3. Security Regulations
Whenever the machine/system is The fuel used in these systems is highly Machines whose main movement is back
completely powered down for maintenance inflammable, toxic and poisonous. Avoid and forth must be moved at least once,
and repair procedures, it has to be contact with eyes and skin, and never rotating machines several times, in order to
secured against unintentional power-on inhale vapors. Should you accidentally make sure that there is no mechanical
or the mains supply has to be cut off swallow fuel, do not induce vomiting, but malfunction in the machine or in the driving
with electrical systems. seek medical attention. part.
* Remove the ignition key, and / or Should fuel come into contact with the Only experienced persons may be
eyes, or in case of eye irritation by vapors, charged with slinging loads and instructing
* Put up a warning sign on the main
flush eyes with plenty of clean water and crane drivers. These instructors must
switch “Attention! Maintenance work.”
seek medical attention. remain within sight of the operator or be in
Close off the complete maintenance
touch with him via walkie-talkie or similar
area, if required. Every time a message is displayed or
device.
there is a suspicion that an internal part
* Disconnect the starter battery.
of the machine has overheated, the During assembly work above body
Before removing or opening any part machine must be shut down. Never open height, use appropriate or otherwise safety-
under pressure, separate the equipment the inspection cover, however, before the relevant climbing aids and working
effectively from all sources of pressure and machine has cooled down sufficiently to platforms. Do not use machine parts as
release the pressure from the complete rule out the possibility of the oil vapors climbing aids! Wear safety belts when
system. igniting spontaneously when mixed with air. carrying out maintenance work at greater
heights.
For moveable machines support the In order to avoid an increase in operating
towing mechanism and axle with temperature, inspect and clean the heat Keep all steps, handles, railings,
appropriate means if work is to be carried transfer surfaces (cooling ribs etc.) platforms, scaffolds, and ladders free of
out underneath the units (a jack is not regularly. Draw up a schedule for the most dirt, snow, and ice.
sufficient). suitable cleaning intervals for each
Before beginning maintenance and
machine.
Observe the safety precautions for work repair, clean the machine, particularly
on batteries. Avoid damaging the safety valves and couplings and bolted connections, of oil,
other pressure-reducing devices. In fuel, and special care products. Do not use
Pay attention to cleanliness. Prevent dirt
particular, make sure that they are not aggressive detergents. Use lintfree cloths
from entering by sealing the parts and
blocked through paint, oil carbon, or for cleaning.
exposed openings with a clean cloth,
dust accumulation, which could impair
paper, or tape. After cleaning, remove all covers and
the effect of these devices.
seals.
Before the aggregate is approved for
The insulation or protective shielding of
operation after maintenance or an After cleaning, check all fuel, engine oil,
parts whose temperature may exceed
overhaul, make sure that operating and hydraulic fluid lines for leaks, loose
80 °C and which may accidentally be
pressures, temperatures, and time settings connections, chafing and damage. Correct
touched by personnel may not be removed
are correct and that the control and any faults immediately.
before these parts have cooled down to
shutdown devices are working properly.
room temperature. Always tighten bolted connections
The electric motor, generator, air filter, loosened during maintenance and repair
Check the accuracy of the pressure
electrical components and control work.
and temperature displays regularly. If the
equipment are to be protected against the
permissible tolerance limits have been If it is necessary to dismantle safety
penetration of dampness - for example
exceeded, then they must be replaced. devices during machine set-up,
when cleaning with a steam jet - by
maintenance, and repair work, the safety
covering or sealing them. Never carry out welding work or any other
devices must be reassembled and checked
work that produces heat in the vicinity of
Under no circumstances should the immediately after completing the
fuel or oil systems. Systems, which could
sound-insulating material be removed or maintenance and repair work.
contain fuel or oil, have to be completely
modified.
drained and cleaned, e.g. by means of a Ensure safe, environment-friendly
Never use solvents with dangerous steam jet, before proceeding with the work disposal of process materials as well as
properties for cleaning parts. to be carried out. replaced parts. Components containing oil,
for example fine separators, and oils must
Maintenance work, tests, and repairs Never carry out any welding work on any
be disposed of. Oil must not enter the soil!
should be carried out in a well ventilated pressure tank or components under
room, away from heat, open flames, or pressure, or modify them in any way.
sparks. Appropriate prohibition signs (fire,
If work causing heat, flames, or sparks Safety precautions for work with
open flames, no smoking) must be put up.
has to be carried out on a machine, the batteries
Wear suitable eye protection when surrounding components must be protected
The fluid contained in batteries is diluted
inspecting the system. Make sure that the with nonflammable material.
sulfuric acid which can cause blindness if
openings of spray containers, valves,
Before dismantling or overhauling a brought into contact with the eyes, or
pipes, or atomizers are never directed at
compressor, engine, or any other machine, serious burns if brought into contact with
yourself or at any other person during the
make sure that no movable part with a the skin. For this reason it is essential to
inspection.
weight of more than 15 kg can move or roll work with the greatest of care when
away. servicing batteries, e.g. when checking
battery charge, and to take all necessary
safety precautions.
70
3. Security Regulations
Always wear long-sleeved overalls, acid- The electrical equipment of a machine / Check all lines, hoses, and bolted
resistant gloves and safety goggles. installation must be inspected / tested connections regularly for leaks and visible
regularly. Faults, such as loose con- damage. Repair any damage immediately.
On charging a battery, an explosive gas
nections or overheated cables, must be It is essential that damaged parts should be
mixture is formed in the cells, which can
corrected immediately. replaced! Spurting fluid can lead to injuries
escape through the vent holes in the
and fires.
sealing caps. If ventilation is poor, a highly If work has to be carried out on live parts,
explosive atmosphere can form around the then call in a second person to operate the Before beginning repair work, relieve the
battery, and can persist for several hours emergency stop switch or master switch pressure in system sections to be opened
after charging. with overvoltage release. Cordon off the and in pressure lines (hydraulic and
working area with a red-and-white safety compressed-air lines) in accordance with
Thus:
chain and a warning sign. the descriptions of the subassemblies.
* Never smoke in the vicinity of batteries
Only use insulated tools. Hydraulic and compressed-air lines
that are being charged or have just been
must be routed and fitted in accordance
charged. Keep an adequate distance between the
with the regulations. Do not confuse the
machine/unit and overhead power lines!
* Put up prohibition signs for fire, open connections!
When working near overhead power lines,
flames and smoking in workshops where
equipment must not come near the power The fittings, length, and quality of
batteries are charged.
lines! Danger! Find out about the safe hoses must be in accordance with the
* Never interrupt a current-carrying circuit distance to be observed! requirements.
at battery terminals because of the
After touching high-voltage lines:
danger of spark formation.
Noise
* Do not leave the machine.
* Proceed particularly cautiously when
Sound-insulating equipment on the
connecting or disconnecting * Move the machine away from the
machine / installation must be in operative
reinforcement cables or quick-charge danger area.
position during operation.
cable clamps.
* Warn outsiders not to come closer or
Wear the prescribed personal ear muffs.
When starting up using jumper cables or touch the machine.
Caution: this may impair communication
auxiliary batteries, first connect the positive
* Make sure that the voltage is switched between persons. Warnings may not be
terminals and then the negative terminals.
off. heard. Inform supervisor.
After starting the engine, first disconnect
the negative terminal (ground cable) and * Do not leave the machine until the line The power of perception may become
only then the positive terminal. Disconnect which has been touched or damaged, adversely affected by the noise and by
the auxiliary battery after the starting has been switched off load! carrying ear protection. Warnings may,
procedure in order to avoid the risk of the therefore, not be heard. Circumspect
When working with high-voltage
release of gas (explosion hazard). behaviour by all concerned is necessary.
assemblies, ground the supply cable after
voltage has been isolated, and short- Noise, even when it is not very loud, can
circuit the components, e.g. capacitors, make us nervous and irritated, and after a
3.7 Instructions concerning with a ground rod! longer period of time our nervous system
particular hazards can suffer serious damage. For this reason
a separate machine room is preferable, in
Gas, dust, steam, smoke
Electrical Energy order to keep the noise from the machines
Only carry out welding, burning, and out of the workshop.
Only use original fuses with the specified grinding work on the machine / installation
amperage. Depending on the number of machines in
when this has been explicitly permitted, as
a machine room, the noise generated can
In case of faults in the electrical power there may be for example risk of fire and/or
be very loud. Depending on the level of
supply, shut down the machine / installation explosion.
sound pressure in places where people are
immediately! Prior to welding, burning and grinding present, the following precautions must be
Work on electrical systems or equipment remove any dirt and inflammable taken:
may only be carried out by a trained substances from the machine/system
Below 70 dB(A): No special measures
electrician or by trained persons under the and its environment and ensure proper
required.
leadership and supervision of a trained ventilation (danger of explosion)!
electrician in accordance with the Above 70 dB(A): Persons permanently
Only operate combustion engines in
standards of electrical engineering. present in the room must
properly ventilated rooms. Ensure
wear ear muffs.
Machine and system parts where service, ventilation is adequate before starting up
maintenance, and repair work is being in closed rooms. Below 85 dB(A): For occasional visitors
carried out must be switched off load, if who are only in the
Follow the local regulations applicable at
required by regulations. First check the room briefly, no special
the respective site of installation.
deenergized parts to make sure they are protective measures are
off load, then connect to ground and short- required.
circuit, and insulate neighbouring parts that Hydraulic and pneumatic systems
Above 85 dB(A): Noisy room. There must
are under tension. be a warning sign at
Work on hydraulic equipment may only
be carried out by persons with special every entrance pointing
knowledge of and experience in hydraulics. out that persons entering
the room - even if only
briefly - must wear ear
muffs.
71
3. Security Regulations
Above 95 dB(A): The warning signs at the 3.8 Symbols and definitions
entrances must be
supplemented by the
recommendation that
even occasional visitors
must wear ear muffs.
Above 105 dB(A):Special ear protectors
adapted to the volume
and spectral composition
of the noise must be
available. A warning sign
to this effect must be put
up at every entrance. Carefully read the Operating Attention Hot surface.
Manual before machine set-up and
Make sure that sound propagated
maintenance.
through walls and frames does not cause
an excessive sound level in the
surroundings.
Note
CompAir accepts no responsibility for any
damage or injury caused by noncompliance
with these safety measures or
noncompliance with normal care and
caution during the handling, operation,
maintenance or repair of this compressor,
even if not expressly stated in this Do not inhale any compressed air Lifting spot
operating manual. from the system.
72
3. Security Regulations
1,5 BAR
73
3. Security Regulations
74
3. Security Regulations
Before connecting the tow bar or commencing to tow consult the operating
manual
75
4. Construction and functional description
Airflow
Fresh air is sucked in through the
14
admission opening at the back of the
compressor. The air intake volume is
1 2 air for the engine and for the compressor
4 11 too, as well as cooling air for the engine
and for the oil cooler of the compressor.
76
4. Construction and functional description
Regulation
Note
It is not possible to start up the compressor
if there is insufficient fuel is available.
Starting up: The control function is
inactive at start up, i.e. as the system rises,
the engine speed is lowered to idling and
the suction throttle closed. Once the diesel
engine has warmed up, the throttle/speed
control is activated pressing the load
button.
The throttle/speed control enables the
volume of air tapped (10) to be adjusted
infinitely between 0% and 100%.
The control valve (2) is connected to the
engine speed control lever over a second
set cylinder. When starting, the engine is
set to full load and the control valve is
open. The compressor (23) starts to
produce and pressure builds up inside the
container (13). When exceeding the
operating pressure the P-controller (3)
feeds the set cylinder of the controller with
air. Each change of the pressure at the
admission opening causes a proportional
pressure raise at the exit. This control
pressure operates the control cylinder.
Over the calibrated opening of the exhaust
air nozzle (5) the control air gets partly into
the atmosphere and any condensate will be
let off. The throttle valve closes (throttle-
type governor) and the engine speed will
be lowered (speed control). That way the
air volume will be adjusted variable to the
required air. If the air output drops down to
zero, the throttle valve is completely closed
and the engine runs under idle running
speed. Over the exhaust air nozzle (5) the
sucked in air will be let off over a leakage
cleft. When the pressure of the container
drops down the control pressure of the
controller drops down too; the throttle valve
opens and the engine speed will increase.
When turning off the engine the backlash
flap inside the controller will be closed
through the system pressure. The release
valve (3), which closes parallel to the
engine lifting magnet, looses power and
opens. The container pressure drops down
to zero.
77
4. Construction and functional description
4.3 System description 19. Oil filter Option oil temperature control
20. Oil cooler compressor 30. Oil temperature control
1. Air filter 21. Oil cooler engine Option After cooler
2. Intake control valve 22. Temperature switch 31. Cooler
3. Control unit (proportional controller + 23. Compressor 32. Condensate separator
start-up without load) 24. Diesel engine 25. Heat exchanger
4. Release valve 27. Engine actuating cylinder 26. Oil temperature control
5. Nozzle controller 29. Nozzle 35. Backlash valve
6. Pressure gauge Generator option 36. Extraction lever oil-free compressed air
8. Oiler reservoir 28. Solenoid valve Option filter
9. Oiler valve Generator with pressure reduction 37. Filter combination
10. Taps option Option clean air
11. Venturi nozzle 28. Solenoid valve 38. Pressure control
12. Safety valve 41. Solenoid valve 39. Activated carbon filter
13. Pressure tank 42. Pressure retaining non-return valve 40. One-hand coupling
14. Fine separator Option Heat exchanger
17. Orifice, evacuation line 25. Heat exchanger
26. Oil temperature control
78
4. Construction and functional description
79
4. Construction and functional description
left stoplamp
green yellow (L) left indicator lamp
80
5. Transport and installation on site
5.1 Transport * The lighting is fully functional. The breakaway cable must be attached in
a way that ensures that even on extremely
Never exceed the maximum towing
sharp bends there is no danger of
speed! Danger! Observe national
activating the locking brake.
regulations!
Please also observe the safety
instructions in Chapter 3 on the subject
of transporting.
Before transporting the compressor,
check to make sure that the drawgear of
the towing vehicle and the drawbar eye or
trailer hitch ball connection are aligned
exactly to each other.
When transporting the screw compressor
Fig. 7 with a vehicle, the following points must be
observed:
Fig. 8
Danger
* The shieldings are closed.
Make sure to check the torque after
* The blocks are firmly hooked in place.
50 kilometers following wheel mounting
and at regular intervals. * The support(s) is(are) retracted and 5.3 Loading/Relocation
locked in position (jockey wheel).
Tighten wheel nuts or screws evenly in
a diagonal sequence to the specified * Tow bar connected to the towing vehicle,
torque using a torque wrench. coupling cable connected to trailer.
* The drawbar is adjusted to the height of
Replacing the trailer coupling ring the towing vehicle.
81
5. Transport and installation on site
82
5. Transport and installation on site
Altitude
For operation at an altitude above
1,000 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.
83
6. Preparing the compressor for operation
6.1 Checking oil levels Danger The batteries used are ready to be
installed and ready for service.
6.1.1 Checking the oil level in the Only check the oil level when the Replacement batteries should be of the
pressure tank compressor engine is at a standstill. same type as the batteries installed
Spill no oil! The oil may be hot. Risk (low gassing). The replacement battery
of scalding! should be unfilled and only be preloaded
Check for leaks. so that it has to be filled with battery
2 acid. The battery and the acid should
Proceed as follows: have a temperature of at least +10 °C.
* Ensure that the screw compressor is Proceed as follows:
standing horizontally.
1 * Fill up with battery acid as far as the
* Ensure that the screw compressor has base of the control insert
been out of operation for some time.
* Leave the battery to stand for some time
* Unscrew dipstick.
* Then shake it gently
* The oil level should be as near as
Fig. 12 possible to the upper dipstick mark. * If required, top up with acid
1 Inspection glass * Correct as required. * Tighten sealing caps
2 Oil filler plug * The battery is ready for use
* Screw in dipstick.
Danger * Close oil filler. * Leave for 1 hour
Only check the oil level when the engine * For oil specifications, see “Engine
is at a standstill and the compressor is Operating Manual”. 6.3 Filling up the fuel tank
not under pressure.
Attention
The pressure tank may be under
pressure and the oil may be hot. After a short test run, the oil level must
Risk of scalding! Spill no oil! not be above or below the upper or
lower dipstick marks. For oil specifi-
Check for leaks. cations, see engine instruction manual.
Proceed as follows:
* Before checking the oil level in the
6.2 Battery
engine and in the compressor ensure
that the vehicle is standing horizontally.
* Ensure that the screw compressor has
been out of operation for some time. Fig. 15
* Check oil level in the inspection glass Danger
* The oil level must be in the middle of the
Only fill up with fuel when the screw
visible range.
compressor is at a standstill.
* Correct as required. Cleanliness is essential! Spill no fuel!
The gases released by the battery are * Close tank tight with tank lid
explosive. Avoid sparks and open fires * With the Deutz engines FM1011, the
in the vicinity of the battery. injection pump is self-ventilating. When
Do not allow acids to come into contact the tank is empty, immediately fill in fuel
with skin or clothing. Wear safety to ensure that the fuel pump is always
goggles. filled with fuel. This condition may result
in starting problems.
Place no tools on the battery.
* Close hood.
The battery is filled and charged in
accordance with DIN 43539. The battery is
Fig. 13 fastened with clamping strips.
84
6. Preparing the compressor for operation
Note
It is not possible to start up the compressor
if there is insufficient fuel is available.
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.
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. 16
When the red service sector in the
transparent part is fully visible, the air filter
is due for maintenance. (See Chapter
Maintenance, air filter replacement.)
Empty the dust emission valve by
pressing together the emission slot in the
direction of the arrow.
Note
Clean the emission slot from time to time.
85
7. Putting the compressor into operation
7.1 Initial operation 7.2 Operating elements of at least 100 mm. The use of extraction
systems is highly recommended in test
Transport inspection Operating panel: rooms for mobile machines.
Every CompAir screw compressor 3 4 5 6 7 Only operate the compressor with the
has already run in the factory and has hood closed. The hood may only be
already undergone a thorough test before opened briefly for minor adjustments
shipment. This test ensures that the while the compressor is running.
compressor complies with the given data Skilled personnel only are authorized to
and works perfectly. Independent of work with the hood open.
the care taken in the factory, it is still
possible for the compressor to be damaged When working with the screw
during transport. For this reason it is compressor in operation and with the
recommended that the unit should be shielding/hood open, wear ear
examined for possible damage during 1 2 protection.
transport. Caution: this may impair
Fig. 18 communication between persons.
Remove any transport seals (dummy
flange, plugs, etc.) and dehydrating agents 1 Ignition switch Warnings may not be heard. Inform
before start-up. Distribution tubes and 2 Start / Run valve supervisor.
connection lines must have the specified 3 Hours of operation counter
dimensions and must be suitable for use 4 "Fault" pilot lamp Attention
with the max. operating pressure and the 5 "Fuel shortage" warning lamp
Opening the hood interferes with the
media to be taken up. 6 "Battery charge" warning lamp
flow of cool air in the compressor
7 Operating pressure gauge
During the first hours of operation, the section.
compressor should be observed in order
Full sound-insulating is only achieved
to be able to ascertain any possible
when the hood is closed.
malfunctions. 8
Check the oil levels in the pressure tank
and in the engine of the compressor
Transport safety locking of the towing
each time before start-up.
arrangement
Do not start the compressor unless the
air tapping cocks are closed.
Note
It is not possible to start up the compressor
Fig. 19 if there is insufficient fuel is available.
Transport safety locking
8 Compressor temperature display
(optional)
Starting up the compressor:
* Close air tapping cocks
86
7. Putting the compressor into operation
* If the engine was started cold, let it Never use the ether cold-starting aid This readjusted operating pressure is to
warm up for approximately 2 minutes while the engine is running, as this can be checked using the pressure gauge on
and then press the START/RUN valve lead to serious damage. the instrument panel at 100% air discharge
(2). If the engine is warm, the START/ and maximum engine speed.
Before using the ether cold-starting aid,
RUN valve can be pressed immediately.
carefully read the instructions and the label
* The installation is now ready to operate. on the tank.
Check that all the hoses and tools have 7.5 Monitoring / fault
been connected correctly and open the Danger
desired air outlet valves. Danger
Never store the ether tank at tempera-
tures above 70 °C. Bridging the safety switch in the
Start-up using jumper cables / auxiliary
automatic monitoring system is not
batteries Note permitted!
Follow the instructions for operating the The display on the pressure gauge may
compressor at an ambient temperature of not go further than the red line.
less than 0 °C, in Chapter 5, Transport and
When the “Fault” indicator lamp lights up,
Installation on Site, in this operating
the screw compressor is automatically shut
manual.
down when the following faults occur:
* Fuel shortage
7.4 Setting the operating pressure * Compressor temperature too high
* Engine oil pressure too low
* Engine oil temperature too high
After one of these faults, it is only
possible to restart the machine after the
Fig. 20
fault that caused the machine to be shut
down has been corrected.
Danger
Longer operation with an auxiliary Attention
battery or jumper cables connected can
Disconnect the battery or generator only
lead to sudden emissions of gas. An
when the engine is not running.
inflammable air / gas mixture is formed.
Explosion hazard! * Switch off the machine if the
compressed air transports oil spray or if
Attention Fig. 21 excessive oil is consumed. (Refer to the
trouble-shooting section)
Serious damage can be caused to the Danger
electrical system if wrongly connected. * Check that the "battery charge" pilot
The setting of the operating pressure lamp is not illuminated. If it glows, even
* Ignition switch in position (Off-Aus) may only be carried out by a specialist. weakly, refer to the trouble-shooting
* First connect positive terminal then The operating overpressure of the screw section.
negative terminal (ground). compressor is set by the manufacturer * Check that the air pressure (7) assumes
* Start as described in section “Starting up (see the identification plate on each a value within the permissible pressure
the compressor.” compressor). range.
Pressure values between 5 or 8 bar and If the machine cuts out, before switching
Note the operating overpressure can be set in off at the ignition switch (1) carry out the
accordance with the identification plate on following checks:
After the engine has started, first each compressor. Pressure values higher
disconnect the negative cable (ground) than this are not permitted. * Interrupt the electric connection to the
and then the positive cable. engine oil pressure switch immediately
Operating pressure is set by a specialist after the engine has cut out and leave it
at the controller. in the interrupted state.
Cold-starting diesel engines with ether * Remove counternut below the control If the "fault" pilot lamp goes out
fuel systems knob of the regulator. immediately this indicates that either a
Attention * Raise pressure by turning the adjusting too low engine oil pressure or a lack of
knob of the regulator clockwise fuel or a defective engine has led to the
For cold starts (winter operation) Start- (towards +). cut-out.
pilot or any other starting aid may be * If the light continues glowing this
sprayed directly into the engine air filter * Lower the pressure by turning the
adjusting knob of the regulator indicates that an excessive engine
(Attention: do not confuse this with the temperature or compressor temperature
air filter for the screw compressor). (It is anticlockwise (towards -).
led to the cut-out.
essential that the engine operating * In order to lower the pressure, open an
manual be observed.) air discharge valve.
* After altering the pressure, lock the
adjusting knob using the knurled nut.
87
7. Putting the compressor into operation
In order to trace the origin of the fault, Display for compressor temperature 7.7 Shutdown
interrupt the engine oil temperature
switch (with the engine oil pressure In order to shut down the compressor:
switch still switched off). If the lamp now
goes dark this indicates that the problem * Close air discharge valves. The screw
is related to the oil temperature. compressor reduces the speed of the
engine back to idling speed after the
* If the lamp continues glowing the fault preset final pressure has been reached.
is located somewhere else. In this case
reconnect the engine oil temperature * Allow the screw compressor to idle for a
switch and interrupt the connection to few minutes.
the compressor temperature switch. If * Return the ignition switch (1) to the
the lamp goes dark the compressor position (Off-Aus).
temperature has led to the cut-out.
* Reconnect all electrical connections Fig. 23 Note
once the fault has been identified in
order to re-establish the function of the Attention This switch can also be used as an
protective elements. Also reconnect
emergency stop switch. No other switching
the engine oil pressure switch. Do not operate the compressor above off method is provided.
the permissible final compression After the installation has come to a
* Switch the ignition switch to its position temperature. standstill all the air is automatically blown
(Off-Aus).
The final compression temperature is out of the pressure tank via the blow-off
Note measured with the temperature sensor and valve.
displayed on the thermometer (option).
These checks must be carried out Danger
The compressor is automatically shut
immediately after the installation has
down when the permissible final It is important that you ensure that the
cut out as the protective circuits reset
compression temperature is exceeded. pressure is completely blown off via the
themselves after cooling down.
blow-off valve.
If the ignition switch is pushed to the very
Should this not be the case, open the air
left while the machine is running it will be
7.6 Operation outlet valves, identify the fault and
switched off.
correct it.
Danger
Pressure gauge for display: “Operating Only operate the compressor at the
pressure” permissible operating pressure and at
the permissible temperature.
Only use the compressor for its
intended purpose (see Chapter 1.2 of
this operating manual) in order to avoid
residual risk for persons and assets.
Only operate the compressor in a safe,
functioning condition.
All components, hoses etc. fitted must
be of the correct size and designed for
the specified operating pressure and
temperature.
Fig. 22 When working with compressed air,
wear suitable protective clothing (e.g.
Danger protective suit, safety goggles, etc.).
Do not operate the compressor at Wearing ear muffs may impair
pressures above the permissible communication between persons.
operating pressure. Warnings may not be heard. Inform
The pressure gauge shows the operating supervisor.
pressure of the compressor. Check the compressor regularly.
The permissible operating pressure is Leaking condensation contains a
indicated on the nameplate! The safety proportion of oil and must be collected
valve pressure is indicated on the pressure and disposed of under safe conditions.
gauge by a red mark. Condensation must not enter the
soil or the rivers. Major quantities of
condensation accumulate particularly
in versions with aftercoolers for
processing compressed air. Provide a
collecting basin.
88
7. Putting the compressor into operation
7.8 Decommissioning
Fig. 24
If the system is to be closed down for a
longer period of time (approx. 3 months
or longer) the following preservation
measures must be taken:
* Engine preservation (see separate
engine operating manual).
* Disconnect battery cables.
* No special measures are required at the
compressor.
* Relieve the strain on tyres by jacking up
the vehicle.
* Check tyre pressure every 2 months.
* Release the handbrake.
Attention
89
8. Fuels
8.1 Recommended lubricant for If other lubricants are to be used, please * Nato Codes F 54, F 75, and F 76
contact: * BS 2869: A1 and A2 (observe sulfur
compressor
content with A2)
CompAir Drucklufttechnik GmbH
* ASTM D 975-81 : 1-D and 2-D
Note Argenthaler Straße 11
* VV-F-800a : DF-A, DF-1, and DF-2.
D-55469 Simmern/Hunsrück
In these screw compressors, circulating oil Telephone 06761 / 832-339 Note
has not only a lubricating function, but in Telefax 06761 / 832-421
particular it also has cooling and sealing See engine instruction manual.
or your authorized dealer or your local
functions. It is therefore exposed to more
branch. At low temperatures, paraffin precipitation
difficult conditions. In particular the
temperature conditions at the installation can cause blocks in the fuel system and
site and the consistency of the air (dust, disruptions in operation. Below outside
dirt, and humidity content, as well as 8.2 Recommended engine oil temperatures of 0 °C use winter diesel fuel
chemical influences) must be taken into (to -15 °C). (This is usually available at gas
account when selecting a suitable lubricant. Lubricant specifications for the driving stations in good time before the winter
engine can be found in the enclosed season begins.) Diesel fuel with additives is
Attention engine operating manual. frequently offered for use at temperatures
as low as -20 °C („Superdiesel“).
Do not mix oils of different
specifications. Note
8.3 Tool lubricants
The maintenance intervals and the Only mix in the tank. First put in the
maximum and minimum operating required quantity of petroleum, then fill up.
Attention
temperatures given in this operating
manual only apply when high-quality See engine instruction manual.
Do not run the machine with an empty
multi-grade oils are used. oiler tank! The tank must always Below -15 °C or -20 °C, petroleum must
Use of the wrong oil leads to impairment contain a minimum of 0.2 l of tool oil. be added.
of function. The wrong tool lubricants lead to If it is necessary to use summer diesel
deposits that cause malfunctions in the fuel below 0 °C, petroleum can also be
Change the compressor oil more
appliances connected! added up to 60 %.
frequently than specified if the
equipment is operated under abnormal For the perfect lubrication of concrete In most cases, adequate resistance to
conditions, i.e. at a high ambient breakers and pneumatic spades, we low temperatures can be achieved by
temperature, high air humidity or in a recommend the use of CompAir oilers or adding a product to improve flow properties
dusty environment. If necessary, automatic pipe oilers, using the special (fuel additive). Consult your engine service
analyse the oil. synthetic CompAir oil AES 82. station.
Out of consideration for the high loads The special advantages of CompAir oil are Attention
imposed on the lubricant in screw as follows:
compressors with oil injection cooling, we The compressor must not be fuelled
recommend the use of suitable, non * Biodegradable, with bio-diesel (DIN 51606) or vegetable
ageing, non foaming, corrosion-protective * Ice guard down to -50 °C, for use with oil.
oils. They must meet the following sound absorbers,
requirements for hydraulic fluids:
H-LP 32 and H-LP 46 in accordance with * Very good lubricity, thus wear-reducing,
DIN 51524, Part 2, June 1985.
* No irritating exhaust gases, work in
8.5 Recommended lubricants for the
The viscosity of the lubricants should enclosed rooms possible, bogies
comply with viscosity class ISO VG 32 DIN For relubrication use only lithium saponified
* Good cleaning effect, no residue
51519, July 1976, with 28 - 35 mm2/s(cSt) / grease which fulfils the following
formation
40 °C, or if the ambient temperature is specifications:
constantly above 25 °C, with viscosity class * Excellent preservation properties,
ISO VG 46 DIN 51519, July 1976, with protects from corrosion. * consistency groups (NLGI) 2
41 - 50 mm2/s(cSt)/40 °C. DIN 51818
When using compressed air consumers
made by other manufacturers, then their * worked penetration 265-295
Attention
regulations must be observed. DIN ISO 2137
Conventional engine oils marked HD * dripping point > 180 °C
must not be used. DIN ISO 2176
When using oils with the “Brief De- 8.4 Diesel fuel * operational temperature
scription HYD 10/HYD 20" in accordance – 40 °C … +140 °C
with the ‘Standard Lubricants for Building Use common diesel fuel with a sulfur
Machinery and Vehicles’ published by the content of less than 0.5 %. If the sulfur This corresponds to a DIN 51502
‘Hauptverband der Deutschen Bauindustrie content is higher, oil has to be changed at lubrication grease, designation KP2N-4U.
e.V.’ (Principal Association of the German shorter intervals.
Greases with different thickeners
Building Industry), only the given hydraulic The following fuel specifications are (soap base) must not be mixed.
fluids may be used in accordance with applicable:
ISO VG 32 and ISO VG 46. Recommended grease: Fuchs Renolit
* DIN 51 601 LZR 2.
90
9. Maintenance
Danger Note
91
9. Maintenance
Operating hours
60 h
500 h
1000 h
1500 h
2000 h
2500 h
3000 h
3500 h
4000 h
4500 h
5000 h
5500 h
6000 h
6500 h
7000 h
7500 h
8000 h
For 2 boxes per annum: Maintenance every 500 h,
although at least every 6 months
1. year
2. year
3. year
4. year
5. year
6. year
7. year
8. year
For 1 boxes per annum: Maintenance every 1000 h,
although at least each year
■ For your own benefit, put a cross on the servicing schedule against maintenance work when performed.
92
9. Maintenance
9.4.1 Oil filter replacement 9.4.2 Oil change (compressor) * Start screw compressor, run for approx.
two minutes, check for leaks
(compressor)
* Switch off screw compressor
* Check oil level, add oil if necessary
Danger
Caution! High voltage! The sensors of
the automatic monitoring system must
Fig. 27 not be short circuited.
Fig. 26
Danger Check individually every 1000 operating
Danger hours:
Only change the oil when the engine is
1. Temperature sensor - screw compressor
Only replace the oil filter cartridge when at a standstill and the screw
(pressure connection)
the engine is at a standstill and the compressor is not under pressure.
screw compressor is not under 2. Oil pressure switch - engine
Caution when draining off hot oil:
pressure. risk of scalding! Spill no oil! 3. Oil temperature gauge - engine
Caution with hot oil: risk of scalding!
Attention
Spill no oil! Checking the automatic monitoring system:
Change the oil filter every 1,000 oper- * Disconnect connecting cable
Attention ating hours, but at least once per year.
* Connect to ground at oil temperature
Change the oil filter every 1,000 oper- The screw compressor must not be gauge.
ating hours, but at least once per year. under pressure during oil change.
* Start screw compressor
Drain the oil at operating temperature.
Note * The automatic monitoring system must
Do not mix oils of different switch off the screw compressor
Dispose of oil filter cartridge in accordance specifications. immediately after starting, and the
with the relevant regulations - hazardous
“Fault” indicator lamp must come on.
waste! Note
Check for leaks. Collect used oil, do not allow it to enter the
Changing the oil filter: soil. Dispose of oil in accordance with the 9.4.4 Inspecting / Replacing the fine
* Unscrew the oil filter cartridge using relevant regulations - hazardous waste!
separator
appropriate tools Spill no oil!
* Dispose of oil filter cartridge Check for leaks. 2
* Apply a thin coat of oil to the seal of the Changing the oil: 1
new oil filter cartridge
* Unscrew dipstick
* Screw on and tighten the new oil filter 3
cartridge (Ident-No. 048 199 74) (follow * Place oil drain pan under oil drain valve
the instructions on the oil filter cartridge)
* Unscrew the sealing cap of the pressure
* Check for leaks vessel
* Check oil level, add oil if necessary * Collect used oil in the oil drain pan
* When the used oil has been drained
completely, use a new sealing ring on Fig. 28
the sealing screw of the pressure
vessel, position and tighten screw or 1 Connection for P controller
close the oil drain valve 2 Connection for compressor suction line
3 Oiler connection
* Fill up with new oil (see section
"Specifications" in chapter 1 for initial Danger
oil capacity; use a little less oil when
performing an oil change). Pressure tank is under pressure. Only
work when the motor is at a standstill
* For lubricants see “Lubricant Table” and the screw compressor is not under
* Check sealing ring on dipstick, replace if pressure.
necessary Caution with hot oil: risk of scalding!
* Screw in and tighten dipstick Spill no oil!
93
9. Maintenance
Danger
Never clean the air filter cartridge with
inflammable liquids.
94
9. Maintenance
hose clip
(engine, compressor/cooler) max. 12 Nm
Fig. 32
Danger
The gases released by the battery are
explosive.
Avoid sparks and open fires in the
vicinity of the battery.
Do not allow acids to come into contact
with skin or clothing. Wear safety
goggles.
Place no tools on the battery.
The battery is maintenance-free in
accordance with DIN.
95
10. Troubleshooting
Clogged oil fine separator filter cartridge Replace compressor oil, oil filter and oil fine
separator filter cartridge
Spring and plunger inside the intake control Clean, replace parts if necessary, readjust
valve are not fully opened
96
10. Troubleshooting
Oil in air line Orifice in oil return line clogged Repair / clean
Oil comes out of the air filter of the Intake control valve defective Check and repair
compressor after the screw compressor (backlash flap, O-ring, spring)
has been shut down
Cable defective or cable cover not plugged Replace or plug onto sensor
onto sensor
97
11. Generator option
11.1 Introduction * The IP 54 protection means the If the generator is overloaded briefly (for
generator is protected against less than the thermal response time of the
This manual describes the operation and splashes, spray and other foreign circuit breaker), or devices with excessive
maintenance of synchronous generators bodies. Do not, however, clean the startup consumption levels are connected,
with switchboxes for no-load and pressure generator with high-pressure the regulator automatically limits the
reduction. equipment. output/startup consumption (through the
excitation current). This leads to a (desired)
All information relates to data available at * Generators may only accept up to
withdrawal of the output voltage. Please
the time of going to press. their nominal load if operated
take account of this when operating several
according to the standard
The manufacturer reserves the right to devices simultaneously on your generator.
temperature range and cooling
make changes at any time, without prior conditions specified. If installed
notice or obligation. It is therefore always Note
under different conditions, or if
advisable to check for updates. cooling of the engine or generator is Switch devices (loads) on one after the
No part of this publication may be impaired, for example in confined other, starting with that with the least
reproduced or transmitted in any form or by spaces or under unfavourable favourable startup characteristics.
any means, without the prior written circumstances, their output must be
reduced. If the generator is extremely dirty,
consent of the manufacturer.
insufficiently ventilated, or operating under
Synchronous generators may only be * Do not modify the generator/ otherwise unacceptable conditions, to
used as such. No other form of use is switchbox. Such changes, or the use prevent it or the regulator being damaged
permitted. of unsuitable parts, will invalidate by overheating, the output voltage is
approval under machinery safety reduced to about half its nominal value if
legislation and certification to the temperature inside the switchbox
EU/EEC Directives. exceeds 80 °C. This compromises the
11.2 Generator safety precautions connected devices, which must be
switched off or unplugged immediately.
Danger Always avoid operating the generator
11.3 Operating principle
under such conditions, and keep it clean
Do not top up current-generating units (particularly fan cowl air inlets, cooling fins).
(generators) with fuel during operation! The generator is a self-excited brushless
synchronous internal pole generator which The generator is fitted with a thermal-
Follow the additional fire and explosion is controlled electronically. It consists of magnetic circuit breaker, which not only
protection regulations in the case of the main machine, exciter, rotary rectifiers protects against overloads, but also
installation in enclosed spaces. and generator regulator assemblies, switches off in the event of an insulation
housed in a common enclosure. The main fault on a connected device. Interruption of
Attention! Exhaust gases are toxic!
machine of the synchronous 3-phase power distribution during operation may be
Do not operate generators in non-
generators has various design features, caused by an insulation fault on a device
ventilated, enclosed spaces!
including a damping cage and balancing (in which case an indicator lamp comes
Check that electrical loads and their system, which allow it to handle an on), or an overload (when it does not). If an
connections are in perfect condition. extremely asymmetrical load. All of the overload has occurred, eliminate its cause,
other equipment required for safe electrical wait for a short time, then reset the circuit
Synchronous generators operate safely
operation is accommodated in the directly breaker. On generators with a hinged glass
and reliably. Before commissioning,
mounted switchbox. cover over the circuit breaker, open the
read through the safety precautions in
this manual carefully. The splashproof and dustproof generator cover, grasp the breaker’s operating
is driven by the engine using V-belts. Over handle and push upwards (always in the
* Ensure that children under the age of centre = yellow mark, not on one side!).
the range from no-load to nominal output,
fourteen and animals do not have Then carefully close the cover again, and
the voltage it supplies is controlled by a
access to the generator while it is tighten its knurled screws, without exerting
highly integrated electronic regulator,
running. force. After the circuit breaker has released
which is fully encapsulated in the cover of
* To avoid endangering people or the switchbox, so that the output voltage due to an overload (indicator lamp off), wait
animals, or causing accidents or over this range complies with IEC 38 for a short time until it can be reset. The
damage to the machine, always requirements. This standard is comparable thermal-magnetic or thermal circuit breaker
carry out the usual checks before with the public mains. is designed in accordance with the
switching the generator on. machine specifications, particularly in
The stability of the output frequency is relation to shock and vibration resistance,
* There is always a risk of electric entirely dependent on that of the speed of and ambient temperature. Only use an
shock if a generator is used the combustion engine. You must therefore original part if replacements are needed.
improperly. Never touch the ensure that this engine is serviced,
generator, or equipment connected maintained and operated properly.
to it, with wet hands.
* When using several generators, or if
the public mains is available, do not
interconnect these systems.
* Caution! Connecting the generator to
the public mains can damage it and
severely endanger personnel.
98
11. Generator option
11.4 Operating the generator The generator must not be used to inject The distribution systems (e.g. extension
power into a construction site distribution cables, device leads) must be carefully
(Working safely with electrical
system. chosen, laid and maintained. Check the
equipment) electrical cables regularly, replacing rather
To avoid unwanted interaction, do not
than repairing any that are faulty.
This state-of-the-art synchronous connect distribution systems with additional
generator has been designed and built insulation monitors to the generator with its To cope with the greater mechanical
with maximum safety in mind. It will help built-in equivalent. strains and stresses on the generator’s
you get the most out of your work or leisure distribution system, use rubber-sheathed
activities. However, like all electrical During insulation and voltage tests
cables to the minimum standard of
equipment, it can represent a source of carried out on the generator by trained
H07RN-F or A07RN-F in accordance with
danger (e.g. risk of electric shock) if the electricians, disconnect the insulation
DIN/VDE 0282 Part 810, or equivalent
operating instructions in this section are not monitor.
designs, as moveable (extension) cables.
followed exactly. Please observe the Because the generator is not earthed, Where the cables may be under severe
instructions and the notes on dangers fault current circuit breakers used in stress, lay them in mechanical protection
affixed to your generator. distribution systems and equipment cannot systems, or with strong covers, or
be relied upon to operate correctly when use NSSHöü cables in accordance with
Before starting the generator, all devices
such units are connected to the generator, VDE 0250.
must be unplugged and switched off. Only
plug the devices in (one after the other) and, due to the Electrical isolation with
The lengths and conductor cross sections
and switch them on after the engine driving insulation monitoring and circuit breaking
of the extension cables must match the
the generator has reached its nominal protective measure, are not actually
type of equipment and the duty.
operating speed. required.
It is essential to ensure supply cables do
Keep the glass cover over the circuit The insulation monitor and circuit breaker
not exceed the maximum lengths specified!
breaker on the front panel closed at all should be checked daily when the
When using extension cables or moveable
times. Tighten the knurled screws by hand generator is in use, following the quick
distribution systems, the sum of the lengths
to maintain IP protection. reference instructions for Testing/insulation
of all extension cables connected to a
monitoring/starting/connecting equipment
generator must not exceed 250 metres
Do not open the generator or the which are affixed to the generator.
(for a copper conductor cross section of
switchbox. The brushless synchronous
Attention 2.5 mm2 - for all sockets). The total length
design does not require maintenance.
of the extension cable, or the moveable
Do not modify the internal wiring. Devices connected the generator which distribution system, connected to any
cause the circuit breaker to release, and particular socket must not exceed 60 m
Repairs to electrical components and to
the red indicator lamp for Insulation for a copper conductor cross section of
electrical operating equipment (supply
fault to light up, must not be connected 1.5 mm2, or 100 metres for one of 2.5 mm2.
cables, loads) may only be carried out by
suitably trained electricians. to other generators (without insulation
monitoring), or to the public mains. Note
The circuit breakers, control, alarm and Have equipment with insulation faults
release devices and the insulation monitors For defined releasing of the circuit breaker,
immediately replaced or repaired by the
are specially designed for the generator a loop resistance of 1.5 Ω per socket must
manufacturer or a suitable electrical
and its sockets. Only use original spare not be exceeded.
specialist.
parts if replacements are needed. The circuit breaker must not be used for
When working in restricted conductive
The generator meets the requirements of routine switching on of the 3-phase
areas, i.e. as defined in DIN/VDE 0100 706
the Protective isolation with equipotential generator. If several devices, particularly
(e.g. in boilers), only one power tool or
bonding conductor and insulation those with different power consumption
mobile measuring instrument may
monitoring with circuit breakers regulation levels, are connected to the AC sockets,
be connected to the generator, or for
in DIN/VDE 0100 Part 728 §4.2.4.2.1 and different voltage drops can arise,
each such load an additional isolating
the German Gas Installation and Plumbing depending on the turn-on time of the
transformer, or one isolating transformer
Association (DVGW) regulation GW 308. neutral.
with several secondary windings, should
The system is an IT type, with neutral and be used. Handheld lights may only ever Avoid overloading the generator. In
PE (equipotential bonding conductor). be used in restricted conductive areas particular, to ensure user safety and
The generator does not have to be when operated off a SELV (safe extra low optimum performance, it is essential to
earthed (with a ground rod for example) to voltage) isolating transformer. observe the following rules:
ensure adequate safety protection. Many portable power tools conform to 1. Only devices whose voltage and
However, if desired or required, defined German protection class II (i.e. they are frequency data on the load identification
earthing of the generator can also be double insulated, symbol ■ ■ ). These plate conform to those on the generator
provided. devices should be used if possible. Use a identification plate may be connected.
Earthing of the neutral (N), or connecting cable and plug to connect any protection
2. Only devices whose power consumption
of the neutral to the equipotential bonding class I device (i.e. with metal housing parts
does not exceed the output specified on
conductor (PE), is prohibited on the that are not double insulated) to be used to
the generator identification plate may be
generator, the distribution system and all the PE (equipotential bonding) conductor.
used. The total power consumption of all
other devices. The use of so-called Only connect devices and distribution of the loads connected to the generator
neutralised devices is not permitted, and systems which are in good condition to the must not exceed its output.
would lead to insulation monitoring being generator. The insulation, and plug and
enabled automatically. socket combinations, must be in good
condition to ensure user safety. Do not use
any damp or dirty connectors.
99
11. Generator option
3. Note that the starting consumption of Attention 4th position (only for 8 kVA and 12 kVA)
devices driven by electric engines is
As 3rd position, with the engine running
generally a multiple of the specified The generator may only be used if the at constant speed
rating. If in doubt, it is advisable to circuit breaker released during the test
contact the equipment manufacturer and the indicator lamp came on until the * Same functions as described for 3rd
directly. reset button was pressed. position, but with the engine running at
constant, maximum speed
The maximum current specified for each
socket must not be exceeded.
Setting the range switch
If normal cooling cannot be maintained, Switching on
or the operating conditions are Turn the range switch to the required
unacceptable in other respects, reduce position:
the consumption, rather than operating 1st position:
the generator right up to its rating.
Compressed air and electrical power,
Ideal operating conditions are: variable engine speed.
1. Ambient temperature: 25 °C * Compressed air and electrical power
2. Air pressure: 100 kPa (1 bar) can be consumed up to maximum
engine speed.
3. Relative humidity: 30% Note that engine speed is reduced in the
Do not operate the generator at ambient event of an overload.
temperatures above 40 °C, below –10 °C, * Compressed air mode without
or in direct sunlight. consumption of electric power: Figure 33
More detailed instructions for operation –> engine speed matched to demand
Danger
under unfavourable conditions can be * Additional consumption of electric power
found in the combustion engine manual. –> variable engine speed is matched Follow safety precautions!
to consumption automatically , up to * Carry out the usual checks (safety
maximum speed precautions, installation location, oil
11.5 Testing insulation monitoring/ * Automatic no-load operation, i.e. the level, fuel, etc) before using the
startup/device connection engine continues to run at maximum machine.
speed for 100 seconds, if the electrical * Ensure that all the devices on the
Testing insulation monitoring power consumption is less than 75 VA generator output sockets have been
for a brief period. disconnected.
Attention
2nd position:
Do not start the generator until you have Note
As 1st position, but with the engine
fully read and thoroughly understood running at constant speed All device switches must be in the
the safety precautions and operating
* Same functions as for 1st position, but AUS / 0 / OFF position.
instructions in this manual.
with the engine running at constant,
During operation, check at least once a Danger
maximum speed
day that the protective measure for the
risk of electric shock through indirect 3rd position(only for 8 kVA and 12 kVA) Unchecked devices may endanger
contact (in accordance with DIN and personnel on startup, and may be
Fuel economy mode damaged or cause damage.
GW 308 requirement for Protective
Electrical power/no compressed air,
isolation with insulation monitoring and * Start the generator.
variable engine speed
circuit breaking) is working properly.
* Electrical power only Note
With the engine running, carry out the * No air consumption possible
Do not load the generator until the
following test: engine has warmed up.
* Compressor pressure relieved, i.e. lower
1. Unplug all devices connected to the fuel consumption due to the reduced
* Check that the circuit breaker is
generator; open the glass cover and power consumption of the compressor
engaged in the ON / I position
switch the circuit breaker to ON/I. (only about 12 kVA)
(close the glass cover).
2. Press the red test button. * When electrical power being consumed
–> engine speed is matched to
3. Check whether the circuit breaker consumption automatically, up to
releases and red the INSULATION maximum speed
FAULT indicator lamp lights up.
* Automatic no-load operation, i.e., the
4. Press and hold down the green reset engine continues to run at maximum
button for at least 2 seconds – the red speed for 100 seconds, if the electrical
indicator lamp must go out. power consumption is less than 75 VA
5. Switch the circuit breaker to ON/I; close for a brief period.
the glass cover (tighten the knurled
screws by hand); the generator is now
ready for use.
Figure 34
100
11. Generator option
101
11. Generator option
102
11. Generator option
Generator regulator
Model . . . . . . . . . . . . . . WLAx
Connector assignment
8 pole Pin Colour Function
1 red F1
2 grey F2
3 not assigned
4 yellow ZU
5 yellow ZV
6 yellow ZW
7 brown L1
8 blue N
Switchbox
Degree of protection . . . IP 54
Dimensions . . . . . . . . . . 211x311x135
Design . . . . . . . . . . . . . . Front panel type
Fusing . . . . . . . . . . . . . . All poles
U1 . . . C32A
U2 . . . 2 x 16A
Insulation monitoring
Model . . . . . . . . . . . . . . GMW-RISO1.0
Controls . . . . . . . . . . . . . Red test button
Green reset
button
Areas of application
engines difficult to get running, welding
devices (incl. inverters), pumps,
compressors, tools, construction
machinery, illumination
Generator data
Winding Colour Ins. class Resistance
(at 20°C)/Ω
103
11. Generator option
YELLOW
LESS SYNCHRONOUS GENERATOR
PINK
GREEN
CONTACTS VIEW
COLOURS FOR PROGRAM
VERSION 1.022
YELLOW/GREEN
BROWN
WHITE
BLACK
FOR ISO MODULE
RESET BUTTON
RED
GREY GREY
PRESSURE
YELLOW
GREEN ELECTRONIC GREEN
BROWN EVALUATION
YELLOW/GREEN
WHITE SYSTEM AUTO NO-LOAD GREY
OPTIONAL ELECTRONIC EVALUATION YELLOW
BROWN SYSTEM, SWITCHES PINK
BLUE
AND␣ 6-PIN CONNECTOR, COLOURS FOR PROGRAM
1/2 U VIOLET OPTIONAL VERSION 1.10
BROWN BROWN
ELECTRONIC GENERATOR
BLUE
RED YELLOW/GREEN
ATTENTION: BLUE
EVALUATION CARD
GREY TRIP-FREE RELEASING OF
ALL CIRCUIT BREAKERS
COUPLED
POWER SUPPLY
AUTOMATIC NO-LOAD OPERATION
OPTIONAL, EXTERNAL PE CONNECTION PRESSURE REDUCTION
YELLOW/GREEN
SWITCHBOX
TOTAL LENGTH OF
EQUIPMENT SUPPLY
CABLES
∑ < 250M
EXAMPLE:
LOAD PROTECTION
CONNECTION WITH COMPR. CLASS␣ I
WIRING HARNESS (ALSO CLASS II/SEE
OPERATING MANUAL)
INSERTION SIDE VIEW 3PH Y L LOAD AC L LOAD AC L LOAD
Fig. 36
6-PIN CONNECTOR
CONTACTS VIEW
YELLOW/GREEN
BLACK
POSITION 1: OPEN
POSITION 2: CLOSED
BLUE
TO 4 POLE
YELLOW/GREEN
AMP PLUG ON
MECHANICAL WLAX
BROWN
COUPLING TO F1
BROWN
BLACK
ELECTRONIC
GENERATOR
REGULATOR
CURRENT CONVERTER
ON WLAX CONTROLLER
BLUE
SWITCHBOX
TOTAL LENGTH OF
EQUIPMENT SUPPLY
CONNECTION WITH COMPR. CABLES
WIRING HARNESS
INSERTION SIDE VIEW ∑ < 250M
EXAMPLE:
LOAD PROTECTION
CLASS␣ I
(ALSO CLASS II/SEE
OPERATING MANUAL) AC-L-LOAD AC-L-LOAD AC-L-LOAD
Fig. 37
104
11. Generator option
11.11 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
services or
take device in for
checking
Fig. 38
105
11. Generator option
The generator supplies no or insufficient The generator circuit breaker has tripped Check electrical load output.
voltage. due to overload or is defective.
Check that all electrical terminals are
properly seated.
Drive motor speed too low. Set to nominal speed, max. 3,100 rpm.
Compressor operating pressure set too Re-adjust the operating pressure at the
high, engine overloaded, speed decreases. adjuster.
Coil of the "Speed increase" solenoid valve Check and replace solenoid valve if
defective. required.
Complete or significant voltage drop during Insufficient engine speed or speed control Have the nominal speed adjusted by the
operation under load. inoperative. engine after-sales service max. 3,100 rpm.
The engine output has been reduced due Do not operate the generator at nominal
to climatic or other conditions. output, see the operating instructions for
the engine.
Excessive generator voltage. Excessive engine speed. Have adjusted to nominal speed.
Voltage fluctuates in short intervals. Diesel engine operates irregularly. Have checked by the engine after-sales
service.
The engine speed control operates
irregularly or is defective. Check according to the operating
instructions supplied by the engine
manufacturer.
Generator heats up to unacceptable levels. Clogged cooling air supply. Ensure that the cooling air supply is not
restricted.
Output reduction due to set-up at too high Partial load operation possible only.
an altitude.
Ambient temperature too high. The generators are designed to ensure that
no danger exists at ambient temperatures
of up to 35 °C. In higher ambient
temperature environments, the generator
may be operated at partial load only.
Danger
When operating the compressor, please
observe the general safety regulations
laid forth in the compressor operating
manual.
The heat exchanger operates fully
automatically. Operating errors at the
heat exchanger are excluded.
12.3 Maintenance/Care
This system is maintenance-free.
For information on engine oil change see
the operating instructions of the engine.
12.4 Troubleshooting
Compressed air temperature too low
Defective oil temperature regulator in
the engine or in the oil line -> replace.
Compressed air temperature too high
Defective oil temperature regulator in
the oil line -> replace.
107
13. Compressed air processing option (After cooler / Filter)
13.1 Safety regulations for alternate In an air cooler (on the cooling air intake 13.3 Maintenance instructions
side), the compressed air is cooled down
compressed air processing
to a temperature close to the prevailing
ambient air temperature downstream of the
Danger
Danger pressure vessel. A condenser is installed Prior to and when carrying out
downstream of the air cooler with automatic maintenance and repair procedures,
When operating the compressor, please
condensation drainage. please do observe the general safety
observe the general safety regulations
laid forth in the compressor operating regulations in chapter 3 of the
Attention compressor operating manual.
manual.
When there is a danger of freezing or
Attention
when the machine is switched off for a
13.2 Design and operation prolonged period, any remaining The filters have to be disposed of.
condensation must be drained from the
System function diagram: secondary cooler. For doing this the The post cooling systems is mainte-
see page 78, fig. 4 bottom cover of the secondary cooler nance-free. For cleaning procedures,
must be opened and it must be emptied see 9.1 „General maintenance“ in the
utilising the pressure remaining in the compressor operating manual.
After cooler option machine.
3 Post option
1 Filter option (ZTV-SIB 90) Filter change is required at latest when
A residual oil contents in the compressed a differential pressure of 400 mbar has
air of < 0.01 ppm is achieved by means of been reached or after approximately
filtering. The filter assembly consists of a 500 operating hours - depending on the
4 fine filter and an extra-fine filter. Both filters degree of contamination.
are equipped with a collecting receiver with
automatic evacuation. The separated or
filtered liquids are brought together to a
2 common drain.
Fig. 38 Attention
1 Filter
The oil-containing condensate has to be
2 Heat exchanger
collected. Do not allow to enter into the
3 After cooler
soil or into the drains!
4 Condensate separator
13.4 Troubleshooting
108
14. Breathing air connection option
Danger
See the separate instruction manual for
the filter unit for notes on safety and
description of function!
System function diagram:
see page 78, fig. 4
109
15. Oil temperature controller option
Danger
Please observe the general safety
regulations in the compressor manual
when operating the compressor.
Operation of the oil temperature
controller is fully automatic. Mal-
operation of the oil temperature
controller itself is impossible.
FROM TO
COOLER COMPRESSOR
(OUTLET)
FROM
PRESSURE
VESSEL
TO
COOLER
(INLET)
Figure 39
15.4 Troubleshooting
Compressed air temperature too low
Oil temperature controller in the oil line
is defective -> replace it.
110
16. Undercarriage
111
16. Undercarriage
Over-run hitches 16.5.2 Preliminary requirements: When the brake is correctly adjusted, the
actuating travel of the control cable [11] will
KNOTT over-run hitches are available for * When carrying out adjustments, always
be 5-8 mm.
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 the
as described, on all the wheel brakes in
code „KH“ wheel only in the direction of forward
succession.
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)! 16.5.4 Adjusting the brake
automatically and requires almost no force. compensating system
* Do not pre-tension the expanding
The system is designed so that when the
locking mechanism in the brake. If
handbrake is applied, sufficient energy is
necessary, loosen the brake linkage [6]
stored within the spring. When transmitted
at the brake compensator [8].
through the brake rods this prevents the
brake shoes from slipping away from the * Check the expanding locking
brake drum. mechanism and control cable [11]
for ease of movement.
* Pull out the drawbar [5] of the overrun- * Bowden cable [14] must not activate
system as far as it will go brake.
* Never readjust the braking system or
brakes by the brake linkage [6] or
turnbuckles (if fitted) in the linkage!
* Remove the security bolt [15]. Brake test * Check tthe bowden cable for slight play
[14]; if neccessary, adjust the cable.
* Operate the handbrake lever [3] and * Recheck the play in the brake linkage [6]
check the position of the compensating and, if necessary, readjust the linkage * Check the tension of the compression
balances [9 and 10]. They should be at [6] for length free of play ( during spring [7]
right angles to the direction of towing. operating braking with empty trailer
should be used maximally 1/2 of the
* If necessary, adjust the position of the
overrun travel )
balance [10] and control cables [11]; in 16.7 Maintenance and care
the case of tandem trailers, also adjust
the master compensator [9] on the KNOTT – overrun systems
linkage [6]. 16.6 Readjusting the braking system
* The overrun system must be lubricated
* The compression spring [7] may only be In general, readjusting the wheel brakes with lithium-soap grease by way of the
lightly pre-tensioned and must not adequately serves to readjust the braking grease nipples and at all the moving
become fully compressed when system, i.e. to compensate for brake lining parts.
activated! wear. To readjust the wheel brakes, a) every 5000 km (3000 miles)
proceed as described under 'Adjusting the b) or every 6 months
16.5.5 Adjusting the brake linkage [6] braking system'. Check the play in the c) or if they become stiff
linkage [6] and readjust if necessary.
Adjust the brake linkage [6] so that it is * Inspect the bellows for damage, replace
free of play longitudinally, without initial Attention if necessary
tension (reversing lever [4] free of play).
* Check the expanding locking * Replace the overrun shock absorber
mechanism and control cable [11] every 20,000 km (12,500 miles) or
Readjustment every 3 years at the latest.
* The expanding lock compensator
* Operate the handbrake lever [3] * Check the play at the coupling point
must not be pre-tensioned in the
powerfully several times in order to every 20,000 km (12,500 miles). If the
brake.
settle the braking system. play exceeds 3 mm, replace the guide
* Do not attempt to compensate for bearing or drawbar.
* Check the position of the brake
ease of movement caused by brake
compensating balances [9 and 10] * Check the tightening torques of the
lining wear by readjusting
which should be at right angles to the fastening screws at the guide bearing
(shortening) the brake linkage [6],
direction of towing every 5000 km (3000 miles);
e.g. by way of the linkage screw
* Check the play in the linkage [6]; if fastenings Screws with grease nipple
necessary, adjust the linkage [6] again 50 +5 Nm
so that it is free of play, but without Screws without grease nipple
Readjustment
initial tension 80 +5 Nm
* Operate the handbrake lever [3]
Slight play in the bowden cable [14] * Check the tightening torques at the
powerfully several times in order to
must persist. clamping block of the drawbar and
settle the braking system
clamping socket (drawbar tube - axle
* Check the position of the handbrake
* Check the position of the brake joint) every 5000 km (3000 miles);
lever [3];
compensating balances [9 and 10]
(which should be at right angles to the M12 screws 80 +5 Nm
when checking the dead centre of the
direction of towing). M14 screws 90 +10 N
lever, resistance starts 10-15 mm above
dead centre
* Recheck the play in the linkage [6];
* Check that the braking system is
* Check that the wheels rotate freely with
if necessary, adjust the linkage [6] again correctly adjusted every 5000 km
the brake released.
so that it is free of play, but without (3000 miles).
initial tension.
Final check
* Check the positions of the handbrake Vertically adjustable drawbars
* Check fastenings for security (secure lever [3], the play in the bowden cable
and compression spring [7] (only light Clean the faces of the tooth systems free
the hexagon locking nuts of the screw
initial tension); of fretting rust or other contamination at
fastenings for the transmission system,
least once a year in order to maintain a
control cables, brake compensators,
* when checking the dead centre of the good fit.
turnbuckle, linkage, etc.).
lever, resistance starts 10-15 mm above
dead centre Lubricate the threaded bolts and joints
* Check the bowden cable for slight play
once a year or at any time if they become
[14]; if neccessary, adjust the cable.
stiff.
* Check the compression spring [7] for Final check
initial tension. Attention
* Check the screw fastenings for the
transmission system (control cables, Do not grease the tooth system!
Test run brake compensators, linkage, etc.).
* If necessary, carry out 2-3 brake tests * during operating braking with empty
trailer should be used maximally 1/2 of
the overrun travel
113
16. Undercarriage
114
16. Undercarriage
Insufficient braking effect Excessive backlash in brake system Re-adjust brake system
Brake linings glazed, oily or damaged Replace brake shoes completely; clean
braking areas in the brake drums
Brake reacts by jerks Excessive backlash in brake system Re-adjust brake system
Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders
Trailer is braked unilaterally Wheel brakes are actuated unilaterally Re-adjust brake system
Trailer is already braked when the Shock absorber of overrunning hitch Replace shock absorber
accelerator pedal is released defective
Reverse driving had to accomplish, or even Brake system adjusted too tightly Re-adjust brake system
impossible
Bowden cables pre-loaded Re-adjust brake system
Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders
Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders
Wheel brakes get hot Brake system incorrectly set Re-adjust brake system
Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders
Handbrake lever not or only partially Set handbrake lever into zero- position
released
115
16. Undercarriage
Ball coupling does not rest on ball Coupling dirty on the inside Clean and grease thoroughly
Danger
Works on the brake system may only be
carried out in specialized workshops.
When replacing braking shoes, make
sure that all brake shoes of the axle are
replaced.
When working at the wheel brakes,
make sure that the springs, the brake
shoes and the spreading lever are
correctly installed; observe the correct
sense of rotation.
When adjusting the wheel brakes, turn
wheels in forward direction!
Basically, a readjustment according to
chapter 17.5 "Fitting of the braking
system" must be effected whenever
works are carried out at the brake
system.
If the wheel brakes or the brake drum
have got very hot, continue to drive
carefully on, if possible, until they have
somewhat cooled down.
116
17. Tool oiler option
Fig. 45
Attention
Danger
Only refill the tool oiler, when the screw
compressor is out of operation and
depressurized!
Only screw off the oiler reservoir, when
the screw compressor is out of
operation and depressurized!
Do not spill any oil!
Watch out for leakage!
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 counterclock-
wise (symbol »+«) will increase the oil
flow.
Fig. 46
* Shut down the screw compressor and
wait until the compressor is
depressurized.
* Unscrew the screw plug.
* The oil must be visible in the oiler
reservoir; refill, if necessary (oil to be
used: CompAir AES 82).
117