Академический Документы
Профессиональный Документы
Культура Документы
Deutz M2011
Powered Compressor
Attention
Questions/Parts orders
Always indicate:
- Machine number (rating plate)
- Machine model.
Danger
Please observe the maintenance
instructions (service intervals and
points) given in the operating
instructions.
Perform inspection, maintenance and
repair work only when the machine is
standing still, not under voltage and not
under pressure.
Safety devices such as guards must not
be removed during operation.
Service Contact Partner, name: ________________________________________________________________ ☎ ____________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
Remarks: __________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
Total operating hours
Time required for service work
Date Maintenance – Inspection – Repair
Hours
Start
End
Oil change (date/hours)
Mechanic's signature
Operating Manual
Deutz M2011
Powered Compressor
3
1. Foreword
max. installation
Delivery volume
Type of cooling
Pressure range
Operating
Ambient Engine
Fuel tank
pressure
capacity
height
Oil fill
temperature speed
[m above
[m3/min] [barg] [barg] [°C] [°C] [l] [kW] [rpm] [rpm] [l] [l]
sea level]
C30 3.0 7.0 5-8 -10 50 1000 9.0 F2M2011 Oil 23.0 1700 2600 7.5 60
C30 G * 3.0 7.0 5-8 -10 50 1000 9.0 F2M2011 Oil 23.0 1700 2600 7.5 60
C35-10 3.5 10.0 5-10 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60
C35-10 G ** 3.5 10.0 5-10 -10 45 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60
C38 3.8 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60
C38 G ** 3.8 7.0 5-8 -10 45 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60
C42 4.2 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60
C42 G ** 4.2 7.0 5-8 -10 45 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60
C50 5.0 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60
C50 G * 5.0 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60
location,distance 1m
max. sound intensity
(heigt-adjustable
max. permissible
at the operators
Compressed air
(rigid chassis)
Length (max.)
Tyre pressure
weight rating
Gross vehicle
distance 7m
connections
Trade name
2000/14/EC
Width with
mudguard
chassis)
Height
Tyres
Rim
[kg] [kg] [kg] [mm] [mm] [mm] [barg] [dB/1pW] [dB(A)] [dB(A)]
C30 1025.0 767 807 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
C30 G * 1025.0 834 874 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
C35-10 1025.0 805 845 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
C35-10 G** 1025.0 889 929 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
C38 1025.0 805 845 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
C38 G ** 1025.0 889 929 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
C42 1025.0 805 845 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
C42 G ** 1025.0 889 929 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
C50 1025.0 868 908 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
C50 G * 1025.0 935 975 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69
4
1. Foreword
max. installation
Delivery volume
Type of cooling
Pressure range
Operating
Fuel tank
Ambient Engine
pressure
capacity
height
Oil fill
temperature speed
C53-9 5.3 8.6 5-9 -10 50 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120
C53-9 G ** 5.3 8.6 5-9 -10 45 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120
C55-14 5.5 14.0 5-14 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C60-12 6.0 12.0 5-12 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C62 6.2 7.0 5-8 -10 50 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120
C62 G ** 6.2 7.0 5-8 -10 45 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120
50 1000
C62HS 6.2 7.0 5-8 -10 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
40 3000
C62HS G ** 6.2 7.0 5-8 -10 50 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
40 3000
C65-10 6.5 10.0 5-10 -10 50 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C65-10 G ** 6.5 10.0 5-10 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C76 7.6 7.0 5-8 -10 50 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C76 G ** 7.6 7.0 5-8 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
location,distance 1m
max. sound intensity
(heigt-adjustable
max. permissible
at the operators
Compressed air
(rigid chassis)
Length (max.)
Tyre pressure
weight rating
Gross vehicle
distance 7m
connections
Trade name
2000/14/EC
Width with
mudguard
chassis)
Height
Tyres
Rim
[kg] [kg] [kg] [mm] [mm] [mm] [barg] [dB/1pW] [dB(A)] [dB(A)]
C53-9 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 98 81 69
2 x 3/4" + 1x 1 1/2", or 3 x 3/4" + 1x 1 1/2" optional
C53-9 G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 98 81 69
C55-14 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70
C60-12 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70
C62 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 98 81 69
C62 G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 98 81 69
C62HS 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70
C62HS G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70
C65-10 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70
C65-10 G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70
C76 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70
C76 G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70
DLT0406
DLT0703
Fig. 2
6
1.5 Maintenance and care 1.6 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 operate Safety regulations
careful execution of care and maintenance the compressor safely, cost-effectively
work are therefore essential, especially and with due care. Compliance with the Danger
under difficult working conditions. instructions in this manual will help to avoid
It is important that you follow the safety
danger, reduce repair costs and downtime,
regulations in Chapter 3 of the operating
and increase the reliability and service life
manual.
Service of the compressor.
In case of faults, or should you require This operating manual is to be
spare parts for the screw compressor, supplemented by instructions concerning Technical modifications
please contact your local CompAir agent. current national regulations for accident
We reserve the right to undertake
prevention and environmental protection. It
In case of damage, the trained technical modifications without notice in the interests
must always be available at the site of the
staff will guarantee a fast, expert repair of technical progress.
compressor. The operating manual is to be
using CompAir spare parts. Original
read and used by all persons in charge of
CompAir spare parts are manufactured
work with the compressor, for example
according to the state of the art and
operation, including setting up, correcting
guarantee continued reliable operation.
faults during operation, disposal of waste
products from production, care, disposal of
If you have important questions, process materials, upkeep (maintenance,
inspection, repair) and transport.
Besides the operating instructions and
CompAir Drucklufttechnik GmbH
Werk 55469 Simmern the current regulations applicable in the
user's country and at the sites of operation
concerning accident prevention, the
recognized technical rules for safe and
proper working are also to be complied
with.
Typ, type, modèle, tipo
1 2
If you give us this data you can be sure that The Guarantee and Liability terms of
you will be given the correct information or CompAir's General Terms and Conditions
sent the spare parts you require. are not extended through the 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.
7
2. Index
1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information on the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Specifications type DLT 0406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Specifications type DLT 0703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Security regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Identification of safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Modifications and alterations to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Loading / Relocation / Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Installation on site / Starting / Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Special jobs / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 Instructions concerning particular hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8 Symbols and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1 Recommended lubricant for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2 Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.3 Tool lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.5 Recommended lubricants for the bogies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8
2. Index
9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.2 Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.3 Maintenance of chassis and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.4 Compressor maintenance / Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.4.1 Oil filter replacement (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.4.2 Oil change (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.4.3 Checking the automatic monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.4.4 Inspecting / Replacing the fine separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.4.5 Air filter replacement (compressor / engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.4.6 Checking the safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.4.7 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.4.8 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.4.9 Torque specifications DLT 0406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.4.10 Torque specifications DLT 0703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.5 Spare parts for maintenance purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
16. Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
16.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
16.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
16.3 KHV13 height-adjustable towing system, model B 3.5.13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
16.4 Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
16.5 Adjusting the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
16.6 Readjusting the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
16.7 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
16.8 Malfunctions and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9
3. Security Regulations
3.1 Identification of safety Personnel delegated to work with the Only trained or specially instructed
machine must have read the operating personnel may be assigned to this work.
instructions
manual before beginning this work, The responsibility of the personnel for
CompAir accepts no responsibility for particularly the chapter on safety operating, setting up, maintaining and
any damage or injury caused by non- instructions. It is too late to do this while repairing the machine / installation must
compliance with these safety measures or working. This applies particularly to be clearly defined.
non-observance of normal care and personnel only using the machine
Make sure that only authorized personnel
caution during the handling, operation, occasionally, e.g. for setting up and
use the machine.
maintenance or repair of this compressor, maintaining the machine.
even if not expressly stated in this Define who is responsible for operating
Safety and danger-conscious working
operating manual. the machine, and authorize him to ignore
by the personnel in compliance with the
instructions from third parties if these
If any of the regulations contained in operating manual should be checked at
instructions could compromise safety.
this manual do not correspond to local least occasionally.
statutory provisions, particularly with Only allow personnel that are training,
The personnel must not have long, loose
reference to safety, then the stricter of that are under instruction or are attending
hair, or wear loose clothing or jewellery,
the two applies. a course of general training to use the
including rings, due to risk of injury through
machine / installation under the constant
These safety instructions are of a general catching. Personal protective equipment
supervision of an experienced person.
nature and are applicable to various types should be worn if necessary or as required
of machine and equipment. For this reason by regulations. Work on the electrical systems of the
it is possible that some information may not machine / installation may only be carried
Pay attention to all safety and danger
apply to the aggregate(s) described in this out by a trained electrician in accordance
warnings on the machine/ installation!
manual. with electrical regulations.
Make sure that all safety and danger
Only persons with special knowledge and
Danger warnings on the machine / installation can
experience of hydraulics may work on
be read.
system elements, for example components
Places thus marked refer to possible
For all safety-relevant modifications to under pressure.
dangers for persons.
the machine / installation or its operating
Attention behavior, stop the machine / installation
immediately and report the fault to the
Places thus marked refer to possible competent authority / person. 3.3 Modifications and alterations
dangers for machines or parts of to the machine
Spare parts must meet the technical
machines. requirements laid down by the No alterations, additions, or modifications
manufacturer. This is always guaranteed to the machine may be carried out without
Note when original spare parts are used. the approval of the manufacturer. This
Places thus marked give general and Replace hydraulic hoses at the given is also true for the installation and the
technical information for optimum, cost- intervals, or at suitable intervals, even if adjustment of safety devices and valves
effective machine use. no safety-relevant defects are visible as well as for welding at supporting
(DIN 20066, Part 5). and pressurized parts. Unauthorized
modifications to the machine are prohibited
Observe the intervals stipulated or those for reasons of safety.
3.2 General safety instructions given in the operating manual for routine
checks and inspections. Original parts are specially designed for
Organizational measures our machines. We must explicitly point out
Workshop equipment suitable for carrying that parts and special accessories not
Please keep this operating manual handy out maintenance work is essential. supplied by us are not approved by us.
at all times on the site of the machine / Installing or using such products may thus
installation, in the bag provided. The location and operation of fire
extinguishers must be made known. adversely affect active and/or passive
Please note and pass on general Observe the instructions concerning fire safety.
statutory and other binding regulations alarm and firefighting. The manufacturer accepts no liability
that may supplement the operating whatsoever for damage resulting from the
manual for the prevention of accidents Limiting values (pressure, temperature,
time settings etc.) must be permanently use of non-original parts or special
and the protection of the environment. accessories. This also applies to the
Such obligations may be for example the marked.
installation and adjustment of safety
handling of hazardous materials, or the devices and valves as well as to welding
provision and/or wearing of personal Personnel selection and qualification; on bearing and pressurized parts.
protective equipment, or traffic regulations. basic tasks
Instructions, including supervisory
Note
Work on or with the machine / installation
responsibility and duty of notification for may only be carried out by reliable The General Type Approval becomes inva-
taking account of special in-plant factors, personnel. Observe the minimum statutory lid in case of modifications or alterations
for example regarding work organization, age. which change or infringe upon the external
sequences of operations, personnel geometry as well as the gross axle weight
assigned to certain tasks, are to be added rating.
to the operating manual.
10
3. Security Regulations
3.4 Loading / Relocation / Transport Before or immediately after completion Do not travel across slopes transversely:
of loading, secure the machine / installation always keep equipment and loads near
Loading / Relocation to prevent accidental shifting. Display an ground level (for example, do not place
appropriate warning. Before putting the them on the bodywork).
All loose parts that could fall down when machine / installation back into operation,
the machine is lifted must first be removed On descents, always adapt speed to the
the securing devices must be duly
or secured; pivoting parts like doors, etc. circumstances! Never change into low gear
removed.
must be immobilized. during the descent, but always beforehand.
Parts to be removed for transport When leaving the driver's seat, always
For lifting heavy parts, hoisting gear and purposes must be carefully refitted and secure the unit to make sure that it cannot
heavy-lift facilities with the appropriate fixed again before putting the machine / roll away or be used without authorization!
capacities, which have been checked and installation back into operation.
approved in accordance with local safety Avoid all operations that adversely affect
regulations, must be used. When putting the machine / installation the stability of the unit.
back into operation again, only proceed in
For lifting machines or parts of machines accordance with the operating manual.
with one or more lifting eyes, only hooks
or shackles complying with local safety 3.5 Installation on site / Starting /
regulations may be used. Never fasten Transporting the complete unit Normal operation
cables, chains or ropes to or through lifting Make sure that the air vessel is not under
eyes. pressure. Installation on site
Lifting hooks, lifting eyes, shackles etc. Lift and secure supporting gear. Besides the general technical operation
must never be bent and must always be in accordance with the regulations of the
stressed in alignment with the load-carrying Make sure that the drawbar eye can local authorities, it is essential that the
axis. The load capacity of the hoisting gear move freely in the tow bar. following guidelines be observed.
is reduced if the lifting force is applied at an Check to make sure that the drawbar is Before switching on the machine /
angle to the axis. adjusted to the bar height of the towing installation, or starting it up, make sure
All bearing parts must be stressed vehicle. that nobody can be injured by the
vertically, as far as possible, for maximum Check to make sure that the body is machine / installation as it starts up.
safety and optimum performance of the closed and locked, and that the cable for The installation is to be set up in such a
hoisting gear. If required, a support is to be the rapid-emergency brake is connected way that it is adequately accessible and
installed between the hoisting gear and the to the towing vehicle. that the necessary cooling is ensured.
load. Secure the load properly.
Join up the connections of the air brake, Never block the admission of air.
When heavy loads are being conveyed if present. The air intake is to be designed in such
by means of hoisting gear, it is imperative
Check to make sure that the wheels are a way that no dangerous admixtures
to keep well clear of the load in order to
properly tightened, that the tyres are in a (inflammable solvent vapors etc., but
avoid accidents.
roadworthy condition, that the tyre pressure also dust and other dangerous or toxic
Never leave the load suspended on the is correct and that the brakes function substances) can be taken in. This also
hoisting gear. properly. applies to flying sparks.
Acceleration or braking of the means of Connect the cable for the signalling The air intake is to be designed in such a
transport must remain within the approved and lighting fittings. Check the proper way that no loose personal clothing can be
limits. functioning of the lighting. drawn in.
The hoisting gear is to be set up in such Release the handbrake. Make sure that the compressed air line
a way that the object is lifted vertically. from the compressor to the air network can
Should this not be possible, precautions Before transporting the unit, always expand as a result of heat and cannot
must be taken to prevent the load from check to make sure that the accessories come into contact with inflammable
swinging. Thus it is possible to use two are firmly attached so that they can cause materials.
sets of hoisting gear, both with an angle of no accidents!
The compressed air line connected at the
inclination of not more than 30° to the When using public roads, tracks and air exit of the unit must not be under strain.
vertical. spaces, observe the current traffic
regulations, and if necessary make the Compressed-air lines have to be marked
Nominate experienced supervisors for the
unit roadworthy first! distinctly according to local regulations.
lifting process.
Never exceed the maximum towing If several compressors are arranged in a
Machines may only be hoisted correctly
speed. Observe national regulations! system, manually operated valves have to
using hoisting gear in accordance with the
be installed so that each machine may be
information in the operating manual (limit Always switch on lights if visibility is poor shut off individually. For the purpose of
stop points for heavy-lift facilities etc.) and during lighting-up time! shutting off pressurized systems, you
Only use a suitable transport vehicle with should never rely on the effectiveness of
When going through underpasses,
sufficient carrying capacity. return valves alone.
bridges, tunnels, overhead power lines,
etc., always make sure that you have Safety devices, protective covers, or
enough clearance! insulations mounted on the system must
not be removed or modified in any way.
Always keep a safe distance from the
edges of foundation ditches and
embankments!
11
3. Security Regulations
All pressure tanks located outside the unit Make sure that: Avoid any working methods that could be
with an approved operating pressure higher considered risky!
* All bolted connections have been
than atmospheric pressure and fitted with
tightened Never play about with compressed air.
two or more pressure feed lines must be
equipped with an additional safety device * All electrical wiring has been connected Never direct compressed air onto the skin
to automatically prevent the approved correctly and is in good condition or towards another person.
operating pressure from being exceeded by
* The engine exhaust system is Never use compressed air for cleaning
more than 10%.
operationally safe and that no clothing. When using compressed air to
Pipes and other parts with a surface inflammable material is in the vicinity clean equipment, work with extreme
temperature of more than 80 °C must be caution and always wear suitable eye
* The wheel nuts are properly tightened;
suitably secured against contact and protection.
never exceed the specified torque.
suitably marked.
The compressed air produced by these
Electrical connections must comply with compressors must not be used as breath-
local regulations. Normal operation able air, unless it has been processed
specially for such an application in
With compressors fitted with generators, Before starting work, make yourself
accordance with the “Safety requirements
use equipotential bonding systems for the familiar with the working environment at the
for breathable air.”
protection of persons. installation site. The working environment
includes, for example, obstacles in the When breathing apparatus with cartridges
Install the machine so that it is as
working and transport areas, the carrying is used, make sure that the correct
horizontal as possible; a slight inclination is
capacity of the ground, and any necessary cartridge has been inserted and that its
permissible (see information in Chapter
cordoning off of the building site from public service life has not expired.
"Installation").
traffic areas.
Never use the machine in environments
Set up the machine in such a way that no
Take the necessary precautions to make where the possibility cannot be ruled out
inlets, outlets or gates are blocked, even
sure that the machine / installation is only that inflammable or toxic vapors may be
when the doors are open.
operated in a safe, functional condition. taken in.
Before disconnecting the machine from
Only operate the machine when all Never operate the system at temperatures
the towing vehicle, apply the handbrake.
protective devices, shutdown devices, and/or pressures below or above the values
Disconnect the rapid-emergency brake
sound-insulating equipment and extraction indicated in the technical data sheet.
cable and lighting cable, disconnect the
equipment is in place and working.
lines of the air brakes, use chocks to Persons working in environments or
ensure that the machine does not roll away. Be careful: loose articles of clothing, hair rooms in which the acoustic pressure is
or limbs can still be drawn in by revolving 85 dB(A) or higher must wear ear muffs.
If a machine with a combustion engine
parts. Caution: this may impair communication
has to work in a fire-risk environment, the
between persons. Warnings may not be
unit must be fitted with a spark catcher. Verify regularly that:
heard. Inform supervisor.
In dusty environments, set up the * All protective equipment is properly
Shieldings and doors must be closed
machine in such a way that the wind does positioned and fixed in place
during operation so that the flow of cool air
not blow dust in its direction. During
* All hoses and/or pipes within the system within the housing is not deflected and the
operation in clean environments, the
are in good condition, are properly fixed efficiency of the sound-insulating is not
intervals for cleaning the air intake filter
in place and do not chafe reduced. Doors and hoods may only be
and the cooler elements are much longer.
opened briefly.
* There are no leaks (fuel, oil or coolant
Do not install the machine directly in
leaks) With water-cooled combustion engines
front of walls. Make sure that the warm air
with a closed cooling circuit, the cap of the
coming from the engine and cooling * All bolted connections have been
coolant recovery bottle must not be
systems is not drawn into the air intake tightened
removed before the system has cooled
under any circumstances. Drawing this
* All electrical wiring is properly connected down to ambient temperature.
warm air in through the engine or cooler
fan could lead to overheating; if it is and is in perfect condition
Never fill up with fuel while the engine is
drawn into the combustion chamber, this * Safety valves and other pressure-relief running. Make sure that fuel does not come
will result in a loss of power. devices are in perfect condition and are into contact with hot machine parts.
Never relocate the machine if external not blocked, for example by dirt or paint
Do not smoke while filling up with fuel.
lines or hoses are connected to the * The safety devices all work properly
Filling up at a pump can cause static
discharge valves, in order to avoid damage
All connected components must be of electricity and possibly sparks. In order to
to the valves and/or collecting pipe and
the correct size and be suitable for the avoid this, a ground cable must be
hoses.
specified operating pressure and connected to the system while it is being
No force may be exerted on the temperature. filled up.
discharge valves, for example by pulling
the hoses or fitting additional equipment Only use the correct type and size of
(e.g. a water separator, compressed air hose coupling and connection.
oiler, etc.) directly to the discharge valve. Before blowing through a hose or air line,
it is essential to hold the open end firmly.
If the open end is not held firmly, it can
whiplash and cause damage or injury.
12
3. Security Regulations
The exhaust emissions of combustion Inform operating personnel before Only carry out inspection, maintenance,
engines contain carbon monoxide - a lethal beginning to carry out special work or and repair work when the screw
gas. If a machine with such an engine has maintenance. Nominate a supervisor. compressor system is at a standstill and is
to work in an enclosed room, the exhaust not under pressure.
After completing repair work, always
gases must therefore be conducted out
check to see whether any tools, loose Protective devices, i. e. protective grids,
of doors by means of a hose or pipe with
parts or cloths have been left in or on the may not be removed during operation.
an internal diameter of at least 100 mm.
machine, driving engine or driving
The use of extraction systems is highly Caution while the screw compressor is in
equipment.
recommended in test rooms for mobile operation.
machines. Maintenance and repair work is only to be
After the work has been completed,
carried out under the supervision of or by a
Before connecting or disconnecting replace any protective devices that have
person qualified for this work.
hoses, always close the compressor air been removed. Operation without
outlet valves. Before disconnecting a hose, For all work concerning the operation, protective devices is not permissible.
always make sure that it is not under production adjustment, conversion, or
Working clothing should be close-fitting
pressure. settings of the machine / installation and its
during work on running screw compressor
safety-relevant equipment, as well as
A hose connected to an air valve must systems.
servicing, maintenance, and repair,
be fitted with a safety wire for operating
observe the operating manual for startup
pressures above 7 bars; it is in fact
and shutdown procedures and the Maintenance
recommended that this safety device
instructions for maintenance work.
should be used for pressures above 4 bars. During maintenance and repair work, the
The steel wire has a diameter of 8 mm All maintenance and repair work may contractor has to inform the personnel
and is firmly clamped to the hose at least only be carried out when the system is shut about the dangers that can occur during
every 500 mm. Both ends are fitted with down, or, with electrical systems, when the their work and about measures to avert
cable lugs. mains power supply is switched off. Make such dangers.
sure that the equipment cannot be
Check the machine / installation for The personnel have to support all
switched on by accident.
external damage and faults at least once measures to improve safety at work.
per shift. Any changes noticed (including Whenever the machine/system is
changes in operating performance) must Safety devices for preventing or
completely powered down for maintenance
be reported immediately to the authority or eliminating dangers must be serviced
and repair procedures, it has to be
person in charge. If necessary, shut down regularly and their functioning tested at
secured against unintentional power-on
and secure the machine immediately. least once per year. Faults discovered must
or the mains supply has to be cut off
be corrected at once or reported to the
with electrical systems.
In case of malfunction, shut down and supervisor.
secure the machine / installation * Switch off battery master switch and/or
immediately. Have malfunctions corrected Only use the correct tools for
detach connector.
immediately. maintenance and repair work.
* Put up a warning sign on the main
Observe the operating manual for start- Only use original spare parts.
switch “Attention! Maintenance work.”
up and shutdown procedures as well as Close off the complete maintenance All maintenance and repair work may
inspection displays. area, if required. only be carried out when the system is shut
down, or, with electrical systems, when the
* Disconnect the starter battery.
mains power supply is switched off. Make
Individual parts and larger subassemblies sure that the aggregate cannot be switched
3.6 Special jobs / Maintenance must be carefully attached to the hoisting on by accident.
gear and secured in case of replacement.
Care Whenever the machine/system is
Only use suitable, technically perfect completely powered down for maintenance
Observe the setting, maintenance, and
hoisting gear and load suspension devices and repair procedures, it has to be
inspection work and intervals stipulated in
with adequate carrying capacity. Keep clear secured against unintentional power-on
the operating manual, including information
of suspended loads. or the mains supply has to be cut off
about the replacement of parts / partial
with electrical systems.
sections. This work may only be carried out Before removing any part under pressure,
by specialists. separate the aggregate effectively from * Switch off battery master switch and/or
all sources of pressure and release the detach connector.
Maintenance work, tests and repairs
pressure from the complete system.
should be carried out in a well ventilated * Put up a warning sign on the main
room, away from heat, open flames, or Never use inflammable solvents or switch “Attention! Maintenance work.”
sparks. Appropriate prohibition signs (fire, carbon tetrachloride to clean parts. Close off the complete maintenance
open flames, no smoking) must be put up. area, if required.
Take precautions to avoid toxic vapors
Loss of oil leads to a very slippery floor. from cleaning fluids. * Disconnect the starter battery.
Statistics have shown that many accidents
Absolute cleanliness is essential during Before removing or opening any part
can be attributed to the installation or
maintenance and when carrying out under pressure, separate the equipment
maintenance of machines on oily floors or
repairs. effectively from all sources of pressure and
machine components. For this reason,
always start maintenance work by cleaning release the pressure from the complete
Only carry out maintenance and repair
the floor and the machine exterior. system.
work when the machine is located on an
even, stable base and is secured against
running away and against buckling.
13
3. Security Regulations
For moveable machines support the In order to avoid an increase in operating Keep all steps, handles, railings,
towing mechanism and axle with temperature, inspect and clean the heat platforms, scaffolds, and ladders free of
appropriate means if work is to be carried transfer surfaces (cooling ribs etc.) dirt, snow, and ice.
out underneath the units (a jack is not regularly. Draw up a schedule for the most
Before beginning maintenance and
sufficient). suitable cleaning intervals for each
repair, clean the machine, particularly
machine.
Observe the safety precautions for work couplings and bolted connections, of oil,
on batteries. Avoid damaging the safety valves and fuel, and special care products. Do not use
other pressure-reducing devices. In aggressive detergents. Use lintfree cloths
Pay attention to cleanliness. Prevent dirt
particular, make sure that they are not for cleaning.
from entering by sealing the parts and
blocked through paint, oil carbon, or
exposed openings with a clean cloth, After cleaning, remove all covers and
dust accumulation, which could impair
paper, or tape. seals.
the effect of these devices.
Before the aggregate is approved for After cleaning, check all fuel, engine oil,
The insulation or protective shielding of
operation after maintenance or an and hydraulic fluid lines for leaks, loose
parts whose temperature may exceed
overhaul, make sure that operating connections, chafing and damage. Correct
80 °C and which may accidentally be
pressures, temperatures, and time settings any faults immediately.
touched by personnel may not be removed
are correct and that the control and
before these parts have cooled down to Always tighten bolted connections
shutdown devices are working properly.
room temperature. loosened during maintenance and repair
The electric motor, generator, air filter, work.
Check the accuracy of the pressure
electrical components and control
and temperature displays regularly. If the If it is necessary to dismantle safety
equipment are to be protected against the
permissible tolerance limits have been devices during machine set-up,
penetration of dampness - for example
exceeded, then they must be replaced. maintenance, and repair work, the safety
when cleaning with a steam jet - by
devices must be reassembled and checked
covering or sealing them. Never carry out welding work or any other
immediately after completing the
work that produces heat in the vicinity of
Under no circumstances should the maintenance and repair work.
fuel or oil systems. Systems, which could
sound-insulating material be removed or
contain fuel or oil, have to be completely Ensure safe, environment-friendly
modified.
drained and cleaned, e.g. by means of a disposal of process materials as well as
Never use solvents with dangerous steam jet, before proceeding with the work replaced parts. Components containing oil,
properties for cleaning parts. to be carried out. for example fine separators, and oils must
be disposed of. Oil must not enter the soil!
Maintenance work, tests, and repairs Never carry out any welding work on any
should be carried out in a well ventilated pressure tank or components under
room, away from heat, open flames, or pressure, or modify them in any way.
Safety precautions for work with
sparks. Appropriate prohibition signs (fire,
If work causing heat, flames, or sparks batteries
open flames, no smoking) must be put up.
has to be carried out on a machine, the
The fluid contained in batteries is diluted
Wear suitable eye protection when surrounding components must be protected
sulfuric acid which can cause blindness if
inspecting the system. Make sure that the with nonflammable material.
brought into contact with the eyes, or
openings of spray containers, valves,
Before dismantling or overhauling a serious burns if brought into contact with
pipes, or atomizers are never directed at
compressor, engine, or any other machine, the skin. For this reason it is essential to
yourself or at any other person during the
make sure that no movable part with a work with the greatest of care when
inspection.
weight of more than 15 kg can move or roll servicing batteries, e.g. when checking
The fuel used in these systems is highly away. battery charge, and to take all necessary
inflammable, toxic and poisonous. Avoid safety precautions.
Machines whose main movement is back
contact with eyes and skin, and never
and forth must be moved at least once, Always wear long-sleeved overalls, acid-
inhale vapors. Should you accidentally
rotating machines several times, in order to resistant gloves and safety goggles.
swallow fuel, do not induce vomiting, but
make sure that there is no mechanical
seek medical attention. On charging a battery, an explosive gas
malfunction in the machine or in the driving
mixture is formed in the cells, which can
Should fuel come into contact with the part.
escape through the vent holes in the
eyes, or in case of eye irritation by vapors,
Only experienced persons may be sealing caps. If ventilation is poor, a highly
flush eyes with plenty of clean water and
charged with slinging loads and instructing explosive atmosphere can form around the
seek medical attention.
crane drivers. These instructors must battery, and can persist for several hours
Every time a message is displayed or remain within sight of the operator or be in after charging.
there is a suspicion that an internal part touch with him via walkie-talkie or similar
Thus:
of the machine has overheated, the device.
machine must be shut down. Never open * Never smoke in the vicinity of batteries
During assembly work above body
the inspection cover, however, before the that are being charged or have just been
height, use appropriate or otherwise safety-
machine has cooled down sufficiently to charged.
relevant climbing aids and working
rule out the possibility of the oil vapors
platforms. Do not use machine parts as * Put up prohibition signs for fire, open
igniting spontaneously when mixed with air.
climbing aids! Wear safety belts when flames and smoking in workshops where
carrying out maintenance work at greater batteries are charged.
heights.
* Never interrupt a current-carrying circuit
at battery terminals because of the
danger of spark formation.
14
3. Security Regulations
* Proceed particularly cautiously when * Warn outsiders not to come closer or Noise
connecting or disconnecting touch the machine.
Sound-insulating equipment on the
reinforcement cables or quick-charge
* Make sure that the voltage is switched machine / installation must be in operative
cable clamps.
off. position during operation.
When starting up using jumper cables or
* Do not leave the machine until the line Wear the prescribed personal ear muffs.
auxiliary batteries, first connect the positive
which has been touched or damaged, Caution: this may impair communication
terminals and then the negative terminals.
has been switched off load! between persons. Warnings may not be
After starting the engine, first disconnect
heard. Inform supervisor.
the negative terminal (ground cable) and When working with high-voltage
only then the positive terminal. Disconnect assemblies, ground the supply cable after The power of perception may become
the auxiliary battery after the starting voltage has been isolated, and short- adversely affected by the noise and by
procedure in order to avoid the risk of the circuit the components, e.g. capacitors, carrying ear protection. Warnings may,
release of gas (explosion hazard). with a ground rod! therefore, not be heard. Circumspect
behaviour by all concerned is necessary.
Noise, even when it is not very loud, can
Gas, dust, steam, smoke
3.7 Instructions concerning make us nervous and irritated, and after a
particular hazards Only carry out welding, burning, and longer period of time our nervous system
grinding work on the machine / installation can suffer serious damage. For this reason
Electrical Energy when this has been explicitly permitted, as a separate machine room is preferable, in
there may be for example risk of fire and/or order to keep the noise from the machines
Only use original fuses with the specified explosion. out of the workshop.
amperage.
Prior to welding, burning and grinding Depending on the number of machines in
In case of faults in the electrical power remove any dirt and inflammable a machine room, the noise generated can
supply, shut down the machine / installation substances from the machine/system be very loud. Depending on the level of
immediately! and its environment and ensure proper sound pressure in places where people are
Work on electrical systems or equipment ventilation (danger of explosion)! present, the following precautions must be
may only be carried out by a trained taken:
Only operate combustion engines in
electrician or by trained persons under the properly ventilated rooms. Ensure Below 70 dB(A): No special measures
leadership and supervision of a trained ventilation is adequate before starting up required.
electrician in accordance with the in closed rooms.
standards of electrical engineering. Above 70 dB(A): Persons permanently
Follow the local regulations applicable at present in the room must
Machine and system parts where service, the respective site of installation. wear ear muffs.
maintenance, and repair work is being
carried out must be switched off load, if Below 85 dB(A): For occasional visitors
required by regulations. First check the Hydraulic and pneumatic systems who are only in the
deenergized parts to make sure they are room briefly, no special
Work on hydraulic equipment may only
off load, then connect to ground and short- protective measures are
be carried out by persons with special
circuit, and insulate neighbouring parts that required.
knowledge of and experience in hydraulics.
are under tension. Above 85 dB(A): Noisy room. There must
Check all lines, hoses, and bolted
The electrical equipment of a machine / be a warning sign at
connections regularly for leaks and visible
installation must be inspected / tested every entrance pointing
damage. Repair any damage immediately.
regularly. Faults, such as loose con- out that persons entering
It is essential that damaged parts should be
nections or overheated cables, must be the room - even if only
replaced! Spurting fluid can lead to injuries
corrected immediately. briefly - must wear ear
and fires.
muffs.
If work has to be carried out on live parts,
Before beginning repair work, relieve the
then call in a second person to operate the Above 95 dB(A): The warning signs at the
pressure in system sections to be opened
emergency stop switch or master switch entrances must be
and in pressure lines (hydraulic and
with overvoltage release. Cordon off the supplemented by the
compressed-air lines) in accordance with
working area with a red-and-white safety recommendation that
the descriptions of the subassemblies.
chain and a warning sign. even occasional visitors
Hydraulic and compressed-air lines must wear ear muffs.
Only use insulated tools.
must be routed and fitted in accordance
Above 105 dB(A):Special ear protectors
Keep an adequate distance between the with the regulations. Do not confuse the
adapted to the volume
machine/unit and overhead power lines! connections!
and spectral composition
When working near overhead power lines, of the noise must be
The fittings, length, and quality of
equipment must not come near the power available. A warning sign
hoses must be in accordance with the
lines! Danger! Find out about the safe to this effect must be put
requirements.
distance to be observed! up at every entrance.
After touching high-voltage lines: Make sure that sound propagated
* Do not leave the machine. through walls and frames does not cause
an excessive sound level in the
* Move the machine away from the surroundings.
danger area.
15
3. Security Regulations
Potentially-explosive environments
The operation of the compressor in areas
where there is a risk of explosion is strictly
forbidden! (Exception: specially-made
compressors with the necessary technical
modifications for use in such areas)
Note
CompAir accepts no responsibility for any
damage or injury caused by noncompliance
with these safety measures or
noncompliance with normal care and
caution during the handling, operation,
maintenance or repair of this compressor,
even if not expressly stated in this
operating manual.
16
3. Security Regulations
Hoisting point
Emergency stop
Do not operate
with the hood
open
Do not step on
pressure-
conducting parts Check filling Observe the
level operating
instructions
Do not remove Tie down point
the compressor
documentation
Do not inhale
compressed air
100 98
98381/5083 A93614780
Only start with the bleed cocks Sound level data
closed Note tyre pressure
17
3. Security Regulations
Options
Condensation
drain from after-
cooler or from
after-cooler with
subsequent
filtering
18
4. Construction and functional description
19
4. Construction and functional description
4.2 Functional description (see fig.5) pressure tank (17). When exceeding the
operating pressure the P-controller (23)
Oil circuit feeds the set cylinder of the controller with
air. Each change of the pressure at the
The oil required for sealing and cooling admission opening causes a proportional
the rotors as well as for lubricating the pressure raise at the exit. This control
roller bearings is injected into the pressure operates the control cylinders
compressor (10) from the pressure tank (11,4). Over the calibrated openings of the
(17), which is under system pressure. The exhaust air nozzles (5,12) the control air
difference in pressure between the gets partly into the atmosphere and any
pressure tank and the oil injection position condensate will be let off. The throttle valve
is approx. 1 bar. The oil hereby passes the (11) closes (throttle-type governor) and the
oil cooler (16) and the oil filter (13). The engine speed will be lowered (speed
intake control valve (11) is fitted with a non- control). That way the air volume will be
return function, so that when the system is adjusted variable to the required air. If the
switched off, flooding of the air filter (9) is air output drops down to zero, the throttle
prevented. valve (11) is completely closed and the
engine runs under idle running speed. Over
the exhaust air nozzles (5,12) the sucked in
Air circuit air will be let off over a leakage cleft. When
The intake air flows through the air filter the pressure of the container drops down
(9) and the suction control valve (11) into the control pressure of the controller drops
the compressor (10). During compression, down too; the throttle valve opens and the
oil is injected in order to lubricate, cool and engine speed will increase.
seal the screw rotors. The compressed air- When turning off the engine the backlash
oil mixture flows into the pressure tank flap inside the controller will be closed
(17). Centrifugal preseparation of the oil is through the system pressure. The release
ensured through tangential entry into the valve (25), which closes parallel to the
tank. engine lifting magnet, looses power and
Any remaining oil is separated from the opens. The container pressure drops down
air in the fine separator (18). to zero.
Regulation
Note
It is not possible to start up the compressor
if there is insufficient fuel is available.
Starting up: The control function is
inactive at start up, i.e. as the system rises,
the engine speed is lowered to idling and
the suction throttle (11) closed. Once the
diesel engine (2) has warmed up, the
throttle/speed control is activated pressing
the load button.
The throttle/speed control enables the
volume of air tapped (10) to be adjusted
infinitely between 0% and 100%.
The control valve (11) is connected to the
engine speed control lever over a second
set cylinder. When starting, the engine is
set to full load and the control valve (11) is
open. The compressor (10) starts to
produce and pressure builds up inside the
20
4. Construction and functional description
21
4. Construction and functional description
22
4. Construction and functional description
left stoplamp
green yellow (L) left indicator lamp
23
5. Transport and installation on site
5.1 Transport * The lighting is fully functional. The breakaway cable must be attached in
a way that ensures that even on extremely
Never exceed the maximum towing
sharp bends there is no danger of
speed! Danger! Observe national
activating the locking brake.
regulations!
Please also observe the safety
instructions in Chapter 3 on the subject
of transporting.
Before transporting the compressor,
check to make sure that the drawgear of
the towing vehicle and the drawbar eye or
trailer hitch ball connection are aligned
exactly to each other.
When transporting the screw compressor
Fig. 8 with a vehicle, the following points must be
observed:
Fig. 9
Danger
* The shieldings are closed.
Make sure to check the torque after
* The blocks are firmly hooked in place.
50 kilometers following wheel mounting
and at regular intervals. * The support(s) is(are) retracted and 5.3 Loading/Relocation
locked in position (jockey wheel).
Tighten wheel nuts or screws evenly in
a diagonal sequence to the specified * Drawbar is connected to the towing
torque using a torque wrench. vehicle.
* The drawbar is adjusted to the height of
Replacing the trailer coupling ring the towing vehicle (option).
24
5. Transport and installation on site
Use proper hoisting gears only such as 5.4 Installation on site The compressor must be set up in as
hoisting straps in compliance with DIN horizontal a position as possible. Maximum
standard 61360 with proper lifting ca- permissible inclination during operation:
pacity for connecting the load
* In direction of pull: 15 degrees
suspension device (e.g. crane) and the
A A A * Backwards: 15 degrees
lifting device.
* To the right and to the left: 15 degrees
Only deploy load bearing equipment
which corresponds to the safety B B B
instructions for lifting gear.
Use a transport harness compliant
with local regulations for transporting A = B = 1,5 m
by helicopter. The eyes provided may
not be used for this purpose (max.
acceleration if the eyes are used = 2 x g) Fig. 11
Never lift up or lash down the unit using Danger
the shieldings!
The air intake must be positioned in
Never relocate the machine if external
such a way that loose personal clothing
lines or hoses are connected to the
cannot be drawn in. Fig. 12
discharge valves, in order to avoid
damage to the valves and/or collecting Make sure that the pressure pipe from Attention
pipe and hoses. the compressor to the aftercooler or the
air system can expand as a result of Greater inclinations endanger the
When loading, the following points must be
heat, and that it does not come into operating reliability of the screw
observed:
contact with inflammable materials. compressor.
* Secure the load suspension device or
The air intake is to be designed in such When setting up the unit on ground that is
the hoisting gear in the lifting device of
a way that no dangerous admixtures not horizontal, or with a variable angle (see
the screw compressor.
(inflammable solvent vapors etc., operating instructions) please consult
* When hoisting the compressor, set up but also other dangerous or toxic CompAir.
the hoisting gear in such a way that the substances) can be taken in. This also
compressor, which must be set up applies to flying sparks. Set up the machine in such a way that
horizontally, is lifted vertically. no inlets, outlets or gates are blocked,
Pipes and other parts with a surface even when the doors are open. Before
* Only relocate the compressor by itself. temperature of more than 80 °C must be disconnecting the machine from the towing
suitably secured against contact and vehicle, apply the handbrake. Disconnect
* Raise and lower the compressor
suitably marked. contact-breaking cable and lighting cable,
carefully.
The operation of the compressor in uncouple air brake lines.
* After relocating, remove the load
areas where there is a risk of explosion Secure wheels with chocks.
suspension device or the hoisting gear
is strictly forbidden! (Exception:
from the lifting device.
specially-made compressors with the Note
* Tie down the compressor on the cargo necessary technical modifications for
area of the means of transport. use in such areas) In dusty environments, set up the machine
in such a way that the wind does not blow
* Only tie it down at towbar and wheel Please also note the safety instructions the dust in the direction of the machine.
axles. in Chapter 3 on the subject of During operation in clean environments,
installation on site. the intervals for cleaning the air intake filter
* When the chassis is being dismantled,
the shieldings with machine group may and the cooler elements are much longer.
only be supported under the base frame.
Location Attention
The complete system is to be set up in
No force may be exerted on the dis-
such a way that it is easily accessible and
charge valves, for example by pulling
that the required cooling is guaranteed.
the hoses or fitting additional
Never block the air intake. Ensure that the
equipment (e.g. a water separator,
entering of moisture and dirt together with
compressed air oiler, etc.) directly at the
the intake air is kept to a minimum.
discharge valve.
The compressor is to be set up away
from walls.
Attention
Temperatures/air humidity
Install the compressor in a location with
maximum possible frost protection. The
suction air temperature must be within the
range specified on the data sheet.
Attention
Altitude
For operation at an altitude above
1,000 m, the compressor and engine must
be adapted (modified design).
Note
Particularly in case of installation out of
doors and at night, observe fuel tempera-
ture. At temperatures below 0 °C, summer
diesel fuel tends to precipitate and block
the fuel filter. In this case use winter diesel
fuel.
26
6. Preparing the compressor for operation
6.1 Checking oil levels 6.1.2 Checking the oil level in the engine 6.2 Battery
6.1.1 Checking the oil level in the
pressure tank
Fig. 14
Fig. 15
Danger
Only check the oil level when the Danger
Fig. 13
compressor engine is at a standstill. When working with battery acid (electro-
Danger Spill no oil! The oil may be hot. Risk lyte), wear acid-resistant goggles,
of scalding! gloves and apron.
Only check the oil level when the engine
Check for leaks.
is at a standstill and the compressor is The gases released by the battery are
not under pressure. Proceed as follows: explosive. Avoid sparks and open fires
* Ensure that the screw compressor is in the vicinity of the battery.
The pressure tank may be under
pressure and the oil may be hot. standing horizontally. Do not allow acids to come into contact
* Ensure that the screw compressor has with skin or clothing. Wear safety
Risk of scalding! Spill no oil!
been out of operation for some time. goggles.
Check for leaks.
* Unscrew dipstick. Place no tools on the battery.
Proceed as follows:
* The oil level should be as near as The battery is filled and charged in
* Before checking the oil level in the possible to the upper dipstick mark. accordance with DIN 43539. The battery is
engine and in the compressor ensure fastened with clamping strips.
that the vehicle is standing horizontally. * Correct as required.
The batteries used are ready to be
* Ensure that the screw compressor has * Screw in dipstick. installed and ready for service.
been out of operation for some time. Replacement batteries should be of the
* Close oil filler.
* Unscrew dipstick. same type as the batteries installed
* For oil specifications, see “Engine (low gassing). The replacement battery
* The oil level should be within the marks Operating Manual”. should be unfilled and only be preloaded
on the dipstick. so that it has to be filled with battery
Attention acid. The battery and the acid should
* Correct as required.
have a temperature of at least +10 °C.
* Check the seal on the dipstick and After a short test run, the oil level must
replace if required. not be above or below the upper or Proceed as follows:
lower dipstick marks. For oil specifi- * Fill up with battery acid as far as the
* Screw in dipstick and tighten firmly. cations, see engine instruction manual. base of the control insert
Attention * Leave the battery to stand for some time
After a short test run, the oil level * Then shake it gently
should be between the markings on the * If required, top up with acid
dip stick. For oil specifications, see
recommended lubricants, Chapter 8.1. * Tighten sealing caps
* The battery is ready for use
* Leave for 1 hour
27
6. Preparing the compressor for operation
6.3 Filling up the fuel tank 6.4 Checking the air filter
maintenance display
Fig. 16
Danger Fig. 17
Only fill up with fuel when the screw When the red service sector in the
compressor is at a standstill. transparent part is fully visible, the air filter
Cleanliness is essential! Spill no fuel! is due for maintenance. (See Chapter
Maintenance, air filter replacement.)
Filling up at a pump can cause static
electricity and possibly sparks. Empty the dust emission valve by
pressing together the emission slot in the
Proceed as follows: direction of the arrow.
* Open tank lid
Note
* Fill up tank with commercially available
branded diesel fuel, using a sieve (use Clean the emission slot from time to time.
summer or winter diesel fuel depending
on outside temperatures)
* Close tank tight with tank lid
* With the Deutz engines M2011, the
injection pump is self-ventilating. When
the tank is empty, immediately fill in fuel
to ensure that the fuel pump is always
filled with fuel. This condition may result
in starting problems.
* Close hood.
Note
It is not possible to start up the compressor
if there is insufficient fuel is available.
The fuel tank should always be filled up in
good time. For outside temperatures below
0 °C, use only winter diesel fuel.
More information on fuel quality, see
engine operating manual.
For outside temperatures below 0 °C,
observe the operating manual of the engine
manufacturer for winter operation.
You can reduce the occurrence of
condensation in the fuel tank considerably
by filling it up in good time. This also
prevents downtimes and starting problems
that can occur when the fuel tank is run
dry.
28
7. Putting the compressor into operation
7.1 Initial operation 7.2 Operating elements room, the exhaust gases must therefore
be conducted out of doors by means of
Transport inspection Operating panel: a pipe or hose with an internal diameter
of at least 100 mm. The use of extraction
Every CompAir screw compressor 1 2 3 4 5 systems is highly recommended in test
has already run in the factory and has rooms for mobile machines.
already undergone a thorough test before
shipment. This test ensures that the Only operate the compressor with the
compressor complies with the given data hood closed. The hood may only be
and works perfectly. Independent of opened briefly for minor adjustments
the care taken in the factory, it is still while the compressor is running.
possible for the compressor to be damaged Skilled personnel only are authorized to
during transport. For this reason it is work with the hood open.
recommended that the unit should be
examined for possible damage during When working with the screw
6 7
transport. compressor in operation and with the
Fig. 19 shielding/hood open, wear ear
Remove any transport seals (dummy protection.
flange, plugs, etc.) and dehydrating agents 1 Ignition switch
before start-up. Distribution tubes and 2 Start / Run valve Caution: this may impair
connection lines must have the specified 3 "Battery charge" pilot lamp communication between persons.
dimensions and must be suitable for use 4 "Fault" pilot lamp Warnings may not be heard. Inform
with the max. operating pressure and the 5 "Fuel shortage" warning lamp supervisor.
media to be taken up. 6 Operating pressure gauge
7 Hours of operation counter Attention
During the first hours of operation, the
compressor should be observed in order Opening the covering interferes with the
to be able to ascertain any possible flow of cool air in the compressor
malfunctions. section.
Full sound-insulating is only achieved
Transport safety locking of the towing when the covering is closed.
arrangement
Check the oil levels in the pressure tank
and in the engine of the compressor
each time before start-up.
Do not start the compressor unless the
air tapping cocks are closed.
Note
Transport safety locking
Fig. 20 Main battery switch
It is not possible to start up the compressor
if there is insufficient fuel is available.
7.3 Start-up
Starting up the compressor:
Fig. 18 Danger
* Close air tapping cocks.
The towing arrangement is positioned
vertically in accordance with Figure 18. Before starting up, make sure that no * Switch on main battery switch.
The clamp must be released and the one is in the danger area of the engine /
screw compressor. * Turn ingnition switch to position "On" I;
spacer removed on initial use. The towing
the indicator lamps “Battery charge” and
arrangement can then be adjusted Compressors may not be operated in “Fault” come on.
according to the required trailer height and hazardous environments unless they
locked with the clamp/ratchet (see here have been specially designed for this * Turn the ignition switch further to
Undercarriage Operating Instructions). purpose (e.g. exhaust protected against position .
emission of flying sparks etc.). * Hold the ignition switch in position
Never, under any circumstances, use until the engine starts running and the
"Startpilot" (Spray-can starting aid), “Battery charge” and “Fault” indicator
ether or other starting aids - Danger of lamps go off.
explosion! * Release the ignition switch.
After service work has been completed: * If the engine has not started after
Make sure that all protective devices
15 seconds at the latest, turn the ignition
have been refitted and that all tools
key back to position (Off-Aus). As
have been removed.
soon as the starter has reached a
The exhaust emissions of combustion standstill and the pressure tank is no
engines contain carbon monoxide - a longer under pressure, the engine can
lethal gas. If a machine with such an be started again.
engine has to work in an enclosed
29
7. Putting the compressor into operation
* After the start, the engine runs at the 7.4 Setting the operating pressure 7.5 Monitoring / fault
idling speed and the compressor at
reduced pressure.
Danger
* If the engine was started cold, let it
warm up for approximately 2 minutes
Bridging the safety switch in the
and then press the START/RUN valve
automatic monitoring system is not
(2). If the engine is warm, the START/ permitted!
RUN valve can be pressed immediately. When the “Fault” indicator lamp lights up,
the screw compressor is automatically shut
* The installation is now ready to operate.
down when the following faults occur:
Check that all the hoses and tools have
been connected correctly and open the * Fuel shortage
desired air outlet valves. * Compressor temperature too high
* Engine oil pressure too low
* Engine oil temperature too high
Start-up using jumper cables / auxiliary Fig. 22
After one of these faults, it is only
batteries
Danger possible to restart the machine after the
fault that caused the machine to be shut
The setting of the operating pressure down has been corrected.
may only be carried out by a specialist.
The operating overpressure of the screw Attention
compressor is set by the manufacturer
Disconnect the battery or generator only
(see the identification plate on each
when the engine is not running.
compressor).
* Switch off the machine if the
Pressure values can be set between
compressed air transports oil spray or if
5 bar and the operating overpressure
excessive oil is consumed. (Refer to the
stated on the rating plate. Pressure values
trouble-shooting section)
higher than this are not permitted.
* Check that the "battery charge" pilot
Fig. 21 Operating pressure is set by a specialist
lamp is not illuminated. If it glows, even
at the controller.
weakly, refer to the trouble-shooting
Danger section.
* Remove counternut below the control
Longer operation with an auxiliary knob of the regulator.
* Check that the air pressure (7) assumes
battery or jumper cables connected can * Raise pressure by turning the adjusting a value within the permissible pressure
lead to sudden emissions of gas. An knob of the regulator clockwise range.
inflammable air / gas mixture is formed. (towards +).
Explosion hazard! If the machine cuts out, before switching
* Lower the pressure by turning the off at the ignition switch (1) carry out the
Attention adjusting knob of the regulator following checks:
anticlockwise (towards -).
* Interrupt the electric connection to the
Serious damage can be caused to the
* In order to lower the pressure, open an engine oil pressure switch immediately
electrical system if wrongly connected.
air discharge valve. after the engine has cut out and leave it
* Ignition switch in position (Off-Aus) in the interrupted state.
* After altering the pressure, lock the
* First connect positive terminal then adjusting knob using the knurled nut. If the "fault" pilot lamp goes out
negative terminal (ground). immediately this indicates that either a
This readjusted operating pressure is to
too low engine oil pressure or a lack of
* Start as described in section “Starting up be checked using the pressure gauge on
fuel or a defective engine has led to the
the compressor.” the instrument panel at 100% air discharge
cut-out.
and maximum engine speed.
Note * If the light continues glowing this
indicates that an excessive engine
After the engine has started, first temperature or compressor temperature
disconnect the negative cable (ground) led to the cut-out.
and then the positive cable.
In order to trace the origin of the fault,
interrupt the engine oil temperature
switch (with the engine oil pressure
switch still switched off). If the lamp now
goes dark this indicates that the problem
is related to the oil temperature.
30
7. Putting the compressor into operation
31
8. Fuels
8.1 Recommended lubricant for If other lubricants are to be used, please * Nato Codes F 54, F 75, and F 76
contact: * BS 2869: A1 and A2 (observe sulfur
compressor
content with A2)
CompAir Drucklufttechnik GmbH
* ASTM D 975-81 : 1-D and 2-D
Note Argenthaler Straße 11
* VV-F-800a : DF-A, DF-1, and DF-2.
D-55469 Simmern/Hunsrück
In these screw compressors, circulating oil Telephone 06761 / 832-339 Note
has not only a lubricating function, but in Telefax 06761 / 832-421
particular it also has cooling and sealing See engine instruction manual.
or your authorized dealer or your local
functions. It is therefore exposed to more
branch. At low temperatures, paraffin precipitation
difficult conditions. In particular the
temperature conditions at the installation can cause blocks in the fuel system and
site and the consistency of the air (dust, disruptions in operation. Below outside
dirt, and humidity content, as well as 8.2 Recommended engine oil temperatures of 0 °C use winter diesel fuel
chemical influences) must be taken into (to -15 °C). (This is usually available at gas
account when selecting a suitable lubricant. Lubricant specifications for the driving stations in good time before the winter
engine can be found in the enclosed season begins.) Diesel fuel with additives is
Attention engine operating manual. frequently offered for use at temperatures
as low as -20 °C („Superdiesel“).
Do not mix oils of different
specifications. Note
8.3 Tool lubricants
The maintenance intervals and the Only mix in the tank. First put in the
maximum and minimum operating required quantity of petroleum, then fill up.
Attention
temperatures given in this operating
manual only apply when high-quality See engine instruction manual.
Do not run the machine with an empty
multi-grade oils are used. oiler tank! The tank must always Below -15 °C or -20 °C, petroleum must
Use of the wrong oil leads to impairment contain a minimum of 0.2 l of tool oil. be added.
of function. The wrong tool lubricants lead to If it is necessary to use summer diesel
deposits that cause malfunctions in the fuel below 0 °C, petroleum can also be
Change the compressor oil more
appliances connected! added up to 60 %.
frequently than specified if the
equipment is operated under abnormal For the perfect lubrication of concrete In most cases, adequate resistance to
conditions, i.e. at a high ambient breakers and pneumatic spades, we low temperatures can be achieved by
temperature, high air humidity or in a recommend the use of CompAir oilers or adding a product to improve flow properties
dusty environment. If necessary, automatic pipe oilers, using the special (fuel additive). Consult your engine service
analyse the oil. synthetic CompAir oil AES 82. station.
Out of consideration for the high loads The special advantages of CompAir oil are Attention
imposed on the lubricant in screw as follows:
compressors with oil injection cooling, we The compressor must not be fuelled
recommend the use of suitable, non * Biodegradable, with bio-diesel (DIN 51606) or vegetable
ageing, non foaming, corrosion-protective * Ice guard down to -50 °C, for use with oil.
oils. They must meet the following sound absorbers,
requirements for hydraulic fluids:
H-LP 32 and H-LP 46 in accordance with * Very good lubricity, thus wear-reducing,
DIN 51524, Part 2, June 1985. 8.5 Recommended lubricants for the
* No irritating exhaust gases, work in
The viscosity of the lubricants should enclosed rooms possible, bogies
comply with viscosity class ISO VG 32 DIN For relubrication use only lithium saponified
* Good cleaning effect, no residue
51519, July 1976, with 28 - 35 mm2/s(cSt) / grease which fulfils the following
formation
40 °C, or if the ambient temperature is specifications:
constantly above 25 °C, with viscosity class * Excellent preservation properties,
ISO VG 46 DIN 51519, July 1976, with protects from corrosion. * consistency groups (NLGI) 2
41 - 50 mm2/s(cSt)/40 °C. DIN 51818
When using compressed air consumers
made by other manufacturers, then their * worked penetration 265-295
Attention
regulations must be observed. DIN ISO 2137
Conventional engine oils marked HD * dripping point > 180 °C
must not be used. DIN ISO 2176
When using oils with the “Brief De- 8.4 Diesel fuel * operational temperature
scription HYD 10/HYD 20" in accordance – 40 °C … +140 °C
with the ‘Standard Lubricants for Building Use common diesel fuel with a sulfur
Machinery and Vehicles’ published by the content of less than 0.5 %. If the sulfur This corresponds to a DIN 51502
‘Hauptverband der Deutschen Bauindustrie content is higher, oil has to be changed at lubrication grease, designation KP2N-4U.
e.V.’ (Principal Association of the German shorter intervals.
Greases with different thickeners
Building Industry), only the given hydraulic The following fuel specifications are (soap base) must not be mixed.
fluids may be used in accordance with applicable:
ISO VG 32 and ISO VG 46. Recommended grease: Fuchs Renolit
* DIN 51 601 LZR 2.
32
9. Maintenance
Danger Note
33
9. Maintenance
Operating hours
500 h
60 h
1000 h
1500 h
2000 h
2500 h
3000 h
3500 h
4000 h
4500 h
5000 h
5500 h
6000 h
6500 h
7000 h
7500 h
8000 h
For 2 boxes per annum: Maintenance every 500 h,
although at least every 6 months
2. year
3. year
4. year
5. year
6. year
7. year
8. year
1. year
For 1 boxes per annum: Maintenance every 1000 h,
although at least each year
■ For your own benefit, put a cross on the servicing schedule against maintenance work when performed.
34
9. Maintenance
9.4.1 Oil filter replacement 9.4.2 Oil change (compressor) * Start screw compressor, run for approx.
two minutes, check for leaks
(compressor)
* Switch off screw compressor
* Check oil level, add oil if necessary
Danger
Caution! High voltage! The sensors of
the automatic monitoring system must
Fig. 27 not be short circuited.
Fig. 26
Danger Check individually every 1000 operating
Danger hours:
Only change the oil when the engine is
1. Temperature sensor - screw compressor
Only replace the oil filter cartridge when at a standstill and the screw
(pressure connection)
the engine is at a standstill and the compressor is not under pressure.
screw compressor is not under 2. Oil pressure switch - engine
Caution when draining off hot oil:
pressure. risk of scalding! Spill no oil! 3. Oil temperature gauge - engine
Caution with hot oil: risk of scalding!
Attention
Spill no oil! Checking the automatic monitoring system:
Change the oil filter every 1,000 oper- * Disconnect connecting cable
Attention ating hours, but at least once per year.
* Connect to ground at oil temperature
Change the oil filter every 1,000 oper- The screw compressor must not be gauge.
ating hours, but at least once per year. under pressure during oil change.
* Start screw compressor
Drain the oil at operating temperature.
Note * The automatic monitoring system must
Do not mix oils of different switch off the screw compressor
Dispose of oil filter cartridge in accordance specifications. immediately after starting, and the
with the relevant regulations - hazardous
“Fault” indicator lamp must come on.
waste! Note
Check for leaks. Collect used oil, do not allow it to enter the
Changing the oil filter: soil. Dispose of oil in accordance with the 9.4.4 Inspecting / Replacing the fine
relevant regulations - hazardous waste!
* Unscrew the oil filter cartridge using separator
appropriate tools Spill no oil!
* Dispose of oil filter cartridge Check for leaks. 2
* Apply a thin coat of oil to the seal of the Changing the oil: 1
new oil filter cartridge * Unscrew dipstick
3
* Screw on and tighten the new oil filter * Place oil drain pan under oil drain valve
cartridge (follow the instructions on the
oil filter cartridge) * Unscrew the sealing cap of the pressure
vessel
* Check for leaks
* Collect used oil in the oil drain pan
* Check oil level, add oil if necessary
* When the used oil has been drained
completely, use a new sealing ring on Fig. 28
the sealing screw of the pressure
vessel, position and tighten screw or 1 Connection for P controller
close the oil drain valve 2 Connection for compressor suction line
3 Oiler connection
* Fill up with new oil (see section
"Specifications" in chapter 1 for initial Danger
oil capacity; use a little less oil when
performing an oil change). Pressure tank is under pressure. Only
work when the motor is at a standstill
* For lubricants see “Lubricant Table” and the screw compressor is not under
* Check sealing ring on dipstick, replace if pressure.
necessary Caution with hot oil: risk of scalding!
* Screw in and tighten dipstick Spill no oil!
35
9. Maintenance
Danger
Never clean the air filter cartridge with
inflammable liquids.
36
9. Maintenance
9.4.7 Control For battery maintenance please also refer 9.5 Spare parts for maintenance
to the manufacturer’s instructions and the
purposes
engine operating manual.
Designation Identification No.
Service Package 1000 h
9.4.9 Torque specifications C30-C42 A19009474
DLT 0406
Service Package 1000 h
For the compressors C30, C30 G, C35-10, C50 A19009574
C35-10 G, C38, C38 G, C42, C42 G and Service Package 1000 h
C50, the following tightening torques apply C53-C76 A19009174
to screwed connections:
Service Package
Wheel screws 90 Nm air-oil separator C30-C50 A19009674
Fig. 31
Pressure vessel cover 40 Nm Service Package
The regulation is designed as continuous air-oil separator C53-C76 A19009274
speed control consisting of: Safety valve 50 Nm
Spare parts list C30-C50 100005900
* The intake control valve, Engine bearing/
Spare parts list C53-C76 100005924
* The engine control cylinder, rubber metal element 90 Nm
Clogged oil fine separator filter cartridge Replace compressor oil, oil filter and oil fine
separator filter cartridge
Spring and plunger inside the intake control Clean, replace parts if necessary, readjust
valve are not fully opened
38
10. Troubleshooting
Oil in air line Orifice in oil return line clogged Repair / clean
Oil comes out of the air filter of the Intake control valve defective Check and repair
compressor after the screw compressor (backlash flap, O-ring, spring)
has been shut down
Cable defective or cable cover not plugged Replace or plug onto sensor
onto sensor
39
11. Generator option
11.1 Introduction * The IP 54 protection means the If the generator is overloaded briefly (for
generator is protected against less than the thermal response time of the
This manual describes the operation and splashes, spray and other foreign circuit breaker), or devices with excessive
maintenance of synchronous generators bodies. Do not, however, clean the startup consumption levels are connected,
with switchboxes. generator with high-pressure the regulator automatically limits the
equipment. output/startup consumption (through the
All information relates to data available at excitation current). This leads to a (desired)
the time of going to press. * Generators may only accept up to
withdrawal of the output voltage. Please
their nominal load if operated
The manufacturer reserves the right to take account of this when operating several
according to the standard
make changes at any time, without prior devices simultaneously on your generator.
temperature range and cooling
notice or obligation. It is therefore always conditions specified. If installed
advisable to check for updates. Note
under different conditions, or if
No part of this publication may be cooling of the engine or generator is Switch devices (loads) on one after the
reproduced or transmitted in any form or by impaired, for example in confined other, starting with that with the least
any means, without the prior written spaces or under unfavourable favourable startup characteristics.
consent of the manufacturer. circumstances, their output must be
reduced. If the generator is extremely dirty,
Synchronous generators may only be insufficiently ventilated, or operating under
used as such. No other form of use is * Do not modify the generator/ otherwise unacceptable conditions, to
permitted. switchbox. Such changes, or the use prevent it or the regulator being damaged
of unsuitable parts, will invalidate by overheating, the output voltage is
approval under machinery safety reduced to about half its nominal value if
legislation and certification to the temperature inside the switchbox
11.2 Generator safety precautions EU/EEC Directives. exceeds 80 °C. This compromises the
connected devices, which must be
Danger switched off or unplugged immediately.
Always avoid operating the generator
Do not top up current-generating units 11.3 Operating principle
under such conditions, and keep it clean
(generators) with fuel during operation! (particularly fan cowl air inlets, cooling fins).
The generator is a self-excited brushless
Follow the additional fire and explosion synchronous internal pole generator which The generator is fitted with a thermal-
protection regulations in the case of is controlled electronically. It consists of magnetic circuit breaker, which not only
installation in enclosed spaces. the main machine, exciter, rotary rectifiers protects against overloads, but also
and generator regulator assemblies, switches off in the event of an insulation
Attention! Exhaust gases are toxic!
housed in a common enclosure. The main fault on a connected device. Interruption of
Do not operate generators in non-
machine of the synchronous 3-phase power distribution during operation may be
ventilated, enclosed spaces!
generators has various design features, caused by an insulation fault on a device
Check that electrical loads and their including a damping cage and balancing (in which case an indicator lamp comes
connections are in perfect condition. system, which allow it to handle an on), or an overload (when it does not). If an
extremely asymmetrical load. All of the overload has occurred, eliminate its cause,
Synchronous generators operate safely
other equipment required for safe electrical wait for a short time, then reset the circuit
and reliably. Before commissioning,
operation is accommodated in the directly breaker. On generators with a hinged glass
read through the safety precautions in
mounted switchbox. cover over the circuit breaker, open the
this manual carefully.
The splashproof and dustproof generator cover, grasp the breaker’s operating
* Ensure that children under the age of handle and push upwards (always in the
is driven by the engine using V-belts. Over
fourteen and animals do not have centre = yellow mark, not on one side!).
the range from no-load to nominal output,
access to the generator while it is Then carefully close the cover again, and
the voltage it supplies is controlled by a
running. tighten its knurled screws, without exerting
highly integrated electronic regulator,
* To avoid endangering people or which is fully encapsulated in the cover of force. After the circuit breaker has released
animals, or causing accidents or the switchbox, so that the output voltage due to an overload (indicator lamp off), wait
damage to the machine, always over this range complies with IEC 38 for a short time until it can be reset. The
carry out the usual checks before requirements. This standard is comparable thermal-magnetic or thermal circuit breaker
switching the generator on. with the public mains. is designed in accordance with the
machine specifications, particularly in
* There is always a risk of electric The stability of the output frequency is relation to shock and vibration resistance,
shock if a generator is used entirely dependent on that of the speed of and ambient temperature. Only use an
improperly. Never touch the the combustion engine. You must therefore original part if replacements are needed.
generator, or equipment connected ensure that this engine is serviced,
to it, with wet hands. maintained and operated properly.
* When using several generators, or if
the public mains is available, do not
interconnect these systems.
* Caution! Connecting the generator to
the public mains can damage it and
severely endanger personnel.
40
11. Generator option
11.4 Operating the generator The generator must not be used to inject The distribution systems (e.g. extension
power into a construction site distribution cables, device leads) must be carefully
(Working safely with electrical
system. chosen, laid and maintained. Check the
equipment) electrical cables regularly, replacing rather
To avoid unwanted interaction, do not
than repairing any that are faulty.
This state-of-the-art synchronous connect distribution systems with additional
generator has been designed and built insulation monitors to the generator with its To cope with the greater mechanical
with maximum safety in mind. It will help built-in equivalent. strains and stresses on the generator’s
you get the most out of your work or leisure distribution system, use rubber-sheathed
activities. However, like all electrical During insulation and voltage tests
cables to the minimum standard of
equipment, it can represent a source of carried out on the generator by trained
H07RN-F or A07RN-F in accordance with
danger (e.g. risk of electric shock) if the electricians, disconnect the insulation
DIN/VDE 0282 Part 810, or equivalent
operating instructions in this section are not monitor.
designs, as moveable (extension) cables.
followed exactly. Please observe the Because the generator is not earthed, Where the cables may be under severe
instructions and the notes on dangers fault current circuit breakers used in stress, lay them in mechanical protection
affixed to your generator. distribution systems and equipment cannot systems, or with strong covers, or
be relied upon to operate correctly when use NSSHöü cables in accordance with
Before starting the generator, all devices
such units are connected to the generator, VDE 0250.
must be unplugged and switched off. Only
plug the devices in (one after the other) and, due to the Electrical isolation with
The lengths and conductor cross sections
and switch them on after the engine driving insulation monitoring and circuit breaking
of the extension cables must match the
the generator has reached its nominal protective measure, are not actually
type of equipment and the duty.
operating speed. required.
It is essential to ensure supply cables do
Keep the glass cover over the circuit The insulation monitor and circuit breaker
not exceed the maximum lengths specified!
breaker on the front panel closed at all should be checked daily when the
When using extension cables or moveable
times. Tighten the knurled screws by hand generator is in use, following the quick
distribution systems, the sum of the lengths
to maintain IP protection. reference instructions for Testing/insulation
of all extension cables connected to a
monitoring/starting/connecting equipment
generator must not exceed 250 metres
Do not open the generator or the which are affixed to the generator.
(for a copper conductor cross section of
switchbox. The brushless synchronous
Attention 2.5 mm2 - for all sockets). The total length
design does not require maintenance.
of the extension cable, or the moveable
Do not modify the internal wiring. Devices connected the generator which distribution system, connected to any
cause the circuit breaker to release, and particular socket must not exceed 60 m
Repairs to electrical components and to
the red indicator lamp for Insulation for a copper conductor cross section of
electrical operating equipment (supply
fault to light up, must not be connected 1.5 mm2, or 100 metres for one of 2.5 mm2.
cables, loads) may only be carried out by
suitably trained electricians. to other generators (without insulation
monitoring), or to the public mains. Note
The circuit breakers, control, alarm and Have equipment with insulation faults
release devices and the insulation monitors For defined releasing of the circuit breaker,
immediately replaced or repaired by the
are specially designed for the generator a loop resistance of 1.5 Ω per socket must
manufacturer or a suitable electrical
and its sockets. Only use original spare not be exceeded.
specialist.
parts if replacements are needed. The circuit breaker must not be used for
When working in restricted conductive
The generator meets the requirements of routine switching on of the 3-phase
areas, i.e. as defined in DIN/VDE 0100 706
the Protective isolation with equipotential generator. If several devices, particularly
(e.g. in boilers), only one power tool or
bonding conductor and insulation those with different power consumption
mobile measuring instrument may
monitoring with circuit breakers regulation levels, are connected to the AC sockets,
be connected to the generator, or for
in IEC 60364-5-551 and the German Gas different voltage drops can arise,
each such load an additional isolating
Installation and Plumbing Association depending on the turn-on time of the
transformer, or one isolating transformer
(DVGW) regulation GW 308.The system is neutral.
with several secondary windings, should
an IT type, with neutral and PE be used. Handheld lights may only ever Avoid overloading the generator. In
(equipotential bonding conductor). be used in restricted conductive areas particular, to ensure user safety and
The generator does not have to be when operated off a SELV (safe extra low optimum performance, it is essential to
earthed (with a ground rod for example) to voltage) isolating transformer. observe the following rules:
ensure adequate safety protection. Many portable power tools conform to 1. Only devices whose voltage and
However, if desired or required, defined German protection class II (i.e. they are frequency data on the load identification
earthing of the generator can also be double insulated, symbol ■ ■ ). These plate conform to those on the generator
provided. devices should be used if possible. Use a identification plate may be connected.
Earthing of the neutral (N), or connecting cable and plug to connect any protection
2. Only devices whose power consumption
of the neutral to the equipotential bonding class I device (i.e. with metal housing parts
does not exceed the output specified on
conductor (PE), is prohibited on the that are not double insulated) to be used to
the generator identification plate may be
generator, the distribution system and all the PE (equipotential bonding) conductor.
used. The total power consumption of all
other devices. The use of so-called Only connect devices and distribution of the loads connected to the generator
neutralised devices is not permitted, and systems which are in good condition to the must not exceed its output.
would lead to insulation monitoring being generator. The insulation, and plug and
enabled automatically. socket combinations, must be in good
condition to ensure user safety. Do not use
any damp or dirty connectors.
41
11. Generator option
3. Note that the starting consumption of Attention * Ensure that all the devices on the
devices driven by electric engines is generator output sockets have been
generally a multiple of the specified The generator may only be used if the disconnected.
rating. If in doubt, it is advisable to circuit breaker released during the test
contact the equipment manufacturer and the indicator lamp came on until the Note
directly. reset button was pressed.
All device switches must be in the
The maximum current specified for each AUS / 0 / OFF position.
socket must not be exceeded.
Setting the range switch Danger
If normal cooling cannot be maintained,
or the operating conditions are Turn the range switch to the required
position: Unchecked devices may endanger
unacceptable in other respects, reduce personnel on startup, and may be
the consumption, rather than operating 1st position: damaged or cause damage.
the generator right up to its rating.
Compressed air and electrical power, * Start the generator.
Ideal operating conditions are: variable engine speed.
1. Ambient temperature: 25 °C Note
* Compressed air and electrical power
2. Air pressure: 100 kPa (1 bar) can be consumed up to maximum Do not load the generator until the
engine speed. engine has warmed up.
3. Relative humidity: 30% Note that engine speed is reduced in the
event of an overload. * Check that the circuit breaker is
Do not operate the generator at ambient
engaged in the ON / I position
temperatures above 40 °C, below –10 °C, * Compressed air mode without (close the glass cover).
or in direct sunlight. consumption of electric power:
More detailed instructions for operation –> engine speed matched to demand
under unfavourable conditions can be * Additional consumption of electric power
found in the combustion engine manual. –> variable engine speed is matched
to consumption automatically , up to
maximum speed
11.5 Testing insulation monitoring/ * Automatic no-load operation, i.e. the
startup/device connection engine continues to run at maximum
speed for 100 seconds, if the electrical
Testing insulation monitoring power consumption is less than 75 VA
for a brief period.
Attention
2nd position:
Do not start the generator until you have As 1st position, but with the engine Figure 34
fully read and thoroughly understood running at constant speed
the safety precautions and operating Connect the devices to the output
instructions in this manual. * Same functions as for 1st position, but sockets one after the other, ensuring
with the engine running at constant, that the current specified for each socket
During operation, check at least once a maximum speed is not exceeded, and the generator is
day that the protective measure for the not overloaded.
risk of electric shock through indirect
contact (in accordance with DIN and Switching on Note
GW 308 requirement for Protective
isolation with insulation monitoring and Turn the devices on, one after the other,
circuit breaking) is working properly. using the device switches.
If possible, plug in/switch on devices
With the engine running, carry out the with high startup currents first. Only
following test: connect suitable equipment in perfect
condition to the generator.
1. Unplug all devices connected to the
generator; open the glass cover and
switch the circuit breaker to ON/I. Switching off
2. Press the red test button. * Turn the devices off, one after the other,
3. Check whether the circuit breaker using the device switches.
releases and red the INSULATION Figure 33
FAULT indicator lamp lights up. Note
Danger
4. Press and hold down the green reset If possible, switch devices with the
button for at least 2 seconds – the red Follow safety precautions! highest current consumption off last.
indicator lamp must go out.
* Carry out the usual checks (safety * Switch the devices off one after the
5. Switch the circuit breaker to ON/I; close precautions, installation location, oil other.
the glass cover (tighten the knurled level, fuel, etc) before using the
screws by hand); the generator is now machine.
ready for use.
42
11. Generator option
43
11. Generator option
44
11. Generator option
YELLOW
GREEN
ELECTRONIC GENERATOR
6-PIN CONNECTOR
CONTACTS VIEW
YELLOW/GREEN
BLACK
FOR ISO MODULE
RESET BUTTON
TO 4 POLE
AMP PLUG
YELLOW/GREEN
MECHANICAL ON LCAR3-
OPTIONAL BROWN COUPLING TO F1 CONTROLLER VERSION 1.10
WHITE WHITE
BLACK BLACK
REGULATOR
BLUE
YELLOW/GREEN
SWITCHBOX
TOTAL LENGTH OF
EQUIPMENT SUPPLY
CABLES
∑ < 250M
EXAMPLE:
CONNECTION WITH COMPR.
WIRING HARNESS LOAD PROTECTION
INSERTION SIDE VIEW CLASS␣ I
(ALSO CLASS II/SEE
OPERATING MANUAL)
3PH Y L LOAD AC L LOAD AC L LOAD
Fig. 36
6-PIN CONNECTOR
CONTACTS VIEW
YELLOW/GREEN
POSITION 1: OPEN
POSITION 2: CLOSED
BLUE
TO 4 POLE
YELLOW/GREEN
AMP PLUG ON
MECHANICAL WLAX
BROWN
COUPLING TO F1
BROWN
BLACK
ELECTRONIC
GENERATOR
REGULATOR
CURRENT CONVERTER
ON WLAX CONTROLLER
BLUE
SWITCHBOX
TOTAL LENGTH OF
EQUIPMENT SUPPLY
CABLES
CONNECTION WITH COMPR.
∑ < 250M
WIRING HARNESS
INSERTION SIDE VIEW
EXAMPLE:
LOAD PROTECTION
CLASS␣ I
(ALSO CLASS II/SEE
OPERATING MANUAL) AC-L-LOAD AC-L-LOAD AC-L-LOAD
Fig. 37
45
11. Generator option
11.11 Troubleshooting
Sockets dead
NO NO
Connected
devices are faulty
Unplug
Does fuse
Has fuse blown? YES connected YES
still blow?
devices
NO NO
Connected
devices are faulty
Contact customer
services or
take device in for
checking
46
11. Generator option
The generator supplies no or insufficient The generator circuit breaker has tripped Check electrical load output.
voltage. due to overload or is defective.
Check that all electrical terminals are
properly seated.
Drive motor speed too low. Set to nominal speed, max. 3,100 rpm.
Compressor operating pressure set too Re-adjust the operating pressure at the
high, engine overloaded, speed decreases. adjuster.
Coil of the "Speed increase" solenoid valve Check and replace solenoid valve if
defective. required.
Complete or significant voltage drop during Insufficient engine speed or speed control Have the nominal speed adjusted by the
operation under load. inoperative. engine after-sales service max. 3,100 rpm.
The engine output has been reduced due Do not operate the generator at nominal
to climatic or other conditions. output, see the operating instructions for
the engine.
Excessive generator voltage. Excessive engine speed. Have adjusted to nominal speed.
Voltage fluctuates in short intervals. Diesel engine operates irregularly. Have checked by the engine after-sales
service.
The engine speed control operates
irregularly or is defective. Check according to the operating
instructions supplied by the engine
manufacturer.
Generator heats up to unacceptable levels. Clogged cooling air supply. Ensure that the cooling air supply is not
restricted.
Output reduction due to set-up at too high Partial load operation possible only.
an altitude.
Ambient temperature too high. The generators are designed to ensure that
no danger exists at ambient temperatures
of up to 35 °C. In higher ambient
temperature environments, the generator
may be operated at partial load only.
Danger
When operating the compressor, please
observe the general safety regulations
laid forth in the compressor operating
manual.
The heat exchanger operates fully
automatically. Operating errors at the
heat exchanger are excluded.
12.3 Maintenance/Care
This system is maintenance-free.
For information on engine oil change see
the operating instructions of the engine.
12.4 Troubleshooting
Compressed air temperature too low
Defective oil temperature regulator in
the engine or in the oil line -> replace.
Compressed air temperature too high
Defective oil temperature regulator in
the oil line -> replace.
48
13. Compressed air processing option (After cooler / Filter)
13.1 Safety regulations for alternate In an air cooler (on the cooling air intake 13.3 Maintenance instructions
side), the compressed air is cooled down
compressed air processing
to a temperature close to the prevailing
Danger
ambient air temperature downstream of the
Danger pressure vessel. A condensate separator Prior to and when carrying out
with continuous condensate discharge is maintenance and repair procedures,
When operating the compressor, please
installed downstream the air-cooler. please do observe the general safety
observe the general safety regulations
laid forth in the compressor operating regulations in chapter 3 of the
Attention compressor operating manual.
manual.
When there is a danger of freezing or
Attention
when the machine is switched off for a
13.2 Design and operation prolonged period, any remaining The filters have to be disposed of.
condensation must be drained from the
System function diagram: secondary cooler. For doing this the The post cooling systems is mainte-
see page 21, fig. 5 bottom cover of the secondary cooler nance-free. For cleaning procedures,
must be opened and it must be emptied see 9.1 „General maintenance“ in the
utilising the pressure remaining in the compressor operating manual.
After cooler option machine.
3 Post option
1 Filter option (ZTV-ING Part 3 Sec. 4) Filter change is required at latest when
A residual oil contents in the compressed a differential pressure of 400 mbar has
air of < 0.01 ppm is achieved by means of been reached or after approximately
filtering. The filter assembly consists of a 500 operating hours - depending on the
4 fine filter and an extra-fine filter. Both filters degree of contamination.
are equipped with a collecting receiver with
continuous condensate discharge. The
separated or filtered liquids are brought
2 together to a common drain.
Fig. 38 Attention
1 Filter
The oil-containing condensate has to be
2 Heat exchanger
collected. Do not allow to enter into the
3 After cooler
soil or into the drains!
4 Condensate separator
13.4 Troubleshooting
49
14. Breathing air connection option
Danger
See the separate instruction manual for
the filter unit for notes on safety and
description of function!
System function diagram:
see page 20, fig. 5
50
15. Oil temperature controller option
Danger
Please observe the general safety
regulations in the compressor manual
when operating the compressor.
Operation of the oil temperature
controller is fully automatic. Mal-
operation of the oil temperature
controller itself is impossible.
FROM TO
COOLER COMPRESSOR
(OUTLET)
FROM
PRESSURE
VESSEL
TO
COOLER
(INLET)
Figure 39
15.4 Troubleshooting
Compressed air temperature too low
Oil temperature controller in the oil line
is defective -> replace it.
51
16. Undercarriage
52
16. Undercarriage
Over-run hitches 16.5.2 Preliminary requirements: When the brake is correctly adjusted, the
actuating travel of the control cable [11] will
KNOTT over-run hitches are available for * When carrying out adjustments, always
be 5-8 mm.
both hydraulic and mechanical brakes. start with the wheel brakes.
Carry out the adjustment procedure,
Handbrake lever with power reservoir, * When carrying out adjustments, turn the
as described, on all the wheel brakes in
code „KH“ wheel only in the direction of forward
succession.
travel.
With the type “KH” the spring reservoir is
under torsion at the centre point. If the * Insert the security bolt [15] (see
handbrake is applied, then it works warning plate)! 16.5.4 Adjusting the brake
automatically and requires almost no force. compensating system
* Do not pre-tension the expanding
The system is designed so that when the
locking mechanism in the brake. If
handbrake is applied, sufficient energy is
necessary, loosen the brake linkage [6]
stored within the spring. When transmitted
at the brake compensator [8].
through the brake rods this prevents the
brake shoes from slipping away from the * Check the expanding locking
brake drum. mechanism and control cable [11]
for ease of movement.
* Pull out the drawbar [5] of the overrun- * Bowden cable [14] must not activate
system as far as it will go brake.
* Never readjust the braking system or
brakes by the brake linkage [6] or
turnbuckles (if fitted) in the linkage!
* Remove the security bolt [15]. Brake test * Check tthe bowden cable for slight play
[14]; if neccessary, adjust the cable.
* Operate the handbrake lever [3] and * Recheck the play in the brake linkage [6]
check the position of the compensating and, if necessary, readjust the linkage * Check the tension of the compression
balances [9 and 10]. They should be at [6] for length free of play ( during spring [7]
right angles to the direction of towing. operating braking with empty trailer
should be used maximally 1/2 of the
* If necessary, adjust the position of the
overrun travel )
balance [10] and control cables [11]; in 16.7 Maintenance and care
the case of tandem trailers, also adjust
the master compensator [9] on the KNOTT – overrun systems
linkage [6]. 16.6 Readjusting the braking system
* The overrun system must be lubricated
* The compression spring [7] may only be In general, readjusting the wheel brakes with lithium-soap grease by way of the
lightly pre-tensioned and must not adequately serves to readjust the braking grease nipples and at all the moving
become fully compressed when system, i.e. to compensate for brake lining parts.
activated! wear. To readjust the wheel brakes, a) every 5000 km (3000 miles)
proceed as described under 'Adjusting the b) or every 6 months
16.5.5 Adjusting the brake linkage [6] braking system'. Check the play in the c) or if they become stiff
linkage [6] and readjust if necessary.
Adjust the brake linkage [6] so that it is * Inspect the bellows for damage, replace
free of play longitudinally, without initial Attention if necessary
tension (reversing lever [4] free of play).
* Check the expanding locking * Replace the overrun shock absorber
mechanism and control cable [11] every 20,000 km (12,500 miles) or
Readjustment every 3 years at the latest.
* The expanding lock compensator
* Operate the handbrake lever [3] * Check the play at the coupling point
must not be pre-tensioned in the
powerfully several times in order to every 20,000 km (12,500 miles). If the
brake.
settle the braking system. play exceeds 3 mm, replace the guide
* Do not attempt to compensate for bearing or drawbar.
* Check the position of the brake
ease of movement caused by brake
compensating balances [9 and 10] * Check the tightening torques of the
lining wear by readjusting
which should be at right angles to the fastening screws at the guide bearing
(shortening) the brake linkage [6],
direction of towing every 5000 km (3000 miles);
e.g. by way of the linkage screw
* Check the play in the linkage [6]; if fastenings Screws with grease nipple
necessary, adjust the linkage [6] again 50 +5 Nm
so that it is free of play, but without Screws without grease nipple
Readjustment
initial tension 80 +5 Nm
* Operate the handbrake lever [3]
Slight play in the bowden cable [14] * Check the tightening torques at the
powerfully several times in order to
must persist. clamping block of the drawbar and
settle the braking system
clamping socket (drawbar tube - axle
* Check the position of the handbrake
* Check the position of the brake joint) every 5000 km (3000 miles);
lever [3];
compensating balances [9 and 10]
(which should be at right angles to the M12 screws 80 +5 Nm
when checking the dead centre of the
direction of towing). M14 screws 90 +10 Nm
lever, resistance starts 10-15 mm above
dead centre * Check that the braking system is
* Recheck the play in the linkage [6];
correctly adjusted every 5000 km
* Check that the wheels rotate freely with
if necessary, adjust the linkage [6] again (3000 miles).
the brake released.
so that it is free of play, but without
initial tension.
Vertically adjustable drawbars
Final check
* Check the positions of the handbrake
lever [3], the play in the bowden cable Clean the faces of the tooth systems free
* Check fastenings for security (secure
and compression spring [7] (only light of fretting rust or other contamination at
the hexagon locking nuts of the screw
initial tension); least once a year in order to maintain a
fastenings for the transmission system,
good fit.
control cables, brake compensators,
* when checking the dead centre of the
turnbuckle, linkage, etc.). Lubricate the threaded bolts and joints
lever, resistance starts 10-15 mm above
dead centre once a year or at any time if they become
* Check the bowden cable for slight play
stiff.
[14]; if neccessary, adjust the cable.
* Check the compression spring [7] for Final check Attention
initial tension.
* Check the screw fastenings for the Do not grease the tooth system!
transmission system (control cables,
Test run brake compensators, linkage, etc.).
* If necessary, carry out 2-3 brake tests * during operating braking with empty
trailer should be used maximally 1/2 of
the overrun travel
54
16. Undercarriage
55
16. Undercarriage
Insufficient braking effect Excessive backlash in brake system Re-adjust brake system
Brake linings glazed, oily or damaged Replace brake shoes completely; clean
braking areas in the brake drums
Brake reacts by jerks Excessive backlash in brake system Re-adjust brake system
Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders
Trailer is braked unilaterally Wheel brakes are actuated unilaterally Re-adjust brake system
Trailer is already braked when the Shock absorber of overrunning hitch Replace shock absorber
accelerator pedal is released defective
Reverse driving had to accomplish, or even Brake system adjusted too tightly Re-adjust brake system
impossible
Bowden cables pre-loaded Re-adjust brake system
Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders
Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders
Wheel brakes get hot Brake system incorrectly set Re-adjust brake system
Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders
Handbrake lever not or only partially Set handbrake lever into zero- position
released
56
16. Undercarriage
Ball coupling does not rest on ball Coupling dirty on the inside Clean and grease thoroughly
Danger
Works on the brake system may only be
carried out in specialized workshops.
When replacing braking shoes, make
sure that all brake shoes of the axle are
replaced.
When working at the wheel brakes,
make sure that the springs, the brake
shoes and the spreading lever are
correctly installed; observe the correct
sense of rotation.
When adjusting the wheel brakes, turn
wheels in forward direction!
Basically, a readjustment according to
chapter 17.5 "Fitting of the braking
system" must be effected whenever
works are carried out at the brake
system.
If the wheel brakes or the brake drum
have got very hot, continue to drive
carefully on, if possible, until they have
somewhat cooled down.
57
17. Tool oiler option
Fig. 45
Attention
Danger
Only refill the tool oiler, when the screw
compressor is out of operation and
depressurized!
Only screw off the oiler reservoir, when
the screw compressor is out of
operation and depressurized!
Do not spill any oil!
Watch out for leakage!
The oil dosage is continuously variable at
the adjusting knob.
* Turning the adjusting knob clockwise
(symbol »–«) will reduce the oil flow up
to 0-quantity (i.e. no oil for tool
lubrication in the compressed air).
* Turning the adjusting knob counterclock-
wise (symbol »+«) will increase the oil
flow.
Fig. 46
* Shut down the screw compressor and
wait until the compressor is
depressurized.
* Unscrew the screw plug.
* The oil must be visible in the oiler
reservoir; refill, if necessary (oil to be
used: CompAir AES 82).
58
CompAir Drucklufttechnik GmbH
Argenthaler Str. 11
55469 Simmern
Deutschland
www.compair.com
e-mail: sales@compair.com