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    40 views34 pages

    Cummins QSB4.5 Powered Compressor

    Uploaded by

    Dennis K Thomas

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    2 CompAir € x Original Operating Manual C125-7, C110-9, C95-12, C85-14 C140-9, C115-12, C105-14 Cummins QSB4.5 Powered Compressor v 4. Index Index . 1 2. Foreword . 3 24 Normal use. 2 22. Maintenance and care. 2 23. General information, 4 2.4 Specications, | 25 Declaration of conformity id 3 Security Regulations... Hassett a sie 6 3.1 Idotitation of safely instructions . 8 7 8 8 9 9 32 General safety regulations 3.3 Parieuar dangers associated with compressed at, 34 Parlicuar dangers associated with machines with combustion engines. 35 Dangers present when loading/moving machines... 3.6 Paticular dangars associated with mobile machines. 37 General workplace dangers. 3.8 Dangers resulting fom neglecting fo perform maintenance. 3.9 Dangers curing maintenance and repairs : 7 3 3.10 Dangers resulting from conversion warkimodificaions on the machine ' ‘0 3.11 Symbols and definitions 7" . " 4 Construction and functional description .. 4.1 Construction, 42. Functional description 43. System description 44° Whing dagram.. 45 Terrinal Diagram DIN EN ISO 11446. 5. Transport and Installation on site 5 Transport 7 5.2 Setting tow bar with height adjustment (option). 8 53 Atachmer: ofthe cntactbreake abe on braked chasse vo 19 5.4 Loading/Relocation z ag 5.5 Installation on site . - . 7 19 6 Preparing the compressor for operation. 2 61 Checking loves. a 6.1.1 Checking the oi level Inthe pressure lark at 6.1.2 Checking the ol evel inthe engine. 2 6.1.3 Checking cootant level oo 2 62. Filing up the ful tank. oo meer 6.3 Cheoking the ai fltor maintenance displays ms 2 7. Putting the compressor into operation . 7.1. Intial operation. 72. Operating eloments 73° Star-up zl 74 Monitoring / fault 75 Operation 718 Shutdown. 7.7 Decommissioning. 8 Fucls 7 5 28 8.1 Recommended lubricant for compressor. 2 82. Recommended engine ol 7 2 83 Toa lubricants . 2 anes 25 Ba Diesel uel : 2 85 Coolant... = 25 9° Maintenance. i ee rns 2B 9.1 General maintenance information 2% 92. Cleaning 26 93. Daly maintenance. cana ‘ 26 9.4 Torque specifications 28 9.5. Inspection intervals for pressure vessels and electrical instalations... 2 96 Maintenance and inspection schedule a sor BB 4. Index 10 Troubleshooting eee 10.1. Goneral fault rectifeation information 10.2 Faults, causes and remedy 40.3 Waring lights, 10.4 Individual error display 11 Tool oller option. 30 30 30 a 2 2 oreoneie--E-HEEEPEE PEPE PH EEE EEC EEE EE EEE J Inthe event of serious queries Bosides the operating instructions and the eurent regulations applicable in tha ‘The comprassors have been bull using THFONER DEWER DEUTSCNANO Gna user's country and at the sites of operation ‘he latest techniques in design and in ‘concerning aceidant praventon, the accordance wth recogrized safety .€4°2007/46* recognized technical rues for safe and regulations proper working are aso to be complied ‘wi ‘The compressors intended forthe production of compressed ai: 2.4 Normal ui Warranty for driving compressed air units ‘Only use the comprossor for its intended purpose and folow this operating manual Gardner Denver assumes no lability inthe ‘event of changes tothe declared ‘conformity. Warranty claims cannot be made in the event of doviations from this operating manual {for transporting bulky materials for transporting screed for sand blasting and paint spraying work for cleaning work on machines, boarding material for blowing out dried holes. ‘The Guarantee and Liability tems of Gardner Denver General Terms and (Conditions are nat extended through the ‘abave instructions Special designs forthe customer's panicular form of intended use can be fetermined in the customer's order specifications. 22 Maintenance and care Fat Safty regulations Care and mainonance are alimportant | _ Please eter the data om the deni ithe scow compressors tometine. | can Hal x you compress. inthe {demands places upon it Compliance with | Spaces above, In case of auestons 0+ the prescribed maintenance intervass and | ders for spare paris, please give us the ‘careful execution of care and maintenance | SOMPreSSor ype, compressor number and Itis important that you follow the ‘safety regulations in Chapter 3 of the GSnaweturtore esscntal copedaiy” | theyear of consructon as gen onthe | °Perating manual Under eificut weraing canaons identfestion pate eee 23. General information ~ | technical mosifiations ‘Contact your Compr representative n | Ths operating manuals to help youto | ,Warenerve he nah andere the event of problems, formantenance, "| gettofmow the compressor andtouse® | Theresa of echnieal romess, serving and yolr opere ana forts intended appiations. it must of tecrical prog Hoqurotsons. Gencne seare parts rom | always be avaiable atthe ste of the Gardner Denver ensure procuct Compressor. The operating manual isto Contormly and high tevels of availabilty. | Be read and used by ll persons in charge of work with the compressor. 2.4 — Specifications a\ i eli] |elel jee]: [2 Pele dan tl: | 3/4 a3)83 3 : 5 pert ele gif s i ae zi "|e |f ge 7 a|3 = e|% 35 3 6 6 min. [ max. > § ES | tev] at a | wm fw fo| a | ow | oe Car Da aseas] wae] oY] aaa) 1900/2 | | BO cssaz | os) 12 24 |asea.s| water | 97 | 2300| 1300| 22 | 11 | 210 cia | ina 86 24 |asees| water | s7 | 2300| 1900) 22 | 1 | 210 125-7 125 | 7 24 |QSB45| Water | 97 | 2300/1300) 22 | 11 | 210 crests | ios 14 /so-t40| 10 | 45 | 3000 | 24 |asees| water | 119 | 2200) 1300] 22 | 44 | 210 cissaz | ins 2 [50-120 10 | 45 | 3000 | 28 (asees| war | 19 | 2200/1300] 22 | 11 | 210 coe | 133 | 86 |50-86| -10 | 45 | s000 | 24 |ases.s| water | 119 | 2200) 1900) 22 | 11 | 210 | [2 Foreword ? Fee z 2 3 . Jee eee z ge » | 2/3 5 | ? 32) 3 | ¢ |e) al) ble fo o§ | BE i 2 By, Ry) Ele | F E é 2 5 3 58 ) 4 | 2/€/814 @ = g 3 id as e13\/3/8/2|2 Be) ze Fy é $ | 2 5 | |? z be 38 i : 3 x $ Feed z tam | ew | ew | ee |e wa | ce 2200 | 1995 | 4585 | 1820 | 1700 | astaH2 |21SRI4G] 45 | 70 cas-12 | 2200 | 1995 | asss | 1820 | 1700 | euraiz |aisRtac| 45 w@ | 2 | 7m cus | 2200 | 1995 | 4555 | 1820 | 1700 | as taHe |2isRiac| 45 x | 2 | 7 cxzs7 | 2200 | 1095 | 4555 | 1920 | 1790 | eu sati2 |aisRtec| 45 x | 2 | 7 ros.t4 | 2200 | 109s | asss | 1220 | 1700 | as une |aisRiac| 45 | aaa 99 | a2 | 70 e1ts12 | 2200 | 1995 | 4565 | 1820 | 1790 | eit4H2 |21SR14c) 45 | axa") 99 | a2 | 70 [ewes | 2200 | ss68 | aces | s220 | sro | evianz [aisntec| as [awene| oo | a | 7 +300 s\O\e | {= bWe “20 “20, ‘0 3) O}8 3 Si ves | as 100 Fig.2 2. Foreword '5. Declaration of conformity 2. CompAir Declaration of conformity in accordance with the EC Mach Directive 2006/42/EC, Supplement IA 2 We.hereby declare Gardner Denver Deutschland GmbH ‘Argenthalor St.11 55469 Simmer that the product: Kompressor ‘ype DLT0206 ; DLT0408 ; DLTO704 ; DLT1303 ; DLT2701 ; DLT2702 ‘rade mark: cw casscessn;cap caso, caeso1ososc56-4 e502 conta: coms crs ‘manufacturer no. in the form as shipped by us complies with the fllowing relevant provisions: 2006) 421 EG 2008) 105/ ES 2004/ 108/ ES 20071 46! EG 20081 95/ EG. ‘This machine is exempt trom 97/2EC the Pressure Equipment Directive, reference Aricle + clauses 3.3 and 3.5, 3, Ifthe machine is modified in a way not agreed upon with us, this statement wil be void. 4. Harmonized standards appied, particularly EN 10124 ENISO 12100 EN 61000-6-2 EN 29001 EN 600341 EN 602041 EN 61000-6-4 5. National engingoring standards and epecifcations applied ‘AD-81/2000 ‘VDE 0100 DIN 3230, Betrsich 6. Recording agency: CCompAlr Oruckluttechrik - 2weigniederiassung der GGarcher Denver DeutscHand GmbH Simmern, a 3. Security Regulations 34 Identification of safety | ofthis compressor. evenifnot expressly | [attention] Tene ‘ated inthis operating manual instructions laces thus marked refer to possible ‘responsibility for any damage or Injury Pieces th rend eter machines. laces thus marked refer to possible ‘eased by non-compliance ith hese cae tne eek J safety measures or non-observance of | “angers for [note normal care and caution curing the lade nis acta verpsooel end handing, operation, mantenance or repair ipetrnealntamnavea torah. ce effective machine use 3.2 General safety regulations Danger Safety measure required ‘Working with compressors wolves Everyone workin withthe machine must have frst read and understood the operating anger that are not immediately maria. Dont leave this unl you stat work =i’ too late apparent Please keep this operating manual handy at all times on the ste of the machine / instalation, n the bag provided. Pay alterton to all safety and danger warrings onthe machine instalation! Depoy trained sta only, The responsibity ofthe personne or operating, setting up and maitairing te machine | instalation must be Gesry defined. Make sure that only authorized personnel use the machine Datine wo is responsive or operating the machine, end authorize him to ignore insructlons trom tid pats I these isictlons coud compromise safely. Symbols onthe machine indicating Ensure that al safety and danger noices on the mactine/system stay fly legible dangers may become dirty Faults and modifications to the machine in case of malfunction, shut down and secure the machine / installation immediately. Have ‘may jeoparcise saroy. ‘malfunctions corracted immediatly CCheck the machine / installation for external ¢amage and faults at least once pe shift. [Any changes noticed (including changes in operating performance) must be reported Immeciataly to the authority oF person in charge. Ifnecessary, shut down and secure the machine immediataly. 3.3. Particular dangers associated with compressed air Danger Safety measure required ‘Compressed ars very powerful. Itcan be Never play about wth compressed ar. Used for example to break open concrate but can aso put lives at risk. ‘Small pars propelled at high speed by When using compressed air to clean equipment, work with extreme caution and always Compressed air can penetrate the skin or wear suitable eye protection destroy an eye. Never direct compressed air onto the skin or towards another person. [Never use comprassed air for cleaning clothing. Compressed alr connections may spl and All connected companenis must be ofthe correc size and be suitable fo the speciied Put people at risk, ‘operating pressure and temperature. ‘Akhoso connected to an air valve must be ited with a safety wire for operating pressures ‘above 7 bar; tis infact recommended that this safety cevice should be usod for pressures above 4 bare. The sieel wire has a diameter of & mm ands firmly clamped to the hose at east every 500 mm. Both ends are ited with cable lugs. ‘Only use the correct type and siz of hose coupling and connection. ‘The compressed air line connected atthe air eit ofthe unt must not be under strain. No force may be exerted on the discharge valves, for example by puling the hoses oF fiting additonal ecuipment (2.9. a water separator, compressed air oer, te.) rectly 0 the discharge valve, (3. Security Regulations Danger Safety measure required ‘Compressed airlines get hot and expand. Loose hose ends may flog ané result in injury, ‘Compression resuits in high temperatures. Risk of explosion from drawn in materials, ‘There is trong suction atthe air inlot “There isa risk ofinjuy, eg. from getting stuck o° being drawn in. ‘Connected compressed ai tools may start Up unexpectedly when switching on ‘Compressed air may contain oll and other substances that may damage your heath \inhales as anus ‘Make sure thatthe compressed ar line from the compressor tothe ar network can expand as a result of heat and cannot come into contact with inflammable materials, Pipes and other parts with a surface temperature of more than 80 °C must be suitably secured against contact and suitably marked Before blowing trough a hese or airline, tis essential 1 hold the open end tly. Before connecting or disconnecting heses, always cose the compressor air outlet valves, Before disconnecting a hose, always make sure that itis not under pressure, ‘The system should be set up such that hazardous mixtures (inflammable solvent vapours te but also dusts and other dangerous or toxic materials) cannot be drawn in. The same applies to fying sparks. Never use the machine in enviconments where the possibilty cannot be ruled out that inflammable or toxic vapours may be taken in. ‘The installation isto be set up in such a way that itis adequately accessible and thatthe necessary cooling is ensured. Never block the acmissian of ar. “The air intake is to be designed in such a way that no lease clothing can be drawn in ‘The personnel must net have long, loose hai, or wear loose clothing or jeweller. including rings. due to risk of injury ough catching, Personal protectve equipment should be worn if necessary ‘Before switching on the machine / Installation, or starting it up, make sure that nobody can be inured by the machine / instalation as itstarts uo “The compressed air produced by these compressors must not be used as breathable ar, Unless it has been processed specially for such an application in accordance with the “Safely requirements for breathable ai.” ‘When breathing apparatus with cartridges is used, make sure thatthe correct carrge has been inserted and that ls Service if has not expired. Tf several compressors are arranged ina system, manually operated valves have to be installed so that each machine may be shut offiividualy, For the purpose of shutting off prossunizes systems, you should never rely on the effaciiveness of return valves alone {All pressure tanks located outside the unt with an approved operating pressure higher than simosphere pressure and fited wilh two or more pressure Teed lines must be equipped ‘ith an additonal safety device o automaticaly prevent the approved operating pressure from being exceeded by more than 10%. ‘Naver operate the systom at temperatures andor pressures below or above the values _ indicated inthe technical data sheet. 3.4 Particul Danger ‘The exhaust emissions of combustion ‘engines contain carbon monoxide - lethal gas ‘Fuel can easily ignite. Filing up at a pump can cause static lectrcty and possibly sparks. In water-cooled combustion engines, water vapour is produced in the cooling circult under high pressure dangers associated with machines with combustion engines Safety measure required Ifa mactine with such an engine has to workin an enclosed room, the exhaust gases must therelore be conducted out of daore by means of a hose or pipe with an internal diameter of atleast 150 mm. The use of extraction systems is highly recommended in test rooms for mobile machines. ‘Make sure that fuel daes not come Into contact with hot machine parts, Do nat smoke while ling up with fuel ‘Naver fil up with fuel while the engine is cunning, In order to avoid this, @ ground cable must be connected to the aystem whi itis being filles up. a “The cap ofthe coolant recovery battle must nol be removed before the system has cooled own fo ambient temperature Sparks from the exhaust may cause fires and explosions in envirorments with fre hazarés. “The operation ofthe compressor in areas where there isa risk of explosion is strictly forbidden! (Exception: spocially-made compressors withthe necessary technica ‘modifications for use in such areas) I amachine with a combustion engine has to workin afrerisk environment, the uit must be fited with a spark catcher. Make sure that the engine exhaust syetom is operationally safe and that no inflammable ‘materials inthe vicinity. ‘even when its not very loud, can make us nervous ane iitated, and ater a longer period of ime our nervous system can suffer serious damage, 3.5_Dangers present when loadingimoving machines ange Loose parts may fal off when iting, The compressor may fall frmistakes are made when iting The compressor may be damaged if lifted incorrety 3.6 Particular dangers associated with mobile machines Danger As anu Pressutised parts may bs overloaded uring travel Wheels may come loose during travel Machine may tip over if positioned at too ‘great an angi, Unsecured machiries may rol away. Safety measure required Persons must be protected against ary risks caused by noise in accardance with EG Guideline 2003/10/EG. Weexing ear muffs may impair communication between persons. Warnings may not be heard Inform supervisor. Shielding and doors must be closed during operation so thatthe flow of coo alr within the housing is not deflected and the efficiency of the sound insulating is not reduced. Safety measure required ‘All loose parts must fst be removed or secured: paris fied so that they can turn ike oot ole. must be secured and made immobi. Parts to bo removed for transport purposes must be carefully refitted and fixed again before puting the machine / installation back into operation, ‘Only usa lifting tackle approved for the weight in question ‘Observe the operating manual forte iting tackle. ‘When heavy loads are being conveyed by means of hosting g wal clear ofthe load in order to avoid accidents. Raise the comprassor by its fing lg oriy, using a hook or shackle thal sates local safely regulations. Cables, chains or ropes must never be fited directly to or through iting tugs Machines may only be hoisted correctly using hosting gear in accordance with the information in the operating manual iting spois for heavysit facies et) Never relocate the machine if external lines or hoses are connected to the discharge valves, in oéer to avoid damage to the valves andlor collecting pipe and hoses. itis imperative to keep Safety measure required (Observe ll the relevant wafic regulations and before staring move, ensure that he macrine isin a stable condition with regard to trafic laws. ‘Saltch off the compressor atleast 10 min, before travel and allow the pressure in the Ins to drop by opening a pressure cock, Make sure that the wheel nuts are properly lightened; never exceed the specified toravs. Insta the machine so that tis as horizontal as possible; a slight inclination is permissible (see information in Chaptor 8.5 “installation on sit"). [Aways ko0p a safe distance from the edges of foundation stchos and embankments, Do not travel across slopes transversaly ‘Before disconnecting the machine from the toving vehicle, apply the handbrake. Disconnect the rapi-omergency brake cable and lighting cabze, cisconnect the lines of the air brakes, use chocks to ensure thatthe machine does not rol away. Ensue thatthe compressor systam is stable bofore starting work and do not pormit ary work that impais this! 3, Security Regulations 3.7_ General workplace dangers Danger Safety measure required This manual only deserbes how ta work Pease note and pass on general statuory and other binging regulations that may ately wih the compressor tool But ther supplement the operating manual or he prevention of accents andthe protection of he angor wll arse during work tnvronmert. Such obligations maybe for exampi the handing of hazardous materials, or the provision andlor wearing of personal protective equipment, or trafic reguations Instruction, including supervisory responsibly an duty of noifcaton for taking account {ot spec i-pant factors, for example regarding work organzation, sequeaces of peratons, personnel assigned to certain tasks, are to be added tothe operating manual Before starting work, make youre fair with the working environment atthe instalation Sto, Te working endronment inte, fr example, obstaces in he working and tranaport areas the carrying capacty of tho ground, and ary necessary cordoning of of the bling sits from pull wtf areas. ‘The location and operation of fire extinguishors must be made known, Observe the Instructions concerning fire alarm and fre fighting ‘Set up the machine in such a way that no inlets, outlets or gates are blocked, Keep an adequate distance between the machinslunt and overhead rower ines! When \workng near overhead power lines, equipment must not come near the power ins! Danger! Find out about the safe distance tobe observed! ‘When handling ols, greases and other chemical substances, observe the safety regulations applicable forthe product Caution when handling process materials risk of burning / sealing) 3.8_Dangers resulting from neglecting to perform maintenance Danger Safety moasure required ‘Components ofimportanca ta safaly wear Observe the setting, maintenance, and inspection work and intervals stipulated in the overtime. ‘operating manual, including information about the replacement of pars / patil sections. ‘This work may only be carried out by specialists ‘Observe the intervals stipulated or those given inthe operating manual fer routine checks and inspections, Verity regularly that safety valves and other pressure-eief devices are in perfect condition and are nat blocked, for example by dit or paint Lines persh, ‘Replace hydraulic hose lines atthe stated oral reasonable intervals even ifno defects of relevance to safely are apparent! (DIN 20066, part 6) Spurting ollcan resultininjries and fre, Check all Ines, hoses, and bolted connections regulary for leaks and visible camage, Repair damage immediately and always arrange for damaged parts tobe replaced! Fisk of electric shock Have the elacrcal equipment on a machinelsystem checked regularly. Have defects like lose connections or charred cables rectified immediately. '3.9_Dangers during maintenance and repairs Danger Safety measure required During matnance and vps, pans The compressor can ony be maltaired by spadallyWarad technicians, Contact your That may bo pressurised mut bo Comeniragen ‘groves: yeu mars he comes ny prone wh spiel knonadg a experience ofhyraulcs may nk on ye creverel toe vanadby CameAh: lone fo exenpiconporens wd Besse Incorecty configured spare pars may Spare pari must meat the tehrcol equaronts lid down by the manutactire. Tiss Ieopardse salty eg tear hen loaded. _alvays guranteed when ongna spare prs ar vod. Rsk of ec shock Work on he elctial ystems cf the machine instalation may only be cared cub a tamed elcian hr atordance wih elec regulon. Fisk of injury from pressurised or moving Only cary oi inspection, maintenance, and repair work whan the screw compressor pans. ‘systems ata standstill and is not under pressure. Make sure thatthe system cannot be switched on by accident ange Safety measure required Modifications to the machine impair safely. Aftor complating repair work, always check to see whether any tole, loose parts or cloths have been left in or on the machine, diving engine or driving equipment. ‘tor the work has been complete, replace any protective devices thet have been removed. Operation without protective devices fs not permissible 3.40 Dangers resulting from conversion work/modifications on the machine Danger Safety measure required Genuine parts ae designed especialy for No aerations,adaions, of modicaons tothe machine may be cared out without the themachine. Modifications may intefere approval ofthe manufacturer Unauthorized modieations tothe machine are ronited fr ‘wih safety equipment or give rise to new —easons of saety dangers fr which protection 1s not Original pats are special designes for our machines. We must expllty point out hat Provider paris and special accessories nat supplied by us are not approved by us. Instaling or using Such products may ths adverslyafet active andlor passive safely ‘The manufacturer accepts no lability whatsoever for camage resting from the use ofon- original parts or speci! aecossorie. Tis also applies othe instalation and axjustment of salety devices and v to welding on Bearing and pressurized pas I protecive eqipmentis not funcboning, Only operate the mactine when allprotectve devices, shutdown devies, ounéinsulaing operating th system may pul ives a risk, equipment and extraction equipment arin place and werking, Safely devices, prctetve covers, oF nauatons mounted on the systom must nt be removed or modes in any way. Jes a8 wal as The General Type Approval becomes invalid in case of modfcations or alterations which change or infringe upon the extemal geometry as well asthe gross axle weight rating. ions 3. Security Regul 3.11 Symbols and definitions Jee | | Carefully read the Operating Manuai | Astonton: Hot surfaces before machine setup and maintenance. ‘Attention: Hot and dangerous exhaust fumes Nover attempt to operate the machine | Attention: Prossurized part or system. | Attention: Danger of electric shock. ut the safety device mounted. l J accent Do not inale any compressed air rom | Liting spot Do not step/stand on maintenance valve the system or other parts ofthe pressurized system. Noveratlomptto operate the machine | Te down pol Aatenton: Maintain specie yr with open or lovee hel pressure Soe Chapter ane : ee Foreword, specifications.) [Security Regulations Protect the generator from moisture, | Warning: Hot surfaces. Dornot clean with a waterivapourjet. | Open the body lids no earlier than 30 minutes after the safety warning has: switched off | A 8 Cj FZ a 4 # sa Peers RA ‘Attention: Do not use an ether aerosol | A Warning BB Parking brake ©. Correct position ofthe hand brake | SOFIE a | ie Do not remove the Operating and Condensation drain Maintenance manual and manual Under very humis operating conditions the condensation should be drained from holder from this machine. the prossure tank every 24 hours. S40 20 all pressure and read the operating instructions. (3. Secur mS Fuel drain arly Regulaions oO il filler plug a Fuol © eee eel combi device ined stop and emergency stop Before connecting the tow bar or commencing to tow consult the operating manual ‘system radiatoricoolant recovery reservoir may bo under prossure. AS ® 4. Construction and functional description Fig 3 1 Screw compressor 2 instrument panel 3 Pressure tank 44 Combined cooler 5 Oi fiter (compressor) 8 Ai itor (compressor) 7 Air fter (engine) 13 Crane ring 14 Chassis type idontifeaton numbar 15 Pressure retaining valve 18 Suction contaller 47 Compensation tank for cooling water 18 Proportional valve 419 Fuel prefiter with manual pump and water sensor 20 Emergency stop 21 Level watchdog for coaing water 22 Display of cooing water level 23 Level watchdog for lose! fuel 24 Fuse F1,F2 44 Construction ‘Compressor and engine The core ofthe sound proofed mobile compressor systern isa single-stage, ol- flooded screw compressor. The CompAir screw profs represents the stateotthe= art The aris delivered pulsation, ‘The drive assombly is a mecium-cocled diasel engine, which drives the screw rotoes of he compressor by flexible couping Falring (Body) “The fairing consists of a subbox, which is mounted on a base frame, and io which {folding cover for servicing ane maintenance access is atached. The hook inside is for hanging up a load suspension device. Frame and chassis ‘The complote comprossor unt is ‘mounted on an easy-to-trarspor single- ‘axle chassis. The chassis le equipped wth ‘automatic overrun brakes and parking brakes, as well as a jockey wheel adjustabie in height Airflow Fresh aris sucked in through the ‘admission opening atthe back of the ‘compressor. The air intake volume is ait for the engine and forthe compressor too, 1 wel as cooling ar forthe engine and for the ol cooler ofthe compressor. 4. Construction and functional desoription 42 Functional description ‘The system is started with closed air bleeding cocks (19). During the starting procedure the rogulation is non-functional (ie. ro air Bleeding possibi). As the ‘system pressure inczeases the suction ‘contraller (6) closed, the engine runs at idling speed. Depending on ambient temperature this is followed by a warmup phase for the engine, The system is then Feady for operation. The throtllspeed control permits a stepless air bleed of betwoon C .. 100%, ‘A.change inthe ar bleed always changes the tank pressure (15). This ‘Signal fs sent to the electronics via the pressure transducer (20) which then regulates the auction contolle (8) and the engine speed, Rising air bleed: “Tank prossure (15) drops. Valve Y1 (22) closes, Suction contralir (8) opens. Engine speed ineroases, Falling alr bleed: “Tank pressure (15) rises. Vave Y1 (22) ‘pens, Suction conta (8) closes, Engine speed crops ‘Any condensate inthe contol air and the alr drawn in by the leak gap is blown ff via @ nozzle (9) on the suction controle (8) Wen the engine (2's switched off the ‘non-return valve inthe suction contraler {6's closes by sysiem pressure. The Teliot valve (23) 's de-anergized end ‘pens against atmosphere. This causes the tank prassure to drop to zero. ‘The system an only be startes again ‘once the tank pressure has dropped below a defined minimum pressure oie) tis not possible fo start up the ‘compressor in case ofa fuel shortage. 43 ‘System description Fig. 4 4 Air fiter 2 Diesal ongine 3 Water coolor 4 Pre-compressed air heat exchanger 5 Fuelievel wich 6 Airfiter - compressor 7 Compressor {8 Suction contaler 9. Nozzle suction controler 410 Temperature switch 11 Oil flter~ compressor oi 42 Ol cooler 43 Orifice, evacuation line 44 Pressure retention valve 45 Pressure tank 16 Fine separator 7 Safety valve 18 Pressure retaining non-return valve 18 Airbieoding cocks 20 Pressure transducer 21 Prossure control 22 Proportional valve Y1 23 Relief valve Y2 24 Bypass viave ¥3 28 Compr. bypass (or2.Wevalve cing) 26 Compr, bypass (non-return valve) 27 Ol temperature contol 813528674 ‘options: 40 Toot aller 41 Olee valve 42. itor cooler 43, Condensate separator ‘44 After iter combination 45 Heat exchanger (WT) 45 Bypass WT 6 4.4 Wiring diagram ‘CompAr ECM [sy cy ae & aL AS 4 jdeegpert weL ei Oo O@OOGOOOO © CompAir ECM sips fa Te Ts fae a | sr ae sy 2 refer for foo 9 | ‘Curmmins ECM Fig. 5 i A13528774 1 Starter 8 Solencid valve emergency tipping 2 Generator 8 Tork pressure (4-204) 3. Ralay for votage supply 410 Control pressure (d.20 ma) 4 Relay for starter 11 Gootng water ivat 5. Solenoid valve for volume fow 12 Pressure gland temperature 8 Solenoid valve pressure reliot 13 Fus lovellow 7 Option [4 Construction and functional description “Terminal Diagram DIN EN ISO 11446 X <—|—>Y | 1 L_| GE | | | 2 eo os OH | | | | 3 ajwr | =o | | ‘emo Le | —to*¢ mmo Fig. 6 anassae74 ‘The terminal clagram is designed for a voltage of 12 Vos! 41. Indicator eft 41 Not assigned R. Brake ight ight 2 Fogtalllamp 12. Not assigned Brake light left 3. Mass fr contacts 1-8 43. Mass for contacts 9-12 Ss. Number plate light 4 Indeator right GE. Indeator ett Taillight left 8 Taillight right BL. Fogtaillamo Gutine andlor side lights 6. Brake lights: WL Mase for contacts 1-8 Reversing ght 7. Taillight of GN. ncicator ight X. Socket on the vehicle 8. Reversing ight B. Gutine andlor side lights Y. Plage on the attachment 9. Permanent positive Taillight right ‘ (0. Charging * for battery ‘Number plate ight 5. Transport and installation on site Fig. 7 Mako sure to check the torque after 50 kilometers following wheel ‘mounting and at regular intervals. Tighten whoo! nuts or screws evenly in a diagonal sequence to the specifiod forque using a torque wrench. Roplacing the trailer coupling ring ‘The coupling arrangements which can be used: Taller coupling ring RD 40 Coupling 60 da Coupling ring 2" da, (only for Uk) Coupling ring 68 x25 dia. only for France} A diferent coupling unit inthe frm of a ‘ompiete kit may be ordered, necessary. ‘Tho clovis may only be replaced by a ‘monitoring body working on behalf ofthe Road Traffic Licensing Regulations (e.g ‘TOV, DEKRA...) The testing Body roducss a catificate that should be kept ‘nth the vehicle's papers The screw compressor may only be transported on public roads if * The machine group (engine) is not running, The pressure tank is not under pressure, * The shielding is closed, * The blocks are firmly hooked in place, * Hoisted and secured tal whoel, * The tyros and brakes are ‘operationally safe and roadworthy, * The lighting is fuly functional. Always keep a safe distance from the edges of foundation ditches and ‘embankments! Do not travel across slopes transversely. 18 Never exceed the maximum towing ‘speed! Dangor of accidents! Observe hnational regulations! Please also observe the safety instructions in Chapter 3.6 on the subject of transporting. Before transporting the compressor, check to make sure that the draw goar of the towing vehicle ane the drawbar eye or trailer hitch ball connection are aligned execly to each other. Whon transporting the screw compressor With avehici, the flowing points ust be observed: * Switch off the compressor at least 410 min. before travel and allow the pressure inthe tines to dop by opening ‘a pressure cock ‘Stow accossories in a safe place, * Flim seal cover. Connect up coupling device to vehicle {and connection ropes to ‘raller. * Hook up wheel chacks, ‘Adjust the height ofthe tow bar tothe towing vehicle (option, see Fig. 7 and ‘chapter 5.2), ‘Attach and secure clevis or coupling, Raise and secure support fixtures, Connect the safety cable tothe towing Vehicle (see chapter 6.3}, Connect electric connection cable (option) batwsen vehicle and screw ‘compresser * Check the lights (option: tl ights, brake lights, indicator lights, and rear fog lame, * Release handbrake Check to make sure that the wheels ‘are property tightened, the tyres are in { foadworthy condition and the tyre Pressurais correct (danger of accidents), Botore cisconnecting the machine from th tractor: Apply the hand brake, ‘Adjust he rear wheel so thatthe compressor is horizontal Release safety cable and cable for lights. Secure wheels with wheel chocks. 5.2. Setting tow bar with height adjustm, ese Fig. 8 1. Towing system 2 Orawoar Alter the spring-loaded plugs have been ‘leased from the fastening nuts, he nuts, ‘can be loosened until the teeth are ‘exposed. The angle of the intermediate ‘arm can then be adjusted, Care must be taken without fll to ensure that the overrun or towing system (Fig. 8, Pos. 1) is always aligned parallel with the drawbar (Fig. 8, Pos. 2). The vohicte must not be driven unless the overrun system Is parallel with the drawbar! After the coupling has boon adjusted for height, the serratons should be locked together wih the lamping nuts and ‘Secured agsinst working loase by means ofthe springoades plugs. ses [nae [BAS [TS [_5. Transport and installation on site Attachment of the contact- broakor cable on braked chassis 53 Ifthe towing connection becomes Lncoupled, the aller is braked by the breakaway cable. Put the breakaway cable inthe eye provided or wind it around the towing colar and hitch it up to the ceabe withthe snap link ‘The breakaway cable must be attached ina way that ensures that even on ‘extremely sharp bends there is no danger cf activating the locking brake Fig, 10 BA LoadingiRelocation Only use hoisting gear (e.g. erane) with ‘appropriate lifting capacity for the leads occurring! Only use the correct suspension gear! ‘Koop clear ofthe swiveling range of the hoisting gear! ‘Keep clear of suspended loads! All oose parts that could fall down during hoisting must first be removed or secured: pivoting parts, like doors, towbars, etc. must be secured in such ‘way that they cannot move. Never leave the load suspended on the hoisting gear. Acceleration or braking Of the means of transport must remain within the approved timits. Please also observe the safety instructions in Chapter 3 on the subject of loading. ‘Attention Do not attompt to use a crane hook or similar load suspension devices direct fon the lifting device to avold damages to the lifting device! Use proper hoisting gears only such as hoisting straps In compliance with DIN randard 61360 with proper lifting ca- pacity for connecting the load Suspension device (e.g. erane) and tho lifting device. Only deploy load bearing equipment which corrosponds to the safety Instructions for iting gear. Use a transport harness compliant with local regulations for transperting by helicopter. The eyes provided may not be used for this purpose. Never lift up or lash down the unit Using the shielding! Never relocate the machine if external lines of hoses are connected to the discharge valves, In order to avoid ‘damage to the vaives andlor collecting pipe and hoses. |Whon loading, the folowing points must be observed! \When hoisting the compressor, set up the hoisting gear in such a way thatthe compressor, which must be sel uo horizontal, ised vertically Oni relocate the comprossor by its Raise and lower the compressor cearetly, [ter relocating, remove the load ‘suspension device or the hoisting gear ‘rom the ting device Tie down the compeossor on the cargo On clamp to te rod and wheel axles, orto the apertures provided in the vehicle frame. \when disassembling the chassis, the ‘cover and machine unit may only be supported under the main fame. The alr intake must be positioned in such a way that (oose personal clothing eannot be drawn in. Make sure that the prossure pipe from the compressor to the aftercooler or the air system can expand as a result (of heat, and that it does not come into ‘contact with inflammable materials. The ar intake is to be designed in such ‘a way that no dangerous admixtures Gintlammable solvent vapours etc, but ‘also other dangerous or toxic ubstances) can bo taken in. This also ‘applies to flying sparks. pas and other parts with a surface temporature of more than 80°C must be suitably secured against contact ‘and suitably marked. The operation of the compressor in arees where there Is risk of oxplosion is strictly forbidden! (Exception: ‘specially-made compressors with the necessary technical modifications for use in such areas) Please also note the safety instructions in Chaptor 3 on the subject of instalation on site. Location Tho complete system sto be setup in such a way that its easily accessible anc that the required cooling is guaranteed Never block the air intake. Ensure thatthe anlering of moisture ane dit together with the intake airs Kept to a minimum. ‘The compressor isto ba set up away from wals, [att ‘The screw compressor should be positioned such that neither waste air hor waste gases are drawn In as this ‘would result in overheating and a reduetion in engine performance. 5. Transport and installation on site The compressor must be set up in as horizontal a position as possiblo Maximum permissibe inclination duing operation: In direction of pul: 18 degrees Backwarcs: 15 degrees To the right and tothe lat 15 degrees Fig. 19 ‘Attention Groator inclinations endanger the operating reliability of the serow compressor. When setting up the unit on ground that Is not horizontal, or with a variable angle (ee operating instructions) please consult Compa. [rx] In dusty environments, set up the machine ln such a way tht the wind does not blow the dustin the direction ofthe machine. During operation in clean environment, the intervas for cleaning th alr intake {ter and the cooler elements are much longer “Attention| No force may be oxerted on the dis- charge valves, for example by pulling the hoses or fitting additional ‘equipment (0.g. a water soparator ‘comprassed air oller, etc) directly at the discharge valve. ‘Temporatures/air humicity Install the compressor in location with ‘maximum possible frost protection. The suction alr temperature must be within the range specified on the data ‘An olltomperature regulator (option) is necessary for operation of the system at high temperatures (+40° C and above) andlor high rel. air humidity (greater than 90 %) or at temperatures Dolow 0°C. For operation involving long eriods of idling andlor low partial loads an oll tamperature regulator Is also required. 2» Altitude For oparation at an altitude above 3.000 m, the compressor and engine must be adapied (modified desian) Nove. Particularly in caso of installation out of {o0rs and at night, observe fuel tompera- ture, At temperatures below 0 °C, summer Giese! fue tends to precioitate and block the fuel iter. In this case use winter dese! Wel ([B: Preparing the compressor for operation a « ‘Checking levels 4 Checking the oil level in the pressure tank Fig. 14 Only check the oll level when the ‘engine is ata standstill and the The mpressor is not under pressure. 1e pressure tank may be under pressure and the oll may be hot. Risk of scalding! Spill no oil! check for leaks. Proceed a3 follows: ‘Shut the compressor down and wait ntl the system is depressurized, inno ‘ease less than 5 minutes. Bofore checking the oll level ensure that the vehicle fs standing horizontally Unscrew dipstick. ‘Tne il level should be within the marks: ‘onthe clpstick Correct as requlted ‘Check the seal on the dipstick and replace i required ‘Screw in dipstick and tighten firmly, [attention] ‘After a short test run, the oil level sh ‘ould be between the markings on the dip stick. For oil specifications, see recommended lubricants, Chapter 8.1 necessary, drain condensate overy day (see Chapter 9.3)! 64.2 Checking the oll levelin | 6.1.9. Checking coolant level the engine ——. Fig. 16 ‘Atention For coolant specifications, After a short ost run, the oll level Should be between the markings on the | Dispose of used coolant in accordance dipstick ‘with th relevant regulations. ‘Always stop the motor before checking ra telat zoiing nate Song scar tahot wk of cad tate sur terreno ak! ‘Only check the oll level whon the “Avoid contact with the eyes endior ‘compressor engine sat a standstill. ae Spill no oll! The ol may be hot. Risk of ‘skin, danger of corrosive burns! scalding! Incase of contact withthe skin andor eyes, wash ouvoff under flowing water {Gheck for eats. ‘nd obtain medical assistance Proceed a fllows immediatly. + shutihe compressor down, Waitfor | Proceed as folows Smintes Setup the screw compressor in @ + Ensue that he screw compressor is rovizontal positon sepa ernie. + Switch ofthe screw compressor for + Pulthedipatick out wie, + Theol level shouldbe as nea a8 + The level of cooling water shouldbe at possible tothe upper dipstick mark least in the midl ofthe inspection tube + Correct ss requires Ais + Putthesipstck back [Attention] + Close il filer Only use coolant recommended and ae Soproved by the engine manufacture se Chaptor Bs. specifications, see Chaptor 8.2 struction manual. a 6. Preparing the compressor for operation 62 Only fil up with fuel when the serow comprossor is at a standstill. Cleanliness is essential Spill ne Tuell Filling up at a pump can cause static electricity and possibly sparks. Proceed as follows: * Open tank tid (1) Fillup tank with commercially available branded dies fuel, using a sieve (use summer or winter diesel fuel depending fn ouside temperatures) Close tank tight with tank lt Close the hood. [Net {tis not possible to startup the compressor in case ofa fel shortage, The fuel tank should always be filed up in geod time Fr outside temperatures below 0°C, use only winter diese fu More nfermation on fuel qual, 286 8.4 For outside temperatures bolow 0°C, ‘observe the operating manual ofthe engine manufacturer for winter operation You can reduce the cccurrence of condensation in the fue tank considerably by fing it up in good time. This also prevents downtimes and stating problems that ean occur when the ful tank is run ty, 6.3 Checking the air filter maintenance displays Fig. 18 When the rod service eeetorin the transparent par is fully visible, the after ue for maintenance, 7. Putting the compressor into operation 7.1 Initial operation ‘Transport inspection Every CompAir screw compressor has already run in the factory ana has already undergone a thorough test before ‘shipment. Ths test ensures that the compressor comies withthe given data and works perfectly. Independent of the eave taken in the factory, it's sll possibie for the compressor to be ‘damaged during transport. For this reason itis recommended thatthe unt should be ‘examined for possible damage during transport Remove any transport seals (dummy flange. plugs, etc.) and debating agents before startup. Distribution tubes ‘and connection lines must have the Spectied dimensions and must be suitable for use with the max. operating pressure ‘and the mecia tobe taken up. During the first hours of operation, the ‘comaresser should be observed in order tobe able o ascertain any possible malfunctions. 7.2 __ Operating elements Operating panel: 7 rary) CompAir oH + @ @ zs 4 pet Fig. 19 + Operating pressure in bar and ps} 2 Individual fault ype gine oll pressure gine water temperature intercooler temperature 4 Airond temperature 5 = Engine water lve! 6 Fu 7 = Water in fuel = Battery voltage = Gable break, Start against pressure 10 = Other ertas from CAN-Bus (engine) 3 Engine speed, operating hours 4 LED green (ok) 5 LED red (faut) 6 Start button 7 Ignition key, Stop (shut down ‘compressor 8 Reset button, Enter 9 Choice of menu 10 Decrease working pressure 11 Increase working pressure 73 Startup Danger Before starting up, make sure that no ‘one is in the danger area of the engine / ‘scrow comprossor. Compressors may not be operated in hazardous environments unless thoy hhave been specially designed for this ‘purpose (0.9. exhaust protected ‘against emission of flying sparks etc). Never, under any circumstances, use *Startpilot”(Spray-can starting aid), ether or other starting aids - Danger of explosion! Attar service work has been ‘completed: Mako sure that all protective devices have been refitied ‘and that al fools have been removed. The exhaust from the system contains carbon monoxide, a lethal gas. The exhaust must be routed to the outside via a pipe or a hose with an Internal dlametar of not less than 100mm Ifthe compressor is usod indoors. Adequate ventilation must be assured. The use of an exhauster system Is urgently recommended Only operate the comprossor with the hood closed. ‘Attention Check the ol! levels in the pressure tank and in the engine of the compressor each time before start-up, Do not start the compressor unless the air tapping cocks are closed, Starting up the compressor: Close ai tapping cooks. ‘Turn ignition key to positon “1 (on). ‘Symbols 1 and Blight up. + Press stert button [ter starting the engine runs in idle and the compressor at reduced Pressure Depending on ambient temperature this willbe felowed oy a warm-up ‘hase of tho engine. ‘The system is now ready for operation Check thatthe hoses / tools are cotrecty connected and open the requis air bleed cocks. [note] ‘After an unsuccessful start wait unl the tank pressure has dropped. The symbol °9" (908 Fig. 19) shows when the tank prossure has dropped enough fo permit a Start release, Start-up using jumper cables | auxiliary batteries: Fig. 20 Longer operation with an auxiliary battery or jumper cables connected ‘can lead to sudden emissions of gas ‘An inflammable air /gas mixture is formed. Explosion hazard! ‘Attention Serious damage can be caused to the electrical system if wrongly connected. * Ignition key In postion "0" (Off Aus) First connect positive terminals then negative terminals (ground) Start as described in section "Starting tp the compressor” (tet) ‘Ater the engine has started, fst tisconnet the negative cables (ground) and then the positive cables. 7A __ Monitoring / fault Interference with the automatic Imonitoring system Is not permitted. \When the "Fault indicator lame lights up the screw compressor is automaticaly shut down when the following faults occur ‘engine ol pressure too low Cooling water temperature too high charge ai temperature to high tengine oil temporature 100 high ‘eoling water lovel too low {uel shortage ‘Water present in uel pre-fiter charge control (e.g. V-belt tear, ‘defective generator...) 23 7. Putting the compressor into operation hardware faut (2g. cable break) * athor fault in the engine electronics The system can fist be started up after these faults once the cause leading to shut-down has been eliminated and the fault has been confiemed withthe reset button "8" (82a Fig. 19). Attention Disconnect the battery or generator ‘only when the engine is net running, Switch the system off fan cll mists senirained in the compressed at o if ‘xcessive ol consumption is apparent (see “Troublesshootng’) 5 Operation Only operate the compressor at the permissible operating pressure and at the permissible temperature. Only use the compressor for its ‘Intended purpose (see Chapter 2.1 of this operating manual) in order to avoid residual risk for persone and assets. Only operate the compressor in a sa functioning condition, All components, hoses ete. fitted must bbe ofthe correct size and designed for the specified operating pressure and temperature. When working with compressed air, wear sultable protective clothing (0.9. protective sult, safety goggles, ec Wearing oar mutts may impair ‘communication between porsons. Warnings may not be heard. Inform ‘supervisor. Check the compressor regularly Gheck the machine installation for ‘extornal damage and faults at feast ‘once per shift. Any changes noticed (inclucing changos in operating performance) must be reported ‘immediately to the authority or person in charge. If necessary, shut dawn and secure the machine immediately. Leaking condensation contains a proportion of oll and must be collected and disposod of under safe conditions. Condensation must not ontor tho soll or the rivers. Major quantities of condensation accumulate particularly in versions with aftercoolers for processing compressed air. Provide a Collecting basin. 24 7.6 Shutdown Z In order to shut down the compressor: * Close air discharge valves. The scrow Compressor reduces the speed of the ‘engine back to idling speed after tho presot final prossure has boon reached. ‘Allow the screw compressor to ile for ‘few minutes, ‘Turn ignition key to positon “0 (ot) The system switches off ater a defines overtravel time, (were) Inthe case of emergency () the system can be closed down via an emergency stop suitch. The system comes to an Immediate stands. This type of Shutdown ls stored in the electronics ‘Attention Arropeated shutdown of the system via the emergency-stop switch may damage the engine! {tis important that you ensure that the pressure is completely blown off via the blow-off valve, Should this not be the case, open air discharge valves and contact service. Fig. 21 the systom is to be closed down for a longer perog of time (approx, 3 months longer) the folowing prasarvation meaeuros 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 tyes by jacking up the vehicle (Check tyre pressure every 2 month. * Release the handbrake, ‘Attention When putting back into operation, fry out the maintenance work 8. Fuels, Recommended lubricant for ‘compressor Note| In these screw compressors, circulating a hhas nat any a lubricating function, but in particular i also has coating and seating Tunetions. It is therefore exposed to more

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