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22 10 14 Ba DLT0704 GB 140618
22 10 14 Ba DLT0704 GB 140618
22 10 14 Ba DLT0704 GB 140618
DLT0704
C76, C65HS, C65-10, C60-12, C55-14
Cummins B3.3TAA
Powered Compressor
●
GB Id. No. 100014463 / 07 - June 2014
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Maintenance and Inspection
Manual for CompAir Compressors
Attention
When starting up your compressor for
the first time, observe the operating
instructions under all circumstances.
Proper operation, care and continuous
supervision of the compressor system are
decisive for the operating reliability,
performance and service life.
We cannot assume any liability for
damage resulting from failure to observe
the operating instructions, improper
repairs or use of other than genuine parts.
Questions/Parts orders
Always indicate:
- Machine number (rating plate)
- Machine model.
Danger
Machine model:_________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
Remarks:
______________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
Total operating hours
Time required for service work
Hours
Start
End
Oil change (date/hours)
Mechanic's signature
Original Operating and Service Manual
DLT0704
C76, C65HS, C65-10, C60-12, C55-14
Cummins B3.3TAA
Powered Compressor
1. Index
1 Index
1 Index .................................................................................................................................................................................................. 2
2 Foreword ........................................................................................................................................................................................... 4
2.1 Information on the compressor................................................................................................................................................... 4
2.2 Normal use................................................................................................................................................................................. 4
2.3 Specifications type DLT 0704..................................................................................................................................................... 4
2.4 Declaration of conformity............................................................................................................................................................ 7
2.5 Maintenance and care................................................................................................................................................................ 8
2.6 General information.................................................................................................................................................................... 8
3 Security Regulations ........................................................................................................................................................................ 9
3.1 Identification of safety instructions.............................................................................................................................................. 9
3.2 General safety instructions......................................................................................................................................................... 9
3.3 Modifications and alterations to the machine.............................................................................................................................. 9
3.4 Loading/Relocation/Transport .................................................................................................................................................. 10
3.5 Installation on site / Starting / Normal operation ....................................................................................................................... 10
3.6 Special jobs / Maintenance ...................................................................................................................................................... 12
3.7 Instructions concerning particular hazards ............................................................................................................................... 14
3.8 Symbols and definitions ........................................................................................................................................................... 15
4 Construction and functional description ...................................................................................................................................... 17
4.1 Construction ............................................................................................................................................................................. 18
4.2 Functional description (see Fig. 6) ........................................................................................................................................... 18
4.3 System description................................................................................................................................................................... 19
4.4 Wiring diagram ......................................................................................................................................................................... 20
4.5 Vehicle Socket Connection Plan 13-pin 12 Volt........................................................................................................................ 21
5 Transport and installation on site.................................................................................................................................................. 22
5.1 Transport ................................................................................................................................................................................. 22
5.2 Attachment of the contact-breaker cable on braked chassis .................................................................................................... 22
5.3 Loading/Relocation .................................................................................................................................................................. 23
5.4 Installation on site .................................................................................................................................................................... 23
6 Preparing the compressor for operation ...................................................................................................................................... 25
6.1 Checking levels ........................................................................................................................................................................ 25
6.1.1 Checking the oil level in the pressure tank ................................................................................................................... 25
6.1.2 Checking the oil level in the engine .............................................................................................................................. 25
6.1.3 Checking coolant level.................................................................................................................................................. 25
6.2 Battery ..................................................................................................................................................................................... 26
6.3 Filling up the fuel tank .............................................................................................................................................................. 26
6.4 Fuel water separator ................................................................................................................................................................ 26
6.5 Checking the air filter maintenance display .............................................................................................................................. 26
7 Putting the compressor into operation ......................................................................................................................................... 27
7.1 Initial operation......................................................................................................................................................................... 27
7.2 Operating elements .................................................................................................................................................................. 27
7.3 Start-up .................................................................................................................................................................................... 27
7.4 Setting the operating pressure ................................................................................................................................................. 28
7.5 Monitoring / fault....................................................................................................................................................................... 29
7.6 Operation ................................................................................................................................................................................. 29
7.7 Shutdown ................................................................................................................................................................................. 29
7.8 Decommissioning..................................................................................................................................................................... 29
8 Fuels ................................................................................................................................................................................................ 30
8.1 Recommended lubricant for compressor.................................................................................................................................. 30
8.2 Recommended engine oil......................................................................................................................................................... 30
8.3 Tool lubricants.......................................................................................................................................................................... 30
8.4 Diesel fuel ................................................................................................................................................................................ 30
8.5 Coolant .................................................................................................................................................................................... 31
8.6 Recommended lubricants for the bogies .................................................................................................................................. 31
2
1. Index
9 Maintenance .................................................................................................................................................................................... 32
9.1 General maintenance ............................................................................................................................................................... 32
9.2 Engine maintenance ................................................................................................................................................................ 32
9.3 Maintenance of the fuel system................................................................................................................................................ 33
9.4 Maintenance of chassis and brakes ......................................................................................................................................... 33
9.5 Service and inspection schedule .............................................................................................................................................. 34
9.5.1 Oil filter replacement (compressor)............................................................................................................................... 36
9.5.2 Oil change (compressor) .............................................................................................................................................. 36
9.5.3 Checking the automatic monitoring system ................................................................................................................. 36
9.5.4 Inspecting / Replacing the fine separator...................................................................................................................... 37
9.5.5 Air filter replacement (compressor / engine) ................................................................................................................. 37
9.5.6 Checking the safety valve............................................................................................................................................. 37
9.5.7 Control ......................................................................................................................................................................... 38
9.5.8 Battery maintenance .................................................................................................................................................... 38
9.5.9 Torque specifications ................................................................................................................................................... 38
9.6 Spare parts for maintenance purposes .................................................................................................................................... 38
9.7 Inspection intervals for pressure vessels and electrical installations ........................................................................................ 38
10 Troubleshooting.............................................................................................................................................................................. 39
11 Generator option............................................................................................................................................................................. 41
11.1 Introduction .............................................................................................................................................................................. 41
11.2 Generator safety precautions ................................................................................................................................................... 41
11.3 Operating principle ................................................................................................................................................................... 41
11.4 Operating the generator (Working safely with electrical equipment) ......................................................................................... 42
11.5 Testing insulation monitoring/startup/device connection........................................................................................................... 43
11.6 Technical characteristics of 9 kVA 400/230 V generator .......................................................................................................... 44
11.7 Technical characteristics of 15 kVA 400/230 V generator ........................................................................................................ 44
11.8 Technical characteristics of 7 kVA 110 V generator ................................................................................................................. 45
11.9 Generator switchbox wiring diagram 9 kVA and 15 KVA 400/230 V......................................................................................... 46
11.10 Troubleshooting ...................................................................................................................................................................... 46
12 Heat exchanger option ................................................................................................................................................................... 48
12.1 Safety regulations for the use of the heat exchanger................................................................................................................ 48
12.2 Design and operation ............................................................................................................................................................... 48
12.3 Maintenance/Care.................................................................................................................................................................... 48
13 Compressed air processing option (after cooler / heat exchanger / filter) ................................................................................ 49
13.1 Safety regulations for alternate compressed air processing ..................................................................................................... 49
13.2 Design and operation ............................................................................................................................................................... 49
13.3 Maintenance instructions.......................................................................................................................................................... 49
13.4 Troubleshooting ....................................................................................................................................................................... 49
14 Oil temperature controller option .................................................................................................................................................. 50
14.1 Safety regulations for the use of an oil temperature controller .................................................................................................. 50
14.2 Design and function ................................................................................................................................................................. 50
14.3 Maintenance / care................................................................................................................................................................... 50
14.4 Troubleshooting ....................................................................................................................................................................... 50
15 Undercarriage ................................................................................................................................................................................. 51
15.1 Introduction .............................................................................................................................................................................. 51
15.2 Safety....................................................................................................................................................................................... 51
15.3 Height-adjustable towing system.............................................................................................................................................. 51
15.4 Braking system ........................................................................................................................................................................ 51
15.5 Adjusting the braking system ................................................................................................................................................... 52
15.5.1 Preparations................................................................................................................................................................. 52
15.5.2 Preliminary requirements:............................................................................................................................................. 52
15.5.3 Adjusting the brake....................................................................................................................................................... 52
15.5.4 Adjusting the brake compensating system ................................................................................................................... 52
15.5.5 Adjusting the brake linkage [6] ..................................................................................................................................... 53
15.6 Readjusting the braking system ............................................................................................................................................... 53
15.7 Maintenance and care.............................................................................................................................................................. 53
15.8 Malfunctions and remedies ...................................................................................................................................................... 54
16 Tool oiler option.............................................................................................................................................................................. 56
3
2. Foreword
2 For ewor d
2.1 Information on the Hazards occur particularly when: The compressor is designed for providing
compressed air:
compressor * The compressor is not used for its
intended purpose * For operating compressed-air
CompAir screw compressors are the appliances
product of many years' research and * The compressor is not operated by
development. These preconditions, trained personnel * For conveying bulk material
together with high quality standards, * Unauthorized changes or modifications * For sandblasting and paint-spraying
guarantee the manufacture of screw are carried out on the compressor operations
compressors with a long service life, a
high degree of reliability and cost-effective * You are not wearing the prescribed * For cleaning machines and shuttering
operation. The strict environmental protective clothing material - do not direct towards
protection standards have of course been persons!
* You do not comply with the safety
complied with.
instructions * For blow-cleaning drilled holes.
* You do not observe the information in Any other use, or any additional use, for
the operating manual example as respiratory air, is regarded as
2.2 Normal use not being for the originally intended
For this reason every person involved in
purpose. The manufacturer / supplier
The compressors have been built using the operation, maintenance and repair of
accepts no liability for any resulting
the latest techniques in design and in the compressor must read and observe
damage. The risk is assumed by the user
accordance with recognized safety the operation manual and the safety
alone.
regulations. regulations. This is to be confirmed by
signature as required. The compressor may only be used in a
Nevertheless, the operator or third technically perfect condition, for its
parties may be exposed to risk to life and Furthermore, the following naturally apply:
intended purpose, with appropriate
limb in the course of the use of the awareness of safety regulations and
* The relevant accident prevention
compressor (e.g. through flying pieces of hazards, subject to compliance with the
regulations
building material, swirling particles of dirt operating manual. In particular, faults
or dust, electrical current, thermal * Generally recognized safety and traffic representing safety hazards are to be
vibrations, noise or mechanical hazards), regulations corrected at once.
and the machine or other tangible assets
* Particular national regulations
may be impaired, for reasons that could
not have been avoided through preventive
constructional safety measures.
Type of cooling
Pressure range
Engine rating
Trade name
Ambient Engine
temperature speed
C55-14 -10 50
5.5 14.0 4.5 - 14.0
C55-14G -10 45
C60-12 -10 50
6.0 12.0 4.5 - 12.0 2350
C60-12G -10 45
C65-10 -10 50
6.5 10.0 4.5 - 7.0 17.5 B3.3TAA water 63.0 1600 2600 16.0 8 140.0
C65-10G -10 45
C65HS -10 50
6.5 7.0 4.5 - 10.0 4000
C65HS G -10 45
C76 -10 50
7.6 7.0 4.5 - 7.0 2350
C76-G -10 45
4
C76
Trade name
C76-G
C65HS
C65-10
C60-12
C55-14
C65-10G
C60-12G
C55-14G
C65HS G
2. Foreword
[kg]
Gross vehicle weight rating
1300
1300
1300
1300
1300
1300
1300
1300
1300
1300
1) Chassis height-adjustable, braked
1230
1145
1230
1145
1230
1145
1230
1145
1230
1145
1170
1085
1170
1085
1170
1085
1170
1085
1170
1085
[kg]
3965
3965
3965
3965
3965
3965
3965
3965
3965
3965
(with coupling ring RD40)
2) Chassis height-adjustable unbraked
[kg]
3620
3620
3620
3620
3620
3620
3620
3620
3620
3620
(with coupling ring RD40)
Length, max.
[kg]
3433
3433
3433
3433
3433
3433
3433
3433
3433
3433
(with coupling ring 3")
1700
Total height
[mm]
1440
5 1/2 J x 14 Rim
Tyre pressure
2.8
[bar]
99
max. permissible noise level, acc. to 2000/14/EC
[dB/1pW]
operators location,distance 1m
distance 7m
5
2. Foreword
Fig. 1
Fig. 2
Fig. 3
6
2. Foreword
1. Declaration of conformity
in accordance with the EC Machinery Directive 2006/42/EC, Supplement II A
trade mark: C20 ; C25 ; C25-10; C30 ; C35-10 ; C38 ; C42 ; C50 ; C55-14 ; C60-12 ; C65-10 ; C65HS ; C76 ;
C85-14 ; C95-12 ; C105-14 ; C110-9 ; C115-12 ; C125-7 ; C140-9 ; C200TS-14 ; C210TS-12 ;
C220TS-10 ; C230TS-9 ; C240TS-14 ; C250TS-12 ; C260TS-10 ; C270TS-9 ; C200TS-24 ;
C210TS-21 ; C203TS-17
manufacturer no.:
This machine is exempt from 97/23/EC the Pressure Equipment Directive, reference Article 1
clauses 3.3 and 3.6
3. If the machine is modified in a way not agreed upon with us, this statement will be void.
Simmern,
Date Signature
7
2. Foreword
2.5 Maintenance and care 2.6 General information This fact results in the termination/
expiration of the guarantee and warranty
Care and maintenance are all-important This operating manual is to help you to claims against the manufacturer.
if the screw compressor is to meet the get to know the compressor and to use it
demands placed upon it. Compliance with for its intended applications. It contains
the prescribed maintenance intervals and important information about how to Safety regulations
careful execution of care and maintenance operate the compressor safely, cost-
work are therefore essential, especially effectively and with due care. Compliance Danger
under difficult working conditions. with the instructions in this manual will
help to avoid danger, reduce repair costs It is important that you follow the
and downtime, and increase the reliability safety regulations in Chapter 3 of the
Service and service life of the compressor. operating manual.
Warranty
Only use this compressor with accurate
knowledge of and in compliance with this
manual.
Gardner Denver do not accept
responsibility for safe functioning of the
compressor for actions that do not
correspond to normal use or for purposes
not mentioned in the manual.
Warranty claims cannot be entertained for:
Fig. 4 * Operating errors
Please enter the data from the identifi- * Inadequate maintenance
cation plate for your compressor, in the
spaces above. In case of questions or * Incorrect fuels
orders for spare parts, please give us the * Damage caused by non-use of original
compressor type, compressor number and CompAir parts
the year of construction as given on the
identification plate. * Modification of the system.
If you give us this data you can be sure The Guarantee and Liability terms of
that you will be given the correct Gardner Denver's General Terms and
information or sent the spare parts you Conditions are not extended through the
require. above instructions.
Any unauthorized modification of the
compressor system/station or the
installation of components (e.g. fine
separators) not released by the
manufacturer result in the loss of the
CE symbol.
8
3. Security Regulations
3 Security Re gulati ons
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
Gardner Denver accepts no particularly the chapter on safety operating, setting up, maintaining and
responsibility for any damage or injury instructions. It is too late to do this while repairing the machine / installation must
caused by non-compliance with these working. This applies particularly to be clearly defined.
safety measures or non-observance of personnel only using the machine
Make sure that only authorized
normal care and caution during the occasionally, e.g. for setting up and
personnel use the machine.
handling, operation, maintenance or repair maintaining the machine.
of this compressor, even if not expressly Define who is responsible for operating
Safety and danger-conscious working by
stated in this operating manual. the machine, and authorize him to ignore
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 the that are under instruction or are attending
hair, or wear loose clothing or jewellery,
two applies. a course of general training to use the
including rings, due to risk of injury
machine / installation under the constant
These safety instructions are of a through catching. Personal protective
supervision of an experienced person.
general nature and are applicable to equipment should be worn if necessary or
various types of machine and equipment. as required by regulations. Work on the electrical systems of the
For this reason it is possible that some machine / installation may only be carried
Pay attention to all safety and danger
information may not apply to the out by a trained electrician in accordance
warnings on the machine/ installation!
aggregate(s) described in this manual. with electrical regulations.
Make sure that all safety and danger
Only persons with special knowledge
Danger warnings on the machine / installation can
and experience of hydraulics may work on
be read.
Places thus marked refer to possible system elements, for example
dangers for persons. For all safety-relevant modifications to components under pressure.
the machine / installation or its operating
Attention behavior, stop the machine / installation
immediately and report the fault to the 3.3 Modifications and alterations
Places thus marked refer to possible competent authority / person.
dangers for machines or parts of to the machine
machines. Spare parts must meet the technical
requirements laid down by the No alterations, additions, or
manufacturer. This is always guaranteed modifications to the machine may be
Note
when original spare parts are used. carried out without the approval of the
Places thus marked give general and manufacturer. This is also true for the
technical information for optimum, cost- Replace hydraulic hoses at the given installation and the adjustment of safety
effective machine use. intervals, or at suitable intervals, even if devices and valves as well as for welding
no safety-relevant defects are visible at supporting and pressurized parts.
(DIN 20066, Part 5). Unauthorized modifications to the machine
3.2 General safety instructions Observe the intervals stipulated or those are prohibited for reasons of safety.
given in the operating manual for routine Original parts are specially designed for
Organizational measures checks and inspections. our machines. We must explicitly point out
Please keep this operating manual Workshop equipment suitable for that parts and special accessories not
handy at all times on the site of the carrying out maintenance work is supplied by us are not approved by us.
machine / installation, in the bag provided. essential. Installing or using such products may thus
adversely affect active and/or passive
Please note and pass on general The location and operation of fire safety.
statutory and other binding regulations extinguishers must be made known.
that may supplement the operating Observe the instructions concerning fire The manufacturer accepts no liability
manual for the prevention of accidents and alarm and fire fighting. whatsoever for damage resulting from the
the protection of the environment. Such use of non-original parts or special
obligations may be for example the Limiting values (pressure, temperature, accessories. This also applies to the
handling of hazardous materials, or the time settings etc.) must be permanently installation and adjustment of safety
provision and/or wearing of personal marked. devices and valves as well as to welding
protective equipment, or traffic regulations. on bearing and pressurized parts.
9
3. Security Regulations
3.4 Loading/Relocation/Transport Parts to be removed for transport On descents, always adapt speed to the
purposes must be carefully refitted and circumstances! Never change into low
Loading / Relocation fixed again before putting the machine / gear during the descent, but always
installation back into operation. beforehand. When leaving the driver's
All loose parts that could fall down when seat, always secure the unit to make sure
the machine is lifted must first be removed When putting the machine / installation
that it cannot roll away or be used without
or secured; pivoting parts like doors, etc. back into operation again, only proceed in
authorization!
must be immobilized. accordance with the operating manual.
Avoid all operations that adversely affect
For lifting heavy parts, hoisting gear and the stability of the unit.
heavy-lift facilities with the appropriate Transporting the complete unit
capacities, which have been checked and
Make sure that the air vessel is not
approved in accordance with local safety
under pressure. 3.5 Installation on site / Starting /
regulations, must be used.
Lift and secure supporting gear. Normal operation
For lifting machines or parts of machines
with one or more lifting eyes, only hooks Make sure that the drawbar eye can Installation on site
or shackles complying with local safety move freely in the tow bar.
regulations may be used. Never fasten Besides the general technical operation
cables, chains or ropes to or through lifting Check to make sure that the drawbar is in accordance with the regulations of the
eyes. adjusted to the bar height of the towing local authorities, it is essential that the
vehicle. following guidelines be observed.
Lifting hooks, lifting eyes, shackles etc.
must never be bent and must always be Check to make sure that the body is Before switching on the machine /
stressed in alignment with the load- closed and locked, and that the cable for installation, or starting it up, make sure
carrying axis. The load capacity of the the rapid-emergency brake is connected that nobody can be injured by the
hoisting gear is reduced if the lifting force to the towing vehicle. machine / installation as it starts up.
is applied at an angle to the axis. Join up the connections of the air brake, The installation is to be set up in such a
All bearing parts must be stressed if present. way that it is adequately accessible and
vertically, as far as possible, for maximum that the necessary cooling is ensured.
Check to make sure that the wheels are
safety and optimum performance of the Never block the admission of air.
properly tightened, that the tyres are in a
hoisting gear. If required, a support is to roadworthy condition, that the tyre The air intake is to be designed in such
be installed between the hoisting gear and pressure is correct and that the brakes a way that no dangerous admixtures
the load. Secure the load properly. function properly. (inflammable solvent vapors etc., but also
When heavy loads are being conveyed dust and other dangerous or toxic
Connect the cable for the signalling
by means of hoisting gear, it is imperative substances) can be taken in. This also
and lighting fittings. Check the proper
to keep well clear of the load in order to applies to flying sparks.
functioning of the lighting.
avoid accidents. The air intake is to be designed in such
Release the handbrake.
Never leave the load suspended on the a way that no loose personal clothing can
hoisting gear. Before transporting the unit, always be drawn in.
check to make sure that the accessories
Acceleration or braking of the means of Make sure that the compressed air line
are firmly attached so that they can cause
transport must remain within the approved from the compressor to the air network
no accidents!
limits. can expand as a result of heat and cannot
When using public roads, tracks and come into contact with inflammable
The hoisting gear is to be set up in such spaces, observe the current traffic materials.
a way that the object is lifted vertically. regulations, and if necessary make the
Should this not be possible, precautions The compressed air line connected at
unit roadworthy first!
must be taken to prevent the load from the air exit of the unit must not be under
swinging. Thus it is possible to use two Never exceed the maximum towing strain.
sets of hoisting gear, both with an angle of speed. Observe national regulations!
Compressed-air lines have to be marked
inclination of not more than 30° to the Always switch on lights if visibility is poor distinctly according to local regulations.
vertical. and during lighting-up time!
If several compressors are arranged in a
Nominate experienced supervisors for When going through underpasses, system, manually operated valves have to
the lifting process. bridges, tunnels, overhead power lines, be installed so that each machine may be
Machines may only be hoisted correctly etc., always make sure that you have shut off individually. For the purpose of
using hoisting gear in accordance with the enough clearance! shutting off pressurized systems, you
information in the operating manual (limit should never rely on the effectiveness of
Always keep a safe distance from the return valves alone.
stop points for heavy-lift facilities etc.) edges of foundation ditches and
Only use a suitable transport vehicle embankments! Safety devices, protective covers, or
with sufficient carrying capacity. insulations mounted on the system must
Do not travel across slopes transversely: not be removed or modified in any way.
Before or immediately after completion always keep equipment and loads near
of loading, secure the machine / ground level (for example, do not place
installation to prevent accidental shifting. them on the bodywork).
Display an appropriate warning. Before
putting the machine / installation back into
operation, the securing devices must be
duly removed.
10
3. Security Regulations
All pressure tanks located outside the Make sure that: Never play about with compressed air.
unit with an approved operating pressure
* All bolted connections have been Never direct compressed air onto the
higher than atmospheric pressure and
tightened skin or towards another person.
fitted with two or more pressure feed lines
must be equipped with an additional * All electrical wiring has been connected Never use compressed air for cleaning
safety device to automatically prevent the correctly and is in good condition clothing. When using compressed air to
approved operating pressure from being clean equipment, work with extreme
exceeded by more than 10%. * The engine exhaust system is
caution and always wear suitable eye
operationally safe and that no
protection.
Pipes and other parts with a surface inflammable material is in the vicinity
temperature of more than 80 °C must be The compressed air produced by these
suitably secured against contact and * The wheel nuts are properly tightened;
compressors must not be used as breath-
suitably marked. never exceed the specified torque.
able air, unless it has been processed
specially for such an application in
Electrical connections must comply with
accordance with the “Safety requirements
local regulations. Normal operation
for breathable air.”
With compressors fitted with generators, Before starting work, make yourself
When breathing apparatus with
use equipotential bonding systems for the familiar with the working environment at
cartridges is used, make sure that the
protection of persons. the installation site. The working
correct cartridge has been inserted and
environment includes, for example,
Install the machine so that it is as that its service life has not expired.
obstacles in the working and transport
horizontal as possible; a slight inclination
areas, the carrying capacity of the ground, Never use the machine in environments
is permissible (see information in Chapter
and any necessary cordoning off of the where the possibility cannot be ruled out
"Installation").
building site from public traffic areas. that inflammable or toxic vapors may be
Set up the machine in such a way that taken in.
Take the necessary precautions to make
no inlets, outlets or gates are blocked,
sure that the machine / installation is only Never operate the system at
even when the doors are open.
operated in a safe, functional condition. temperatures and/or pressures below or
Before disconnecting the machine from above the values indicated in the technical
Only operate the machine when all
the towing vehicle, apply the handbrake. data sheet.
protective devices, shutdown devices,
Disconnect the rapid-emergency brake
sound-insulating equipment and extraction Persons working in environments or
cable and lighting cable, disconnect the
equipment is in place and working. rooms in which the acoustic pressure is
lines of the air brakes, use chocks to
85 dB(A) or higher must wear ear muffs.
ensure that the machine does not roll Be careful: loose articles of clothing, hair
Caution: this may impair communication
away. or limbs can still be drawn in by revolving
between persons. Warnings may not be
parts.
If a machine with a combustion engine heard. Inform supervisor.
has to work in a fire-risk environment, the Verify regularly that:
Shieldings and doors must be closed
unit must be fitted with a spark catcher.
* All protective equipment is properly during operation so that the flow of cool air
In dusty environments, set up the positioned and fixed in place within the housing is not deflected and the
machine in such a way that the wind does efficiency of the sound-insulating is not
not blow dust in its direction. During * All hoses and/or pipes within the reduced. Doors and hoods may only be
operation in clean environments, the system are in good condition, are opened briefly.
intervals for cleaning the air intake filter properly fixed in place and do not chafe
With water-cooled combustion engines
and the cooler elements are much longer. * There are no leaks (fuel, oil or coolant with a closed cooling circuit, the cap of the
Do not install the machine directly in leaks) coolant recovery bottle must not be
front of walls. Make sure that the warm air * All bolted connections have been removed before the system has cooled
coming from the engine and cooling tightened down to ambient temperature.
systems is not drawn into the air intake
* All electrical wiring is properly Never fill up with fuel while the engine is
under any circumstances. Drawing this
connected and is in perfect condition running. Make sure that fuel does not
warm air in through the engine or cooler
come into contact with hot machine parts.
fan could lead to overheating; if it is drawn * Safety valves and other pressure-relief
into the combustion chamber, this will devices are in perfect condition and are Do not smoke while filling up with fuel.
result in a loss of power. not blocked, for example by dirt or paint Filling up at a pump can cause static
Never relocate the machine if external * The safety devices all work properly electricity and possibly sparks. In order to
lines or hoses are connected to the avoid this, a ground cable must be
discharge valves, in order to avoid All connected components must be of connected to the system while it is being
damage to the valves and/or collecting the correct size and be suitable for the filled up.
pipe and hoses. specified operating pressure and
temperature. The exhaust from the system contains
No force may be exerted on the carbon monoxide, a lethal gas.
discharge valves, for example by pulling Only use the correct type and size of
the hoses or fitting additional equipment hose coupling and connection. The exhaust must be routed to the
(e.g. a water separator, compressed air outside via a pipe or a hose with an
Before blowing through a hose or air internal diameter of not less than 100 mm
oiler, etc.) directly to the discharge valve.
line, it is essential to hold the open end if the compressor is used indoors.
firmly. If the open end is not held firmly, it
can whiplash and cause damage or injury. Adequate ventilation must be assured.
Avoid any working methods that could The use of an exhauster system is
be considered risky! urgently recommended.
11
3. Security Regulations
Before connecting or disconnecting For all work concerning the operation, After the work has been completed,
hoses, always close the compressor air production adjustment, conversion, or replace any protective devices that have
outlet valves. Before disconnecting a settings of the machine / installation and been removed. Operation without
hose, always make sure that it is not its safety-relevant equipment, as well as protective devices is not permissible.
under pressure. servicing, maintenance, and repair,
Working clothing should be close-fitting
observe the operating manual for startup
A hose connected to an air valve must during work on running screw compressor
and shutdown procedures and the
be fitted with a safety wire for operating systems.
instructions for maintenance work.
pressures above 7 bars; it is in fact
recommended that this safety device All maintenance and repair work may
Maintenance
should be used for pressures above only be carried out when the system is
4 bars. The steel wire has a diameter of shut down, or, with electrical systems, During maintenance and repair work, the
8 mm and is firmly clamped to the hose at when the mains power supply is switched contractor has to inform the personnel
least every 500 mm. Both ends are fitted off. Make sure that the equipment cannot about the dangers that can occur during
with cable lugs. be switched on by accident. their work and about measures to avert
such dangers.
Check the machine / installation for Whenever the machine/system is com-
external damage and faults at least once pletely powered down for maintenance The personnel have to support all
per shift. Any changes noticed (including and repair procedures, it has to be measures to improve safety at work.
changes in operating performance) must secured against unintentional power-on or
be reported immediately to the authority or the mains supply has to be cut off with Safety devices for preventing or
person in charge. If necessary, shut down electrical systems. eliminating dangers must be serviced
and secure the machine immediately. regularly and their functioning tested at
* Switch off battery master switch and/or least once per year. Faults discovered
In case of malfunction, shut down and detach connector. must be corrected at once or reported to
secure the machine / installation the supervisor.
* Put up a warning sign on the main
immediately. Have malfunctions corrected
switch “Attention! Maintenance work.” Only use the correct tools for
immediately.
Close off the complete maintenance maintenance and repair work.
Observe the operating manual for start- area, if required.
up and shutdown procedures as well as Only use original spare parts.
* Disconnect the starter battery.
inspection displays. All maintenance and repair work may
Individual parts and larger subassem- only be carried out when the system is
blies must be carefully attached to the shut down, or, with electrical systems,
3.6 Special jobs / Maintenance hoisting gear and secured in case of when the mains power supply is switched
replacement. off. Make sure that the aggregate cannot
Care be switched on by accident.
Only use suitable, technically perfect
Observe the setting, maintenance, and hoisting gear and load suspension devices Whenever the machine/system is com-
inspection work and intervals stipulated with adequate carrying capacity. Keep pletely powered down for maintenance
in the operating manual, including clear of suspended loads. and repair procedures, it has to be
information about the replacement of parts secured against unintentional power-on or
Before removing any part under
/ partial sections. This work may only be the mains supply has to be cut off with
pressure, separate the aggregate
carried out by specialists. electrical systems.
effectively from all sources of pressure
Maintenance work, tests and repairs and release the pressure from the * Switch off battery master switch and/or
should be carried out in a well ventilated complete system. detach connector.
room, away from heat, open flames, or
Never use inflammable solvents or * Put up a warning sign on the main
sparks. Appropriate prohibition signs (fire,
carbon tetrachloride to clean parts. switch “Attention! Maintenance work.”
open flames, no smoking) must be put up.
Close off the complete maintenance
Take precautions to avoid toxic vapors
Loss of oil leads to a very slippery floor. area, if required.
from cleaning fluids.
Statistics have shown that many accidents
can be attributed to the installation or * Disconnect the starter battery.
Absolute cleanliness is essential during
maintenance of machines on oily floors or maintenance and when carrying out Before removing or opening any part
machine components. For this reason, repairs. under pressure, separate the equipment
always start maintenance work by effectively from all sources of pressure
cleaning the floor and the machine Only carry out maintenance and repair
and release the pressure from the
exterior. work when the machine is located on an
complete system.
even, stable base and is secured against
Inform operating personnel before running away and against buckling. For moveable machines support the
beginning to carry out special work or towing mechanism and axle with
maintenance. Nominate a supervisor. Only carry out inspection, maintenance,
appropriate means if work is to be carried
and repair work when the screw com-
After completing repair work, always out underneath the units (a jack is not
pressor system is at a standstill and is not
check to see whether any tools, loose sufficient).
under pressure.
parts or cloths have been left in or on the Observe the safety precautions for work
machine, driving engine or driving Protective devices, i. e. protective grids,
on batteries.
equipment. may not be removed during operation.
Pay attention to cleanliness. Prevent dirt
Maintenance and repair work is only to Caution while the screw compressor is
from entering by sealing the parts and
be carried out under the supervision of or in operation.
exposed openings with a clean cloth,
by a person qualified for this work. paper, or tape.
12
3. Security Regulations
Before the aggregate is approved for The insulation or protective shielding of Always tighten bolted connections
operation after maintenance or an parts whose temperature may exceed loosened during maintenance and repair
overhaul, make sure that operating 80 °C and which may accidentally be work.
pressures, temperatures, and time touched by personnel may not be re-
If it is necessary to dismantle safety
settings are correct and that the control moved before these parts have cooled
devices during machine set-up, mainte-
and shutdown devices are working down to room temperature.
nance, and repair work, the safety devices
properly.
Check the accuracy of the pressure and must be reassembled and checked imme-
The electric motor, generator, air filter, temperature displays regularly. If the diately after completing the maintenance
electrical components and control permissible tolerance limits have been and repair work.
equipment are to be protected against the exceeded, then they must be replaced.
Ensure safe, environment-friendly
penetration of dampness - for example
Never carry out welding work or any disposal of process materials as well as
when cleaning with a steam jet - by
other work that produces heat in the replaced parts. Oil containing
covering or sealing them.
vicinity of fuel or oil systems. Systems, components, such as fine separators and
Under no circumstances should the which could contain fuel or oil, have to be oils, must be disposed of in accordance
sound-insulating material be removed or completely drained and cleaned, e.g. by with the relevant legal provisions. Oil must
modified. means of a steam jet, before proceeding not enter the soil!
with the work to be carried out.
Never use solvents with dangerous
properties for cleaning parts. Never carry out any welding work on any
Safety precautions for work with
pressure tank or components under
Maintenance work, tests, and repairs batteries
pressure, or modify them in any way.
should be carried out in a well ventilated
The fluid contained in batteries is diluted
room, away from heat, open flames, or If work causing heat, flames, or sparks
sulfuric acid which can cause blindness if
sparks. Appropriate prohibition signs (fire, has to be carried out on a machine, the
brought into contact with the eyes, or
open flames, no smoking) must be put up. surrounding components must be
serious burns if brought into contact with
protected with nonflammable material.
Wear suitable eye protection when the skin. For this reason it is essential to
inspecting the system. Make sure that the Before dismantling or overhauling a work with the greatest of care when
openings of spray containers, valves, compressor, engine, or any other servicing batteries, e.g. when checking
pipes, or atomizers are never directed at machine, make sure that no movable part battery charge, and to take all necessary
yourself or at any other person during the with a weight of more than 15 kg can safety precautions.
inspection. move or roll away.
Always wear long-sleeved overalls, acid-
The fuel used in these systems is highly Machines whose main movement is resistant gloves and safety goggles.
inflammable, toxic and poisonous. Avoid back and forth must be moved at least
On charging a battery, an explosive gas
contact with eyes and skin, and never once, rotating machines several times, in
mixture is formed in the cells, which can
inhale vapors. Should you accidentally order to make sure that there is no
escape through the vent holes in the
swallow fuel, do not induce vomiting, but mechanical malfunction in the machine or
sealing caps. If ventilation is poor, a highly
seek medical attention. in the driving part.
explosive atmosphere can form around
Should fuel come into contact with the Only experienced persons may be the battery, and can persist for several
eyes, or in case of eye irritation by vapors, charged with slinging loads and instructing hours after charging.
flush eyes with plenty of clean water and crane drivers. These instructors must
Thus:
seek medical attention. remain within sight of the operator or be in
touch with him via walkie-talkie or similar * Never smoke in the vicinity of batteries
Every time a message is displayed or
device. that are being charged or have just
there is a suspicion that an internal part of
been charged.
the machine has overheated, the machine During assembly work above body
must be shut down. Never open the height, use appropriate or otherwise * Put up prohibition signs for fire, open
inspection cover, however, before the safety-relevant climbing aids and working flames and smoking in workshops
machine has cooled down sufficiently to platforms. Do not use machine parts as where batteries are charged.
rule out the possibility of the oil vapors climbing aids! Wear safety belts when
igniting spontaneously when mixed with carrying out maintenance work at greater * Never interrupt a current-carrying
air. heights. circuit at battery terminals because of
the danger of spark formation.
In order to avoid an increase in Keep all steps, handles, railings,
operating temperature, inspect and clean platforms, scaffolds, and ladders free of * Proceed particularly cautiously when
the heat transfer surfaces (cooling ribs dirt, snow, and ice. connecting or disconnecting rein-
etc.) regularly. Draw up a schedule for the forcement cables or quick-charge cable
Before beginning maintenance and clamps.
most suitable cleaning intervals for each
repair, clean the machine, particularly
machine. When starting up using jumper cables or
couplings and bolted connections, of oil,
Avoid damaging the safety valves and fuel, and special care products. Do not auxiliary batteries, first connect the
other pressure-reducing devices. In use aggressive detergents. Use lint free positive terminals and then the negative
particular, make sure that they are not cloths for cleaning. terminals. After starting the engine, first
blocked through paint, oil carbon, or dust disconnect the negative terminal (ground
After cleaning, remove all covers and cable) and only then the positive terminal.
accumulation, which could impair the
seals. Disconnect the auxiliary battery after the
effect of these devices.
starting procedure in order to avoid the
After cleaning, check all fuel, engine oil,
risk of the release of gas (explosion
and hydraulic fluid lines for leaks, loose
hazard).
connections, chafing and damage. Correct
any faults immediately.
13
3. Security Regulations
Machine and system parts where Always adhere to the legal provisions
service, maintenance, and repair work is applicable to the particular location!
being carried out must be switched off Follow the local regulations applicable at
load, if required by regulations. First check the respective site of installation.
the deenergized parts to make sure they
are off load, then connect to ground and
short-circuit, and insulate neighbouring Hydraulic and pneumatic systems
parts that are under tension.
Work on hydraulic equipment may only
The electrical equipment of a machine / be carried out by persons with special
installation must be inspected / tested knowledge of and experience in
regularly. Faults, such as loose con- hydraulics.
nections or overheated cables, must be
Check all lines, hoses, and bolted
corrected immediately.
connections regularly for leaks and visible
If work has to be carried out on live damage. Repair any damage immediately.
parts, then call in a second person to It is essential that damaged parts should
operate the emergency stop switch or be replaced! Spurting fluid can lead to
master switch with over voltage release. injuries and fires.
Cordon off the working area with a red-
Before beginning repair work, relieve the
and-white safety chain and a warning
pressure in system sections to be opened
sign.
and in pressure lines (hydraulic and
Only use insulated tools. compressed-air lines) in accordance with
the descriptions of the subassemblies.
Keep an adequate distance between the
machine/unit and overhead power lines! Hydraulic and compressed-air lines
When working near overhead power lines, must be routed and fitted in accordance
equipment must not come near the power with the regulations. Do not confuse the
lines! Danger! Find out about the safe connections!
distance to be observed!
The fittings, length, and quality of
After touching high-voltage lines: hoses must be in accordance with the
requirements.
* Do not leave the machine.
* Move the machine away from the
Noise
danger area.
Protect personnel at risk from noise, in
* Warn outsiders not to come closer or
accordance with EU Directive 2003/10/EU.
touch the machine.
* Make sure that the voltage is switched
off. Potentially-explosive environments
* Do not leave the machine until the line The operation of the compressor in
which has been touched or damaged, areas where there is a risk of explosion is
has been switched off load! strictly forbidden! (Exception: specially-
made compressors with the necessary
When working with high-voltage technical modifications for use in such
assemblies, ground the supply cable after areas)
voltage has been isolated, and short-
circuit the components, e.g. capacitors,
with a ground rod!
14
3. Security Regulations
Hoisting point
Emergency stop
Master switch
100009377
Do not operate
with the hood
open
Caution: Hot
surfaces
A93630300
Caution: Hot surfaces
Caution: Hot and
dangerous Caution: Do not move with the
exhaust fumes transport safety locking
Caution: Under
A13222974
pressure
Caution: Hot and dangerous exhaust
fumes
Only operate with
protective grating
Caution: Remember the handbrake
100003144
Caution: Do not use ether spray
2,8 BAR
A13145774
Note tyre pressure: 2.8 bar
Shut down
99
A983815083
Sound level data 99 dB
15
3. Security Regulations
Options
Condensation drain
from after-cooler or
from after-cooler with
subsequent filtering
16
4. Construction and functional description
4 Constr uction and func tional desc riptio n
17
4. Construction and functional description
4.1 Construction 4.2 Functional description When the preset operating pressure is
(see Fig. 6) exceeded the P controller (23) of the
Compressor and engine control unit feeds control air to the
Oil circuit adjusting cylinder (4) of the engine speed
The core of the sound proofed mobile adjustment system and the intake suction
compressor system is a single-stage, oil- The oil required for sealing and cooling controller (11) in order to modify the
flooded screw compressor. The CompAir the rotors as well as for lubricating the comnpressor's intake volume.
screw profile represents the state-of-the- roller bearings is injected into the
art. The air is delivered pulsation-free. compressor (10) from the pressure tank This causes a change in engine speed
(17), which is under system pressure. The and in compressor intake volume until the
The drive assembly is a medium-cooled preset operating pressure is maintained
difference in pressure between the
diesel engine, which drives the screw constant.
pressure tank and the oil injection position
rotors of the compressor by a flexible
is approx. 1 bar. The oil hereby passes The system is kept in equilibrium and
coupling.
the oil cooler (16) and the oil filter (13). any condensate occurring in the control
The suction controller (11) is fitted with a line is blown off by means of the nozzle
non-return function, so that when the (5) of the engine management system (4)
Fairing (Body)
system is switched off, flooding of the air and the nozzle (12) of the suction
The fairing consists of a subbox, which filter (9) is prevented. controller (11).
is mounted on a base frame, and to
which a folding cover for servicing and The speed/intake regulation system
maintenance access is attached. The Air circuit steplessly matches the volumetric flow to
opening of the cover is effectively air take-off between 0 and 100 %.
The intake air flows through the air filter
supported by pneumatic springs. The If air tale-off drops to zero, the intake
(9) and the suction controller (10) into the
hook inside is for hanging up a load controller (11) is closed and the diesel
compressor (10). During compression, oil
suspension device. The machine rests on engine (2) is run down to idling speed by
is injected in order to lubricate, cool and
rubber elements to prevent vibrations and the engine control cylinder (4).
seal the screw rotors. The compressed
noise.
air-oil mixture flows into the pressure tank If operating pressure drops below the
For convenient assembly, all individual (17). Centrifugal preseparation of the oil is preset value, the control air pressure of
parts of the cover are screwed together ensured through tangential entry into the the P controller (23) of the control unit; the
with machine screws. For the prevention tank. Any remaining oil is separated from intake controller (11) opens and engine
of corrosion, the compressor body is fully the air in the fine separator. speed in increased by the engine control
galvanised, electrostatically powder cylinder (4).
The compressed air is fed via the
coated and burnt at °C 220. The sound
pressure retention valve (20) to the When turning off the engine the
absorbing mats are inserted and easy to
compressed air discharge (21). The backlash flap inside the suction controller
be cleaned.
pressure retention valve effectively (11) will be closed through the system
prevents the system pressure from falling pressure. The release valve (25), which
below the minimum operating pressure closes parallel to the engine lifting
Frame and chassis
required for the system to work properly. magnet, looses power and opens. The
The complete compressor unit is A temperature monitoring device (14) as container pressure drops down to zero.
mounted on an easy-to-transport single- well as an operational pressure
axle chassis. The chassis is equipped manometer (22) are integral parts of the
with automatic overrun brakes and air circuit.
parking brakes, as well as a jockey wheel
adjustable in height.
Regulation
Airflow Note
Fresh air is sucked in through the It is not possible to start the compressor if
admission opening at the back of the the fuel level is low, or if there is water in
compressor. The air intake volume is the main fuel filter.
air for the engine and for the compressor
Starting procedure: The control system
too, as well as cooling air for the engine
is out of operation when the system is
and for the oil cooler of the compressor.
started, i.e., motor speed is reduced to
idling speed as system pressure increases
and the suction controller (11) is closed.
Switching from idling to operating speed
takes place by means of actuation of the
load knob load switching valve (24).
The compressor then starts to deliver
(10) and system pressure in the vessel
(17) increases.
18
4. Construction and functional description
Fig. 6 A13538074
19
4. Construction and functional description
M1 Starter
Fig. 7 A13537774
20
4. Construction and functional description
Not assigned
Not assigned
Socket plug
21
5. Transport and installation on site
5 Tra nspo rt a nd ins tallatio n o n site
5.1 Transport Replacing the trailer coupling ring * The contact-breaking cable is
connected to the towing vehicle. Safety
The coupling arrangements which can be
Transport safety locking of the towing chains are attached on towing vehicle.
used:
arrangement * The electrical cable (option) is
* Trailer coupling ring RD 40
connected to the vehicle and to the
* Coupling 50 dia. screw compressor.
* Coupling ring 2" dia. (only for UK) * Check the lights (tail lights, brake
lights, indicator lights, and rear fog
* Coupling ring 68 x 25 dia. (only for lamp) (option).
France)
Transport safety locking * Check to make sure that the wheels
A different coupling unit in the form of a are properly tightened and the tyres are
complete kit may be ordered, if necessary. in a roadworthy condition.
Replacing the trailer coupling ring is
permitted only if proper fitting is carried out Attention
by an inspectorate for the sector covered
by the Regulations Authorizing the Use of Check tyre pressure, and adjust if
Vehicles for Road Traffic (e.G. the TÜV - necessary (risk of accident). A too
Fig. 9 Technical Inspectorate, DEKRA - German high tyre pressure can lead to
Before moving the compressor for the Motor Vehicle Monitoring Association, overstraining of safety parts.
first time slacken the ratchet on height- etc.). The inspection station provides a
* When parking the compressor prior to
adjustable towing gear and remove the fitting certificate to be kept with the vehicle uncoupling from the towing vehicle
transport securement. Then adjust the documents.
actuate the handbrake, detach the
towing gear from the vertical transport contact-breaker cable and the lighting
position to the required attachment height Danger
cable, and secure the compressor
for the towing vehicle and lock it in place against rolling using chocks. Then
The screw compressor may only be
in the toothing using the ratchet (see adjust to the horizontal position by
transported on public roads if
Section 15. Undercarriage, height- means of a support or support wheel.
adjustable towing gear). * The machine group (engine) is not
running, Attention
* The pressure tank is not under Always keep a safe distance from the
pressure, edges of foundation ditches and
* The shielding is closed, embankments! Do not travel across
slopes transversely.
* The blocks are firmly hooked in
place,
* Hoisted and secured tail wheel,
* The tyres and brakes are 5.2 Attachment of the contact-
operationally safe and roadworthy, breaker cable on braked
* The lighting is fully functional. chassis
Never exceed the maximum towing If the towing connection becomes
Fig. 10 speed! Danger! Observe national uncoupled, the trailer is braked by the
regulations! breakaway cable. Put the breakaway
Danger cable in the eye provided or wind it around
Please also observe the safety
instructions in Chapter 3 on the subject the towing collar and hitch it up to the
Make sure to check the torque after
of transporting. cable with the snap link.
50 kilometers following wheel
mounting and at regular intervals. Before transporting the compressor, The breakaway cable must be attached
check to make sure that the draw gear of in a way that ensures that even on
Tighten wheel nuts or screws evenly in
the towing vehicle and the drawbar eye or extremely sharp bends there is no danger
a diagonal sequence to the specified
trailer hitch ball connection are aligned of activating the locking brake.
torque using a torque wrench.
exactly to each other.
When transporting the screw compressor
with a vehicle, the following points must
be observed:
* The shielding is closed.
* The blocks are firmly hooked in place.
* The support(s) is(are) retracted and
locked in position (jockey wheel).
* Drawbar is connected to the towing
vehicle.
Fig. 11
* The drawbar is adjusted to the height
of the towing vehicle (option).
22
5. Transport and installation on site
5.3 Loading/Relocation Never relocate the machine if external 5.4 Installation on site
lines or hoses are connected to the
discharge valves, in order to avoid
damage to the valves and/or collecting
pipe and hoses.
When loading, the following points must
be observed:
* Secure the load suspension device or
the hoisting gear in the lifting device of
the screw compressor.
* When hoisting the compressor, set up
the hoisting gear in such a way that the
compressor, which must be set up
Fig. 12 Fig. 13
horizontally, is lifted vertically.
* Raise and lower the compressor The air intake must be positioned in
Only use hoisting gear (e.g. crane) with
carefully. such a way that loose personal
appropriate lifting capacity for the
loads occurring! clothing cannot be drawn in.
* After relocating, remove the load
suspension device or the hoisting gear Make sure that the pressure pipe from
Only use the correct suspension gear!
from the lifting device. the compressor to the aftercooler or
Keep clear of the swiveling range of the the air system can expand as a result
* Tie down the compressor on the cargo
hoisting gear! of heat, and that it does not come into
area of the means of transport.
contact with inflammable materials.
Keep clear of suspended loads!
* Lash only on the tow pipe of the
The air intake is to be designed in such
All loose parts that could fall down chassis and on the rear fixing point.
a way that no dangerous admixtures
during hoisting must first be removed
* When dismantling the chassis, the (inflammable solvent vapors etc., but
or secured; pivoting parts, like doors,
fairing and the machine set may be also other dangerous or toxic
towbars, etc. must be secured in such
supported only under the longitudinal substances) can be taken in. This also
a way that they cannot move.
stringers of the subframe box. New applies to flying sparks.
Never leave the load suspended on the self-locking nuts must be used for
Pipes and other parts with a surface
hoisting gear. Acceleration or braking installation. See section 9.5.9 for
temperature of more than 80 °C must
of the means of transport must remain tightening torques.
be suitably secured against contact
within the approved limits.
and suitably marked.
Please also observe the safety
The operation of the compressor in
instructions in Chapter 3 on the subject
areas where there is a risk of explosion
of loading.
is strictly forbidden! (Exception:
Attention specially-made compressors with the
necessary technical modifications for
Do not attempt to use a crane hook or use in such areas)
similar load suspension devices direct
Please also note the safety instructions
on the lifting device to avoid damages
in Chapter 3 on the subject of
to the lifting device!
installation on site.
Use proper hoisting gears only such as
hoisting straps in compliance with DIN
standard 61360 with proper lifting ca- Location
pacity for connecting the load
suspension device (e.g. crane) and the The complete system is to be set up in
lifting device. such a way that it is easily accessible and
that the required cooling is guaranteed.
Only deploy load bearing equipment Never block the air intake. Ensure that the
which corresponds to the safety entering of moisture and dirt together with
instructions for lifting gear. the intake air is kept to a minimum.
Use a transport harness compliant with The compressor is to be set up away
local regulations for transporting by from walls.
helicopter. The eyes provided may not
be used for this purpose (max.
acceleration if the eyes are used =
2 x g)
Never lift up or lash down the unit
using the shieldings!
23
5. Transport and installation on site
Attention Attention
The screw compressor is to be set up No force may be exerted on the dis-
in such a way that no air reflection can charge valves, for example by pulling
take place, i.e. neither waste air nor the hoses or fitting additional
exhaust emissions may be drawn in; equipment (e.g. a water separator,
the same applies to dangerous compressed air oiler, etc.) directly at
admixtures to the air. Drawing this the discharge valve.
waste air in could lead to overheating
and a loss of power.
Temperatures/air humidity
The compressor must be set up in as
horizontal a position as possible. Install the compressor in a location with
Maximum permissible inclination during maximum possible frost protection. The
operation: suction air temperature must be within the
range specified on the data
* In direction of pull: 15 degrees
* Backwards: 15 degrees For optimum functioning the screw
* To the right and to the left: 15 degrees compressor is fitted with an oil
temperature regulator as standard. This
ensures optimal oil temperature for the
compressorʼs functioning requirements.
Altitude
For operation at an altitude above
2.350 m, the compressor and engine must
be adapted (modified design).
Note
Note
24
6. Preparing the compressor for operation
6 Prepari ng t he c omp ress or f or o per ation
6.1 Checking levels 6.1.2 Checking the oil level in the 6.1.3 Checking coolant level
engine
6.1.1 Checking the oil level in the
pressure tank
Fig. 16 Fig. 17
Fig. 15
Danger Danger
Danger
Only check the oil level when the The coolant header tank may be under
Only check the oil level when the compressor engine is at a standstill. pressure and its contents may be hot!
engine is at a standstill and the Spill no oil! The oil may be hot. Risk of
compressor is not under pressure. Caution when opening the cap, danger
scalding!
of scalding!
The pressure tank may be under Check for leaks.
pressure and the oil may be hot. Avoid contact with the eyes and/or
Proceed as follows: skin, danger of corrosive burns!
Risk of scalding! Spill no oil!
* Shut the compressor down and wait for In case of contact with the skin and/or
Check for leaks. 5 minutes. eyes, wash out/off under flowing water
Proceed as follows: and obtain medical assistance
* Before checking the oil level ensure immediately.
* Shut the compressor down and wait that the vehicle is standing horizontally.
until the system is depressurized, in no Proceed as follows:
* Pull the dipstick out.
case less than 5 minutes. * Shut down the compressor,
* The oil level should be within the marks
* Before checking the oil level ensure on the dipstick. * Position the compressor horizontally
that the vehicle is standing horizontally. before checking the coolant level,
* Correct as required.
* Unscrew dipstick. * Check the level of coolant through the
* Put the dipstick back.
* The oil level should be within the marks inspection glass in the tank. The level
on the dipstick. * Close oil filler. must lie between the top and bottom of
the inspection glass (see Fig. 17)
* Correct as required. * For oil specifications, see “Engine
Operating Manual”. * Correct as required.
* Check the seal on the dipstick and
replace if required. Attention Attention
* Screw in dipstick and tighten firmly. After a short test run, the oil level The coolant must be changed not less
should be between the markings on frequently than every two years.
Attention the dip stick.
Only use corrosion inhibitors and
After a short test run, the oil level For oil specifications, see engine antifreezes recommended and
should be between the markings on instruction manual. approved by the engine manufacturer!
the dip stick.
Dispose of used coolant in accordance
For oil specifications, see with the relevant regulations.
recommended lubricants, Chapter 8.1.
25
6. Preparing the compressor for operation
6.2 Battery 6.3 Filling up the fuel tank For outside temperatures below 0 °C,
observe the operating manual of the
engine manufacturer for winter operation.
You can reduce the occurrence of
condensation in the fuel tank considerably
by filling it up in good time. This also
prevents downtimes and starting problems
that can occur when the fuel tank is run
dry.
Fig. 18 Fig. 19
Proceed as follows:
* Fill up with battery acid as far as the Bleeding
base of the control insert
Danger
* Leave the battery to stand for some
time To avoid accidents, never bleed the
fuel system with the engine in hot
* Then shake it gently condition. Danger of fire!
* If required, top up with acid Bleeding of the fuel system is described
* Tighten sealing caps in the operating manual for the engine. It Fig. 21
is necessary in the following cases:
* Leave for 1 hour Maintenance work on the fuel system The air filter element must be replaced
(priming pump, filter, water separator, when the red section of the servicing
* The battery is ready for use indicator (2) is fully visible (see
piping), failure of the engine due to lack of
fuel, before restarting after prolonged Section 9.5.5, "Air filter replacement")
periods of non-use. Empty the dust emission valve by
pressing together the emission slot (1) in
Note the direction of the arrow.
The fuel tank should always be filled up in
good time. For outside temperatures Note
below 0 °C, use only winter diesel fuel. Clean the emission slot from time to time.
More information on fuel quality, see
engine operating manual.
26
7. Putting the compressor into operation
7 Putting t he co mp resso r int o op era tion
Attention
Opening the covering interferes with
the flow of cool air in the compressor
section.
Full sound-insulating is only achieved
when the covering is closed.
Check the oil levels in the pressure
Fig. 24 Main switch 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.
27
7. Putting the compressor into operation
Note Start-up using jumper cables / auxiliary 7.4 Setting the operating
batteries pressure
It is not possible to start up the
compressor in case of a fuel shortage.
28
7. Putting the compressor into operation
7.5 Monitoring / fault 7.6 Operation * Turn off power to the system using the
main switch.
Danger Danger After the installation has come to a
standstill all the air is automatically blown
Interference with the automatic Only operate the compressor at the out of the pressure tank via the blow-off
monitoring system is not permitted. permissible operating pressure and at valve.
the permissible temperature.
Attention Danger
Only use the compressor for its
Disconnect the battery or generator intended purpose (see Chapter 2.2 of
It is important that you ensure that the
only when the engine is not running. this operating manual) in order to avoid
pressure is completely blown off via
residual risk for persons and assets.
In case of a problem the blow-off valve.
Only operate the compressor in a safe,
* Compressor temperature too high Should this not be the case, open the
functioning condition.
* Engine oil pressure too low air outlet valves, identify the fault and
* Engine temperature too high All components, hoses etc. fitted must correct it.
* Battery voltage too low be of the correct size and designed for
* Fuel shortage the specified operating pressure and
temperature. 7.8 Decommissioning
the system switches off automatically and
indicates the problem that caused the trip. When working with compressed air,
wear suitable protective clothing (e.g.
The fault indication goes off when
protective suit, safety goggles, etc.).
ignition switch S1 is turned to the (Off)
position. If the system is started without Wearing ear muffs may impair
elimination of the problem, it will stop communication between persons.
again after a function test and indicate the Warnings may not be heard. Inform
problem. supervisor.
Switch the system off if an oil mist is Check the compressor regularly.
entrained in the compressed air or if Check the machine / installation for
excessive oil consumption is apparent external damage and faults at least
(see "Trouble-shooting") once per shift. Any changes noticed
(including changes in operating
Check whether operating pressure is Fig. 28
performance) must be reported
within the permissible limits.
immediately to the authority or person If the system is to be closed down for a
in charge. If necessary, shut down and longer period of time (approx. 3 months
Pressure gauge for display: secure the machine immediately. or longer) the following preservation
“Operating pressure” measures must be taken:
Leaking condensation contains a
proportion of oil and must be collected * Engine preservation (see separate
and disposed of under safe conditions. engine operating manual).
Condensation must not enter the soil
* Disconnect battery cables.
or the rivers. Major quantities of
condensation accumulate particularly * No special measures are required at
in versions with aftercoolers for the compressor.
processing compressed air. Provide a
collecting basin. * Relieve the strain on tyres by jacking
up the vehicle.
* Check tyre pressure every 2 months.
7.7 Shutdown * Release the handbrake.
In order to shut down the compressor:
Attention
* Close air discharge valves. The screw
When putting back into operation,
compressor reduces the speed of the
carry out the maintenance work
engine back to idling speed after the
Fig. 27 in accordance with Chapter 9
preset final pressure has been
“Maintenance.”
reached.
Danger
Attention
Do not operate the compressor at
pressures above the permissible Allow the screw compressor to idle
operating pressure. for a few minutes.
The pressure gauge shows the * Return the ignition switch (1) to the
operating pressure of the compressor. position (Off-Aus).
The permissible operating pressure is Note
indicated on the nameplate!
This switch can also be used as an
emergency stop switch. No other
switching off method is provided.
29
8. Fuels
8 Fuels
8.1 Recommended lubricant for When using oils with the “Brief De- 8.4 Diesel fuel
scription HYD 10/HYD 20" in accordance
compressor
with the ʻStandard Lubricants for Building Use common diesel fuel with a sulfur
Machinery and Vehiclesʼ published by the content of less than 0.5 %. If the sulfur
Note ʻHauptverband der Deutschen Bauin- content is higher, oil has to be changed at
In these screw compressors, circulating oil dustrie e.V.ʼ (Principal Association of the shorter intervals.
has not only a lubricating function, but in German Building Industry), only the
given hydraulic fluids may be used in The following fuel specifications are
particular it also has cooling and sealing applicable:
functions. It is therefore exposed to more accordance with ISO VG 32 and
difficult conditions. In particular the ISO VG 46. * DIN 51 601
temperature conditions at the installation If other lubricants are to be used, please * Nato Codes F 54, F 75, and F 76
site and the consistency of the air (dust, contact: * BS 2869: A1 and A2 (observe sulfur
dirt, and humidity content, as well as content with A2)
chemical influences) must be taken into Gardner Denver Deutschland GmbH * ASTM D 975-81 : 1-D and 2-D
account when selecting a suitable Argenthaler Straße 11 * VV-F-800a : DF-A, DF-1, and DF-2.
lubricant. D-55469 Simmern/Hunsrück
Telephone 06761 / 832-339 Note
Attention Telefax 06761 / 832-421
See engine instruction manual.
Do not mix oils of different or your authorized dealer or your local
At low temperatures,paraffin
specifications. branch.
precipitation can cause blocks in the fuel
The maintenance intervals and the system and disruptions in operation.
maximum and minimum operating Below outside temperatures of 0 °C use
temperatures given in this operating 8.2 Recommended engine oil winter diesel fuel (to -15 °C). (This is
manual only apply when high-quality usually available at gas stations in good
Detailed lubricant specifications for the time before the winter season begins.)
multi-grade oils are used.
driving engine can be found in the
Diesel fuel with additives is frequently
Use of the wrong oil leads to enclosed engine operating manual. offered for use at temperatures as low as
impairment of function. -20 °C („Superdiesel“).
For normal service conditions:
Change the compressor oil more
15W40 API CH-415J (ACEA E-3, Note
frequently than specified if the
ACEA E 5)
equipment is operated under abnormal Only mix in the tank. First put in the
conditions, i.e. at a high ambient required quantity of petroleum, then fill up.
temperature, high air humidity or in a
dusty environment. If necessary, 8.3 Tool lubricants See engine instruction manual.
analyse the oil.
Below -15 °C or -20 °C, petroleum must
Attention
Out of consideration for the high loads be added.
imposed on the lubricant in screw Do not run the machine with an empty If it is necessary to use summer diesel
compressors with oil injection cooling, we oiler tank! The tank must always fuel below 0 °C, petroleum can also be
recommend the use of suitable, non contain a minimum of 0.2 l of tool oil. added up to 60 %.
ageing, non foaming, corrosion-protective
oils. They must meet the following The wrong tool lubricants lead to In most cases, adequate resistance to
requirements for hydraulic fluids: H-LP 32 deposits that cause malfunctions in the low temperatures can be achieved by
and H-LP 46 in accordance with appliances connected! adding a product to improve flow
DIN 51524, Part 2, June 1985. For the perfect lubrication of concrete properties (fuel additive). Consult your
breakers and pneumatic spades, we engine service station.
At normal operating temperatures, the
viscosity of the lubricating oils used recommend the use of CompAir oilers or
automatic pipe oilers, using the special Attention
should conform with Viscosity Class
ISO VG 32 DIN 51519, July 1976, viz. synthetic CompAir oil AES 82. The compressor must not be fuelled
28-35 mm2/s (cSt)/40 °C (obtainable in The special advantages of CompAir oil are with bio-diesel (DIN 51606) or
20 l canisters under CompAir ID No.: as follows: vegetable oil.
SACO32-20).
* Biodegradable,
At ambient temperatures continuously
above +25 °C, the viscosity of the * Ice guard down to -50 °C, for use with
lubricating oils sued should conform with sound absorbers,
Viscosity Class ISO VG 46 DIN 51519, * Very good lubricity, thus wear-reducing,
July 1976, viz. 41-50 mm2/s(cSt)/40 °C
(obtainable in 25 l canisters under * No irritating exhaust gases, work in
CompAir ID No.: SACO46-25). enclosed rooms possible,
* Good cleaning effect, no residue
Attention
formation
Conventional engine oils marked HD
* Excellent preservation properties,
must not be used.
protects from corrosion.
When using compressed air consumers
made by other manufacturers, then their
regulations must be observed.
30
8. Fuels
The coolant consists of 50% water and Greases with different thickeners
50% corrosion protection/antifreeze fluid. (soap base) must not be mixed.
31
9. Maintenance
9 Mainte nan ce
9.1 General maintenance If your engine is equipped with a * Antifreeze check interval is every
component or accessory not 500 hours or 6 months. The operator
manufactured by Cummins Inc., refer to must use a heavy-duty year-round
Danger
the component manufacturerʼs antifreeze that meets the chemical
Install a "Caution maintenance work" maintenance recommendations. composition of GM6038M. The
warning sign and cordon off a wide antifreeze change interval is 1 year or
Use the chart provided in this section as
area around the workplace before 1000 hours.
a convenient way to record maintenance
starting any work. performed. Antifreeze is essential for freeze,
During inspection, adjustment, or overheat, and corrosion protection.
Perform maintenance at whichever
maintenance work, remember that the interval occurs first. At each scheduled
surfaces of machine parts can be hot, Attention
maintenance interval, perform all previous
particularly the exhaust system (risk checks that are due for scheduled Recommendation:
of burning) and that the control device maintenance. Texaco: Havoline AFC
may move during operation (risk of
crushing). Rinse the entire cooling system with
Daily or refueling - maintenance check clear water before using a different
Clean the screw compressor at regular, antifreeze type. Otherwise a chemical
not too long intervals: * Air intake piping - inspect
reaction may plug the cooling system.
* Engine coolant level - check/correct
* Blow-clean all valves, controllers, * Drive Belts - check/correct Full load speed is factory-set by the
fittings, pressure tank, oil cooler, * Cooling fan - check/correct manufacturer and must not be
radiator, screw compressor, and * Fuel-water separator - drain modified.
engine with compressed air or a steam * Engine lubricating oil level -
jet appliance. The idling speed must not be changed
check/correct
either, as this might cause serious
* Inspect the cooling ribs of the radiator * Crankcase breather tube - inspect
damage to the screw compressor, e.g.
to make sure that air can pass through. damage to the coupling!
First 50 hours of operation -
* Clean the body at regular intervals. maintenance check
Then grease or oil the hinges of the
body hood with multi-purpose grease. * Check engine mounting, and tighten if
necessary
If sound-absorbing matting has to be
replaced, remove the retaining brackets, First 250 hours of operation -
replace the old sound-absorbing matting maintenance check
with new matting, replace the retaining
brackets. * Check cylinder head group (valve
clearance) and adjust if necessary
32
9. Maintenance
9.3 Maintenance of the fuel Emptying the fuel/water separator Changing the fuel filter (Fig. 29, Pos. 3)
system (Fig. 29, Pos. 3)
Intervals for filter changing in
accordance with the engine operating
manual.
Danger
Attention
The fuel system must be bled in
accordance with the engine operating
manual!
33
9. Maintenance
50 h
250 h
500 h
570 h
5,500 h
1,000 h
1,250 h
1,500 h
1,650 h
2,000 h
2,250 h
2,500 h
2,650 h
3,000 h
3,250 h
3,500 h
3,650 h
4,000 h
4,250 h
4,500 h
4,650 h
5,000 h
5,250 h
5,650 h
6,000 h
Due at x hours run
■
X For your own benefit, put a cross on the servicing schedule against maintenance work when performed.
34
9. Maintenance
10,000 h
10,250 h
10,500 h
10,650 h
10,000 h
11,250 h
11,500 h
11,650 h
12,000 h
12,250 h
12,500 h
12,650 h
13,000 h
13,250 h
13,500 h
13,650 h
14,000 h
14,250 h
14,500 h
14,650 h
15,000 h
15,250 h
15,500 h
15,650 h
16,000 h
16,250 h
16,500 h
16,650 h
17,000 h
17,250 h
17,500 h
17,650 h
18,000 h
18,250 h
18,500 h
18,650 h
19,000 h
19,250 h
19,500 h
19,650 h
20,000 h
6,250 h
6,500 h
6,650 h
7,000 h
7,250 h
7,500 h
7,650 h
8,000 h
8,250 h
8,500 h
8,650 h
9,000 h
9,250 h
9,500 h
9,650 h
7 yrs 8 yrs 9 yrs 10 yrs 11 yrs 12 yrs 13 yrs 14 yrs 15 yrs 16 yrs 17 yrs 18 yrs 19 yrs 20 yrs
■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■ ■■■■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■
■ ■ ■
■ ■
35
9. Maintenance
9.5.1 Oil filter replacement 9.5.2 Oil change (compressor) * Start screw compressor, run for approx.
(compressor) two minutes, check for leaks
* Switch off screw compressor
* Check oil level, add oil if necessary
Danger
36
9. Maintenance
9.5.4 Inspecting / Replacing the * Fit the lid. Insert the hexagon screws * Remove safety cartridge from the
fine separator and tighten them across the diagonal housing.
(tightening torque see Chapter 9.5.9
* Replace filter cartridge.
"Torque specifications").
* Check for leakage. Danger
* Dispose of the old fine separator Never clean the air filter cartridge with
cartridge in the specified manner. inflammable liquids.
* Insert a new fine separator into the * Remove filter cartridge from the filter A mixture of oil and air will escape
pressure vessel and fit a new seal. hood. when the valve is checked/tested.
37
9. Maintenance
9.5.8 Battery maintenance Rubber metal element / frame 85 Nm 9.7 Inspection intervals for
pressure vessels and
Chassis mounting screw 90 Nm
electrical installations
suspension / frame 85 Nm
Pressure vessels
suspension cross girder 85 Nm
As per the requirements of the 97/23/EC
hose clips (engine, 3 Nm Pressure Equipment Directive, a qualified
compressor/cooler) person must inspect the pressure vessel
from inside every five years.
As per the requirements of the 97/23/EC
Pressure Equipment Directive, an
appointed body must perform a strength
test on the pressure vessel after ten
years.
Fig. 37
The gases released by the battery are The electrical installation must be
explosive. inspected by a qualified electrician after
four years and also each time work has
Avoid sparks and open fires in the been performed on it.
vicinity of the battery.
Should stricter inspection intervals apply
Do not allow acids to come into contact in your country, these must be observed.
with skin or clothing. Wear safety
goggles.
Place no tools on the battery.
The battery is maintenance-free in
accordance with DIN.
38
10. Troubleshooting
10 Tro ublesh ootin g
Screw compressor will not start No power on instrument panel Switch on fuse F1
(starter motor not turning)
Temperature switch on engine or Replace / allow to cool down
compressor malfunctioning, or temperature
too high
Coolant level switch malfunctioning of level Replace / top up coolant
to lowg
Operating voltage low Charge battery or replace
No fuel or fuel level switch defective Fill up with fuel / replace switch
Electrical connection loose, corroded, Replace
or broken
Starter defective Replace
Switch defective Replace
No control system test (LEDs flashing) after Check and switch on main fuse F1
activation of S1
Screw compressor will not start Fuel filter clogged Replace fuel filter cartridge and vent fuel
(starter motor turning) system (see engine operating manual)
Fuel line loose, broken, or jammed Repair line
Air in system Vent fuel system (see engine operating
manual)
Lifter magnet not working Replace
Other engine problems See engine operating manual
39
10. Troubleshooting
40
11. Generator option
11 Gene rato r op tion
11.1 Introduction generator with high-pressure The stability of the output frequency is
equipment. entirely dependent on that of the speed of
This manual describes the operation the combustion engine. You must there-
* Generators may only accept up to
and maintenance of synchronous fore ensure that this engine is serviced,
their nominal load if operated
generators with switchboxes. maintained and operated properly.
according to the standard tempera-
All information relates to data available ture range and cooling conditions If the generator is overloaded briefly (for
at the time of going to press. specified. If installed under different less than the thermal response time of the
conditions, or if cooling of the circuit breaker), or devices with excessive
The manufacturer reserves the right to engine or generator is impaired, for startup consumption levels are connected,
make changes at any time, without prior example in confined spaces or the regulator automatically limits the
notice or obligation. It is therefore always under unfavourable circumstances, output/startup consumption (through the
advisable to check for updates. their output must be reduced. excitation current). This leads to a
No part of this publication may be (desired) withdrawal of the output voltage.
* Do not modify the generator/ switch-
reproduced or transmitted in any form or Please take account of this when
box. Such changes, or the use of
by any means, without the prior written operating several devices simultaneously
unsuitable parts, will invalidate
consent of the manufacturer. on your generator.
approval under machinery safety
Synchronous generators may only be legislation and certification to Note
used as such. No other form of use is EU/EEC Directives.
permitted. Switch devices (loads) on one after the
Opening of the terminal box / fuse box
other, starting with that with the least
only by trained, qualified staff. Opening favourable startup characteristics.
of the terminal box not earlier than
11.2 Generator safety precautions 5 seconds after motor shutdown. If the generator is extremely dirty,
insufficiently ventilated, or operating under
Observe the following safety rules: otherwise unacceptable conditions, to
Danger
* Disconnect the system from the prevent it or the regulator being damaged
Do not top up current-generating units power supply. by overheating, the output voltage is
(generators) with fuel during operation! reduced to about half its nominal value if
* Secure the system against being the temperature inside the switchbox
Follow the additional fire and explosion switched on again. exceeds 80 °C. This compromises the
protection regulations in the case of
* Ensure that the system is de- connected devices, which must be
installation in enclosed spaces. switched off or unplugged immediately.
energised.
Attention! Exhaust gases are toxic! Always avoid operating the generator
Do not operate generators in non- * Earth the system and short-circuit it. under such conditions, and keep it clean
ventilated, enclosed spaces! * Cover or cordon off neighbouring (particularly fan cowl air inlets, cooling
energised parts. fins).
Check that electrical loads and their
connections are in perfect condition. The generator is fitted with a thermal-
magnetic circuit breaker, which not only
Synchronous generators operate safely protects against overloads, but also
and reliably. Before commissioning, 11.3 Operating principle switches off in the event of an insulation
read through the safety precautions in fault on a connected device. Interruption of
this manual carefully. The generator is a self-excited brushless
power distribution during operation may be
synchronous internal pole generator which
* Ensure that children under the age caused by an insulation fault on a device
is controlled electronically. It consists of
of fourteen and animals do not have (in which case an indicator lamp comes
the main machine, exciter, rotary rectifiers
access to the generator while it is on), or an overload (when it does not). If
and generator regulator assemblies,
running. an overload has occurred, eliminate its
housed in a common enclosure. The main
cause, wait for a short time, then reset the
* To avoid endangering people or machine of the synchronous 3-phase
circuit breaker. Grasp the breakerʼs
animals, or causing accidents or generators has various design features,
operating handle and push upwards
damage to the machine, always including a damping cage and balancing
without exerting force. After the circuit
carry out the usual checks before system, which allow it to handle an
breaker has released due to an overload
switching the generator on. extremely asymmetrical load. All of the
(indicator lamp off), wait for a short time
other equipment required for safe
* There is always a risk of electric until it can be reset. The thermal-magnetic
electrical operation is accommodated in
shock if a generator is used or thermal circuit breaker is designed in
the unit (generator - switchbox).
improperly. Never touch the accordance with the machine
generator, or equipment connected The splashproof and dustproof specifications, particularly in relation to
to it, with wet hands. generator is driven by the engine using shock and vibration resistance, and
V-belts. Over the range from no-load to ambient temperature. Only use an original
* When using several generators, or if nominal output, the voltage it supplies is part if replacements are needed.
the public mains is available, do not controlled by a highly integrated electronic
interconnect these systems. regulator, which is fully encapsulated in
* Caution! Connecting the generator the cover of the switchbox, so that the
output voltage over this range complies
to the public mains can damage it
and severely endanger personnel. with IEC 38 requirements. This standard is
comparable with the public mains.
* The IP 54 protection means the
generator is protected against
splashes, spray and other foreign
bodies. Do not, however, clean the
41
11. Generator option
11.4 Operating the generator additional insulation monitors to the To cope with the greater mechanical
(Working safely with electrical generator with its built-in equivalent. strains and stresses on the generatorʼs
distribution system, use rubber-sheathed
equipment) During insulation and voltage tests
cables to the minimum standard of
carried out on the generator by trained
This state-of-the-art synchronous H07RN-F or A07RN-F in accordance with
electricians, disconnect the insulation
generator has been designed and built DIN/VDE 0282 Part 810, or equivalent
monitor.
with maximum safety in mind. It will help designs, as moveable (extension) cables.
you get the most out of your work or Because the generator is not earthed, Where the cables may be under severe
leisure activities. However, like all fault current circuit breakers used in stress, lay them in mechanical protection
electrical equipment, it can represent a distribution systems and equipment systems, or with strong covers, or
source of danger (e.g. risk of electric cannot be relied upon to operate correctly use NSSHöü cables in accordance with
shock) if the operating instructions in this when such units are connected to the VDE 0250.
section are not followed exactly. Please generator, and, due to the Electrical
The lengths and conductor cross
observe the instructions and the notes on isolation with insulation monitoring and
sections of the extension cables must
dangers affixed to your generator. circuit breaking protective measure, are
match the type of equipment and the duty.
not actually required.
Before starting the generator, all devices It is essential to ensure supply cables do
must be unplugged and switched off. Only The insulation monitor and circuit
not exceed the maximum lengths
plug the devices in (one after the other) breaker should be checked daily when the
specified! When using extension cables or
and switch them on after the engine generator is in use, following the quick
moveable distribution systems, the sum of
driving the generator has reached its reference instructions for Testing/
the lengths of all extension cables
nominal operating speed. insulation monitoring/starting/connecting
connected to a generator must not exceed
equipment which are affixed to the
Do not open the generator or the 250 metres (for a copper conductor cross
generator.
switchbox. The brushless synchronous section of 2.5 mm2 - for all sockets). The
design does not require maintenance. total length of the extension cable, or the
Attention
moveable distribution system, connected
Do not modify the internal wiring. Devices connected the generator to any particular socket must not exceed
Repairs to electrical components and to which cause the circuit breaker to 60 m for a copper conductor cross section
electrical operating equipment (supply release, and the red indicator lamp for of 1.5 mm2, or 100 metres for one of
cables, loads) may only be carried out by Insulation fault to light up, must not be 2.5 mm2.
suitably trained electricians. connected to other generators (without
insulation monitoring), or to the public Note
The circuit breakers, control, alarm and mains. Have equipment with insulation For defined releasing of the circuit
release devices and the insulation faults immediately replaced or repaired breaker, a loop resistance of 1.5 Ω per
monitors are specially designed for the by the manufacturer or a suitable socket must not be exceeded.
generator and its sockets. Only use electrical specialist.
original spare parts if replacements are The circuit breaker must not be used for
needed. When working in restricted conductive routine switching on of the 3-phase
areas, i.e. as defined in DIN/VDE 0100 generator. If several devices, particularly
The generator meets the requirements 706 (e.g. in boilers), only one power tool those with different power consumption
of the Protective isolation with equi- or mobile measuring instrument may levels, are connected to the AC sockets,
potential bonding conductor and insulation be connected to the generator, or for different voltage drops can arise, depend-
monitoring with circuit breakers regulation each such load an additional isolating ing on the turn-on time of the neutral.
in IEC 60364-5-551 and the German Gas transformer, or one isolating transformer
Installation and Plumbing Association with several secondary windings, should Avoid overloading the generator. In
(DVGW) regulation GW 308. The system be used. Handheld lights may only ever particular, to ensure user safety and
is an IT type, with neutral and PE be used in restricted conductive areas optimum performance, it is essential to
(equipotential bonding conductor). when operated off a SELV (safe extra low observe the following rules:
voltage) isolating transformer. 1. Only devices whose voltage and fre-
The generator does not have to be
earthed (with a ground rod for example) to Many portable power tools conform to quency data on the load identification
ensure adequate safety protection. German protection class II (i.e. they are plate conform to those on the generator
However, if desired or required, defined double insulated, symbol ■ ■ ). These identification plate may be connected.
earthing of the generator can also be devices should be used if possible. Use a 2. Only devices whose power
provided. cable and plug to connect any protection consumption does not exceed the
Earthing of the neutral (N), or connecting class I device (i.e. with metal housing output specified on the generator
of the neutral to the equipotential bonding parts that are not double insulated) to be identification plate may be used. The
conductor (PE), is prohibited on the used to the PE (equipotential bonding) total power consumption of all of the
generator, the distribution system and all conductor. loads connected to the generator must
other devices. The use of so-called Only connect devices and distribution not exceed its output.
neutralised devices is not permitted, and systems which are in good condition to the 3. Note that the starting consumption of
would lead to insulation monitoring being generator. The insulation, and plug and devices driven by electric engines is
enabled automatically. socket combinations, must be in good generally a multiple of the specified
The generator must not be used to inject condition to ensure user safety. Do not rating. If in doubt, it is advisable to
power into a construction site distribution use any damp or dirty connectors. contact the equipment manufacturer
system. directly.
The distribution systems (e.g. extension
To avoid unwanted interaction, do not cables, device leads) must be carefully The maximum current specified for each
connect distribution systems with chosen, laid and maintained. Check the socket must not be exceeded.
electrical cables regularly, replacing rather
than repairing any that are faulty.
42
11. Generator option
The generator may only be used if the * Ensure that all the devices on the
circuit breaker released during the test generator output sockets have been
and the red indicator lamps came on. disconnected.
Note
All device switches must be in the
AUS / 0 / OFF position.
43
11. Generator option
44
11. Generator option
Generator data
Winding Colour Ins. class Resistance
(at 20°C)/Ω)
U-N brown-blue F 0.29
V-N white-blue F 0.29
W-N black-blue F 0.29
1/2 U-N yellow-blue 0.15
1/2 V-N yellow-blue 0.15
1/2 W-N yellow-blue 0.15
1F1-1F2 red-grey H 25.4
45
11. Generator option
RESET
TEST
RED 1
GREY 2
ORANGE 8
YELLOW 3
YELLOW 4
YELLOW 5
BROWN 1
BLUE 4
BLUE 5
WHITE 2
BLACK 3
GREEN/YELLOW 6
FUSE 5A
braun
blau
Fig. 41
11.10 Troubleshooting
Sockets dead
no no
Connected
devices are faulty
Unplug
Does fuse
Has fuse blown? yes connected yes
still blow?
devices
no no
Connected
devices are faulty
Contact customer
service or
take device in for
checking.
46
11. Generator option
Attention
Use genuine spare parts only!
47
12. Heat exchanger option
12 Heat exc han ger opti on
Danger
12.3 Maintenance/Care
This system is maintenance-free.
48
13. Compressed air processing option (after cooler / heat exchanger / filter)
13 Compr esse d air pr ocessin g op tion (aft er c oole r / h eat excha nge r / filt er)
13.1 Safety regulations for In an air cooler (on the cooling air intake 13.3 Maintenance instructions
side), the compressed air is cooled down
alternate compressed air
to a temperature close to the prevailing Danger
processing ambient air temperature downstream of
the pressure vessel. A condensate Prior to and when carrying out
Danger separator with continuous condensate maintenance and repair procedures,
discharge is installed downstream the air- please do observe the general safety
When operating the compressor,
cooler. regulations in chapter 3 of the
please observe the general safety
regulations laid forth in the compressor operating manual.
Attention
compressor operating manual.
Attention
When there is a danger of freezing or
when the machine is switched off for a The filters have to be disposed of.
13.2 Design and operation prolonged period, any remaining
condensation must be drained from the The post cooling systems is mainte-
System function diagram: secondary cooler. For doing this the nance-free. For cleaning procedures,
bottom cover of the secondary cooler see 9.1 „General maintenance“ in the
see page 19, Fig. 6
must be opened and it must be compressor operating manual.
emptied utilising the pressure
After cooler option remaining in the machine.
Post option
The oil-containing condensate has to
be collected. Do not allow to enter into Filter change is required at latest when
the soil or into the drains! a differential pressure of 400 mbar has
been reached or after approximately
500 operating hours - depending on the
Filter option (ZTV-ING Part 3 Sec. 4) degree of contamination.
13.4 Troubleshooting
49
14. Oil temperature controller option
14 Oil tem per atur e co ntroll er o ption
Danger
Fig. 43
14.4 Troubleshooting
Compressed air temperature too low
Oil temperature controller in the oil line
is defective -> replace it.
50
15. Undercarriage
15 Underc ar riage
* The wheel brakes are matched to the Care must be taken without fail to With the rubber spring axles the axle
overrun devices. ensure that the overrun or towing tube bears the axle by pretensioned
Before using an overrun from another system is always aligned parallel with rubber strings. The results of the
the drawbar. stretching are exceptionally long life
manufacturer, please check the
compatibility with our Technical - The vehicle must not be driven unless and zero maintenance.
Department. the overrun system is parallel with the
Attention
drawbar!
Attention * Use the jack only under the fixing
After the coupling has been adjusted for
Model details must not be obscured by height, the serrations should be locked brackets or at the chassis, never in
paint now concealed by components. together with the clamping nuts and the centre.
secured against working loose by means * Towing eye and ball coupling may
of the spring-loaded plugs. only be changed by specialists.
* Use a new safety nut every time one
of these items is changed.
* Use specified torque setting:
Ball coupling
M12 8.8: T = 77 Nm
M14 10.9: T = 125 Nm
Towing eyes
M12 10.9: T = 115 Nm
M14 10.9: T = 180 Nm
* When using the ball coupling,
please follow the instructions given.
Fig. 44
51
15. Undercarriage
Over-run hitches 15.5.2 Preliminary requirements: When the brake is correctly adjusted,
the actuating travel of the control cable
KNOTT over-run hitches are available * When carrying out adjustments, always [11] will be 5-8 mm.
for both hydraulic and mechanical brakes. start with the wheel brakes.
Carry out the adjustment procedure,
Handbrake lever with power reservoir, * When carrying out adjustments, turn as described, on all the wheel brakes
code „KH“ the wheel only in the direction of in succession.
forward travel.
With the type “KH” the spring reservoir is
under torsion at the centre point. If the * Insert the security bolt [15] (see
handbrake is applied, then it works warning plate)! 15.5.4 Adjusting the brake
automatically and requires almost no compensating system
force. The system is designed so that * Do not pre-tension the expanding
when the handbrake is applied, sufficient locking mechanism in the brake. If
energy is stored within the spring. When necessary, loosen the brake linkage [6]
transmitted through the brake rods this at the brake compensator [8].
prevents the brake shoes from slipping * Check the expanding locking
away from the brake drum. mechanism and control cable [11]
for ease of movement.
52
15. Undercarriage
* If necessary, adjust the position of the 15.6 Readjusting the braking 15.7 Maintenance and care
balance [10] and control cables [11]; in system
the case of tandem trailers, also adjust KNOTT – overrun systems
the master compensator [9] on the In general, readjusting the wheel brakes
linkage [6]. * The overrun system must be lubricated
adequately serves to readjust the braking
with lithium-soap grease by way of the
* The compression spring [7] may only system, i.e. to compensate for brake lining
grease nipples and at all the moving
be lightly pre-tensioned and must not wear. To readjust the wheel brakes,
parts.
become fully compressed when proceed as described under 'Adjusting the
activated! braking system'. Check the play in the a) every 5000 km (3000 miles)
linkage [6] and readjust if necessary. b) or every 6 months
c) or if they become stiff
Attention
15.5.5 Adjusting the brake linkage [6] * Inspect the bellows for damage,
* Check the expanding locking replace if necessary
Adjust the brake linkage [6] so that it is mechanism and control cable [11]
free of play longitudinally, without initial * Replace the overrun shock absorber
tension (reversing lever [4] free of play). * The expanding lock compensator every 20,000 km (12,500 miles) or
must not be pre-tensioned in the every 3 years at the latest.
brake.
Readjustment * Check the play at the coupling point
* Do not attempt to compensate for every 20,000 km (12,500 miles). If the
* Operate the handbrake lever [3] ease of movement caused by brake play exceeds 3 mm, replace the guide
powerfully several times in order to lining wear by readjusting (shorten- bearing or drawbar.
settle the braking system. ing) the brake linkage [6], e.g. by
* Check the tightening torques of the
* Check the position of the brake way of the linkage screw fastenings
fastening screws at the guide bearing
compensating balances [9 and 10] every 5000 km (3000 miles);
which should be at right angles to the Readjustment
direction of towing Screws with grease nipple
* Operate the handbrake lever [3] 50 +5 Nm
* Check the play in the linkage [6]; if powerfully several times in order to Screws without grease nipple
necessary, adjust the linkage [6] again settle the braking system 80 +5 Nm
so that it is free of play, but without
initial tension * Check the position of the brake * Check the tightening torques at the
compensating balances [9 and 10] clamping block of the drawbar and
Slight play in the bowden cable [14] (which should be at right angles to the clamping socket (drawbar tube - axle
must persist. direction of towing). joint) every 5000 km (3000 miles);
* Check the position of the handbrake * Recheck the play in the linkage [6]; M12 screws 80 +5 Nm
lever [3]; M14 screws 90 +10 Nm
if necessary, adjust the linkage [6]
when checking the dead centre of the again so that it is free of play, but * Check that the braking system is
lever, resistance starts 10-15 mm without initial tension. correctly adjusted every 5000 km
above dead centre (3000 miles).
* Check the positions of the handbrake
* Check that the wheels rotate freely with lever [3], the play in the bowden cable
the brake released. and compression spring [7] (only light Vertically adjustable drawbars
initial tension);
Clean the faces of the tooth systems
Final check * when checking the dead centre of the free of fretting rust or other contamination
* Check fastenings for security (secure lever, resistance starts 10-15 mm at least once a year in order to maintain a
the hexagon locking nuts of the screw above dead centre good fit.
fastenings for the transmission system, Lubricate the threaded bolts and joints
control cables, brake compensators, Final check once a year or at any time if they become
turnbuckle, linkage, etc.). stiff.
* Check the screw fastenings for the
* Check the bowden cable for slight play transmission system (control cables,
[14]; if neccessary, adjust the cable. Attention
brake compensators, linkage, etc.).
* Check the compression spring [7] for Do not grease the tooth system!
* during operating braking with empty
initial tension. trailer should be used maximally 1/2 of If desired, a lifting and adjusting system
the overrun travel can be installed between the drawbar
Test run and the overrun system. The control arms
* Check tthe bowden cable for slight play
of the adjusting system permit swivelling
* If necessary, carry out 2-3 brake tests [14]; if neccessary, adjust the cable.
about an angle of -10° to +49° in six
* Check the tension of the compression positions. In every case, the overrun
Brake test spring [7] system or drawgear always remains
horizontal.
* Recheck the play in the brake linkage
[6] and, if necessary, readjust the An integral gas-filled strut automatically
linkage [6] for length free of play generates lifting force which reduces the
(during operating braking with empty force required by the user. If the strut
trailer should be used maximally 1/2 of becomes damaged or develops a leak, it
the overrun travel) must be replaced.
53
15. Undercarriage
54
15. Undercarriage
55
16. Tool oiler option
16 Tool oiler optio n
Fig. 50
Attention
Fig. 51
Do not run the machine with an empty
* Shut down the screw compressor and
oiler tank! The tank must always
wait until the compressor is
contain a minimum of 0.2 l of tool oil.
depressurized.
Danger * Unscrew the screw plug.
Only refill the tool oiler, when the * The oil must be visible in the oiler
screw compressor is out of operation reservoir; refill, if necessary (oil to be
and depressurized! used: CompAir AES 82).
Only screw off the oiler reservoir, when * Check the seal of the screw plug,
the screw compressor is out of replace if required.
operation and depressurized!
* Screw in the screw plug with the seal
Do not spill any oil! and tighten.
Watch out for leakage! * Check for leaks after start-up of the
screw compressor.
The oil dosage is continuously variable
at the adjusting knob.
* Turning the adjusting knob clockwise
(symbol »–«) will reduce the oil flow up
to 0-quantity (i.e. no oil for tool
lubrication in the compressed air).
* Turning the adjusting knob
counterclockwise (symbol »+«) will
increase the oil flow.
56
Gardner Denver Deutschland GmbH
Argenthaler Str. 11
55469 Simmern
Deutschland
www.compair.com
e-mail: sales@compair.com