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2205600637-AIB-S1.5-CP
2205600637-AIB-S1.5-CP
Original
instructions
Printed matter No
2205 6006 37
06/2013
Instruction Manual
Follow the instructions in this booklet and we guarantee you In all correspondence always mention the compressor type and
years of trouble free operation. Please read the following serial number, shown on the data plate.
instructions carefully before starting to use your machine
The company reserves the right to make changes without prior
Always keep the manual available near the machine. notice.
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Instruction Manual
1.6 Tool applications safety ............................................ 8 4.6.7 Topping up after limited quantity draining ................
from the cooling system ..........................................25
1.7 Specific safety precautions ........................................ 9
4.6.8 Replacing the coolant ..............................................26
4.7 Cleaning coolers ......................................................26
2 Leading particulars ............................................................ 10
4.8 Cleaning fuel tank ...................................................26
2.1 Description of safety pictograms used .......................
in this manual .......................................................... 10 4.9 Battery care .............................................................26
2.2 General description ................................................. 10 4.9.1 Electrolyte ...............................................................27
2.3 Markings and information labels ............................. 11 4.9.2 Activating a dry-charged battery .............................27
2.4 Main parts ............................................................... 12 4.9.3 Recharging a battery................................................27
2.5 Air flow (see Fig. 2.3) ............................................. 13 4.9.4 Battery maintenance ................................................27
2.6 Oil system (see Fig. 2.3) ......................................... 14 4.10 Storage ....................................................................27
2.7 Continuous regulating system (see Fig. 2.3) .......... 14 4.11 Service paks ............................................................27
2.8 Electrical system ..................................................... 15 4.12 Service kits ..............................................................27
2.8.1 Circuit diagram (no cold start) ................................ 15 4.13 Compressor element overhaul .................................27
4.14 Liability ...................................................................27
3 Operating instructions ........................................................ 16
3.1 Parking, towing and lifting instructions .................. 16 5 Adjustments and servicing procedures .............................28
3.1.1 Parking instructions................................................. 16 5.1 Adjustment of the continuous regulating system .....28
3.1.2 Towing instructions................................................. 16 5.2 Air filter engine/compressor ....................................29
3.1.3 Lifting instructions .................................................. 16 5.2.1 Main parts ...............................................................29
3.2 Before starting ......................................................... 17 5.2.2 Recommendations ...................................................29
3.3 Starting/stopping ..................................................... 17 5.2.3 Cleaning the dust trap ..............................................29
3.3.1 General .................................................................... 17 5.2.4 Replacing the air filter element ...............................29
3.3.2 Starting .................................................................... 18 5.3 Air receiver..............................................................29
3.3.3 Stopping .................................................................. 18 5.4 Safety valve .............................................................29
3.4 During operation ..................................................... 18 5.5 Fuel system..............................................................30
5.6 Brake system ...........................................................30
4 Maintenance ........................................................................ 19 5.6.1 Main parts ...............................................................30
4.1 Use of service paks ................................................. 19 5.6.2 Brake shoe adjustment.............................................30
4.2 Preventive maintenance schedule ...............................
for the compressor ................................................... 19 6 Problem solving ...................................................................31
4.3 Lubrication oils ....................................................... 20 6.1 Alternator precautions .............................................31
4.4 Oil level check ........................................................ 21
4.4.1 Check engine oil level ............................................. 21 7 Technical specifications ......................................................34
4.4.2 Check compressor oil level ..................................... 21 7.1 Torque values ..........................................................34
4.5 Oil and oil filter change........................................... 21 7.1.1 For general applications ..........................................34
4.5.1 Engine oil and oil filter change ............................... 21 7.1.2 For important assemblies.........................................34
4.5.2 Compressor oil and oil filter change ....................... 21 7.1.3 Settings of shutdown switches and safety valves ....34
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Instruction Manual
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Instruction Manual
1.1 INTRODUCTION
The policy of Chicago Pneumatic is to provide the users of their When handling, operating, overhauling and/or performing
equipment with safe, reliable and efficient products. Factors taken maintenance or repair on Chicago Pneumatic equipment, the
into account are among others: mechanics are expected to use safe engineering practices and to
observe all relevant local safety requirements and ordinances. The
- the intended and predictable future use of the products, and following list is a reminder of special safety directives and
the environments in which they are expected to operate, precautions mainly applicable to Chicago Pneumatic equipment.
- applicable rules, codes and regulations, These safety precautions apply to machinery processing or
consuming air.
- the expected useful product life, assuming proper service and
maintenance, Processing of any other gas requires additional safety precautions
typical to the application and are not included herein.
- providing the manual with up-to-date information.
Neglecting the safety precautions may endanger people as well as
Before handling any product, take time to read the relevant environment and machinery:
instruction manual. Besides giving detailed operating instructions,
it also gives specific information about safety, preventive - endanger people due to electrical, mechanical or chemical
maintenance, etc. influences,
- endanger the environment due to leakage of oil, solvents or
Keep the manual always at the unit location, easy accessible to the
other substances,
operating personnel. See also the safety precautions of the engine
and possible other equipment, which are separately sent along or - endanger the machinery due to function failures.
are mentioned on the equipment or parts of the unit. All responsibility for any damage or injury resulting from
These safety precautions are general and some statements will neglecting these precautions or by non-observance of ordinary
therefore not always apply to a particular unit. caution and due care required in handling, operating, maintenance
or repair, also if not expressly mentioned in this instruction
Only people that have the right skills should be allowed to operate, manual, is disclaimed by Chicago Pneumatic.
adjust, perform maintenance or repair on Chicago Pneumatic
equipment. It is the responsibility of management to appoint The manufacturer does not accept any liability for any damage
operators with the appropriate training and skill for each category arising from the use of non-original parts and for modifications,
of job. additions or conversions made without the manufacturer’s
approval in writing.
Skill level 1: Operator
An operator is trained in all aspects of operating the unit with the If any statement in this manual does not comply with local
pushbuttons, and is trained to know the safety aspects. legislation, the stricter of the two shall be applied. Statements in
these safety precautions should not be interpreted as suggestions,
Skill level 2: Mechanical technician recommendations or inducements that it should be used in
A mechanical technician is trained to operate the unit the same as violation of any applicable laws or regulations.
the operator. In addition, the mechanical technician is also trained
to perform maintenance and repair, as described in the instruction
manual, and is allowed to change settings of the control and safety 1.2 GENERAL SAFETY PRECAUTIONS
system. A mechanical technician does not work on live electrical
components. 1 The owner is responsible for maintaining the unit in a safe
operating condition. Unit parts and accessories must be
Skill level 3: Electrical technician replaced if missing or unsuitable for safe operation.
An electrical technician is trained and has the same qualifications
as both the operator and the mechanical technician. In addition, 2 The supervisor, or the responsible person, shall at all times
the electrical technician may carry out electrical repairs within the make sure that all instructions regarding machinery and
various enclosures of the unit. This includes work on live equipment operation and maintenance are strictly followed
electrical components. and that the machines with all accessories and safety devices,
as well as the consuming devices, are in good repair, free of
Skill level 4: Specialist from the manufacturer abnormal wear or abuse, and are not tampered with.
This is a skilled specialist sent by the manufacturer or its agent to
3 Whenever there is an indication or any suspicion that an
perform complex repairs or modifications to the equipment.
internal part of a machine is overheated, the machine shall be
In general it is recommended that not more than two people stopped but no inspection covers shall be opened before
operate the unit, more operators could lead to unsafe operating sufficient cooling time has elapsed; this to avoid the risk of
conditions. Take necessary steps to keep unauthorized persons spontaneous ignition of oil vapour when air is admitted.
away from the unit and eliminate all possible sources of danger at
4 Normal ratings (pressures, temperatures, speeds, etc.) shall be
the unit.
durably marked.
5 Operate the unit only for the intended purpose and within its
rated limits (pressure, temperature, speeds, etc.).
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Instruction Manual
6 The machinery and equipment shall be kept clean, i.e. as free - check the towing and brake capability of the towing vehicle,
as possible from oil, dust or other deposits.
- check that the towbar and stand leg are safely locked in the
7 To prevent an increase in working temperature, inspect and raised position,
clean heat transfer surfaces (cooler fins, intercoolers, water
jackets, etc.) regularly. See the maintenance schedule. - ascertain that the towing eye can swivel freely on the hook,
8 All regulating and safety devices shall be maintained with due - check that the wheels are secure and that the tyres are in good
care to ensure that they function properly. They may not be condition and inflated correctly,
put out of action. - attach the safety break-away cable or safety chain to the
9 Care shall be taken to avoid damage to safety valves and other towing vehicle,
pressure relief devices, especially to avoid plugging by paint, - remove wheel chocks, if applied, and disengage the parking
oil coke or dirt accumulation, which could interfere with the brake.
functioning of the device.
2 To tow a unit use a towing vehicle of ample capacity. Refer to
10 Pressure and temperature gauges shall be checked regularly the documentation of the towing vehicle.
with regard to their accuracy. They shall be replaced
whenever outside acceptable tolerances. 3 If the unit is to be backed up by the towing vehicle, disengage
the overrun brake mechanism (if it is not an automatic
11 Safety devices shall be tested as described in the maintenance mechanism).
schedule of the instruction manual to determine that they are
in good operating condition. 4 Never exceed the maximum towing speed of the unit (mind
the local regulations).
12 Mind the markings and information labels on the unit.
5 Place the unit on level ground and apply the parking brake
13 In the event the safety labels are damaged or destroyed, they before disconnecting the unit from the towing vehicle. Unclip
must be replaced to ensure operator safety. the safety break-away cable or safety chain. If the unit has no
14 Keep the work area neet. Lack of order will increase the risk parking brake or jockey wheel, immobilize the unit by placing
of accidents. chocks in front of and/or behind the wheels. When the towbar
can be positioned vertically, the locking device must be
15 When working on the unit, wear safety clothing. Depending applied and kept in good order.
on the kind of activities these are: safety glasses, ear
protection, safety helmet (including visor), safety gloves, 6 To lift heavy parts, a hoist of ample capacity, tested and
protective clothing, safety shoes. Do not wear the hair long approved according to local safety regulations, shall be used.
and loose (protect long hair with a hairnet), or wear loose 7 Lifting hooks, eyes, shackles, etc., shall never be bent and
clothing or jewelry. shall only have stress in line with their design load axis. The
16 Take precautions against fire. Handle fuel, oil and anti-freeze capacity of a lifting device diminishes when the lifting force
with care because they are inflammable substances. Do not is applied at an angle to its load axis.
smoke or approach with naked flame when handling such 8 For maximum safety and efficiency of the lifting apparatus all
substances. Keep a fire extinguisher in the vicinity. lifting members shall be applied as near to perpendicular as
17 Portable compressors with generator (with earthing pin): possible. If required, a lifting beam shall be applied between
Earth the generator as well as the load properly. hoist and load.
9 Never leave a load hanging on a hoist.
10 A hoist has to be installed in such a way that the object will be
1.3 SAFETY DURING TRANSPORT AND lifted perpendicular. If that is not possible, the necessary
INSTALLATION precautions must be taken to prevent load-swinging, e.g. by
using two hoists, each at approximately the same angle not
To lift a unit, all loose or pivoting parts, e.g. doors and towbar, exceeding 30° from the vertical.
shall first be securely fastened.
11 Locate the unit away from walls. Take all precautions to
Do not attach cables, chains or ropes directly to the lifting eye; ensure that hot air exhausted from the engine and driven
apply a crane hook or lifting shackle meeting local safety machine cooling systems cannot be recirculated. If such hot
regulations. Never allow sharp bends in lifting cables, chains or air is taken in by the engine or driven machine cooling fan,
ropes. this may cause overheating of the unit; if taken in for
Helicopter lifting is not allowed. combustion, the engine power will be reduced.
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Instruction Manual
1.4 SAFETY DURING USE AND OPERATION 14 All doors shall be shut during operation so as not to disturb
the cooling air flow inside the bodywork and/or render the
1 When the unit has to operate in a fire-hazardous environment, silencing less effective. A door should be kept open for a
each engine exhaust has to be provided with a spark arrestor short period only e.g. for inspection or adjustment.
to trap incendiary sparks.
15 Periodically carry out maintenance works according to the
2 The exhaust contains carbon monoxide which is a lethal gas. maintenance schedule.
When the unit is used in a confined space, conduct the engine
exhaust to the outside atmosphere by a pipe of sufficient 16 Stationary housing guards are provided on all rotating or
diameter; do this in such a way that no extra back pressure is reciprocating parts not otherwise protected and which may be
created for the engine. If necessary, install an extractor. hazardous to personnel. Machinery shall never be put into
Observe any existing local regulations. Make sure that the operation, when such guards have been removed, before the
unit has sufficient air intake for operation. If necessary, install guards are securely reinstalled.
extra air intake ducts. 17 Noise, even at reasonable levels, can cause irritation and
3 When operating in a dust-laden atmosphere, place the unit so disturbance which, over a long period of time, may cause
that dust is not carried towards it by the wind. Operation in severe injuries to the nervous system of human beings. When
clean surroundings considerably extends the intervals for the sound pressure level, at any point where personnel
cleaning the air intake filters and the cores of the coolers. normally has to attend, is:
4 Close the compressor air outlet valve before connecting or below 70dB(A):
disconnecting a hose. Ascertain that a hose is fully no action needs to be taken,
depressurized before disconnecting it. Before blowing above 70 dB(A):
compressed air through a hose or air line, ensure that the open noise-protective devices should be provided for people
end is held securely, so that it cannot whip and cause injury. continuously being present in the room,
5 The air line end connected to the outlet valve must be below 85 dB(A):
safeguarded with a safety cable, attached next to the valve. no action needs to be taken for occasional visitors staying a
6 No external force may be exerted on the air outlet valves, e.g. limited time only,
by pulling on hoses or by installing auxiliary equipment above 85 dB(A):
directly to a valve, e.g. a water separator, a lubricator, etc. Do room to be classified as a noise-hazardous area and an
not step on the air outlet valves. obvious warning shall be placed permanently at each entrance
7 Never move a unit when external lines or hoses are connected to alert people entering the room, for even relatively short
to the outlet valves, to avoid damage to valves, manifold and times, about the need to wear ear protectors,
hoses. above 95 dB(A):
8 Do not use compressed air from any type of compressor, the warning(s) at the entrance(s) shall be completed with the
without taking extra measures, for breathing purposes as this recommendation that also occasional visitors shall wear ear
may result in injury or death. For breathing air quality, the protectors,
compressed air must be adequately purified according to local above 105 dB(A):
legislation and standards. Breathing air must always be special ear protectors that are adequate for this noise level and
supplied at stable, suitable pressure. the spectral composition of the noise shall be provided and a
9 Distribution pipework and air hoses must be of correct special warning to that effect shall be placed at each entrance.
diameter and suitable for the working pressure. Never use 18 Insulation or safety guards of parts the temperature of which
frayed, damaged or deteriorated hoses. Replace hoses and can be in excess of 80 °C (175 °F) and which may be
flexibles before the lifetime expires. Use only the correct type accidentally touched by personnel shall not be removed
and size of hose end fittings and connections. before the parts have cooled to room temperature.
10 If the compressor is to be used for sand-blasting or will be 19 Never operate the unit in surroundings where there is a
connected to a common compressed-air system, fit an possibility of taking in flammable or toxic fumes.
appropriate non-return valve (check valve) between
compressor outlet and the connected sandblasting or 20 If the working process produces fumes, dust or vibration
compressed-air system. Observe the right mounting position/ hazards, etc., take the necessary steps to eliminate the risk of
direction. personnel injury.
11 Before removing the oil filler plug, ensure that the pressure is 21 When using compressed air or inert gas to clean down
released by opening an air outlet valve. equipment, do so with caution and use the appropriate
protection, at least safety glasses, for the operator as well as
12 Never remove a filler cap of the cooling water system of a hot for any bystander. Do not apply compressed air or inert gas to
engine. Wait until the engine has sufficiently cooled down. your skin or direct an air or gas stream at people. Never use it
13 Never refill fuel while the unit is running, unless otherwise to clean dirt from your clothes.
stated in the Chicago Pneumatic Instruction Book. Keep fuel 22 When washing parts in or with a cleaning solvent, provide the
away from hot parts such as air outlet pipes or the engine required ventilation and use appropriate protection such as a
exhaust. Do not smoke when fuelling. When fuelling from an breathing filter, safety glasses, rubber apron and gloves, etc.
automatic pump, an earthing cable should be connected to the
unit to discharge static electricity. Never spill nor leave oil, 23 Safety shoes should be compulsory in any workshop and if
fuel, coolant or cleansing agent in or around the unit. there is a risk, however small, of falling objects, wearing of a
safety helmet should be included.
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Instruction Manual
24 If there is a risk of inhaling hazardous gases, fumes or dust, 12 Support the towbar and the axle(s) securely if working
the respiratory organs must be protected and depending on the underneath the unit or when removing a wheel. Do not rely on
nature of the hazard, so must the eyes and skin. jacks.
25 Remember that where there is visible dust, the finer, invisible 13 Do not remove any of, or tamper with, the sound-damping
particles will almost certainly be present too; but the fact that material. Keep the material free of dirt and liquids such as
no dust can be seen is not a reliable indication that dangerous, fuel, oil and cleansing agents. If any sound-damping material
invisible dust is not present in the air. is damaged, replace it to prevent the sound pressure level
from increasing.
26 Never operate the unit at pressures or speeds below or in
excess of its limits as indicated in the technical specifications. 14 Use only lubricating oils and greases recommended or
approved by Chicago Pneumatic or the machine manufacturer.
Ascertain that the selected lubricants comply with all
applicable safety regulations, especially with regard to
1.5 SAFETY DURING MAINTENANCE AND explosion or fire-risk and the possibility of decomposition or
REPAIR generation of hazardous gases. Never mix synthetic with
Maintenance, overhaul and repair work shall only be carried out mineral oil.
by adequately trained personnel; if required, under supervision of 15 Protect the engine, alternator, air intake filter, electrical and
someone qualified for the job. regulating components, etc., to prevent moisture ingress, e.g.
1 Use only the correct tools for maintenance and repair work, when steam-cleaning.
and only tools which are in good condition. 16 When performing any operation involving heat, flames or
2 Parts shall only be replaced by genuine Chicago Pneumatic. sparks on a machine, the surrounding components shall first
be screened with non-flammable material.
3 All maintenance work, other than routine attention, shall only
be undertaken when the unit is stopped. Steps shall be taken 17 Never use a light source with open flame for inspecting the
to prevent inadvertent starting. In addition, a warning sign interior of a machine.
bearing a legend such as “work in progress; do not start” shall 18 When repair has been completed, the machine shall be barred
be attached to the starting equipment. over at least one revolution for reciprocating machines,
On engine-driven units the battery shall be disconnected and several revolutions for rotary ones to ensure that there is no
removed or the terminals covered by insulating caps. On mechanical interference within the machine or driver. Check
electrically driven units the main switch shall be locked in the direction of rotation of electric motors when starting up
open position and the fuses shall be taken out. A warning sign the machine initially and after any alteration to the electrical
bearing a legend such as “work in progress; do not supply connection(s) or switch gear, to check that the oil pump and
voltage” shall be attached to the fuse box or main switch. the fan function properly.
4 Before dismantling any pressurized component, the 19 Maintenance and repair work should be recorded in an
compressor or equipment shall be effectively isolated from all operator’s log book for all machinery. Frequency and nature
sources of pressure and the entire system shall be relieved of of repairs can reveal unsafe conditions.
pressure. Do not rely on non-return valves (check valves) to
isolate pressure systems. In addition, a warning sign bearing a 20 When hot parts have to be handled, e.g. shrink fitting, special
legend such as “work in progress; do not open” shall be heat-resistant gloves shall be used and, if required, other body
attached to each of the outlet valves. protection shall be applied.
5 Prior to stripping an engine or other machine or undertaking 21 When using cartridge type breathing filter equipment,
major overhaul on it, prevent all movable parts from rolling ascertain that the correct type of cartridge is used and that its
over or moving. useful service life is not surpassed.
6 Make sure that no tools, loose parts or rags are left in or on 22 Make sure that oil, solvents and other substances likely to
the machine. Never leave rags or loose clothing near the pollute the environment are properly disposed of.
engine air intake. 23 Before clearing the unit for use after maintenance or overhaul,
7 Never use flammable solvents for cleaning (fire-risk). check that operating pressures, temperatures and speeds are
correct and that the control and shutdown devices function
8 Take safety precautions against toxic vapours of cleaning correctly. Submit the generator to a testrun, check that the AC
liquids. power performance is correct.
9 Never use machine parts as a climbing aid.
10 Observe scrupulous cleanliness during maintenance and repair.
Keep away dirt, cover the parts and exposed openings with a
1.6 TOOL APPLICATIONS SAFETY
clean cloth, paper or tape. Apply the proper tool for each job. With the knowledge of correct
tool use and knowing the limitations of tools, along with some
11 Never weld on or perform any operation involving heat near
common sense, many accidents can be prevented.
the fuel or oil systems. Fuel and oil tanks must be completely
purged, e.g. by steam-cleaning, before carrying out such Special service tools are available for specific jobs and should be
operations. Never weld on, or in any way modify, pressure used when recommended. The use of these tools will save time
vessels. Disconnect the alternator cables during arc welding and prevent damage to parts.
on the unit.
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Instruction Manual
• Cooling system
The engine is provided with a coolant cooler and intercooler and
compressor is provided with an oil cooler. The cooling air is
generated by a fan, driven by the engine.
• Safety devices
A thermal shut-down switch protects the compressor against
Fig. 2.1 General view overheating. The air receiver is provided with a safety valve. The
engine is equipped with low oil pressure and high coolant
temperature shut-down switches.
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Instruction Manual
Accumulator is not being charged. Read the instruction manual before starting.
Engine water temperature high. Do not run the motor with open doors.
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Instruction Manual
A Alternator
AFCE Compressor Air Filter
AFe Engine Air Filter
AOV Air Outlet Valves
AR Air Receiver
C Canopy
CC Coolant Cooler
CE Compressor Element
CF Coolant Filter
CP Control Panel
E Engine
EB Electric Box
F Fan
FF Fuel Filter
Fr Frame IC CC OC E FT SR LY FF FWS PFF VV AFE TV OFCE
RV SV AFCE
FP Filler Plug
FT Fuel Tank
FWS Fuel Water Separator
IC Intercooler
LY Lifting Yoke
M Muffler
MPV Minimum Pressure Valve
OFCE Oil Filter
(Compressor Element)
OFE Oil Filter (Engine)
OC Oil cooler
PB Parking Brake
PFF Pre-Fuel Filter
RV Regulating Valve MPV SLV AR FP CE UV M EB CF OFE A F
SLV Solenoid Valve
SR Engine Speed Regulator
C
SV Safety Valve
TB Towbar
Tr Tire
TV Thermostatic Valve
UV Unloading Valve
TB
VV Vacuator Valve
CP
PB
Tr Fr
AOV
Fig. 2.2 Main parts
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Instruction Manual
UNIT SYSTEM
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Instruction Manual
A temperature switch (TS) and a working pressure gauge (PG) are When starting the compressor, the unloading valve (UV) is kept
comprised in the system. open by spring force, the engine runs at maximum speed. The
compressor element (CE) takes in air and pressure builds up in the
A blow-down valve is fitted in the unloading valve (UV) to air receiver (AR).
automatically depressurize the air receiver (AR) when the
compressor is stopped. The air output is controlled from maximum output (100%) to no
output (0%) by:
1. Speed control of the engine between maximum load speed
2.6 OIL SYSTEM (SEE FIG. 2.3) and unloading speed (the output of a screw compressor is
proportional to the rotating speed).
The system comprises:
2. Air inlet throttling.
AR/OS Air receiver/oil separator
If the air consumption is equal to or exceeds the maximum air
OC Oil cooler
output, the engine speed is held at maximum load speed and the
OFCE Oil filter unloading valve (UV) is fully open.
OSV Oil stop valve If the air consumption is less than the maximum air output, the
regulating valve supplies control air to unloading valve (UV) to
The lower part of the air receiver (AR) serves as oil tank. Air reduce the air output and holds air receiver pressure between the
pressure forces the oil from the air receiver/oil separator (AR/OS) normal working pressure and the corresponding unloading
through the oil cooler (OC), oil filter (OF) and the oil stop valve pressure of approx. 2.3 bar above the normal working pressure.
(OSV) to the compressor element (CE). The thermostatic valve
(TV) starts opening when the oil temperature is 80 °C (176 °F). When the air consumption is resumed, the unloading valve (UV)
gradually opens the air intake and the engine speed regulator (SR)
The compressor element has an oil gallery in the bottom of its increases the engine speed.
casing. The oil for rotor lubrication, cooling and sealing is
injected through holes in the gallery. The construction of the regulating valve (RV) is such that any
increase (decrease) of the air receiver pressure above the pre-set
Lubrication of the bearings is ensured by oil injected into the valve opening pressure results in a proportional increase (decrease)
bearing housings. The injected oil, mixed with the compressed air, of the control pressure to the unloading valve and the speed
leaves the compressor element and re-enters the air receiver, regulator.
where it is separated from the air as described in section 2.5. The
oil that collects in the bottom of the oil separator element is Part of the control air is vented to the atmosphere, and any
returned to the system through a scavenging line, which is condensate discharged, through the vent holes fitted in the
provided with a flow restrictor (Rs). unloading valve (UV).
The oil filter by-pass valve opens when the pressure drop over the
filter is above normal because of a clogged filter. The oil then
bypasses the filter without being filtered. For this reason, the oil
filter must be replaced at regular intervals (see section 4.2).
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Instruction Manual
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Instruction Manual
3 OPERATING INSTRUCTIONS
3.1 PARKING, TOWING AND LIFTING 3.1.2 TOWING INSTRUCTIONS
INSTRUCTIONS
Before towing the compressor, ensure that the
Safety precautions towing equipment of the vehicle matches the
The operator is expected to apply all relevant towing eye. The height of the towing device must
safety precautions, including those mentioned on be 815-845 mm.
the pages 5 - 9 of this book.
1
Fig. 3.1 Brake handle
Apply parking brake by moving parking brake handle (1)
forwards. Place the compressor as level as possible; however, it
can be operated temporarily in an out-of-level position not
exceeding 15°. If the compressor is parked on sloping ground,
immobilize the compressor by placing wheel chocks in front of or
behind the wheels. Locate the front-end of the compressor upwind,
(see Fig. 3.2), away from contaminated wind-streams and walls.
Avoid recirculation of exhaust air from the engine. This causes 1 2
overheating and engine power decrease.
Fig. 3.3 Lifting eye
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Instructio
on Manual
3.2 BE
EFORE STAR
RTING 3.3
3 STARTING/STOPPPING
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Instruction Manual
3.3.2 STARTING When the engine is running, the air outlet valves
a. Make sure the electrical circuit is not interrupted by the circuit (ball valves) must always be put in a fully opened
breaker, located at the electrical box (Fig. 2.2 EB). or fully closed position.
switch the key to position “ I ”. The fuel gauge , the green Regularly carry out following checks:
1. That the regulating valve (RV) is correctly adjusted, i.e. starts
On/Running lamp, and the red charge indication lamp will go
decreasing the engine speed when reaching the preset working
on. pressure in the receiver.
2. Check the air filter vacuum indicator (VI). If the yellow piston
d. When the ambient temperature is below -10°C, the engine reaches the red marked service range, replace the filter
element. Reset the indicator by pushing the reset button.
must be preheated first. Switch the key to the preheat position
not necessary.
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Instruction Manual
Keep the bolts of the housing, the lifting eye, the towbar and the axle securely tightened.
Refer to section 7. Technical specifications for the torque values.
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Instruction Manual
*
If you want to use another brand of oil, consult the
engine instruction manual.
**
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Instruction Manual
4.4 OIL LEVEL CHECK 4.5 OIL AND OIL FILTER CHANGE
4.4.1 CHECK ENGINE OIL LEVEL 4.5.2 COMPRESSOR OIL AND OIL FILTER CHANGE
Consult also the Engine Operation Manual for the oil The quality and the temperature of the oil determine the oil
specifications, viscosity recommendations and oil change change interval.
intervals.
The prescribed interval (see section 4.2) is based on an oil
See schedule. temperature of up to 100 °C and normal operating conditions.
Check engine oil level according to the instructions in the Engine When operating in high ambient temperatures, in very dusty or
Operation Manual and top up with oil if necessary. high humidity conditions, it is recommended to change the oil
more frequently.
In this case, contact Chicago Pneumatic dealer.
4.4.2 CHECK COMPRESSOR OIL LEVEL
1. Run the compressor until warm. Close the outlet valve(s) and
With the unit standing level, check the level of the compressor oil. stop the compressor. Wait until the pressure is released
The pointer of the oil level gauge (2) must register in the upper through the automatic blow-down valve in the Unloading
extremity of the green range. Add oil if necessary. valve. Unscrew the oil filler plug one turn. This uncovers a
vent hole, which permits any pressure in the system to escape.
Before removing oil filler plug (1), ensure that the
pressure is released by opening an air outlet valve. 2. Drain the oil by removing all relevant drain plugs. Drain plugs
are located at the air receiver, compressor element and
compressor oil cooler. Catch the oil in a drain pan. Screw out
the filler plug to speed up draining. Tighten the plugs after
draining.
3. Remove the oil filter, e.g. by means of a special tool. Catch
the oil in a drain pan.
4. Clean the filter seat on the manifold, taking care that no dirt
drops into the system. Oil the gasket of the new filter element.
Screw it into place until the gasket contacts its seat, then
tighten one half turn only.
5. Fill the air receiver until the pointer of the oil level gauge
1
registers in the upper extremity of the green range. Take care
that no dirt drops into the system. Reinstall and tighten the
2 filler plug.
6. Run the unit at no load for a few minutes to circulate the oil
and to evacuate the air trapped in the oil system.
7. Stop the compressor. Let the oil settle for a few minutes.
Fig. 4.1 Check compressor oil level Check that the pressure is released by opening an air outlet
valve. Screw out filler plug and add oil until the pointer of the
oil level gauge again registers in the upper extremity of the
green range. Reinstall and tighten the filler plug.
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Instruction Manual
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Instruction Manual
In order to guarantee the lifetime and quality of the product, thus − Topping up the coolant with water only, changes the
to optimise engine protection, regular coolant-condition-analysis concentration of additives and is therefore not allowed.
is advisable. The quality of the product can be determined by
three parameters:
Visual check
− Verify the outlook of the coolant regarding colour and make
sure that no loose particles are floating around.
pH measurement
− Check the pH value of the coolant using a pH-measuring
device.
− The pH-meter can be ordered from Chicago Pneumatic with
part number 2913 0029 00.
− Typical value for EG = 8.6.
− If the pH-level is below 7 or above 9.5, the coolant should be
replaced.
Glycol concentration measurement
− To optimise the unique engine protection features of the
GENCOOL EG the concentration of the Glycol in the water
should be always above 33 vol.%.
− Mixtures with more than 68 vol.% mix ratio in water are not
recommended, as this will lead to high engine operating
temperatures.
− A refractometer can be ordered from Chicago Pneumatic with
part number 2913 0028 00.
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Instruction Manual
Example:
Total volume coolant = 14 Liter
Measured concentration = 33 Vol %
50- 33 = 17 * 14 / 50 = 4,8 Liter GENCOOL EG Concentrate
6,0
5,5 1
5,0 2
4,5
Top-up volume (liter)
4,0
3,5
3
3,0
2,5
2,0
4
1,5
1,0
0,5
5
0,0
4 5 6 7 8 9 10 11 12 13 14 15 16
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Instruction Manual
4.6.7 TOPPING UP AFTER LIMITED QUANTITY DRAINING FROM THE COOLING SYSTEM
The quantity of GENCOOL EG Concentrate to be topped up after
draining a calculated volume from the cooling system, can be
estimated with the following formula and/or graph:
Corrections concentrate in measured system towards 50%
volume by using GENCOOL EG Concentrate
PN: 1626 2257 00
Example:
Total volume coolant = 80 Liter
Measured concentration = 33 Vol %
50- 33 = 17 * 80 / 67 = 20 Liter GENCOOL EG Concentrate
100- 33 = 67
In case of expansion tank at normal level, this quantity is to
be drained from the cooling system.
25,0
22,5 1
20,0 2
17,5
Top-up volume (liter)
15,0 3
12,5
10,0
4
7,5
5,0
2,5
5
0,0
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84
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Instruction Manual
Keep the coolers (1), (2) and (3) clean to maintain the cooling If the battery is still dry, it must be activated as described in
efficiency. section 4.9.2.
The battery must be in operation within 2 months from being
activated; if not, it needs to be recharged first.
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Instruction Manual
− Remove cover and/or plug from each cell. It guarantees that all necessary parts are replaced at the same time
keeping down time to a minimum.
− Fill each cell with electrolyte until the level reaches 10 to 15
mm above the plates, or to the level marked on the battery. The order numbers of the Service Paks are listed in the Chicago
Pneumatic Parts List.
− Rock the battery a few times so that possible air bubbles can
escape; wait 10 minutes and check the level in each cell once
more; if required, add electrolyte.
4.12 SERVICE KITS
− Refit plugs and/or cover.
A service kit is a collection of parts to fit a specific repair or
− Place the battery in the compressor. rebuilding task.
It guarantees that all necessary parts are replaced at the same time
which improves the uptime of the unit.
4.9.3 RECHARGING A BATTERY The order numbers of the Service Kits are listed in the Chicago
Pneumatic Parts List.
Before and after charging a battery, always check the electrolyte
level in each cell; if required, top up with distilled water only.
When charging batteries, each cell must be open, i.e. plugs and/or Contact Chicago Pneumatic.
cover removed.
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Instruction Manual
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Instruction Manual
5.2 AIR FILTER ENGINE/COMPRESSOR 5.2.4 REPLACING THE AIR FILTER ELEMENT
5.2.1 MAIN PARTS 1. Release the snap clips (1) and remove the dust trap (2). Clean
the trap.
(8)
(7)
(9)
The Chicago Pneumatic air filters are specially All adjustments or repairs are to be done by an
designed for the application. The use of non- authorized representative of the valve supplier.
genuine air filters may lead to severe damage of
engine and/or compressor element.
Following checks must be carried out:
Never run the compressor without air filter
element. − A check of the opening of the lifting gear, twice a year.
− This can be done by screwing the cap of the valve anti-
New elements must also be inspected for tears or punctures before clockwise.
installation.
− An annual check of the set pressure according to local
Discard the element (4) when damaged. A dirty safety cartridge (3) regulations. This check cannot be done on the machine and
is an indication of a malfunctioning air filter element. Replace the must be carried out on a proper test bench.
element and the safety cartridge in this case.
The safety cartridge can not be cleaned.
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Instruction Manual
1 2 3 4
1. Fuel filter
2. Fuel water separator
3. Pre-fuel filter
4. Pre-fuel water separator
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Instruction Manual
1. Starter motor does not a. Low battery output. a. Check electrolyte level and charge battery.
crank engine after turning If no cells are shorted and battery is
Start/Run/Stop Switch discharged, trace cause and correct.
to ” ”.
2. Starter motor does not a. Low battery output. a. See corrective action 1.
crank engine after turning
Start/Run/Stop Switch
to ” ”, but engine does
not fire.
3. Engine fires, but engine a. Regulator defective. a. Check and correct if necessary.
stops when releasing
Start/Run/Stop Switch.
5. Engine is running, but a. Start/Run/Stop Switch released too soon. a. Release button after engine oil pressure
shuts down immediately has built up above the minimum allowed
after Start/Run/Stop level.
Switch has been released. b. Insufficient engine oil pressure. b. Stop at once, consult the engine instruction
manual.
c. Fuel tank contains insufficient fuel. c. Fill fuel tank.
6. Unit does not load, engine a. Solenoid valve defective. a. Check and if necessary replace.
does not speed up and b. Regulating valve incorrectly set or b. Adjust or repair regulating valve, see
compressor does not defective. section 5.1.
deliver air immediately c. Engine speed regulator defective. c. Check and, if necessary consult Chicago
after turning Pneumatic.
Load/Unload Switch
d. Unloading valve stuck in closed position. d. Check and, if necessary consult Chicago
to ” ”. Pneumatic.
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Instruction Manual
7. Excessive compressor oil a. Restrictor in oil scavenging line clogged. a. Dismount, clean and refit restrictor.
consumption. Oil mist b. Oil separator element defective. b. Replace element.
being discharged from air c. Oil level too high. c. Check for overfilling. Release pressure
outlet valve. and drain oil to correct level.
9. Compressor does not a. Air leaks in regulating system. a. Check hose and their fittings. Stop leaks
unload and engine keeps and, if necessary consult Chicago
running at maximum speed Pneumatic.
when closing the air outlet b. Regulating valve incorrectly set or b. Adjust or repair regulating valve; see
valves; safety valve blows. defective. section 5.1.
c. Unloading valve or its actuating piston c. Repair unloading valve.
stuck.
10. Working pressure rises a. Air leaks in regulating system. a. Check hose and their fittings. Stop leaks
during operation and and, if necessary consult Chicago
causes safety valve to Pneumatic.
blow. b. Regulating valve incorrectly set or b. Adjust or repair regulating valve; see
defective. section 5.1.
c. Unloading valve or its actuating piston c. Repair unloading valve.
stuck.
d. Safety valve opens too soon. d. Have safety valve adjusted; consult
Chicago Pneumatic.
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Instruction Manual
11. After working some time, a. Fuel level is too low. a. Fill fuel tank.
the unit stops suddenly b. Air in fuel system, or insufficient fuel b. Check filters and hoses for leaks, dirt and
through a shutdown supply. bends.
switch. c. Compressor temperature too high. c. See corrective actions 13.
d. Engine oil pressure too low. d. Refer to Engine Operation Manual.
e. Engine temperature too high. e. See corrective actions 14.
f. Low coolant level. f. Top up cooling system.
12. Air and oil mist expelled a. Unloading valve defective. a. Repair valve. Consult Chicago Pneumatic.
from air filter after b. Wrong oil type (without foam-retarding b. Consult Chicago Pneumatic.
stopping. additives).
13. Compressor overheating. a. Insufficient compressor cooling. a. Locate compressor away from walls.
When banked with other compressors,
leave space between them.
b. Oil cooler clogged externally. b. Clean oil cooler; see section 4.6.
c. Oil system clogged internally. c. Consult Chicago Pneumatic.
d. Oil level too low. d. See section 4.6.
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Instruction Manual
The following tables list the recommended torques applied for Engine oil pressure bar(e) 1
general applications at assembly of the compressor.
Engine oil temperature °C 100
Compressor temperature °C 120
For hexagon screws and nuts with strength grade 8.8
Safety valve opening pressure MPa 1.2
Thread size M6 M8 M10 M12 M14 M16 CPS 850,CPS 850L,CPS830-9L
Nm 9 23 46 80 125 205 Safety valve opening pressure MPa 1.6
CPS830-9,CPS 750-10, CPS 650-
12
For hexagon screws and nuts with strength grade 12.9
Safety valve opening pressure MPa 1.8
Thread size M6 M8 M10 M12 M14 M16 CPS 580-14
Nm 15 39 78 135 210 345
Note:
Secure the tank cap handtight.
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Instruction Manual
Compressor type CPS 850L CPS 830-9L CPS 850 CPS 830-9 CPS 750-10 CPS 650-12 CPS 580-14
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Instruction Manual
Compressor type CPS 850L CPS 830-9L CPS 850 CPS 830-9 CPS 750-10 CPS 650-12 CPS 580-14
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Instruction Manual
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Instruction Manual
8 DATA PLATE
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Printed in Belgium - 06/2013 - 2950 5230 03