C62, C76, C59-10, C58-12, C57-14

Deutz M1011FPowered Compressor

Id. Nr. 100 001 897 / 04 - März 2003

Operating Manual

GB

61

1.1 Information on the compressor

CompAir screw compressors are theproduct of many years' research anddevelopment. These preconditions,together with high quality standards,guarantee the manufacture of screwcompressors with a long service life, a highdegree of reliability and cost-effectiveoperation. The strict environmentalprotection standards have of course beencomplied with.

Confirmation of Conformity

The compressor and its accessoriesconform to the safety requirements laidout in the EC Directives 89/392 and95g368 EEC and in EN 474-1.

Fig. 1

1.2 Normal use

The compressors have been built usingthe latest techniques in design and inaccordance with recognized safetyregulations.

Nevertheless, the operator or third partiesmay be exposed to risk to life and limb inthe course of the use of the compressor(e.g. through flying pieces of buildingmaterial, swirling particles of dirt or dust,electrical current, thermal vibrations, noiseor mechanical hazards), and the machineor other tangible assets may be impaired,for reasons that could not have beenavoided through preventive constructionalsafety measures.

Hazards occur particularly when:

* The compressor is not used for itsintended purpose

* The compressor is not operated bytrained personnel

* Unauthorized changes or modificationsare carried out on the compressor

* You are not wearing the prescribedprotective clothing

* You do not comply with the safetyinstructions

* You do not observe the information inthe operating manual

For this reason every person involved inthe operation, maintenance and repair ofthe compressor must read and observethe operation manual and the safetyregulations. This is to be confirmed bysignature as required.

Furthermore, the following naturally apply:

* The relevant accident preventionregulations

* Generally recognized safety and trafficregulations

* Particular national regulations

The compressor is designed for providingcompressed air:

* For operating compressed-airappliances

* For conveying bulk material

* For sandblasting and paint-sprayingoperations

* For cleaning machines and shutteringmaterial - do not direct towards persons!

* For blow-cleaning drilled holes.

Any other use, or any additional use,for example as respiratory air, is regardedas not being for the originally intendedpurpose. The manufacturer / supplieraccepts no liability for any resultingdamage. The risk is assumed by the useralone.

The compressor may only be used ina technically perfect condition, for itsintended purpose, with appropriateawareness of safety regulations andhazards, subject to compliance with theoperating manual. In particular, faultsrepresenting safety hazards are to becorrected at once.

1. Foreword

62

1. Foreword

1.3 Specifications type DLT 0702

[kg] [kg] [mm] [mm] [mm] [bar] [dB/1 pW] [dB(A)] [dB(A)]

C 62 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 100 83 71

C 62 G 1300 1175 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

C 62 HS 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

C 76 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

C 76 G 1300 1175 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

C 59-10 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

C 59-10 G 1300 1175 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

C 58-12 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

C 57-14 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

Ambient Enginetemperature speed

min. max. No-load On-load

[m3/min] [bar] [bar] [°C] [°C] [m] [l] [kW] [rpm] [rpm] [l] [l]

C 62 6.2 7 5 - 8 -10 +50 1000 14 F4M1011F Oil 43.3 1450 2600 10 120

C 62 G 6.2 7 5 - 8 -10 +45 1000 14 F4M1011F Oil 43.3 1450 2600 10 120

C 62 HS 6.2 7 5 - 8 -10 +50 1000 14 BF4M1011F Oil 61 1650 2800 10 120+40 3000

C 76 7.6 7 5 - 8 -10 +50 1000 14 BF4M1011F Oil 61 1650 2800 10 120

C 76 G 7.6 7 5 - 8 -10 +45 1000 14 BF4M1011F Oil 61 1650 2800 10 120

C 59-10 5.9 10 5 - 10 -10 +50 1000 14 BF4M1011F Oil 61 1650 2800 10 120

C 59-10 G 5.9 10 5 - 10 -10 +45 1000 14 BF4M1011F Oil 61 1650 2800 10 120

C 58-12 5.8 12 5 - 12 -10 +45 1000 14 BF4M1011F Oil 61 1650 2800 10 120

C 57-14 5.7 14 5 - 14 -10 +45 1000 14 BF4M1011F Oil 61 1650 2800 10 120

Trad

e na

me

Del

iver

y vo

lum

e

Ope

ratin

gpr

essu

re

Pre

ssur

e ra

nge

max

. ins

talla

tion

heig

ht

Oil

fill

(com

pres

sor)

Eng

ine

Type

of c

oolin

g

Eng

ine

pow

er

Oil

fill (

engi

ne)

Fue

l tan

kca

paci

ty

3 X

3/4

" +

1 X

1 1

/2"

Trad

e na

me

Gro

ss v

ehic

lew

eigh

t rat

ing

Ope

ratin

gw

eigh

tbra

ked

Leng

th (

max

.)

Wid

th w

ithm

udgu

ard

Hei

ght

Rim

Tyre

s

Tyre

pre

ssur

e

Com

pres

sed

air

conn

ectio

ns

max

. per

mis

sibl

eno

ise

leve

l, ac

c.to

200

0/14

/EC

max

. sou

nd in

tens

ityac

c. to

PN8

NTC

2.2

at th

e op

erat

ors

loca

tion,

dist

ance

1m

max

. sou

nd in

tens

ityac

c. to

PN8

NTC

2.2

dist

ance

7m

63

1.4 Maintenance and care

Care and maintenance are all-importantif the screw compressor is to meet thedemands placed upon it. Compliance withthe prescribed maintenance intervals andcareful execution of care and maintenancework are therefore essential, especiallyunder difficult working conditions.

Service

In case of faults, or should you requirespare parts for the screw compressor,please contact your local CompAir agent.

In case of damage, the trained technicalstaff will guarantee a fast, expert repairusing CompAir spare parts. OriginalCompAir spare parts are manufacturedaccording to the state of the art andguarantee continued reliable operation.

If you have important questions,

Fig. 2

Please enter the data from the identifi-cation plate for your compressor, in thespaces above. In case of questions ororders for spare parts, please give us thecompressor type, compressor numberand the year of construction as given onthe identification plate.

If you give us this data you can be sure thatyou will be given the correct information orsent the spare parts you require.

Auftrags-Nr., order number,numéro de commande, numero d'ordine

Typ, type, modèle, tipo

Volumenstrom, flow rateflux volumique, flusso volumetrico

Stufendrücke, stages pressures,pression d'etages, pressioni degli stadi di compressione

Drehzahl, revolutions per minute,régime de rotation, numero dei giri

Installierte Motorleistung, installed engine power,puissance moteur installée, pressione di aspirazione

Ansaugdruck, intake pressure,pression d'aspiration, pressione d'aspirazione

m3/min

bar

min-1

kW

bar

max. Stützlast an Kupplung, max. tongue load at

coupling, charge d'appui à l'attelage,carico di appoggio massimo sulla frizione

Baujahr, year,année, anno

N

Handelsbezeichnung, trade name, dénominationcommerciale, denominazione commerciale

7

9

10

11

8

6

4

5

2

3

1

CompAir Drucklufttechnik GmbHWerk 55469 Simmern

1. Foreword

1.5 General information

This operating manual is to help you toget to know the compressor and to use itfor its intended applications. It containsimportant information about how to operatethe compressor safely, cost-effectivelyand with due care. Compliance with theinstructions in this manual will help to avoiddanger, reduce repair costs and downtime,and increase the reliability and service lifeof the compressor.

This operating manual is to besupplemented by instructions concerningcurrent national regulations for accidentprevention and environmental protection. Itmust always be available at the site of thecompressor. The operating manual is to beread and used by all persons in charge ofwork with the compressor, for exampleoperation, including setting up, correctingfaults during operation, disposal of wasteproducts from production, care, disposal ofprocess materials, upkeep (maintenance,inspection, repair) and transport.

Besides the operating instructions andthe current regulations applicable in theuser's country and at the sites of operationconcerning accident prevention, therecognized technical rules for safe andproper working are also to be compliedwith.

Warranty

Only use this compressor with accurateknowledge of and in compliance with thismanual.

CompAir Drucklufttechnik GmbHdo not accept responsibility for safefunctioning of the compressor for actionsthat do not correspond to normal use or forpurposes not mentioned in the manual.

Warranty claims cannot be entertained for:

* Operating errors

* Inadequate maintenance

* Incorrect fuels

* Damage caused by non-use of originalCompAir parts

* Modification of the system.

The Guarantee and Liability terms ofCompAir's General Terms and Conditionsare not extended through the aboveinstructions.

Any unauthorized modification of thecompressor system/station or theinstallation of components (e.g. fineseparators) not released by themanufacturer result in the loss of theCE symbol.

This fact results in the termination/expiration of the guarantee and warrantyclaims against the manufacturer.

Safety regulations

Danger

It is important that you follow the safetyregulations in Chapter 3 of the operatingmanual.

Technical modifications

We reserve the right to undertakemodifications without notice in the interestsof technical progress.

64

2. Index

1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1.1 Information on the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611.2 Normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611.3 Specifications type DLT 0702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621.4 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631.5 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3. Security regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.1 Identification of safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.3 Modifications and alterations to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.4 Loading / Relocation / Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673.5 Installation on site / Starting / Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673.6 Special jobs / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693.7 Instructions concerning particular hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713.8 Symbols and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4. Construction and functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784.4 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 794.5 Terminal Diagram DIN ISO 1724 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5. Transport and installation on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.2 Link up breakaway cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.3 Loading / Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.4 Installation on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6. Preparing the compressor for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

6.1 Checking oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846.1.1 Checking pressure tank oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846.1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

6.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846.3 Filling up the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846.4 Checking the air filter maintenance display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7. Putting the compressor into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

7.1 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 867.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 867.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 867.4 Setting the operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 877.5 Monitoring / fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 877.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 887.7 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 887.8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8. Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

8.1 Recommended lubricant for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908.2 Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908.3 Tool lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908.4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908.5 Recommended lubricants for the bogies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

65

9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

9.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919.2 Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919.3 Maintenance of chassis and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919.4 Compressor maintenance / Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

9.4.1 Oil filter replacement (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939.4.2 Oil change (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939.4.3 Checking the automatic monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939.4.4 Inspecting / Replacing the fine separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939.4.5 Air filter replacement (compressor / engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 949.4.6 Checking the safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 949.4.7 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 959.4.8 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 959.4.9 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

11. Generator option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9811.2 Generator safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9811.3 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9811.4 Operating the generator (Working safely with electrical equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9911.5 Testing insulation monitoring/startup/device connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10011.6 Technical characteristics of 8 kVA 400/230 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10111.7 Technical characteristics of 12 kVA 400/230 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10211.8 Technical characteristics of 7 kVA 110 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10211.9 Generator switchbox wiring diagram of 8 kVA and 12 kVA 400/230 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10411.10 Generator switchbox wiring diagram of 7 kVA 110 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10411.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

12. Heat exchanger option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

12.1 Safety regulations for the use of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10712.2 Design and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10712.3 Maintenance / Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10712.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

13. Compressed air processing option (After cooler / Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

13.1 Safety regulations for alternate compressed air processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10813.2 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10813.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10813.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

14. Breathing air connection option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

14.1 Notes on safety and description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

15. Oil temperature controller option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

15.1 Safety regulations for the use of an oil temperature controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11015.2 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11015.3 Maintenance / care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11015.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

16. Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

16.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11116.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11116.3 KHV13 height-adjustable towing system, model B 3.5.13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11116.4 Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11116.5 Adjusting the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11216.6 Readjusting the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11316.7 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11316.8 Malfunctions and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

17. Tool oiler option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

2. Index

66

3.1 Identification of safetyinstructions

CompAir accepts no responsibility forany damage or injury caused by non-compliance with these safety measures ornon-observance of normal care andcaution during the handling, operation,maintenance or repair of this compressor,even if not expressly stated in thisoperating manual.

If any of the regulations contained inthis manual do not correspond to localstatutory provisions, particularly withreference to safety, then the stricter ofthe two applies.

These safety instructions are of a generalnature and are applicable to various typesof machine and equipment. For this reasonit is possible that some information may notapply to the aggregate(s) described in thismanual.

Danger

Places thus marked refer to possibledangers for persons.

Attention

Places thus marked refer to possibledangers for machines or parts ofmachines.

Note

Places thus marked give general andtechnical information for optimum, cost-effective machine use.

3.2 General safety instructions

Organizational measures

Please keep this operating manual handyat all times on the site of the machine /installation, in the bag provided.

Please note and pass on generalstatutory and other binding regulationsthat may supplement the operatingmanual for the prevention of accidentsand the protection of the environment.Such obligations may be for example thehandling of hazardous materials, or theprovision and/or wearing of personalprotective equipment, or traffic regulations.

Instructions, including supervisoryresponsibility and duty of notification fortaking account of special in-plant factors,for example regarding work organization,sequences of operations, personnelassigned to certain tasks, are to be addedto the operating manual.

Personnel delegated to work with themachine must have read the operatingmanual before beginning this work,particularly the chapter on safetyinstructions. It is too late to do this whileworking. This applies particularly topersonnel only using the machineoccasionally, e.g. for setting up andmaintaining the machine.

Safety and danger-conscious workingby the personnel in compliance with theoperating manual should be checked atleast occasionally.

The personnel must not have long, loosehair, or wear loose clothing or jewellery,including rings, due to risk of injury throughcatching. Personal protective equipmentshould be worn if necessary or as requiredby regulations.

Pay attention to all safety and dangerwarnings on the machine/ installation!

Make sure that all safety and dangerwarnings on the machine / installation canbe read.

For all safety-relevant modifications tothe machine / installation or its operatingbehavior, stop the machine / installationimmediately and report the fault to thecompetent authority / person.

Spare parts must meet the technicalrequirements laid down by themanufacturer. This is always guaranteedwhen original spare parts are used.

Replace hydraulic hoses at the givenintervals, or at suitable intervals, even ifno safety-relevant defects are visible(DIN 20066, Part 5).

Observe the intervals stipulated or thosegiven in the operating manual for routinechecks and inspections.

Workshop equipment suitable for carryingout maintenance work is essential.

The location and operation of fireextinguishers must be made known.Observe the instructions concerning firealarm and firefighting.

Limiting values (pressure, temperature,time settings etc.) must be permanentlymarked.

Personnel selection and qualification;basic tasks

Work on or with the machine / installationmay only be carried out by reliablepersonnel. Observe the minimum statutoryage.

Only trained or specially instructedpersonnel may be assigned to this work.The responsibility of the personnel foroperating, setting up, maintaining andrepairing the machine / installation mustbe clearly defined.

Make sure that only authorized personneluse the machine.

Define who is responsible for operatingthe machine, and authorize him to ignoreinstructions from third parties if theseinstructions could compromise safety.

Only allow personnel that are training,that are under instruction or are attendinga course of general training to use themachine / installation under the constantsupervision of an experienced person.

Work on the electrical systems of themachine / installation may only be carriedout by a trained electrician in accordancewith electrical regulations.

Only persons with special knowledge andexperience of hydraulics may work onsystem elements, for example componentsunder pressure.

3.3 Modifications and alterationsto the machine

No alterations, additions, or modificationsto the machine may be carried out withoutthe approval of the manufacturer. Thisis also true for the installation and theadjustment of safety devices and valvesas well as for welding at supportingand pressurized parts. Unauthorizedmodifications to the machine are prohibitedfor reasons of safety.

Original parts are specially designed forour machines. We must explicitly point outthat parts and special accessories notsupplied by us are not approved by us.Installing or using such products may thusadversely affect active and/or passivesafety.

The manufacturer accepts no liabilitywhatsoever for damage resulting from theuse of non-original parts or specialaccessories. This also applies to theinstallation and adjustment of safetydevices and valves as well as to weldingon bearing and pressurized parts.

Note

The General Type Approval becomes inva-lid in case of modifications or alterationswhich change or infringe upon the externalgeometry as well as the gross axle weightrating.

3. Security Regulations

67

3.4 Loading / Relocation / Transport

Loading / Relocation

All loose parts that could fall down whenthe machine is lifted must first be removedor secured; pivoting parts like doors, etc.must be immobilized.

For lifting heavy parts, hoisting gear andheavy-lift facilities with the appropriatecapacities, which have been checked andapproved in accordance with local safetyregulations, must be used.

For lifting machines or parts of machineswith one or more lifting eyes, only hooksor shackles complying with local safetyregulations may be used. Never fastencables, chains or ropes to or through liftingeyes.

Lifting hooks, lifting eyes, shackles etc.must never be bent and must always bestressed in alignment with the load-carryingaxis. The load capacity of the hoisting gearis reduced if the lifting force is applied at anangle to the axis.

All bearing parts must be stressedvertically, as far as possible, for maximumsafety and optimum performance of thehoisting gear. If required, a support is to beinstalled between the hoisting gear and theload. Secure the load properly.

When heavy loads are being conveyedby means of hoisting gear, it is imperativeto keep well clear of the load in order toavoid accidents.

Never leave the load suspended on thehoisting gear.

Acceleration or braking of the means oftransport must remain within the approvedlimits.

The hoisting gear is to be set up in sucha way that the object is lifted vertically.Should this not be possible, precautionsmust be taken to prevent the load fromswinging. Thus it is possible to use twosets of hoisting gear, both with an angle ofinclination of not more than 30° to thevertical.

Nominate experienced supervisors for thelifting process.

Machines may only be hoisted correctlyusing hoisting gear in accordance with theinformation in the operating manual (limitstop points for heavy-lift facilities etc.)

Only use a suitable transport vehicle withsufficient carrying capacity.

Before or immediately after completionof loading, secure the machine / installationto prevent accidental shifting. Display anappropriate warning. Before putting themachine / installation back into operation,the securing devices must be dulyremoved.

Parts to be removed for transportpurposes must be carefully refitted andfixed again before putting the machine /installation back into operation.

When putting the machine / installationback into operation again, only proceed inaccordance with the operating manual.

Transporting the complete unit

Make sure that the air vessel is not underpressure.

Lift and secure supporting gear.

Make sure that the drawbar eye canmove freely in the tow bar.

Check to make sure that the drawbar isadjusted to the bar height of the towingvehicle.

Check to make sure that the body isclosed and locked, and that the cable forthe rapid-emergency brake is connectedto the towing vehicle.

Join up the connections of the air brake,if present.

Check to make sure that the wheels areproperly tightened, that the tyres are in aroadworthy condition, that the tyre pressureis correct and that the brakes functionproperly.

Connect the cable for the signallingand lighting fittings. Check the properfunctioning of the lighting.

Release the handbrake.

Before transporting the unit, alwayscheck to make sure that the accessoriesare firmly attached so that they can causeno accidents!

When using public roads, tracks andspaces, observe the current trafficregulations, and if necessary make theunit roadworthy first!

Never exceed the maximum towingspeed. Observe national regulations!

Always switch on lights if visibility is poorand during lighting-up time!

When going through underpasses,bridges, tunnels, overhead power lines,etc., always make sure that you haveenough clearance!

Always keep a safe distance from theedges of foundation ditches andembankments!

Do not travel across slopes transversely:always keep equipment and loads nearground level (for example, do not placethem on the bodywork).

On descents, always adapt speed to thecircumstances! Never change into low gearduring the descent, but always beforehand.When leaving the driver's seat, alwayssecure the unit to make sure that it cannotroll away or be used without authorization!

Avoid all operations that adversely affectthe stability of the unit.

3.5 Installation on site / Starting /Normal operation

Installation on site

Besides the general technical operationin accordance with the regulations of thelocal authorities, it is essential that thefollowing guidelines be observed.

Before switching on the machine /installation, or starting it up, make surethat nobody can be injured by themachine / installation as it starts up.

The installation is to be set up in such away that it is adequately accessible andthat the necessary cooling is ensured.Never block the admission of air.

The air intake is to be designed in sucha way that no dangerous admixtures(inflammable solvent vapors etc., butalso dust and other dangerous or toxicsubstances) can be taken in. This alsoapplies to flying sparks.

The air intake is to be designed in such away that no loose personal clothing can bedrawn in.

Make sure that the compressed air linefrom the compressor to the air network canexpand as a result of heat and cannotcome into contact with inflammablematerials.

The compressed air line connected at theair exit of the unit must not be under strain.

Compressed-air lines have to be markeddistinctly according to local regulations.

If several compressors are arranged in asystem, manually operated valves have tobe installed so that each machine may beshut off individually. For the purpose ofshutting off pressurized systems, youshould never rely on the effectiveness ofreturn valves alone.

Safety devices, protective covers, orinsulations mounted on the system mustnot be removed or modified in any way.

3. Security Regulations

68

All pressure tanks located outside the unitwith an approved operating pressure higherthan atmospheric pressure and fitted withtwo or more pressure feed lines must beequipped with an additional safety deviceto automatically prevent the approvedoperating pressure from being exceeded bymore than 10%.

Pipes and other parts with a surfacetemperature of more than 80 °C must besuitably secured against contact andsuitably marked.

Electrical connections must comply withlocal regulations.

With compressors fitted with generators,use equipotential bonding systems for theprotection of persons.

Install the machine so that it is ashorizontal as possible; a slight inclination ispermissible (see information in Chapter"Installation").

Set up the machine in such a way that noinlets, outlets or gates are blocked, evenwhen the doors are open.

Before disconnecting the machine fromthe towing vehicle, apply the handbrake.Disconnect the rapid-emergency brakecable and lighting cable, disconnect thelines of the air brakes, use chocks toensure that the machine does not roll away.

If a machine with a combustion enginehas to work in a fire-risk environment, theunit must be fitted with a spark catcher.

In dusty environments, set up themachine in such a way that the wind doesnot blow dust in its direction. Duringoperation in clean environments, theintervals for cleaning the air intake filterand the cooler elements are much longer.

Do not install the machine directly infront of walls. Make sure that the warm aircoming from the engine and coolingsystems is not drawn into the air intakeunder any circumstances. Drawing thiswarm air in through the engine or coolerfan could lead to overheating; if it isdrawn into the combustion chamber, thiswill result in a loss of power.

Never relocate the machine if externallines or hoses are connected to thedischarge valves, in order to avoid damageto the valves and/or collecting pipe andhoses.

No force may be exerted on thedischarge valves, for example by pullingthe hoses or fitting additional equipment(e.g. a water separator, compressed airoiler, etc.) directly to the discharge valve.

Make sure that:

* All bolted connections have beentightened

* All electrical wiring has been connectedcorrectly and is in good condition

* The engine exhaust system isoperationally safe and that noinflammable material is in the vicinity

* The wheel nuts are properly tightened;never exceed the specified torque.

Cold-starting diesel engines with etherfuel systems

The fuel used in these systems is highlyinflammable, toxic and poisonous. Avoidcontact with eyes and skin, and neverinhale vapors. Should you accidentallyswallow fuel, do not induce vomiting, butseek medical attention.

Before using the ether cold-startingsystem, please read the instructionscarefully.

Never use the ether cold-starting systemwhile the engine is running, as this canlead to serious damage.

Wear suitable eye protection wheninspecting the system. Make sure that theopenings of containers, valves, or pipes arenever directed at yourself or at any otherperson during inspection.

Never store ether containers attemperatures above 70 °C.

Normal operation

Before starting work, make yourselffamiliar with the working environment at theinstallation site. The working environmentincludes, for example, obstacles in theworking and transport areas, the carryingcapacity of the ground, and any necessarycordoning off of the building site from publictraffic areas.

Take the necessary precautions to makesure that the machine / installation is onlyoperated in a safe, functional condition.

Only operate the machine when allprotective devices, shutdown devices,sound-insulating equipment and extractionequipment is in place and working.

Be careful: loose articles of clothing, hairor limbs can still be drawn in by revolvingparts.

Verify regularly that:

* All protective equipment is properlypositioned and fixed in place

* All hoses and/or pipes within the systemare in good condition, are properly fixedin place and do not chafe

* There are no leaks (fuel, oil or coolantleaks)

* All bolted connections have beentightened

* All electrical wiring is properly connectedand is in perfect condition

* Safety valves and other pressure-reliefdevices are in perfect condition and arenot blocked, for example by dirt or paint

* The safety devices all work properly

All connected components must be ofthe correct size and be suitable for thespecified operating pressure andtemperature.

Only use the correct type and size ofhose coupling and connection.

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 canwhiplash and cause damage or injury.

Avoid any working methods that could beconsidered risky!

Never play about with compressed air.

Never direct compressed air onto the skinor towards another person.

Never use compressed air for cleaningclothing. When using compressed air toclean equipment, work with extremecaution and always wear suitable eyeprotection.

The compressed air produced by thesecompressors must not be used as breath-able air, unless it has been processedspecially for such an application inaccordance with the “Safety requirementsfor breathable air.”

When breathing apparatus with cartridgesis used, make sure that the correctcartridge has been inserted and that itsservice life has not expired.

Never use the machine in environmentswhere the possibility cannot be ruled outthat inflammable or toxic vapors may betaken in.

Never operate the system at temperaturesand/or pressures below or above the valuesindicated in the technical data sheet.

Persons working in environments orrooms in which the acoustic pressure is85 dB(A) or higher must wear ear muffs.Caution: this may impair communicationbetween persons. Warnings may not beheard. Inform supervisor.

Shieldings and doors must be closedduring operation so that the flow of cool airwithin the housing is not deflected and theefficiency of the sound-insulating is notreduced. Doors and hoods may only beopened briefly.

3. Security Regulations

69

With water-cooled combustion engineswith a closed cooling circuit, the cap of thecoolant recovery bottle must not beremoved before the system has cooleddown to ambient temperature.

Never fill up with fuel while the engine isrunning. Make sure that fuel does not comeinto contact with hot machine parts.

Do not smoke while filling up with fuel.

Filling up at a pump can cause staticelectricity and possibly sparks. In order toavoid this, a ground cable must beconnected to the system while it is beingfilled up.

The exhaust emissions of combustionengines contain carbon monoxide - a lethalgas. If a machine with such an engine hasto work in an enclosed room, the exhaustgases must therefore be conducted outof doors by means of a hose or pipe withan internal diameter of at least 100 mm.The use of extraction systems is highlyrecommended in test rooms for mobilemachines.

Before connecting or disconnectinghoses, always close the compressor airoutlet valves. Before disconnecting a hose,always make sure that it is not underpressure.

A hose connected to an air valve mustbe fitted with a safety wire for operatingpressures above 7 bars; it is in factrecommended that this safety deviceshould be used for pressures above 4 bars.The steel wire has a diameter of 8 mmand is firmly clamped to the hose at leastevery 500 mm. Both ends are fitted withcable lugs.

Check the machine / installation forexternal damage and faults at least onceper shift. Any changes noticed (includingchanges in operating performance) mustbe reported immediately to the authority orperson in charge. If necessary, shut downand secure the machine immediately.

In case of malfunction, shut down andsecure the machine / installationimmediately. Have malfunctions correctedimmediately.

Observe the operating manual for start-up and shutdown procedures as well asinspection displays.

3.6 Special jobs / Maintenance

Care

Observe the setting, maintenance, andinspection work and intervals stipulated inthe operating manual, including informationabout the replacement of parts / partialsections. This work may only be carried outby specialists.

Maintenance work, tests and repairsshould be carried out in a well ventilatedroom, away from heat, open flames, orsparks. Appropriate prohibition signs (fire,open flames, no smoking) must be put up.

Loss of oil leads to a very slippery floor.Statistics have shown that many accidentscan be attributed to the installation ormaintenance of machines on oily floors ormachine components. For this reason,always start maintenance work by cleaningthe floor and the machine exterior.

Inform operating personnel beforebeginning to carry out special work ormaintenance. Nominate a supervisor.

After completing repair work, alwayscheck to see whether any tools, looseparts or cloths have been left in or on themachine, driving engine or drivingequipment.

Maintenance and repair work is only to becarried out under the supervision of or by aperson qualified for this work.

For all work concerning the operation,production adjustment, conversion, orsettings of the machine / installation and itssafety-relevant equipment, as well asservicing, maintenance, and repair,observe the operating manual for startupand shutdown procedures and theinstructions for maintenance work.

All maintenance and repair work mayonly be carried out when the system is shutdown, or, with electrical systems, when themains power supply is switched off. Makesure that the equipment cannot beswitched on by accident.

Whenever the machine/system iscompletely powered down for maintenanceand repair procedures, it has to besecured against unintentional power-onor the mains supply has to be cut offwith electrical systems.

* Remove the ignition key, and / or

* Put up a warning sign on the mainswitch “Attention! Maintenance work.”Close off the complete maintenancearea, if required.

* Disconnect the starter battery.

Individual parts and larger subassembliesmust be carefully attached to the hoistinggear and secured in case of replacement.

Only use suitable, technically perfecthoisting gear and load suspension deviceswith adequate carrying capacity. Keep clearof suspended loads.

Before removing any part under pressure,separate the aggregate effectively fromall sources of pressure and release thepressure from the complete system.

Never use inflammable solvents orcarbon tetrachloride to clean parts.

Take precautions to avoid toxic vaporsfrom cleaning fluids.

Absolute cleanliness is essential duringmaintenance and when carrying outrepairs.

Only carry out maintenance and repairwork when the machine is located on aneven, stable base and is secured againstrunning away and against buckling.

Only carry out inspection, maintenance,and repair work when the screwcompressor system is at a standstill and isnot under pressure.

Protective devices, i. e. protective grids,may not be removed during operation.

Caution while the screw compressor is inoperation.

After the work has been completed,replace any protective devices that havebeen removed. Operation withoutprotective devices is not permissible.

Working clothing should be close-fittingduring work on running screw compressorsystems.

Maintenance

During maintenance and repair work, thecontractor has to inform the personnelabout the dangers that can occur duringtheir work and about measures to avertsuch dangers.

The personnel have to support allmeasures to improve safety at work.

Safety devices for preventing oreliminating dangers must be servicedregularly and their functioning tested atleast once per year. Faults discovered mustbe corrected at once or reported to thesupervisor.

Only use the correct tools formaintenance and repair work.

Only use original spare parts.

All maintenance and repair work mayonly be carried out when the system is shutdown, or, with electrical systems, when themains power supply is switched off. Makesure that the aggregate cannot be switchedon by accident.

3. Security Regulations

70

Whenever the machine/system iscompletely powered down for maintenanceand repair procedures, it has to besecured against unintentional power-onor the mains supply has to be cut offwith electrical systems.

* Remove the ignition key, and / or

* Put up a warning sign on the mainswitch “Attention! Maintenance work.”Close off the complete maintenancearea, if required.

* Disconnect the starter battery.

Before removing or opening any partunder pressure, separate the equipmenteffectively from all sources of pressure andrelease the pressure from the completesystem.

For moveable machines support thetowing mechanism and axle withappropriate means if work is to be carriedout underneath the units (a jack is notsufficient).

Observe the safety precautions for workon batteries.

Pay attention to cleanliness. Prevent dirtfrom entering by sealing the parts andexposed openings with a clean cloth,paper, or tape.

Before the aggregate is approved foroperation after maintenance or anoverhaul, make sure that operatingpressures, temperatures, and time settingsare correct and that the control andshutdown devices are working properly.

The electric motor, generator, air filter,electrical components and controlequipment are to be protected against thepenetration of dampness - for examplewhen cleaning with a steam jet - bycovering or sealing them.

Under no circumstances should thesound-insulating material be removed ormodified.

Never use solvents with dangerousproperties for cleaning parts.

Maintenance work, tests, and repairsshould be carried out in a well ventilatedroom, away from heat, open flames, orsparks. Appropriate prohibition signs (fire,open flames, no smoking) must be put up.

Wear suitable eye protection wheninspecting the system. Make sure that theopenings of spray containers, valves,pipes, or atomizers are never directed atyourself or at any other person during theinspection.

The fuel used in these systems is highlyinflammable, toxic and poisonous. Avoidcontact with eyes and skin, and neverinhale vapors. Should you accidentallyswallow fuel, do not induce vomiting, butseek medical attention.

Should fuel come into contact with theeyes, or in case of eye irritation by vapors,flush eyes with plenty of clean water andseek medical attention.

Every time a message is displayed orthere is a suspicion that an internal partof the machine has overheated, themachine must be shut down. Never openthe inspection cover, however, before themachine has cooled down sufficiently torule out the possibility of the oil vaporsigniting spontaneously when mixed with air.

In order to avoid an increase in operatingtemperature, inspect and clean the heattransfer surfaces (cooling ribs etc.)regularly. Draw up a schedule for the mostsuitable cleaning intervals for eachmachine.

Avoid damaging the safety valves andother pressure-reducing devices. Inparticular, make sure that they are notblocked through paint, oil carbon, ordust accumulation, which could impairthe effect of these devices.

The insulation or protective shielding ofparts whose temperature may exceed80 °C and which may accidentally betouched by personnel may not be removedbefore these parts have cooled down toroom temperature.

Check the accuracy of the pressureand temperature displays regularly. If thepermissible tolerance limits have beenexceeded, then they must be replaced.

Never carry out welding work or any otherwork that produces heat in the vicinity offuel or oil systems. Systems, which couldcontain fuel or oil, have to be completelydrained and cleaned, e.g. by means of asteam jet, before proceeding with the workto be carried out.

Never carry out any welding work on anypressure tank or components underpressure, or modify them in any way.

If work causing heat, flames, or sparkshas to be carried out on a machine, thesurrounding components must be protectedwith nonflammable material.

Before dismantling or overhauling acompressor, engine, or any other machine,make sure that no movable part with aweight of more than 15 kg can move or rollaway.

Machines whose main movement is backand forth must be moved at least once,rotating machines several times, in order tomake sure that there is no mechanicalmalfunction in the machine or in the drivingpart.

Only experienced persons may becharged with slinging loads and instructingcrane drivers. These instructors mustremain within sight of the operator or be intouch with him via walkie-talkie or similardevice.

During assembly work above bodyheight, use appropriate or otherwise safety-relevant climbing aids and workingplatforms. Do not use machine parts asclimbing aids! Wear safety belts whencarrying out maintenance work at greaterheights.

Keep all steps, handles, railings,platforms, scaffolds, and ladders free ofdirt, snow, and ice.

Before beginning maintenance andrepair, clean the machine, particularlycouplings and bolted connections, of oil,fuel, and special care products. Do not useaggressive detergents. Use lintfree clothsfor cleaning.

After cleaning, remove all covers andseals.

After cleaning, check all fuel, engine oil,and hydraulic fluid lines for leaks, looseconnections, chafing and damage. Correctany faults immediately.

Always tighten bolted connectionsloosened during maintenance and repairwork.

If it is necessary to dismantle safetydevices during machine set-up,maintenance, and repair work, the safetydevices must be reassembled and checkedimmediately after completing themaintenance and repair work.

Ensure safe, environment-friendlydisposal of process materials as well asreplaced parts. Components containing oil,for example fine separators, and oils mustbe disposed of. Oil must not enter the soil!

Safety precautions for work withbatteries

The fluid contained in batteries is dilutedsulfuric acid which can cause blindness ifbrought into contact with the eyes, orserious burns if brought into contact withthe skin. For this reason it is essential towork with the greatest of care whenservicing batteries, e.g. when checkingbattery charge, and to take all necessarysafety precautions.

3. Security Regulations

71

Always wear long-sleeved overalls, acid-resistant gloves and safety goggles.

On charging a battery, an explosive gasmixture is formed in the cells, which canescape through the vent holes in thesealing caps. If ventilation is poor, a highlyexplosive atmosphere can form around thebattery, and can persist for several hoursafter charging.

Thus:

* Never smoke in the vicinity of batteriesthat are being charged or have just beencharged.

* Put up prohibition signs for fire, openflames and smoking in workshops wherebatteries are charged.

* Never interrupt a current-carrying circuitat battery terminals because of thedanger of spark formation.

* Proceed particularly cautiously whenconnecting or disconnectingreinforcement cables or quick-chargecable clamps.

When starting up using jumper cables orauxiliary batteries, first connect the positiveterminals and then the negative terminals.After starting the engine, first disconnectthe negative terminal (ground cable) andonly then the positive terminal. Disconnectthe auxiliary battery after the startingprocedure in order to avoid the risk of therelease of gas (explosion hazard).

3.7 Instructions concerningparticular hazards

Electrical Energy

Only use original fuses with the specifiedamperage.

In case of faults in the electrical powersupply, shut down the machine / installationimmediately!

Work on electrical systems or equipmentmay only be carried out by a trainedelectrician or by trained persons under theleadership and supervision of a trainedelectrician in accordance with thestandards of electrical engineering.

Machine and system parts where service,maintenance, and repair work is beingcarried out must be switched off load, ifrequired by regulations. First check thedeenergized parts to make sure they areoff load, then connect to ground and short-circuit, and insulate neighbouring parts thatare under tension.

The electrical equipment of a machine /installation must be inspected / testedregularly. Faults, such as loose con-nections or overheated cables, must becorrected immediately.

If work has to be carried out on live parts,then call in a second person to operate theemergency stop switch or master switchwith overvoltage release. Cordon off theworking area with a red-and-white safetychain and a warning sign.

Only use insulated tools.

Keep an adequate distance between themachine/unit and overhead power lines!When working near overhead power lines,equipment must not come near the powerlines! Danger! Find out about the safedistance to be observed!

After touching high-voltage lines:

* Do not leave the machine.

* Move the machine away from thedanger area.

* Warn outsiders not to come closer ortouch the machine.

* Make sure that the voltage is switchedoff.

* Do not leave the machine until the linewhich has been touched or damaged,has been switched off load!

When working with high-voltageassemblies, ground the supply cable aftervoltage has been isolated, and short-circuit the components, e.g. capacitors,with a ground rod!

Gas, dust, steam, smoke

Only carry out welding, burning, andgrinding work on the machine / installationwhen this has been explicitly permitted, asthere may be for example risk of fire and/orexplosion.

Prior to welding, burning and grindingremove any dirt and inflammablesubstances from the machine/systemand its environment and ensure properventilation (danger of explosion)!

Only operate combustion engines inproperly ventilated rooms. Ensureventilation is adequate before starting upin closed rooms.

Follow the local regulations applicable atthe respective site of installation.

Hydraulic and pneumatic systems

Work on hydraulic equipment may onlybe carried out by persons with specialknowledge of and experience in hydraulics.

Check all lines, hoses, and boltedconnections regularly for leaks and visibledamage. Repair any damage immediately.It is essential that damaged parts should bereplaced! Spurting fluid can lead to injuriesand fires.

Before beginning repair work, relieve thepressure in system sections to be openedand in pressure lines (hydraulic andcompressed-air lines) in accordance withthe descriptions of the subassemblies.

Hydraulic and compressed-air linesmust be routed and fitted in accordancewith the regulations. Do not confuse theconnections!

The fittings, length, and quality ofhoses must be in accordance with therequirements.

Noise

Sound-insulating equipment on themachine / installation must be in operativeposition during operation.

Wear the prescribed personal ear muffs.Caution: this may impair communicationbetween persons. Warnings may not beheard. Inform supervisor.

The power of perception may becomeadversely affected by the noise and bycarrying ear protection. Warnings may,therefore, not be heard. Circumspectbehaviour by all concerned is necessary.

Noise, even when it is not very loud, canmake us nervous and irritated, and after alonger period of time our nervous systemcan suffer serious damage. For this reasona separate machine room is preferable, inorder to keep the noise from the machinesout of the workshop.

Depending on the number of machines ina machine room, the noise generated canbe very loud. Depending on the level ofsound pressure in places where people arepresent, the following precautions must betaken:

Below 70 dB(A): No special measuresrequired.

Above 70 dB(A): Persons permanentlypresent in the room mustwear ear muffs.

Below 85 dB(A): For occasional visitorswho are only in theroom briefly, no specialprotective measures arerequired.

Above 85 dB(A): Noisy room. There mustbe a warning sign atevery entrance pointingout that persons enteringthe room - even if onlybriefly - must wear earmuffs.

3. Security Regulations

72

Above 95 dB(A): The warning signs at theentrances must besupplemented by therecommendation thateven occasional visitorsmust wear ear muffs.

Above 105 dB(A):Special ear protectorsadapted to the volumeand spectral compositionof the noise must beavailable. A warning signto this effect must be putup at every entrance.

Make sure that sound propagatedthrough walls and frames does not causean excessive sound level in thesurroundings.

Oils, Greases and Other ChemicalSubstances

When handling oils, greases and otherchemical substances, observe the safetyregulations applicable for the product.

Caution when handling process materials(risk of burning / scalding).

Potentially-explosive environments

The operation of the compressor in areaswhere there is a risk of explosion is strictlyforbidden! (Exception: specially-madecompressors with the necessary technicalmodifications for use in such areas)

Note

CompAir accepts no responsibility for anydamage or injury caused by noncompliancewith these safety measures ornoncompliance with normal care andcaution during the handling, operation,maintenance or repair of this compressor,even if not expressly stated in thisoperating manual.

3.8 Symbols and definitions

Carefully read the OperatingManual before machine set-up andmaintenance.

Never attempt to operate themachine without the safety devicemounted.

Do not inhale any compressed airfrom the system.

Never attempt to operate themachine with open or looseshielding.

Attention Hot surface.

Attention Pressurized part orsystem.

Lifting spot

Tie down point

3. Security Regulations

73

Attention Hot and harmful exhaustgas.

Attention Danger of electric shock.

Do not step/stand on maintenancevalve or other parts of thepressurized system.

Attention Maintain specified tyrepressure! (See ChapterForeword, specifications.)

Protect the generator frommoisture. Do not clean with a water/vapor jet.

Attention Do not use an etheraerosol

Do not remove the Operating andMaintenance manual and manualholder from this machine.

Attention Max. permissible noiselevel (See ChapterForeword, specifications.)

3. Security Regulations

1,5BAR

74

Fuel drain

Oil filler plug

Fuel

Combined stop and emergency stopdevice

Warning: Hot surfaces.Open the body lids no earlier than 30 minutes after the safety warning hasswitched off.

A. WarningB. Parking brakeC. Correct position of the hand brake

Condensation drain:Under very humid operating conditions the condensation should bedrained from the pressure tank every 24 hours.

Pressure tank:Before topping up the oil, release all pressure and read the operatinginstructions.

3. Security Regulations

75

3. Security Regulations

Remove transportation braces before commissioning.

Before connecting the tow bar or commencing to tow consult the operatingmanual

76

4. Construction and functional description

Fig. 3

1. Screw compressor2. Instrument panel3. Pressure tank4. Oil cooler5. Oil filter (compressor)6. Air filter (compressor)7. Air filter (engine)8. Taps9. Hood

10. Fuel tank11. Battery12. Diesel engine13. Chassis14. Tool oiler15. Crane ring16. Vehicle and chassis type identification

number

4.1 Construction

Compressor and engine

The DLT 0702 series is a sound proofedmobile compressor system. The core is asingle-stage, oil-flooded screw compressor.The CompAir screw profile represents thestate-of-the-art. The air is deliveredpulsation-free.

Frame and chassis

The complete compressor unit ismounted on an easy-to-transport single-axle chassis. The chassis is equippedwith automatic overrun brakes andparking brakes, as well as a jockey wheeladjustable in height.

Airflow

Fresh air is sucked in through theadmission opening at the back of thecompressor. The air intake volume isair for the engine and for the compressortoo, as well as cooling air for the engineand for the oil cooler of the compressor.

4.2 Functional description (see fig.4)

Oil circuit

The oil required for sealing and coolingthe rotors as well as for lubricating theroller bearings is injected into thecompressor (23) from the pressure tank(13), which is under system pressure. Thedifference in pressure between thepressure tank and the oil injection positionis approx. 1 bar. The oil hereby passes theoil cooler (20) and the oil filter (19). Theintake control valve (2) is fitted with a non-return function, so that when the system isswitched off, flooding of the air filter (1) isprevented.

Air circuit

The intake air flows through the air filter(1) and the suction control valve (2) into thecompressor (23). During compression, oil isinjected in order to lubricate, cool and sealthe screw rotors. The compressed air-oilmixture flows into the pressure tank (13).Centrifugal preseparation of the oil isensured through tangential entry into thetank.

Any remaining oil is separated from theair in the fine separator.

The compressed air is fed via the Venturinozzle (11) / the pressure retention valve(option) to the compressed air discharge.The venturi nozzle (11) effectively preventsthe system pressure from falling below theminimum operating pressure required forthe system to work properly. A temperaturemonitoring device (22, 6) as well as anoperational pressure manometer areintegral parts of the air circuit.

The drive assembly is a medium-cooleddiesel engine, which drives the screwrotors of the compressor by a flexiblecoupling.

Shielding (Body)

The shielding consists of a low boxmounted on a base-frame. A cover, whichcan be opened wide for servicing is fixed tothe base-frame. The opening of the coveris effectively supported by pneumaticsprings. The hook inside is for hanging upa load suspension device. The machinerests on rubber elements to preventvibrations and noise.

For convenient assembly, all individualparts of the cover are screwed togetherwith machine screws. For the prevention ofcorrosion, the compressor body is fullygalvanised, electrostatically powder coatedand burnt at °C 220. The sound absorbingmats are inserted and easy to be cleaned.

13

9

15

4

1210

6

3

7

11

16

1

5

8

2

14

77

Regulation

Note

It is not possible to start up the compressorif there is insufficient fuel is available.

Starting up: The control function isinactive at start up, i.e. as the system rises,the engine speed is lowered to idling andthe suction throttle closed. Once the dieselengine has warmed up, the throttle/speedcontrol is activated pressing the loadbutton.

The throttle/speed control enables thevolume of air tapped (10) to be adjustedinfinitely between 0% and 100%.

The control valve (2) is connected to theengine speed control lever over a secondset cylinder. When starting, the engine isset to full load and the control valve isopen. The compressor (23) starts toproduce and pressure builds up inside thecontainer (13). When exceeding theoperating pressure the P-controller (3)feeds the set cylinder of the controller withair. Each change of the pressure at theadmission opening causes a proportionalpressure raise at the exit. This controlpressure operates the control cylinder.Over the calibrated opening of the exhaustair nozzle (5) the control air gets partly intothe atmosphere and any condensate will belet off. The throttle valve closes (throttle-type governor) and the engine speed willbe lowered (speed control). That way theair volume will be adjusted variable to therequired air. If the air output drops down tozero, the throttle valve is completely closedand the engine runs under idle runningspeed. Over the exhaust air nozzle (5) thesucked in air will be let off over a leakagecleft. When the pressure of the containerdrops down the control pressure of thecontroller drops down too; the throttle valveopens and the engine speed will increase.

When turning off the engine the backlashflap inside the controller will be closedthrough the system pressure. The releasevalve (3), which closes parallel to theengine lifting magnet, looses power andopens. The container pressure drops downto zero.

4. Construction and functional description

78

Fig. 4 135 028 74

4. Construction and functional description

4.3 System description

1. Air filter2. Intake control valve3. Control unit (proportional controller +

start-up without load)4. Release valve5. Nozzle controller6. Pressure gauge8. Oiler reservoir9. Oiler valve

10. Taps11. Venturi nozzle12. Safety valve13. Pressure tank14. Fine separator17. Orifice, evacuation line

19. Oil filter20. Oil cooler compressor21. Oil cooler engine22. Temperature switch23. Compressor24. Diesel engine27. Engine actuating cylinder29. NozzleGenerator option28. Solenoid valveGenerator with pressure reductionoption28. Solenoid valve41. Solenoid valve42. Pressure retaining non-return valveOption Heat exchanger25. Heat exchanger26. Oil temperature control

Option oil temperature control30. Oil temperature controlOption After cooler31. Cooler32. Condensate separator25. Heat exchanger26. Oil temperature control35. Backlash valve36. Extraction lever oil-free compressed airOption filter37. Filter combinationOption clean air38. Pressure control39. Activated carbon filter40. One-hand coupling

79

Fig. 5 135 033 74

4. Construction and functional description

4.4 Wiring diagram

S1 Main switchS2 Start switchS3 Signal interrupt switchS4 Engine temperature switchS5 Compressor temperature switchS6 Engine oil pressure switchS7 Fuel shortageOptional:S8 Generator automatic idling control

(optional)S9 Generator pressure reduction (optional)

Y1 Solenoid actuatorY2 Solenoid valve for pressure relief

Optional:Y3 Solenoid valve generator automatic

idling control (optional)Y4 Solenoid valve generator pressure

reduction (optional)Y5 Solenoid valve aftercooler condensation

drainage (optional)

D1 DiodeOptional:D2 Fuel shortage shut down

H1 Battery charge pilot lampH2 Fault pilot lampH3 Fuel shortage

K1 Relay - faultK2 Relay - fuel shortageK3 Relay – start-upK4 Relay – start lock

G1 Three-phase generatorG2 Battery

M1 Starter

P1 Hours of operation counter

F1 Fuse 5 AF2 Fuse 5 A (generator)

80

105 580 74

rear fog lamp

right taillamp

right indicator lamp

right stoplamp

left stoplamp

left indicator lamp

left taillamp

ground

white

black

yellow

red

green

brown

blue

Terminal Diagram DIN ISO 1724

Connector Circuit connector

blue (54 G)

brown (58 R)

green (R)

red (54)

yellow (L)

black (58 L)

white (31)

4. Construction and functional description

4.5 Terminal Diagram DIN ISO 1724

Fig. 6

The terminal diagram is designed for a voltage of 12 Volts!

81

5.1 Transport

Fig. 7

Danger

Make sure to check the torque after50 kilometers following wheel mountingand at regular intervals.

Tighten wheel nuts or screws evenly ina diagonal sequence to the specifiedtorque using a torque wrench.

Replacing the trailer coupling ring

The coupling arrangements which can beused:

* Trailer coupling ring RD 40

* Coupling 50 dia.

* Coupling ring 2" dia. (only for UK)

* Coupling ring 68 x 25 dia. (only forFrance)

A different coupling unit in the form of acomplete kit may be ordered, if necessary.Replacing the trailer coupling ring ispermitted only if proper fitting is carried outby an inspectorate for the sector coveredby the Regulations Authorizing the Use ofVehicles for Road Traffic (e.G. the TÜV -Technical Inspectorate, DEKRA - GermanMotor Vehicle Monitoring Association, etc.).The inspection station provides a fittingcertificate to be kept with the vehicledocuments.

Danger

The screw compressor may only betransported on public roads if

* The machine group (engine) is notrunning,

* The pressure tank is not underpressure,

* The shieldings are closed,

* The blocks are firmly hooked inplace,

* Hoisted and secured tail wheel,

* The tyres and brakes areoperationally safe and roadworthy,

* The lighting is fully functional.

Never exceed the maximum towingspeed! Danger! Observe nationalregulations!

Please also observe the safetyinstructions in Chapter 3 on the subjectof transporting.

Before transporting the compressor,check to make sure that the drawgear ofthe towing vehicle and the drawbar eye ortrailer hitch ball connection are alignedexactly to each other.

When transporting the screw compressorwith a vehicle, the following points must beobserved:

* The shieldings are closed.

* The blocks are firmly hooked in place.

* The support(s) is(are) retracted andlocked in position (jockey wheel).

* Tow bar connected to the towing vehicle,coupling cable connected to trailer.

* The drawbar is adjusted to the height ofthe towing vehicle.

* Connect the contact-breaking cable tothe towing vehicle. Raise and secure thesupporting device.

* Connect the electrical connecting cablebetween the vehicle and the screwcompressor.

* Check the lighting (tail lights, brake lights,indicator lamps, and rear fog lights).

* Check to make sure that the wheels areproperly tightened, the tyres are in aroadworthy condition and the tyrepressure is correct (danger ofaccidents).

When parking the compressor, use thesupport or the jockey wheel to secure thecompressor in a horizontal position. Applythe parking brake. Use chocks to ensurethat the machine does not roll away.

Attention

Always keep a safe distance from theedges of foundation ditches andembankments! Do not travel acrossslopes transversely.

5.2 Link up breakaway cable

If the towing connection becomesuncoupled, the trailer is braked by thebreakaway cable. Put the breakaway cablein the eye provided or wind it around thetowing collar and hitch it up to the cablewith the snaplink.

The breakaway cable must be attached ina way that ensures that even on extremelysharp bends there is no danger ofactivating the locking brake.

Fig. 8

5.3 Loading/Relocation

Fig. 9

Danger

Only use hoisting gear (e.g. crane) withappropriate lifting capacity for the loadsoccurring!

Only use the correct suspension gear!

Keep clear of the swiveling range of thehoisting gear!

Keep clear of suspended loads!

All loose parts that could fall downduring hoisting must first be removedor secured; pivoting parts, like doors,towbars, etc. must be secured in sucha way that they cannot move.

Never leave the load suspended on thehoisting gear. Acceleration or brakingof the means of transport must remainwithin the approved limits.

Please also observe the safetyinstructions in Chapter 3 on the subjectof loading.

Attention

Do not attempt to use a crane hook orsimilar load suspension devices directon the lifting device to avoid damagesto the lifting device!

5. Transport and installation on site

82

5. Transport and installation on site

A A A

B B

A = B = 1,5 m

B

Use proper hoisting gears only such ashoisting straps in compliance with DINstandard 61360 with proper lifting ca-pacity for connecting the loadsuspension device (e.g. crane) and thelifting device.

Only deploy load bearing equipmentwhich corresponds to the safetyinstructions for lifting gear.

Use a transport harness compliantwith local regulations for transportingby helicopter. The eyes provided maynot be used for this purpose (max.acceleration if the eyes are used = 2 x g)

Never lift up or lash down the unit usingthe shieldings!

Never relocate the machine if externallines or hoses are connected to thedischarge valves, in order to avoiddamage to the valves and/or collectingpipe and hoses.

When loading, the following points must beobserved:

* Secure the load suspension device orthe hoisting gear in the lifting device ofthe screw compressor.

* When hoisting the compressor, set upthe hoisting gear in such a way that thecompressor, which must be set uphorizontally, is lifted vertically.

* Only relocate the compressor by itself.

* Raise and lower the compressorcarefully.

* After relocating, remove the loadsuspension device or the hoisting gearfrom the lifting device.

* Tie down the compressor on the cargoarea of the means of transport.

* Only tie it down at towbar and wheelaxles.

* When the chassis is being dismantled,the shieldings with machine group mayonly be supported under the base frame.

5.4 Installation on site

Fig. 10

Danger

The air intake must be positioned insuch a way that loose personal clothingcannot be drawn in.

Make sure that the pressure pipe fromthe compressor to the aftercooler or theair system can expand as a result ofheat, and that it does not come intocontact with inflammable materials.

The air intake is to be designed in sucha way that no dangerous admixtures(inflammable solvent vapors etc.,but also other dangerous or toxicsubstances) can be taken in. This alsoapplies to flying sparks.

Pipes and other parts with a surfacetemperature of more than 80 °C must besuitably secured against contact andsuitably marked.

The operation of the compressor inareas where there is a risk of explosionis strictly forbidden! (Exception:specially-made compressors with thenecessary technical modifications foruse in such areas)

Please also note the safety instructionsin Chapter 3 on the subject ofinstallation on site.

Location

The complete system is to be set up insuch a way that it is easily accessible andthat the required cooling is guaranteed.Never block the air intake. Ensure that theentering of moisture and dirt together withthe intake air is kept to a minimum.

The compressor is to be set up awayfrom walls.

Attention

The screw compressor is to be set up insuch a way that no air reflection cantake place, i.e. neither waste air norexhaust emissions may be drawn in; thesame applies to dangerous admixturesto the air. Drawing this waste air in couldlead to overheating and a loss of power.

The compressor must be set up in ashorizontal a position as possible. Maximumpermissible inclination during operation:

* In direction of pull: 15 degrees* Backwards: 15 degrees* To the right and to the left: 15 degrees

Fig. 11

Attention

Greater inclinations endanger theoperating reliability of the screwcompressor.

When setting up the unit on ground that isnot horizontal, or with a variable angle (seeoperating instructions) please consultCompAir.

Set up the machine in such a way thatno inlets, outlets or gates are blocked,even when the doors are open. Beforedisconnecting the machine from the towingvehicle, apply the handbrake. Disconnectcontact-breaking cable and lighting cable,uncouple air brake lines.

Secure wheels with chocks.

Note

In dusty environments, set up the machinein such a way that the wind does not blowthe dust in the direction of the machine.During operation in clean environments,the intervals for cleaning the air intake filterand the cooler elements are much longer.

Attention

No force may be exerted on the dis-charge valves, for example by pullingthe hoses or fitting additionalequipment (e.g. a water separator,compressed air oiler, etc.) directly at thedischarge valve.

Temperatures/air humidity

Install the compressor in a location withmaximum possible frost protection. Thesuction air temperature must be within therange specified on the data sheet.

Attention

When the system is deployed at hightemperatures (+40 °C and above) andhigh air humidity (higher than 90 %) anoil temperature controller (optional) isrequired. For operation involving longperiods of idling and/or low partial loadsan oil temperature controller is alsorequired.

83

Altitude

For operation at an altitude above1,000 m, the compressor and engine mustbe adapted (modified design).

Note

Particularly in case of installation out ofdoors and at night, observe fuel tempera-ture. At temperatures below 0 °C, summerdiesel fuel tends to precipitate and blockthe fuel filter. In this case use winter dieselfuel.

5. Transport and installation on site

84

6.1 Checking oil levels

6.1.1 Checking the oil level in thepressure tank

Fig. 12

1 Inspection glass2 Oil filler plug

Danger

Only check the oil level when the engineis at a standstill and the compressor isnot under pressure.

The pressure tank may be underpressure and the oil may be hot.

Risk of scalding! Spill no oil!

Check for leaks.

Proceed as follows:

* Before checking the oil level in theengine and in the compressor ensurethat the vehicle is standing horizontally.

* Ensure that the screw compressor hasbeen out of operation for some time.

* Check oil level in the inspection glass

* The oil level must be in the middle of thevisible range.

* Correct as required.

Attention

After a short test run, the oil levelmust be in the middle of the visiblerange. For oil specifications, seerecommended lubricants, Chapter 8.1.

6.1.2 Checking the oil level in the engine

Fig. 13

Danger

Only check the oil level when thecompressor engine is at a standstill.Spill no oil! The oil may be hot. Riskof scalding!

Check for leaks.

Proceed as follows:

* Ensure that the screw compressor isstanding horizontally.

* Ensure that the screw compressor hasbeen out of operation for some time.

* Unscrew dipstick.

* The oil level should be as near aspossible to the upper dipstick mark.

* Correct as required.

* Screw in dipstick.

* Close oil filler.

* For oil specifications, see “EngineOperating Manual”.

Attention

After a short test run, the oil level mustnot be above or below the upper orlower dipstick marks. For oil specifi-cations, see engine instruction manual.

6.2 Battery

Fig. 14

Danger

When working with battery acid (electro-lyte), wear acid-resistant goggles,gloves and apron.

The gases released by the battery areexplosive. Avoid sparks and open firesin the vicinity of the battery.

Do not allow acids to come into contactwith skin or clothing. Wear safetygoggles.

Place no tools on the battery.

The battery is filled and charged inaccordance with DIN 43539. The battery isfastened with clamping strips.

The batteries used are ready to beinstalled and ready for service.Replacement batteries should be of thesame type as the batteries installed(low gassing). The replacement batteryshould be unfilled and only be preloadedso that it has to be filled with batteryacid. The battery and the acid shouldhave a temperature of at least +10 °C.

Proceed as follows:

* Fill up with battery acid as far as thebase of the control insert

* Leave the battery to stand for some time

* Then shake it gently

* If required, top up with acid

* Tighten sealing caps

* The battery is ready for use

* Leave for 1 hour

6.3 Filling up the fuel tank

Fig. 15

Danger

Only fill up with fuel when the screwcompressor is at a standstill.Cleanliness is essential! Spill no fuel!

Filling up at a pump can cause staticelectricity and possibly sparks.

Proceed as follows:

* Open tank lid

* Fill up tank with commercially availablebranded diesel fuel, using a sieve (usesummer or winter diesel fuel dependingon outside temperatures)

* Close tank tight with tank lid

* With the Deutz engines FM1011, theinjection pump is self-ventilating. Whenthe tank is empty, immediately fill in fuelto ensure that the fuel pump is alwaysfilled with fuel. This condition may resultin starting problems.

* Close hood.

6. Preparing the compressor for operation

2

1

85

Note

It is not possible to start up the compressorif there is insufficient fuel is available.

The fuel tank should always be filled up ingood time. For outside temperatures below0 °C, use only winter diesel fuel.

More information on fuel quality, seeengine operating manual.

For outside temperatures below 0 °C,observe the operating manual of the enginemanufacturer for winter operation.

You can reduce the occurrence ofcondensation in the fuel tank considerablyby filling it up in good time. This alsoprevents downtimes and starting problemsthat can occur when the fuel tank is rundry.

6.4 Checking the air filtermaintenance display

Fig. 16

When the red service sector in thetransparent part is fully visible, the air filteris due for maintenance. (See ChapterMaintenance, air filter replacement.)

Empty the dust emission valve bypressing together the emission slot in thedirection of the arrow.

Note

Clean the emission slot from time to time.

6. Preparing the compressor for operation

86

7.1 Initial operation

Transport inspection

Every CompAir screw compressorhas already run in the factory and hasalready undergone a thorough test beforeshipment. This test ensures that thecompressor complies with the given dataand works perfectly. Independent ofthe care taken in the factory, it is stillpossible for the compressor to be damagedduring transport. For this reason it isrecommended that the unit should beexamined for possible damage duringtransport.

Remove any transport seals (dummyflange, plugs, etc.) and dehydrating agentsbefore start-up. Distribution tubes andconnection lines must have the specifieddimensions and must be suitable for usewith the max. operating pressure and themedia to be taken up.

During the first hours of operation, thecompressor should be observed in orderto be able to ascertain any possiblemalfunctions.

Transport safety locking of the towingarrangement

Fig. 17

The towing arrangement is positionedvertically in accordance with Figure 17.The clamp must be released and thespacer removed on initial use. The towingarrangement can then be adjustedaccording to the required trailer height andlocked with the clamp/ratchet (see hereUndercarriage Operating Instructions).

7.2 Operating elements

Operating panel:

Fig. 18

1 Ignition switch2 Start / Run valve3 Hours of operation counter4 "Fault" pilot lamp5 "Fuel shortage" warning lamp6 "Battery charge" warning lamp7 Operating pressure gauge

Fig. 19

8 Compressor temperature display(optional)

7.3 Start-up

Danger

Before starting up, make sure that noone is in the danger area of the engine /screw compressor.

Compressors may not be operated inhazardous environments unless theyhave been specially designed for thispurpose (e.g. exhaust protected againstemission of flying sparks etc.).

After service work has been completed:Make sure that all protective deviceshave been refitted and that all toolshave been removed.

The exhaust emissions of combustionengines contain carbon monoxide - alethal gas. If a machine with such anengine has to work in an enclosedroom, the exhaust gases must thereforebe conducted out of doors by means ofa pipe or hose with an internal diameter

of at least 100 mm. The use of extractionsystems is highly recommended in testrooms for mobile machines.

Only operate the compressor with thehood closed. The hood may only beopened briefly for minor adjustmentswhile the compressor is running.

Skilled personnel only are authorized towork with the hood open.

When working with the screwcompressor in operation and with theshielding/hood open, wear earprotection.

Caution: this may impaircommunication between persons.Warnings may not be heard. Informsupervisor.

Attention

Opening the hood interferes with theflow of cool air in the compressorsection.

Full sound-insulating is only achievedwhen the hood is closed.

Check the oil levels in the pressure tankand in the engine of the compressoreach time before start-up.

Do not start the compressor unless theair tapping cocks are closed.

Note

It is not possible to start up the compressorif there is insufficient fuel is available.

Starting up the compressor:

* Close air tapping cocks

* Turn ingnition switch to position "On" I;the indicator lamps “Battery charge” and“Fault” come on.

* Turn the ignition switch further toposition .

* Hold the ignition switch in position until the engine starts running and the“Battery charge” and “Fault” indicatorlamps go off.

* Release the ignition switch.

* If the engine has not started after15 seconds at the latest, turn the ignitionkey back to position (Off-Aus). Assoon as the starter has reached astandstill and the pressure tank is nolonger under pressure, the engine canbe started again.

* After the start, the engine runs at theidling speed and the compressor atreduced pressure.

Transport safety locking

8

7. Putting the compressor into operation

1 2

3 4 5 6 7

87

* If the engine was started cold, let itwarm up for approximately 2 minutesand then press the START/RUN valve(2). If the engine is warm, the START/RUN valve can be pressed immediately.

* The installation is now ready to operate.Check that all the hoses and tools havebeen connected correctly and open thedesired air outlet valves.

Start-up using jumper cables / auxiliarybatteries

Fig. 20

Danger

Longer operation with an auxiliarybattery or jumper cables connected canlead to sudden emissions of gas. Aninflammable air / gas mixture is formed.Explosion hazard!

Attention

Serious damage can be caused to theelectrical system if wrongly connected.

* Ignition switch in position (Off-Aus)

* First connect positive terminal thennegative terminal (ground).

* Start as described in section “Starting upthe compressor.”

Note

After the engine has started, firstdisconnect the negative cable (ground)and then the positive cable.

Cold-starting diesel engines with etherfuel systems

Attention

For cold starts (winter operation) Start-pilot or any other starting aid may besprayed directly into the engine air filter(Attention: do not confuse this with theair filter for the screw compressor). (It isessential that the engine operatingmanual be observed.)

Never use the ether cold-starting aidwhile the engine is running, as this canlead to serious damage.

Before using the ether cold-starting aid,carefully read the instructions and the labelon the tank.

Danger

Never store the ether tank at tempera-tures above 70 °C.

Note

Follow the instructions for operating thecompressor at an ambient temperature ofless than 0 °C, in Chapter 5, Transport andInstallation on Site, in this operatingmanual.

7.4 Setting the operating pressure

Fig. 21

Danger

The setting of the operating pressuremay only be carried out by a specialist.

The operating overpressure of the screwcompressor is set by the manufacturer(see the identification plate on eachcompressor).

Pressure values between 5 or 8 bar andthe operating overpressure can be set inaccordance with the identification plate oneach compressor. Pressure values higherthan this are not permitted.

Operating pressure is set by a specialistat the controller.

* Remove counternut below the controlknob of the regulator.

* Raise pressure by turning the adjustingknob of the regulator clockwise(towards +).

* Lower the pressure by turning theadjusting knob of the regulatoranticlockwise (towards -).

* In order to lower the pressure, open anair discharge valve.

* After altering the pressure, lock theadjusting knob using the knurled nut.

This readjusted operating pressure is tobe checked using the pressure gauge onthe instrument panel at 100% air dischargeand maximum engine speed.

7.5 Monitoring / fault

Danger

Bridging the safety switch in theautomatic monitoring system is notpermitted!

The display on the pressure gauge maynot go further than the red line.

When the “Fault” indicator lamp lights up,the screw compressor is automatically shutdown when the following faults occur:

* Fuel shortage* Compressor temperature too high* Engine oil pressure too low* Engine oil temperature too high

After one of these faults, it is onlypossible to restart the machine after thefault that caused the machine to be shutdown has been corrected.

Attention

Disconnect the battery or generator onlywhen the engine is not running.

* Switch off the machine if thecompressed air transports oil spray or ifexcessive oil is consumed. (Refer to thetrouble-shooting section)

* Check that the "battery charge" pilotlamp is not illuminated. If it glows, evenweakly, refer to the trouble-shootingsection.

* Check that the air pressure (7) assumesa value within the permissible pressurerange.

If the machine cuts out, before switchingoff at the ignition switch (1) carry out thefollowing checks:

* Interrupt the electric connection to theengine oil pressure switch immediatelyafter the engine has cut out and leave itin the interrupted state.

If the "fault" pilot lamp goes outimmediately this indicates that either atoo low engine oil pressure or a lack offuel or a defective engine has led to thecut-out.

* If the light continues glowing thisindicates that an excessive enginetemperature or compressor temperatureled to the cut-out.

7. Putting the compressor into operation

88

In order to trace the origin of the fault,interrupt the engine oil temperatureswitch (with the engine oil pressureswitch still switched off). If the lamp nowgoes dark this indicates that the problemis related to the oil temperature.

* If the lamp continues glowing the faultis located somewhere else. In this casereconnect the engine oil temperatureswitch and interrupt the connection tothe compressor temperature switch. Ifthe lamp goes dark the compressortemperature has led to the cut-out.

* Reconnect all electrical connectionsonce the fault has been identified inorder to re-establish the function of theprotective elements. Also reconnectthe engine oil pressure switch.

* Switch the ignition switch to its position (Off-Aus).

Note

These checks must be carried outimmediately after the installation hascut out as the protective circuits resetthemselves after cooling down.

If the ignition switch is pushed to the veryleft while the machine is running it will beswitched off.

Pressure gauge for display: “Operatingpressure”

Fig. 22

Danger

Do not operate the compressor atpressures above the permissibleoperating pressure.

The pressure gauge shows the operatingpressure of the compressor.

The permissible operating pressure isindicated on the nameplate! The safetyvalve pressure is indicated on the pressuregauge by a red mark.

Display for compressor temperature

Fig. 23

Attention

Do not operate the compressor abovethe permissible final compressiontemperature.

The final compression temperature ismeasured with the temperature sensor anddisplayed on the thermometer (option).

The compressor is automatically shutdown when the permissible finalcompression temperature is exceeded.

7.6 Operation

Danger

Only operate the compressor at thepermissible operating pressure and atthe permissible temperature.

Only use the compressor for itsintended purpose (see Chapter 1.2 ofthis operating manual) in order to avoidresidual risk for persons and assets.

Only operate the compressor in a safe,functioning condition.

All components, hoses etc. fitted mustbe of the correct size and designed forthe specified operating pressure andtemperature.

When working with compressed air,wear suitable protective clothing (e.g.protective suit, safety goggles, etc.).

Wearing ear muffs may impaircommunication between persons.Warnings may not be heard. Informsupervisor.

Check the compressor regularly.

Leaking condensation contains aproportion of oil and must be collectedand disposed of under safe conditions.Condensation must not enter thesoil or the rivers. Major quantities ofcondensation accumulate particularlyin versions with aftercoolers forprocessing compressed air. Provide acollecting basin.

7.7 Shutdown

In order to shut down the compressor:

* Close air discharge valves. The screwcompressor reduces the speed of theengine back to idling speed after thepreset final pressure has been reached.

* Allow the screw compressor to idle for afew minutes.

* Return the ignition switch (1) to theposition (Off-Aus).

Note

This switch can also be used as anemergency stop switch. No other switchingoff method is provided.

After the installation has come to astandstill all the air is automatically blownout of the pressure tank via the blow-offvalve.

Danger

It is important that you ensure that thepressure is completely blown off via theblow-off valve.

Should this not be the case, open the airoutlet valves, identify the fault andcorrect it.

7. Putting the compressor into operation

89

7.8 Decommissioning

Fig. 24

If the system is to be closed down for alonger period of time (approx. 3 monthsor longer) the following preservationmeasures must be taken:

* Engine preservation (see separateengine operating manual).

* Disconnect battery cables.

* No special measures are required at thecompressor.

* Relieve the strain on tyres by jacking upthe vehicle.

* Check tyre pressure every 2 months.

* Release the handbrake.

Attention

When putting back into operation,carry out the maintenance workin accordance with Chapter 9“Maintenance.”

7. Putting the compressor into operation

90

8.1 Recommended lubricant forcompressor

Note

In these screw compressors, circulating oilhas not only a lubricating function, but inparticular it also has cooling and sealingfunctions. It is therefore exposed to moredifficult conditions. In particular thetemperature conditions at the installationsite and the consistency of the air (dust,dirt, and humidity content, as well aschemical influences) must be taken intoaccount when selecting a suitable lubricant.

Attention

Do not mix oils of differentspecifications.

The maintenance intervals and themaximum and minimum operatingtemperatures given in this operatingmanual only apply when high-qualitymulti-grade oils are used.

Use of the wrong oil leads to impairmentof function.

Change the compressor oil morefrequently than specified if theequipment is operated under abnormalconditions, i.e. at a high ambienttemperature, high air humidity or in adusty environment. If necessary,analyse the oil.

Out of consideration for the high loadsimposed on the lubricant in screwcompressors with oil injection cooling, werecommend the use of suitable, nonageing, non foaming, corrosion-protectiveoils. They must meet the followingrequirements for hydraulic fluids:H-LP 32 and H-LP 46 in accordance withDIN 51524, Part 2, June 1985.

The viscosity of the lubricants shouldcomply with viscosity class ISO VG 32 DIN51519, July 1976, with 28 - 35 mm2/s(cSt) /40 °C, or if the ambient temperature isconstantly above 25 °C, with viscosity classISO VG 46 DIN 51519, July 1976, with41 - 50 mm2/s(cSt)/40 °C.

Attention

Conventional engine oils marked HDmust not be used.

When using oils with the “Brief De-scription HYD 10/HYD 20" in accordancewith the ‘Standard Lubricants for BuildingMachinery and Vehicles’ published by the‘Hauptverband der Deutschen Bauindustriee.V.’ (Principal Association of the GermanBuilding Industry), only the given hydraulicfluids may be used in accordance withISO VG 32 and ISO VG 46.

If other lubricants are to be used, pleasecontact:

CompAir Drucklufttechnik GmbHArgenthaler Straße 11D-55469 Simmern/HunsrückTelephone 06761 / 832-339Telefax 06761 / 832-421

or your authorized dealer or your localbranch.

8.2 Recommended engine oil

Lubricant specifications for the drivingengine can be found in the enclosedengine operating manual.

8.3 Tool lubricants

Attention

Do not run the machine with an emptyoiler tank! The tank must alwayscontain a minimum of 0.2 l of tool oil.

The wrong tool lubricants lead todeposits that cause malfunctions in theappliances connected!

For the perfect lubrication of concretebreakers and pneumatic spades, werecommend the use of CompAir oilers orautomatic pipe oilers, using the specialsynthetic CompAir oil AES 82.

The special advantages of CompAir oil areas follows:

* Biodegradable,

* Ice guard down to -50 °C, for use withsound absorbers,

* Very good lubricity, thus wear-reducing,

* No irritating exhaust gases, work inenclosed rooms possible,

* Good cleaning effect, no residueformation

* Excellent preservation properties,protects from corrosion.

When using compressed air consumersmade by other manufacturers, then theirregulations must be observed.

8.4 Diesel fuel

Use common diesel fuel with a sulfurcontent of less than 0.5 %. If the sulfurcontent is higher, oil has to be changed atshorter intervals.

The following fuel specifications areapplicable:

* DIN 51 601

* Nato Codes F 54, F 75, and F 76* BS 2869: A1 and A2 (observe sulfur

content with A2)* ASTM D 975-81 : 1-D and 2-D* VV-F-800a : DF-A, DF-1, and DF-2.

Note

See engine instruction manual.

At low temperatures, paraffin precipitationcan cause blocks in the fuel system anddisruptions in operation. Below outsidetemperatures of 0 °C use winter diesel fuel(to -15 °C). (This is usually available at gasstations in good time before the winterseason begins.) Diesel fuel with additives isfrequently offered for use at temperaturesas low as -20 °C („Superdiesel“).

Note

Only mix in the tank. First put in therequired quantity of petroleum, then fill up.

See engine instruction manual.

Below -15 °C or -20 °C, petroleum mustbe added.

If it is necessary to use summer dieselfuel below 0 °C, petroleum can also beadded up to 60 %.

In most cases, adequate resistance tolow temperatures can be achieved byadding a product to improve flow properties(fuel additive). Consult your engine servicestation.

Attention

The compressor must not be fuelledwith bio-diesel (DIN 51606) or vegetableoil.

8.5 Recommended lubricants for thebogies

For relubrication use only lithium saponifiedgrease which fulfils the followingspecifications:

* consistency groups (NLGI) 2DIN 51818

* worked penetration 265-295DIN ISO 2137

* dripping point > 180 °CDIN ISO 2176

* operational temperature– 40 °C … +140 °C

This corresponds to a DIN 51502lubrication grease, designation KP2N-4U.

Greases with different thickeners(soap base) must not be mixed.

Recommended grease: Fuchs RenolitLZR 2.

8. Fuels

91

9.1 General maintenance

Clean the screw compressor at regular, nottoo long intervals:

* Blow-clean all valves, controllers,fittings, pressure tank, oil cooler,radiator, screw compressor, and enginewith compressed air or a steam jetappliance.

* Inspect the cooling ribs of the radiator tomake sure that air can pass through.

* Clean the body at regular intervals.Then grease or oil the hinges of thebody hood with multi-purpose grease.

If sound-absorbing matting has to bereplaced, remove the retaining brackets,replace the old sound-absorbing mattingwith new matting, replace the retainingbrackets.

9.2 Engine maintenance

The maintenance of the engine is to becarried out in accordance with the engineoperating manual.

Danger

During inspection, adjustment, ormaintenance work, remember that thesurfaces of machine parts can be hot,particularly the exhaust system (riskof burning) and that the control devicemay move during operation (risk ofcrushing).

Attention

In addition to the maintenace chartsof the KHD engine the following items ofthe engine operating instruction applyafter 50 operating hours after the start-up of new or overhauled engines:

* Check engine for leaks, repair ifnecessary

* Change engine oil

* Replace oil filter cartridge

* Changing the fuel filter cartridge andadvance fuel filter

* Check tappet clearance, adjust ifnecessary

* Check engine mounts, tighten ifnecessary

* Check V-belt, tension if necessary

Full load speed is factory-set by themanufacturer and must not be modified.

The idling speed must not be changedeither, as this might cause seriousdamage to the screw compressor, e.g.damage to the coupling!

Advance fuel filter

Fig. 25

Danger

Only change filters when the engine isat a standstill.

Do not spill fuel.

Attention

The filter changing intervals arespecified in the engine manual.

Change the advance filter more oftenif there is considerable dirt.

Note

Ensure the system is free from leakage.Check the hoses for cracks and replaceif necessary.

Dispose of contaminated filters inaccordance with the regulations.

Changing the advance fuel filter:

* Release the clamps.* Draw the ends of the hoses off.* Insert a new filter.* Fit the hose ends.* Fasten the clamps.

9.3 Maintenance of chassis andbrakes

The maintenance of the chassis and thebrakes must be carried out in accordancewith the chassis instruction manual.

Work on the brakes may only be carriedout by trained technical staff or byspecialist brake services!

Danger

During inspection, adjustment, ormaintenance work, remember that thesurfaces of machine parts can be hot,particularly the exhaust system (riskof burning) and that the control devicemay move during operation (risk ofcrushing).

9. Maintenance

92

60 h

500

h

1000

h

1500

h

2000

h

2500

h

3000

h

3500

h

4000

h

4500

h

5000

h

5500

h

6000

h

6500

h

7000

h

7500

h

8000

hOperating hours

For 2 boxes per annum: Maintenance every 500 h,although at least every 6 monthsFor 1 boxes per annum: Maintenance every 1000 h,although at least each year

Install a "Caution maintenance work" warning signand cordon off a wide area around the workplace before starting any work

Check the oil level in the diesel engine dailyCheck the oil level in the compressor dailyEmpty fuel water separator (option) daily

Check tyre pressure and wheel nuts,retighten if necessary

Adjust brake system (option) or have checked

Lubricate chassis / draw gear

Inspect safety valve

Lubricate hood hinges

Clean cooler (more frequently if used in a dusty environment)

Change oil filter in the screw compressor

Oil change (screw compressor)

Inspect automatic operational monitoring

Change fine separatorevery year or if differential pressure > 1bar

Clean air filter (screw compressor/engine)between times or renew if the red field appears Note the maintenance indicator

Clean screen of the suction-off line

Inspect control (adjustment/function)

Inspect solenoid valves

Check the battery acid level

Check clamping bolts and nuts and retighten,if necessary (chassis, frame and bodywork)

Check suspension components

Engine maintenance See the engine operating instructions for maintaining the engine

Unscrew vessel for tool oil and check inside for any corrosion. If rust is found, replace thevessel with a new, original spare part.

These maintenance intervals must be observed!

For your own benefit, put a cross on the servicing schedule against maintenance work when performed.

9.4 Compressor maintenance / Maintenance schedule

9. Maintenance

1. y

ear

2. y

ear

3. y

ear

4. y

ear

5. y

ear

6. y

ear

7. y

ear

8. y

ear

93

9.4.1 Oil filter replacement(compressor)

Fig. 26

Danger

Only replace the oil filter cartridge whenthe engine is at a standstill and thescrew compressor is not underpressure.

Caution with hot oil: risk of scalding!

Spill no oil!

Attention

Change the oil filter every 1,000 oper-ating hours, but at least once per year.

Note

Dispose of oil filter cartridge in accordancewith the relevant regulations - hazardouswaste!

Check for leaks.

Changing the oil filter:* Unscrew the oil filter cartridge using

appropriate tools

* Dispose of oil filter cartridge

* Apply a thin coat of oil to the seal of thenew oil filter cartridge

* Screw on and tighten the new oil filtercartridge (Ident-No. 048 199 74) (followthe instructions on the oil filter cartridge)

* Check for leaks

* Check oil level, add oil if necessary

9.4.2 Oil change (compressor)

Fig. 27

Danger

Only change the oil when the engine isat a standstill and the screwcompressor is not under pressure.

Caution when draining off hot oil:risk of scalding! Spill no oil!

Attention

Change the oil filter every 1,000 oper-ating hours, but at least once per year.

The screw compressor must not beunder pressure during oil change.

Drain the oil at operating temperature.

Do not mix oils of differentspecifications.

Note

Collect used oil, do not allow it to enter thesoil. Dispose of oil in accordance with therelevant regulations - hazardous waste!

Spill no oil!

Check for leaks.

Changing the oil:

* Unscrew dipstick

* Place oil drain pan under oil drain valve

* Unscrew the sealing cap of the pressurevessel

* Collect used oil in the oil drain pan

* When the used oil has been drainedcompletely, use a new sealing ring onthe sealing screw of the pressurevessel, position and tighten screw orclose the oil drain valve

* Fill up with new oil (see section"Specifications" in chapter 1 for initialoil capacity; use a little less oil whenperforming an oil change).

* For lubricants see “Lubricant Table”

* Check sealing ring on dipstick, replace ifnecessary

* Screw in and tighten dipstick

* Start screw compressor, run for approx.two minutes, check for leaks

* Switch off screw compressor

* Check oil level, add oil if necessary

9.4.3 Checking the automaticmonitoring system

Danger

Caution! High voltage! The sensors ofthe automatic monitoring system mustnot be short circuited.

Check individually every 1000 operatinghours:

1. Temperature sensor - screw compressor(pressure connection)

2. Oil pressure switch - engine

3. Oil temperature gauge - engine

Checking the automatic monitoring system:

* Disconnect connecting cable

* Connect to ground at oil temperaturegauge.

* Start screw compressor

* The automatic monitoring system mustswitch off the screw compressorimmediately after starting, and the“Fault” indicator lamp must come on.

9.4.4 Inspecting / Replacing the fineseparator

Fig. 28

1 Connection for P controller2 Connection for compressor suction line3 Oiler connection

Danger

Pressure tank is under pressure. Onlywork when the motor is at a standstilland the screw compressor is not underpressure.

Caution with hot oil: risk of scalding!Spill no oil!

9. Maintenance

1

2

3

94

Note

Dispose of fine separator in accordancewith the relevant regulations - hazardouswaste!

Check for leaks.

Replace the fine separator at least onceper year or measure the differentialpressure as follows:

* When the engine is at a standstill andthe screw compressor is not underpressure, unscrew the dipstick from thepressure tank.

* Screw in the reducing adapter.

* Screw the pressure gauge into thereducing adapter.

* Start the screw compressor.

* The difference in pressure between thepressure gauge on the pressure tankand the pressure gauge on theinstrument panel must not exceed 1 bar.

If the differential pressure is > 1 bar, thefine separator cartridge must be replaced.

* Remove all hexagon screws around thecircumference of the lid.

* Remove the lid and the old fineseparator.

* Remove the old seals from the pressurevessel, clean the sealing surface and fita new seal (part no. 931 820 00).

* Insert a new fine separator (part no.131 382 74) into the pressure vesseland fit a new seal (part no. 931 820 00).

* Fit the lid. Insert the hexagon screwsand tighten them across the diagonal(tightening torque see Chapter 9.4.9"Torque specifications").

* Check for leakage.

* Dispose of the old fine separatorcartridge in the specified manner.

9.4.5 Air filter replacement(compressor / engine)

Danger

All inspections and servicing work mustbe carried out when the engine is at astandstill and the screw compressor isnot under pressure.

Fig. 29

Note

Check the air filter every week for dust.

Every air filter is supplied with amaintenance indicator, which indicatesthe adding of the filter cartridge. Themaintenance intervals of the air filterdepend on the air pollution.

If the red field of the maintenance indicatoris visible and stays engaged when thescrew compressor is turned off, you mustexchange the air filter cartridge (at leastevery 12 months).

Replace the air filters of the screwcompressor and of the engine once yearly.

Do not clean or reuse the air filter.

Attention

Replace the safety cartridge (optional)at the latest every third time the air filterelement is replaced.

Replace air filter.

* Loosen the tensioning brackets at the airfilter and fold away.

* Remove filter hood.

* Remove filter cartridge from the filterhood.

* Remove safety cartridge (optional)from the housing.

* Replace filter cartridge.

Danger

Never clean the air filter cartridge withinflammable liquids.

9. Maintenance

Reassembling the air filter:

* Clean the sealing surface in the filterhousing.

* Insert safety cartridge (optional) andensure correct seating.

* Insert the filter cartridge and make surethat the seal is properly seated.

* Replace filter hood and fasten using thetensioning brackets (the tensioningbrackets can only be closed if the filtercartridge with seal is seated properly onthe sealing surface of the filter housing).

* Reset the maintenance indicator bypressing the reset lever.

9.4.6 Checking the safety valve

Fig. 30

Check the operation of the safety valve atleast twice a year. The check is carried outwith the system pressurised. Carefully turnthe knob anti-clockwise, until the internalpressure lifts the valve cone, releasing amixture of oil and air. Then turn the knobfully clockwise again.

In accordance with national standards,but at least once a year, carry out asuitable test to check whether the valveblows down at the correct pressure.

If the valve is not working properly,replace it immediately with a new onedesigned for the system. This type ofoperation may only be carried out bytrained personnel.

Danger

The screw compressor must not beoperated with a faulty safety valve!

A mixture of oil and air will escape whenthe valve is checked/tested.

95

9.4.7 Control

Fig. 31

The regulation is designed as continuousspeed control consisting of:

* The intake control valve,

* The engine control cylinder,

* The regulator itself.

The intake control valve comprises:

* the control piston for the volume flow-rate throttle control and acts as a checkvalve preventing flooding of the suctioncontrol valve and the air filter with oilwhen the screw compressor is switchedoff.

9.4.8 Battery maintenance

Fig. 32

Danger

The gases released by the battery areexplosive.

Avoid sparks and open fires in thevicinity of the battery.

Do not allow acids to come into contactwith skin or clothing. Wear safetygoggles.

Place no tools on the battery.

The battery is maintenance-free inaccordance with DIN.

9. Maintenance

Attention

Check the acid level after a maximumof 1,000 operating hours, or after24 months, whichever occurs first, andfill up with distilled water if necessary.

For battery maintenance please also referto the manufacturer’s instructions and theengine operating manual.

9.4.9 Torque specifications

The following torque specifications apply tothe screw connections:

Wheel screws 90 Nm

Pressure vessel cover 40 Nm

Safety valve 50 Nm

Engine bearing/rubber metal element 90 Nm

Compressor bearing/rubber metal element 90 Nm

Chassis mounting screw 90 Nm

suspension / frameproperty class 8.8 90 Nm

suspension cross girder 90 Nm

96

Problem

Insufficient or no air supply

Insufficient pressure

Compressor becomes excessively hot(automatic shutdown)

Screw compressor will not start

Possible cause(s)

Clogged air filter

Screw compressor engine speedmisadjusted

Clogged oil fine separator filter cartridge

Wrong setting at controller

Spring and plunger inside the intake controlvalve are not fully opened

Pressure control valve defective

Outflow valve dirty

Control line defective

Intake control valve defective

Wrong oil

Compressor oil level too low

Fan broken

Oil cooler dirty (outside)

Oil filter clogged

Leak in oil line

Air short circuit

No fuel

Fuel filter clogged

Fuel line loose, broken, or jammed

Operating voltage low

Electrical connection loose, corroded, orbroken

Air in system

Solenoid valve out of order

Relay defective

Starter defective

Other engine problems

Fuse defective

Switch defective

Correction

Clean air filter

Set speed

Replace compressor oil, oil filter and oil fineseparator filter cartridge

Adjust

Clean, replace parts if necessary, readjust

Repair or replace

Clean

Repair or replace

Repair or replace

Replace

Fill up with oil

Replace

Clean

Replace

Repair or replace

Repair

Fill up with fuel

Replace fuel filter cartridge

Repair line

Charge battery or replace

Replace

Extend starting operation (automaticventilation)

Replace

Replace

Replace

See engine operating manual

Replace (on the back of the instrumentpanel).

Replace

10. Troubleshooting

97

10. Troubleshooting

Problem

Oil in air line

Safety valve blows off

Oil comes out of the air filter of thecompressor after the screw compressorhas been shut down

Engine starts but switches off againimmediately, or the system switches offwhile running

Possible cause(s)

Orifice in oil return line clogged

Oil fine separator defective

Too much oil in pressure tank

Controller set too high

Pressure control valve defective

Intake control valve, control cylinder,engine, or connected control lines defective

Valve for intake control valve is missing /is defective

Safety valve defective

Intake control valve defective(backlash flap, O-ring, spring)

V-belt defective

Oil pressure switch/engine defective

Oil temperature switch defective

Engine temperature switch defective

Compressor defective

Cable defective or cable cover not pluggedonto sensor

Relay defective

Solenoid valve defective

Generator defective

Generator controller defective

Other engine problems

Correction

Repair / clean

Replace

Correct

Set

Replace or repair

Replace

Repair or replace

Replace

Check and repair

Replace

Replace

Replace

Replace

Check

Replace or plug onto sensor

Replace

Replace

Repair or replace

Repair or replace

See engine operating manual

98

11. Generator option

11.1 Introduction

This manual describes the operation andmaintenance of synchronous generatorswith switchboxes for no-load and pressurereduction.

All information relates to data available atthe time of going to press.

The manufacturer reserves the right tomake changes at any time, without priornotice or obligation. It is therefore alwaysadvisable to check for updates.

No part of this publication may bereproduced or transmitted in any form or byany means, without the prior writtenconsent of the manufacturer.

Synchronous generators may only beused as such. No other form of use ispermitted.

11.2 Generator safety precautions

Danger

Do not top up current-generating units(generators) with fuel during operation!

Follow the additional fire and explosionprotection regulations in the case ofinstallation in enclosed spaces.

Attention! Exhaust gases are toxic!Do not operate generators in non-ventilated, enclosed spaces!

Check that electrical loads and theirconnections are in perfect condition.

Synchronous generators operate safelyand reliably. Before commissioning,read through the safety precautions inthis manual carefully.

* Ensure that children under the age offourteen and animals do not haveaccess to the generator while it isrunning.

* To avoid endangering people oranimals, or causing accidents ordamage to the machine, alwayscarry out the usual checks beforeswitching the generator on.

* There is always a risk of electricshock if a generator is usedimproperly. Never touch thegenerator, or equipment connectedto it, with wet hands.

* When using several generators, or ifthe public mains is available, do notinterconnect these systems.

* Caution! Connecting the generator tothe public mains can damage it andseverely endanger personnel.

* The IP 54 protection means thegenerator is protected againstsplashes, spray and other foreignbodies. Do not, however, clean thegenerator with high-pressureequipment.

* Generators may only accept up totheir nominal load if operatedaccording to the standardtemperature range and coolingconditions specified. If installedunder different conditions, or ifcooling of the engine or generator isimpaired, for example in confinedspaces or under unfavourablecircumstances, their output must bereduced.

* Do not modify the generator/switchbox. Such changes, or the useof unsuitable parts, will invalidateapproval under machinery safetylegislation and certification toEU/EEC Directives.

11.3 Operating principle

The generator is a self-excited brushlesssynchronous internal pole generator whichis controlled electronically. It consists ofthe main machine, exciter, rotary rectifiersand generator regulator assemblies,housed in a common enclosure. The mainmachine of the synchronous 3-phasegenerators has various design features,including a damping cage and balancingsystem, which allow it to handle anextremely asymmetrical load. All of theother equipment required for safe electricaloperation is accommodated in the directlymounted switchbox.

The splashproof and dustproof generatoris driven by the engine using V-belts. Overthe range from no-load to nominal output,the voltage it supplies is controlled by ahighly integrated electronic regulator,which is fully encapsulated in the cover ofthe switchbox, so that the output voltageover this range complies with IEC 38requirements. This standard is comparablewith the public mains.

The stability of the output frequency isentirely dependent on that of the speed ofthe combustion engine. You must thereforeensure that this engine is serviced,maintained and operated properly.

If the generator is overloaded briefly (forless than the thermal response time of thecircuit breaker), or devices with excessivestartup consumption levels are connected,the regulator automatically limits theoutput/startup consumption (through theexcitation current). This leads to a (desired)withdrawal of the output voltage. Pleasetake account of this when operating severaldevices simultaneously on your generator.

Note

Switch devices (loads) on one after theother, starting with that with the leastfavourable startup characteristics.

If the generator is extremely dirty,insufficiently ventilated, or operating underotherwise unacceptable conditions, toprevent it or the regulator being damagedby overheating, the output voltage isreduced to about half its nominal value ifthe temperature inside the switchboxexceeds 80 °C. This compromises theconnected devices, which must beswitched off or unplugged immediately.Always avoid operating the generatorunder such conditions, and keep it clean(particularly fan cowl air inlets, cooling fins).

The generator is fitted with a thermal-magnetic circuit breaker, which not onlyprotects against overloads, but alsoswitches off in the event of an insulationfault on a connected device. Interruption ofpower distribution during operation may becaused by an insulation fault on a device(in which case an indicator lamp comeson), or an overload (when it does not). If anoverload has occurred, eliminate its cause,wait for a short time, then reset the circuitbreaker. On generators with a hinged glasscover over the circuit breaker, open thecover, grasp the breaker’s operatinghandle and push upwards (always in thecentre = yellow mark, not on one side!).Then carefully close the cover again, andtighten its knurled screws, without exertingforce. After the circuit breaker has releaseddue to an overload (indicator lamp off), waitfor a short time until it can be reset. Thethermal-magnetic or thermal circuit breakeris designed in accordance with themachine specifications, particularly inrelation to shock and vibration resistance,and ambient temperature. Only use anoriginal part if replacements are needed.

99

11.4 Operating the generator(Working safely with electricalequipment)

This state-of-the-art synchronousgenerator has been designed and builtwith maximum safety in mind. It will helpyou get the most out of your work or leisureactivities. However, like all electricalequipment, it can represent a source ofdanger (e.g. risk of electric shock) if theoperating instructions in this section are notfollowed exactly. Please observe theinstructions and the notes on dangersaffixed to your generator.

Before starting the generator, all devicesmust be unplugged and switched off. Onlyplug the devices in (one after the other)and switch them on after the engine drivingthe generator has reached its nominaloperating speed.

Keep the glass cover over the circuitbreaker on the front panel closed at alltimes. Tighten the knurled screws by handto maintain IP protection.

Do not open the generator or theswitchbox. The brushless synchronousdesign does not require maintenance.

Do not modify the internal wiring.

Repairs to electrical components and toelectrical operating equipment (supplycables, loads) may only be carried out bysuitably trained electricians.

The circuit breakers, control, alarm andrelease devices and the insulation monitorsare specially designed for the generatorand its sockets. Only use original spareparts if replacements are needed.

The generator meets the requirements ofthe Protective isolation with equipotentialbonding conductor and insulationmonitoring with circuit breakers regulationin DIN/VDE 0100 Part 728 §4.2.4.2.1 andthe German Gas Installation and PlumbingAssociation (DVGW) regulation GW 308.The system is an IT type, with neutral andPE (equipotential bonding conductor).

The generator does not have to beearthed (with a ground rod for example) toensure adequate safety protection.However, if desired or required, definedearthing of the generator can also beprovided.

Earthing of the neutral (N), or connectingof the neutral to the equipotential bondingconductor (PE), is prohibited on thegenerator, the distribution system and allother devices. The use of so-calledneutralised devices is not permitted, andwould lead to insulation monitoring beingenabled automatically.

The generator must not be used to injectpower into a construction site distributionsystem.

To avoid unwanted interaction, do notconnect distribution systems with additionalinsulation monitors to the generator with itsbuilt-in equivalent.

During insulation and voltage testscarried out on the generator by trainedelectricians, disconnect the insulationmonitor.

Because the generator is not earthed,fault current circuit breakers used indistribution systems and equipment cannotbe relied upon to operate correctly whensuch units are connected to the generator,and, due to the Electrical isolation withinsulation monitoring and circuit breakingprotective measure, are not actuallyrequired.

The insulation monitor and circuit breakershould be checked daily when thegenerator is in use, following the quickreference instructions for Testing/insulationmonitoring/starting/connecting equipmentwhich are affixed to the generator.

Attention

Devices connected the generator whichcause the circuit breaker to release, andthe red indicator lamp for Insulationfault to light up, must not be connectedto other generators (without insulationmonitoring), or to the public mains.Have equipment with insulation faultsimmediately replaced or repaired by themanufacturer or a suitable electricalspecialist.

When working in restricted conductiveareas, i.e. as defined in DIN/VDE 0100 706(e.g. in boilers), only one power tool ormobile measuring instrument maybe connected to the generator, or foreach such load an additional isolatingtransformer, or one isolating transformerwith several secondary windings, shouldbe used. Handheld lights may only everbe used in restricted conductive areaswhen operated off a SELV (safe extra lowvoltage) isolating transformer.

Many portable power tools conform toGerman protection class II (i.e. they aredouble insulated, symbol ). Thesedevices should be used if possible. Use acable and plug to connect any protectionclass I device (i.e. with metal housing partsthat are not double insulated) to be used tothe PE (equipotential bonding) conductor.

Only connect devices and distributionsystems which are in good condition to thegenerator. The insulation, and plug andsocket combinations, must be in goodcondition to ensure user safety. Do not useany damp or dirty connectors.

The distribution systems (e.g. extensioncables, device leads) must be carefullychosen, laid and maintained. Check theelectrical cables regularly, replacing ratherthan repairing any that are faulty.

To cope with the greater mechanicalstrains and stresses on the generator’sdistribution system, use rubber-sheathedcables to the minimum standard ofH07RN-F or A07RN-F in accordance withDIN/VDE 0282 Part 810, or equivalentdesigns, as moveable (extension) cables.Where the cables may be under severestress, lay them in mechanical protectionsystems, or with strong covers, oruse NSSHöü cables in accordance withVDE 0250.

The lengths and conductor cross sectionsof the extension cables must match thetype of equipment and the duty.

It is essential to ensure supply cables donot exceed the maximum lengths specified!When using extension cables or moveabledistribution systems, the sum of the lengthsof all extension cables connected to agenerator must not exceed 250 metres(for a copper conductor cross section of2.5 mm2 - for all sockets). The total lengthof the extension cable, or the moveabledistribution system, connected to anyparticular socket must not exceed 60 mfor a copper conductor cross section of1.5 mm2, or 100 metres for one of 2.5 mm2.

Note

For defined releasing of the circuit breaker,a loop resistance of 1.5 Ω per socket mustnot be exceeded.

The circuit breaker must not be used forroutine switching on of the 3-phasegenerator. If several devices, particularlythose with different power consumptionlevels, are connected to the AC sockets,different voltage drops can arise,depending on the turn-on time of theneutral.

Avoid overloading the generator. Inparticular, to ensure user safety andoptimum performance, it is essential toobserve the following rules:

1. Only devices whose voltage andfrequency data on the load identificationplate conform to those on the generatoridentification plate may be connected.

2. Only devices whose power consumptiondoes not exceed the output specified onthe generator identification plate may beused. The total power consumption of allof the loads connected to the generatormust not exceed its output.

11. Generator option

100

3. Note that the starting consumption ofdevices driven by electric engines isgenerally a multiple of the specifiedrating. If in doubt, it is advisable tocontact the equipment manufacturerdirectly.

The maximum current specified for eachsocket must not be exceeded.

If normal cooling cannot be maintained,or the operating conditions areunacceptable in other respects, reducethe consumption, rather than operatingthe generator right up to its rating.

Ideal operating conditions are:

1. Ambient temperature: 25 °C

2. Air pressure: 100 kPa (1 bar)

3. Relative humidity: 30%

Do not operate the generator at ambienttemperatures above 40 °C, below –10 °C,or in direct sunlight.

More detailed instructions for operationunder unfavourable conditions can befound in the combustion engine manual.

11.5 Testing insulation monitoring/startup/device connection

Testing insulation monitoring

Attention

Do not start the generator until you havefully read and thoroughly understoodthe safety precautions and operatinginstructions in this manual.

During operation, check at least once aday that the protective measure for therisk of electric shock through indirectcontact (in accordance with DIN andGW 308 requirement for Protectiveisolation with insulation monitoring andcircuit breaking) is working properly.

With the engine running, carry out thefollowing test:

1. Unplug all devices connected to thegenerator; open the glass cover andswitch the circuit breaker to ON/I.

2. Press the red test button.

3. Check whether the circuit breakerreleases and red the INSULATIONFAULT indicator lamp lights up.

4. Press and hold down the green resetbutton for at least 2 seconds – the redindicator lamp must go out.

5. Switch the circuit breaker to ON/I; closethe glass cover (tighten the knurledscrews by hand); the generator is nowready for use.

Attention

The generator may only be used if thecircuit breaker released during the testand the indicator lamp came on until thereset button was pressed.

Setting the range switch

Turn the range switch to the requiredposition:

1st position:

Compressed air and electrical power,variable engine speed.

* Compressed air and electrical powercan be consumed up to maximumengine speed.Note that engine speed is reduced in theevent of an overload.

* Compressed air mode withoutconsumption of electric power:–> engine speed matched to demand

* Additional consumption of electric power–> variable engine speed is matchedto consumption automatically, up tomaximum speed

* Automatic no-load operation, i.e. theengine continues to run at maximumspeed for 100 seconds, if the electricalpower consumption is less than 75 VAfor a brief period.

2nd position:

As 1st position, but with the enginerunning at constant speed

* Same functions as for 1st position, butwith the engine running at constant,maximum speed

3rd position(only for 8 kVA and 12 kVA)

Fuel economy modeElectrical power/no compressed air,variable engine speed

* Electrical power only

* No air consumption possible

* Compressor pressure relieved, i.e. lowerfuel consumption due to the reducedpower consumption of the compressor(only about 12 kVA)

* When electrical power being consumed–> engine speed is matched toconsumption automatically, up tomaximum speed

* Automatic no-load operation, i.e., theengine continues to run at maximumspeed for 100 seconds, if the electricalpower consumption is less than 75 VAfor a brief period.

4th position (only for 8 kVA and 12 kVA)

As 3rd position, with the engine runningat constant speed

* Same functions as described for 3rdposition, but with the engine running atconstant, maximum speed

Switching on

Figure 33

Danger

Follow safety precautions!

* Carry out the usual checks (safetyprecautions, installation location, oillevel, fuel, etc) before using themachine.

* Ensure that all the devices on thegenerator output sockets have beendisconnected.

Note

All device switches must be in theAUS / 0 / OFF position.

Danger

Unchecked devices may endangerpersonnel on startup, and may bedamaged or cause damage.

* Start the generator.

Note

Do not load the generator until theengine has warmed up.

* Check that the circuit breaker isengaged in the ON / I position(close the glass cover).

Figure 34

11. Generator option

101

Connect the devices to the outputsockets one after the other, ensuringthat the current specified for each socketis not exceeded, and the generator isnot overloaded.

Note

Turn the devices on, one after the other,using the device switches.

If possible, plug in/switch on deviceswith high startup currents first. Onlyconnect suitable equipment in perfectcondition to the generator.

Switching off

* Turn the devices off, one after the other,using the device switches.

Note

If possible, switch devices with thehighest current consumption off last.

* Switch the devices off one after theother.

Note

Ensure the covers of unused socketsare closed again properly.

Figure 35

* Allow the engine to continue running forabout 2 minutes, so that the generatorcools down.

* Stop the generator.

11.6 Technical characteristics of8 kVA 400/230 V generator

Generator model . . . . . . GTS-DWG8/5-2-ZE

Generator type . . . . . . . Synchronous,internal pole

Generator frame . . . . . . B3/two bearingsDegree of protection . . . IP 54

11. Generator option

Generator characteristics:Extremely low dynamic internal resistance,same output voltage whether hot or cold,no dangerous overvoltage during dynamicoverspeed, small reactive effect from non-linear or very inductive equipment, trouble-free operation of equipment with phasecontrol, no dangerous overvoltage of theunloaded phases, load current may havesignificant DC components

Power system(IEC 38/50Hz) . . . . . . . . 3-phase AC

400V/230V

Amplified phases . . . . . . 3

Nominal output (0.8 cap/ind)single-phase . . . . . . . . . 5000VA3-phase (sym) . . . . . . . . 8000VANominal currentsingle-phase . . . . . . . . . 21.6A3-phase (sym) . . . . . . . . 11.5AStartup current . . . . . . . 4.1 times Irated

Operating mode . . . . . . S1, continuousProtective measure . . . . Electrical

isolation, withequipotentialbondingconductor inaccordance withVDE 0100.728

Coolant . . . . . . . . . . . . . Air/externallyventilated withown fan, inde-pendent ofdirection ofrotation

Permissible speed range 0 to 4000 rpmSpeed for nominal output 3000 to 4000 rpm

Efficiency at nominal outputat 0.8 ind . . . . . . . . . . . . 0.80at 1.0 . . . . . . . . . . . . . . . 0.82

Distortion factor . . . . . . . < 5%Weight . . . . . . . . . . . . . . 53 kgOverall size . . . . . . . . . . BG132Overall length . . . . . . . . 426 mm

Generator regulatorModel . . . . . . . . . . . . . . LCAR 3Connector assignment

Pin Colour Function1 red F12 grey F23 violet 1/2 U4 violet 1/2 V5 violet 1/2 W

SwitchboxDegree of protection . . . IP 54Dimensions . . . . . . . . . . 211x311x135Design . . . . . . . . . . . . . . Front panel typeFusing . . . . . . . . . . . . . . All poles

L1 . . . B16AL2 . . . B16AL3 . . . B16AN . . . . leading N

Insulation monitoringModel . . . . . . . . . . . . . . GMW-RISO1.0Controls . . . . . . . . . . . . . Red test button

Green resetbutton

Electronic evaluation systemModel . . . . . . . . . . . . . . LLA1.0xPower supply . . . . . . . . self-powered

230VPower loss . . . . . . . . . . . < 15WPermissible load current 0 – 26.1AActivation of speedreduction . . . . . . . . . . . . < about 75 WTime to reduce speed . . 100 seconds

OutputsFor speed reduction . . . Floating two-way

contact withneutral position

For pressure reduction . Floating two-waycontact withneutral position

Max. switching voltage . 60V DC250V AC

Max. current . . . . . . . . . 7APower . . . . . . . . . . . . . . 170W DC

1750VA ACMin. switching load . . . . 0.1A DC

5V DC

Range switchType . . . . . . . . . . . . . . . 4-positionMax. voltage atswitching contacts . . . . . 54V (DC)Measurement referencepotential . . . . . . . . . . . . N

Generator dataWinding Colour Ins. class Resistance

(at 20°C)/Ω

U-N brown-blue F 0.48V-N white-blue F 0.48W-N black-blue F 0.481F1-1F2 red-grey H 22.5

(All resistances measured using the 4-wireR method)

102

11. Generator option

11.7 Technical characteristics of12 kVA 400/230 V generator

Generator model . . . . . . GTS-DWG (BL4)13/6-2-ZE

Generator type . . . . . . . Synchronous,internal pole,brushless withexciter,electronicallycontrolled

Generator frame . . . . . . B3/two bearingsDegree of protection . . . IP 54

Generator characteristics:Extremely low dynamic internal resistance,same output voltage whether hot or cold,no dangerous overvoltage during dynamicoverspeed, small reactive effect from non-linear or very inductive equipment, trouble-free operation of equipment with phasecontrol, no dangerous overvoltage of theunloaded phases, load current may havesignificant DC components

Power system(IEC 38/50Hz) . . . . . . . . 3-phase AC

400V/230V

Amplified phases . . . . . . 3

Nominal output (0.8 cap/ind)single-phase . . . . . . . . . 6000VA3-phase (sym) . . . . . . . . 12000VANominal currentsingle-phase . . . . . . . . . 26.1A3-phase (sym) . . . . . . . . 18.9AStartup current . . . . . . . 4.1 times Irated

Operating mode . . . . . . S1, continuousProtective measure . . . . Electrical

isolation, withequipotentialbondingconductor inaccordance withVDE 0100.728

Coolant . . . . . . . . . . . . . Air/externallyventilated withown fan, inde-pendent ofdirection ofrotation

Permissible speed range 0 to 4000 rpmSpeed for nominal output 3000 to 4000 rpm

Efficiency at nominal outputat 0.8 ind . . . . . . . . . . . . 0.80at 1.0 . . . . . . . . . . . . . . . 0.82

Distortion factor . . . . . . . < 5%Weight . . . . . . . . . . . . . . 64.4 kgOverall size . . . . . . . . . . BG132Overall length . . . . . . . . 508 mm

Generator regulatorModel . . . . . . . . . . . . . . LCAR 3 BLConnector assignment

Pin Colour Function1 red F12 grey F23 violet 1/2 U4 violet 1/2 V5 violet 1/2 W

SwitchboxDegree of protection . . . IP 54Dimensions . . . . . . . . . . 211x311x135Design . . . . . . . . . . . . . . Front panel typeFusing . . . . . . . . . . . . . . All poles

L1 . . . B16AL2 . . . B16AL3 . . . B16AN . . . . leading N

Insulation monitoringModel . . . . . . . . . . . . . . GMW-RISO1.0Controls . . . . . . . . . . . . . Red test button

Green resetbutton

Electronic evaluation systemModel . . . . . . . . . . . . . . LLA1.0xPower supply . . . . . . . . self-powered

230VPower loss . . . . . . . . . . . < 15WPermissible load current 0 – 26.1AActivation of speedreduction . . . . . . . . . . . . < about 75 WTime to reduce speed . . 100 seconds

OutputsFor speed reduction . . . Floating two-way

contact withneutral position

For pressure reduction . Floating two-waycontact withneutral position

Max. switching voltage . 60V DC250V AC

Max. current . . . . . . . . . 7APower . . . . . . . . . . . . . . 170W DC

1750VA ACMin. switching load . . . . 0.1A DC

5V DC

Range switchType . . . . . . . . . . . . . . . 4-positionMax. voltage atswitching contacts . . . . . 54V (DC)Measurement referencepotential . . . . . . . . . . . . N

Generator dataWinding Colour Ins. class Resistance

(at 20°C)/Ω

U-N brown-blue F 0.28V-N white-blue F 0.28W-N black-blue F 0.281/2 U-N yellow-blue 0.141/2 V-N yellow-blue 0.141/2 W-N yellow-blue 0.141F1-1F2 red-grey H 22.12U1-2U2 H 5.42F1-2F2 red-grey F 22.4

(All resistances measured using the 4-wireR method)

11.8 Technical characteristics of7 kVA 110 V generator

Generator model . . . . . . WG 7/5-2Generator type . . . . . . . Synchronous,

internal pole,electronicallycontrolled

Generator frame . . . . . . B3/two bearingsDegree of protection . . . IP 54

Generator characteristics:Extremely low dynamic internal resistance,same output voltage whether hot or cold,no dangerous overvoltage during dynamicoverspeed, small reactive effect from non-linear or very inductive equipment, trouble-free operation of equipment with phasecontrol, no dangerous overvoltage of theunloaded phases, load current may havesignificant DC components

Power system(IEC 38/50Hz) . . . . . . . . 1-phase AC

2 x 115V

Amplified phases . . . . . . 3

Nominal output(0.8 cap/ind) . . . . . . . . . 7000VANominal current . . . . . . . 32A + 2 x 16AStartup current . . . . . . . 4.1 times Irated

Operating mode . . . . . . S1, continuousProtective measure . . . . Electrical

isolation, withequipotentialbondingconductor inaccordance withVDE 0100.728

Coolant . . . . . . . . . . . . . Air/externallyventilated withown fan, inde-pendent ofdirection ofrotation

Nominal speed fornominal frequency . . . . . 3000 rpmMin. speed fornominal output . . . . . . . 3000 rpm

103

11. Generator option

Efficiency at nominal outputat 0.8 ind . . . . . . . . . . . . 0.80at 1.0 . . . . . . . . . . . . . . . 0.82

Distortion factor . . . . . . . < 5%Weight . . . . . . . . . . . . . . 53 kgOverall size . . . . . . . . . . BG132Overall length . . . . . . . . 357 mm

Generator regulatorModel . . . . . . . . . . . . . . WLAxConnector assignment8 pole Pin Colour Function

1 red F12 grey F23 not assigned4 yellow ZU5 yellow ZV6 yellow ZW7 brown L18 blue N

4-pole 1 black switch contact2 black switch contact3 not assigned4 not assigned

SwitchboxDegree of protection . . . IP 54Dimensions . . . . . . . . . . 211x311x135Design . . . . . . . . . . . . . . Front panel typeFusing . . . . . . . . . . . . . . All poles

U1 . . . C32AU2 . . . 2 x 16A

Insulation monitoringModel . . . . . . . . . . . . . . GMW-RISO1.0Controls . . . . . . . . . . . . . Red test button

Green resetbutton

Areas of applicationengines difficult to get running, weldingdevices (incl. inverters), pumps,compressors, tools, constructionmachinery, illumination

Generator dataWinding Colour Ins. class Resistance

(at 20°C)/Ω

U1-N brown-blue F 0.165U2-N black-blue F 0.165W-N black-blue F 0.28ZU-ZN yellow-yellow F 2.5ZV-ZN yellow-yellow F 2.5ZW-ZN yellow-yellow F 2.51F1-1F2 red-grey H 22.1

(All resistances measured using the 4-wireR method)

104

11. Generator option

11.9 Generator switchbox wiring diagram 8 KVA and 12 KVA 400/230 V

Fig. 36

11.10 Generator switchbox wiring diagram 7 KVA 110 V

Fig. 37

ELEC

TRON

IC G

ENER

ATOR

REG

ULAT

OR F

OR B

RUSH

-LE

SS S

YNCH

RONO

US G

ENER

ATOR

PROTECTIVE ISOLATION WITH INSULATION MONITORINGAND FUSING/CIRCUIT BREAKING FOR ALL POLES

K = OPERATING CURRENT CIRCUIT BREAKERH =INSULATION FAULT INDICATOR LAMPR = GMW/ISO INSULATION MONITORP = TEST BUTTON

RESE

T BU

TTON

FOR

ISO

MOD

ULE

OPTIONAL

6-PIN CONNECTORCONTACTS VIEW

YELLOWGREYPINK

COLOURS FOR PROGRAMVERSION 1.022

YELLOW/GREEN

GREEN

YELL

OWGR

EEN

ELEC

TRON

IC G

ENER

ATOR

REGU

LATO

R

ELECTRONIC EVALUATIONSYSTEM, SWITCHESAND 6-PIN CONNECTOR,OPTIONAL

GREYYELLOWGREENBROWNWHITE

BLAC

K

BROW

N WHITE

BROWN

WHITE

BLACK

BLUE

YELLOW/GREEN

ELECTRONICEVALUATIONSYSTEM

PRESSURE

AUTO NO-LOAD

BROW

N

YELL

OW/G

REEN

BLUE

OPTIONAL, EXTERNAL PE CONNECTION

ATTENTION:TRIP-FREE RELEASING OFALL CIRCUIT BREAKERSCOUPLED

EVALUATION CARD

POWER SUPPLYAUTOMATIC NO-LOAD OPERATIONPRESSURE REDUCTION

SWITCHBOX

TOTAL LENGTH OFEQUIPMENT SUPPLYCABLES

∑ < 250M

EXAMPLE:

LOAD PROTECTIONCLASS I(ALSO CLASS II/SEEOPERATING MANUAL)

CONNECTION WITH COMPR.WIRING HARNESSINSERTION SIDE VIEW

YELL

OW/G

REEN

BROWN

WHITE

BLACK

BLUE

GREYYELLOWPINKCOLOURS FOR PROGRAMVERSION 1.10

3PH Y L LOAD AC L LOAD AC L LOAD

3mΩ

3mΩ

3mΩ

REDGREY

1/2 U VIOLET

1/2 V VIOLET

1/2 W VIOLET

RED

GREY

PROTECTIVE ISOLATION WITH INSULATION MONITORINGAND FUSING/CIRCUIT BREAKING FOR ALL POLES K = OPERATING CURRENT CIRCUIT BREAKER

H =INSULATION FAULT INDICATOR LAMPR = GMW/ISO INSULATION MONITORP = TEST BUTTON

RESE

T BU

TTON

FOR

ISO

MOD

ULE

6-PIN CONNECTORCONTACTS VIEW

YELLOW/GREEN

YELL

OWGR

EEN

ELEC

TRON

ICGE

NERA

TOR

REGU

LATO

R

BLAC

K

BROWN

BLACK

BLUE

BROW

N

YELL

OW/G

REEN BL

UE

OPTIONAL, EXTERNAL PE CONNECTION

ATTENTION:TRIP-FREE RELEASING OFALL CIRCUIT BREAKERSCOUPLED

POWER SUPPLYAUTOMATIC NO-LOAD OPERATIONPRESSURE REDUCTION

SWITCHBOX

TOTAL LENGTH OFEQUIPMENT SUPPLYCABLES

∑ < 250M

EXAMPLE:

LOAD PROTECTIONCLASS I(ALSO CLASS II/SEEOPERATING MANUAL)

CONNECTION WITH COMPR.WIRING HARNESSINSERTION SIDE VIEW

YELL

OW/G

REEN

AC-L-LOAD AC-L-LOAD AC-L-LOAD

MECHANICALCOUPLING TO F1

TO 4 POLEAMP PLUG ON

WLAX

MODE SELECTOR SWITCHPOSITION 1: OPENPOSITION 2: CLOSED

CURRENT CONVERTERON WLAX CONTROLLER

YELL

OW/G

REEN

105

Has insulationmonitor released?(indicator lamp lit)

Unplugconnecteddevices

Press greenreset button

Plug in devicesone after theother

Is insulationmonitoring stillenabled?

YES YES

Connecteddevices are faulty

Has fuse blown?

NO

Connecteddevices are faulty

Contact customerservices ortake device in forchecking

YES

NO

NO

NO

Unplugconnecteddevices

Does fusestill blow? YES

Sockets dead

Fig. 38

11.11 Troubleshooting

11. Generator option

106

11. Generator option

Problem

The generator supplies no or insufficientvoltage.

Complete or significant voltage drop duringoperation under load.

Excessive generator voltage.

Voltage fluctuates in short intervals.

Generator heats up to unacceptable levels.

When additional problems occur, call forcompressor service!

Possible cause(s)

The generator circuit breaker has trippeddue to overload or is defective.

Drive motor speed too low.

Mode switch in position 0.

Generator circuit breaker not depressed.

Compressor operating pressure set toohigh, engine overloaded, speed decreases.

Coil of the "Speed increase" solenoid valvedefective.

Insufficient engine speed or speed controlinoperative.

The engine output has been reduced dueto climatic or other conditions.

Compressor operating pressure set too high.

Excessive engine speed.

Diesel engine operates irregularly.

The engine speed control operatesirregularly or is defective.

Clogged cooling air supply.

Machine is dusted.

Output reduction due to set-up at too highan altitude.

Ambient temperature too high.

Attention

Use genuine spare parts only!

Correction

Check electrical load output.

Check that all electrical terminals areproperly seated.

Check generator protective switch andreplace if required.

Check connected electrical loads for shortor earth contact.

Set to nominal speed, max. 3,100 rpm.

Position switch in position 1.

Press the protective switch.

Re-adjust the operating pressure at theadjuster.

Check and replace solenoid valve ifrequired.

Have the nominal speed adjusted by theengine after-sales service max. 3,100 rpm.

Check that all electrical terminals areproperly seated.

Check connected electrical loads for shortor earth contact.

Do not operate the generator at nominaloutput, see the operating instructions forthe engine.

Re-adjust.

Have adjusted to nominal speed.

Have checked by the engine after-salesservice.

Check according to the operatinginstructions supplied by the enginemanufacturer.

Ensure that the cooling air supply is notrestricted.

Clean the machine and position in a waythat dust-free cooling air only will be takenin. It is strictly recommended that thecooling air is cleaned at regular intervals.

Partial load operation possible only.

The generators are designed to ensure thatno danger exists at ambient temperaturesof up to 35 °C. In higher ambienttemperature environments, the generatormay be operated at partial load only.

107

12.1 Safety regulations for the useof the heat exchanger

Danger

When operating the compressor, pleaseobserve the general safety regulationslaid forth in the compressor operatingmanual.

The heat exchanger operates fullyautomatically. Operating errors at theheat exchanger are excluded.

12.2 Design and operation

System function diagram:see page 78, fig. 4

* The compressed air is heated up in aheat exchanger by means of the engineoil.

* The diesel engine is equipped with anoil temperature regulator, which ensuresthat the engine oil has the properminimum temperature required foroperation and which bypasses the heatexchanger at the diesel engine duringstart-up and warm-up until the requiredengine oil temperature has beenreached.

The second oil temperature regulator,which is located in the oil line, for heatingup the compressed air ensures that thecompressed air may not be heated upexceeding maximum specifiedtemperatures during summer operation.

This fully automatical uniformtemperature control ensures both theproper temperature of the compressed airand the proper engine oil temperatureirrespective of the ambient temperatureswhich the installation will be operated in.

12.3 Maintenance/Care

This system is maintenance-free.

For information on engine oil change seethe operating instructions of the engine.

12.4 Troubleshooting

Compressed air temperature too low

Defective oil temperature regulator inthe engine or in the oil line -> replace.

Compressed air temperature too high

Defective oil temperature regulator inthe oil line -> replace.

12. Heat exchanger option

108

13. Compressed air processing option (After cooler / Filter)

13.1 Safety regulations for alternatecompressed air processing

Danger

When operating the compressor, pleaseobserve the general safety regulationslaid forth in the compressor operatingmanual.

13.2 Design and operation

System function diagram:see page 78, fig. 4

After cooler option

Fig. 38

1 Filter2 Heat exchanger3 After cooler4 Condensate separator

In an air cooler (on the cooling air intakeside), the compressed air is cooled downto a temperature close to the prevailingambient air temperature downstream of thepressure vessel. A condenser is installeddownstream of the air cooler with automaticcondensation drainage.

Attention

When there is a danger of freezing orwhen the machine is switched off for aprolonged period, any remainingcondensation must be drained from thesecondary cooler. For doing this thebottom cover of the secondary coolermust be opened and it must be emptiedutilising the pressure remaining in themachine.

Filter option (ZTV-SIB 90)

A residual oil contents in the compressedair of < 0.01 ppm is achieved by means offiltering. The filter assembly consists of afine filter and an extra-fine filter. Both filtersare equipped with a collecting receiver withautomatic evacuation. The separated orfiltered liquids are brought together to acommon drain.

Attention

The oil-containing condensate has to becollected. Do not allow to enter into thesoil or into the drains!

13.3 Maintenance instructions

Danger

Prior to and when carrying outmaintenance and repair procedures,please do observe the general safetyregulations in chapter 3 of thecompressor operating manual.

Attention

The filters have to be disposed of.

The post cooling systems is mainte-nance-free. For cleaning procedures,see 9.1 „General maintenance“ in thecompressor operating manual.

Post option

Filter change is required at latest whena differential pressure of 400 mbar hasbeen reached or after approximately500 operating hours - depending on thedegree of contamination.

1

2

4

3

13.4 Troubleshooting

Problem

Increased air humidity of the compressedair

Oil in discharge air line

Possible cause(s)

Contaminated air cooler.

Defective discharge valve in the collectingreceiver of the condensate separator.

See chapter 10 "Troubleshooting" in thismanual.

Defective discharge valve in the filter.

Faulty filter cartridges.

Correction

Clean

Replace

Replace

Replace

109

14. Breathing air connection option

14.1 Notes on safety anddescription of function

Danger

See the separate instruction manual forthe filter unit for notes on safety anddescription of function!

System function diagram:see page 78, fig. 4

110

15. Oil temperature controller option

15.1 Safety regulations for the useof an oil temperature controller

Danger

Please observe the general safetyregulations in the compressor manualwhen operating the compressor.

Operation of the oil temperaturecontroller is fully automatic. Mal-operation of the oil temperaturecontroller itself is impossible.

15.2 Design and function

See page 78, fig. 4, for system functiondiagram.

With the aid of the oil temperaturecontroller, the compressor oil circuit is keptat an optimum service temperature.

The oil temperature controller regulationsthe temperature of the oil within the settemperature limits, and only feeds as muchoil to the cooler as is necessary to achievethe desired oil temperature.

Figure 39

15.3 Maintenance / care

This system is maintenance-free.

15.4 Troubleshooting

Compressed air temperature too low

Oil temperature controller in the oil lineis defective -> replace it.

TOCOMPRESSOR

FROMCOOLER(OUTLET)

TOCOOLER(INLET)

FROMPRESSURE

VESSEL

111

16.1 Introduction

Attention

The user forfeits all rights to claim ifparts other than those of themanufacturer are used.

We reserve the right to modify design andperformance without prior notice. Pleasequote axle number, model and articlenumber when contacting us with queries orordering spare parts.

16.2 Safety

* It is most important that the wheel andthe hub are compatible dimensionally.This means that the P.C.D., wheel boltsand inset must all be compatible bothwith the hub and the rim. Particularattention must be paid to therecommended torque figures for thewheel bolts.

* No welding is permitted on the AL-KOaxle.

* Please note the swing arm movement.(See assembly instructions).

* The AL-KO wheel brakes are matchedto the AL-KO overrun devices.Before using an overrun from anothermanufacturer, please check thecompatibility with our TechnicalDepartment.

Attention

Model details must not be obscured bypaint now concealed by components.

16. Undercarriage

16.3 KHV13 height-adjustabletowing system, model B 3.5.13

The adjustable joint between the drawbarand intermediate arm, and between theoverrun system and intermediate arm,consists of toothed heads or retainers withHirth-type or radial serrations.

The radial serrations are secured withfastening screws. The fastening nut mustbe tightened to the specified torque in orderto establish a no-play, torque transmittingconnection. The tightening torque dependson the permitted gross weight of the trailerand the length of intermediate (swivelling)arm

Adjusting procedure

After the spring-loaded plugs have beenreleased from the fastening nuts, the nutscan be loosened until the teeth areexposed. The angle of the intermediatearm can then be adjusted.

Danger

Care must be taken without fail toensure that the overrun or towingsystem is always aligned parallel withthe drawbar.

The vehicle must not be driven unlessthe overrun system is parallel with thedrawbar!

After the coupling has been adjusted forheight, the serrations should be lockedtogether with the clamping nuts andsecured against working loose by meansof the spring-loaded plugs.

The radial serrations of the intermediarypiece and the drawbar are joined by unionbolts M28x1.5 and M36x1.5 respectively.

M28x1.5 T = 400 NmM36x1.5 T = 650 Nm

The radial serrations of the intermediarypiece and the run-up assembly are joinedby union bolts M20x1.5 and M28x1.5respectively.

M20x1.5 T = 250 NmM28x1.5 T = 400 Nm

16.4 Braking system

Introduction

* KNOTT over-run brake systems consistof over-run hitches and wheel brakesused in combination with KNOTTtorsional thrust spring axles. They areapproved in all countries of the EC andin Switzerland.

* With the KNOTT autoreverse system‘Backmat’ there is no problem changingthe direction of travel from forward toreverse. The braking system is ready forimmediate operation again whenchanging from reverse to forward travel.

* KNOTT torsional thrust spring axles aswell as rubber spring axles have superbspringing and excellent dampeningcharacteristics. With the torsional thrustspring axles the spring elements withtheir vulcanized rubber are pretensionedbefore being pressed into the axletubes. There is no squashing of therubber during spring action. Instead therubber is stretched in accordance withits characteristics.

With the rubber spring axles theaxletube bears the axle by pretensionedrubber strings. The results of thestretching are exceptionally long life andzero maintenance.

Attention

* Use the jack only under the fixingbrackets or at the chassis, never inthe centre.

* Towing eye and ball coupling mayonly be changed by specialists.

* Use a new safety nut every time oneof these items is changed.

* Use specified torque setting:

Ball couplingM12 8.8: T = 77 NmM14 10.9: T = 125 Nm

Towing eyesM12 10.9: T = 115 NmM14 10.9: T = 180 Nm

* When using the ball coupling, pleasefollow the instructions given.

112

Over-run hitches

KNOTT over-run hitches are available forboth hydraulic and mechanical brakes.

Handbrake lever with power reservoir,code „KH“

With the type “KH” the spring reservoir isunder torsion at the centre point. If thehandbrake is applied, then it worksautomatically and requires almost no force.The system is designed so that when thehandbrake is applied, sufficient energy isstored within the spring. When transmittedthrough the brake rods this prevents thebrake shoes from slipping away from thebrake drum.

16.5 Adjusting the braking system

16.5.1 Preparations

* Jack up the trailer

* Release the handbrake

* Pull out the drawbar [5] of the overrun-system as far as it will go

Fig. 40: KNOTT overrun brake

1 Contact-breaking cable2 Trailer coupling ring (varies by type)3 Handbrake lever4 Transmission lever5 Drawbar and bellows

Danger

When any disconnection of the brakingsystem takes place, secure handbrakelever by reinserting the security bolt[15] (see warning plate [16]).

Fig. 41

15 security bolt16 Warning plate

16.5.2 Preliminary requirements:

* When carrying out adjustments, alwaysstart with the wheel brakes.

* When carrying out adjustments, turn thewheel only in the direction of forwardtravel.

* Insert the security bolt [15] (seewarning plate)!

* Do not pre-tension the expandinglocking mechanism in the brake. Ifnecessary, loosen the brake linkage [6]at the brake compensator [8].

* Check the expanding lockingmechanism and control cable [11]for ease of movement.

Attention

* The compression spring [7] may onlybe lightly pre-tensioned and must notbecome fully compressed whenactivated!

* Bowden cable [14] must not activatebrake.

* Never readjust the braking system orbrakes by the brake linkage [6] orturnbuckles (if fitted) in the linkage!

16.5.3 Adjusting the brake

Fig. 42: KNOTT wheel brake

12 Adjusting screw13 Cable entry

Tighten the adjusting screw [12] (on theoutside of the brake plate, opposite thecable entry [13]), turning clockwise until thewheel can only be turned with difficulty ornot at all.

Wrench sizes for adjusting screws [12]

Brake size Wrench size

160x35 / 200x50 SW 17250x40 SW 19300x60 SW 22

Ease off the adjusting screw [12] in theanticlockwise direction (approx. 1/2 turn)until the wheel turns freely. Slight rubbingnoises, which do not effect the free turningof the wheel, are permitted.

16. Undercarriage

When the brake is correctly adjusted, theactuating travel of the control cable [11] willbe 5-8 mm.

Carry out the adjustment procedure,as described, on all the wheel brakes insuccession.

16.5.4 Adjusting the brakecompensating system

Fig. 43 KNOTT transmission system fortandem and single-axle chassis.

6 Brake linkage7 Compression spring8 Compensating balance assembly9 Compensating balance (tandem) or

master compensator10 Compensating balance (single axle)11 Control cable

Fig. 44 KNOTT transmission system fortandem and single-axle chassis.

14 Bowden cable for handbrake

* Insert the security bolt [15] (seewarning plate)!

* Remove the bowden cable [14].

* Preadjust the length of the brake linkage[6] (slight play permitted).

* Insert the bowden cable [14].

15

14

16

113

* Remove the security bolt [15].

* Operate the handbrake lever [3] andcheck the position of the compensatingbalances [9 and 10]. They should be atright angles to the direction of towing.

* If necessary, adjust the position of thebalance [10] and control cables [11]; inthe case of tandem trailers, also adjustthe master compensator [9] on thelinkage [6].

* The compression spring [7] may only belightly pre-tensioned and must notbecome fully compressed whenactivated!

16.5.5 Adjusting the brake linkage [6]

Adjust the brake linkage [6] so that it isfree of play longitudinally, without initialtension (reversing lever [4] free of play).

Readjustment

* Operate the handbrake lever [3]powerfully several times in order tosettle the braking system.

* Check the position of the brakecompensating balances [9 and 10]which should be at right angles to thedirection of towing

* Check the play in the linkage [6]; ifnecessary, adjust the linkage [6] againso that it is free of play, but withoutinitial tension

Slight play in the bowden cable [14]must persist.

* Check the position of the handbrakelever [3];

when checking the dead centre of thelever, resistance starts 10-15 mm abovedead centre

* Check that the wheels rotate freely withthe brake released.

Final check

* Check fastenings for security (securethe hexagon locking nuts of the screwfastenings for the transmission system,control cables, brake compensators,turnbuckle, linkage, etc.).

* Check the bowden cable for slight play[14]; if neccessary, adjust the cable.

* Check the compression spring [7] forinitial tension.

Test run

* If necessary, carry out 2-3 brake tests

16. Undercarriage

Brake test

* Recheck the play in the brake linkage [6]and, if necessary, readjust the linkage[6] for length free of play ( duringoperating braking with empty trailershould be used maximally 1/2 of theoverrun travel )

16.6 Readjusting the braking system

In general, readjusting the wheel brakesadequately serves to readjust the brakingsystem, i.e. to compensate for brake liningwear. To readjust the wheel brakes,proceed as described under 'Adjusting thebraking system'. Check the play in thelinkage [6] and readjust if necessary.

Attention

* Check the expanding lockingmechanism and control cable [11]

* The expanding lock compensatormust not be pre-tensioned in thebrake.

* Do not attempt to compensate forease of movement caused by brakelining wear by readjusting(shortening) the brake linkage [6],e.g. by way of the linkage screwfastenings

Readjustment

* Operate the handbrake lever [3]powerfully several times in order tosettle the braking system

* Check the position of the brakecompensating balances [9 and 10](which should be at right angles to thedirection of towing).

* Recheck the play in the linkage [6];

if necessary, adjust the linkage [6] againso that it is free of play, but withoutinitial tension.

* Check the positions of the handbrakelever [3], the play in the bowden cableand compression spring [7] (only lightinitial tension);

* when checking the dead centre of thelever, resistance starts 10-15 mm abovedead centre

Final check

* Check the screw fastenings for thetransmission system (control cables,brake compensators, linkage, etc.).

* during operating braking with emptytrailer should be used maximally 1/2 ofthe overrun travel

* Check tthe bowden cable for slight play[14]; if neccessary, adjust the cable.

* Check the tension of the compressionspring [7]

16.7 Maintenance and care

KNOTT – overrun systems

* The overrun system must be lubricatedwith lithium-soap grease by way of thegrease nipples and at all the movingparts.

a) every 5000 km (3000 miles)b) or every 6 monthsc) or if they become stiff

* Inspect the bellows for damage, replaceif necessary

* Replace the overrun shock absorberevery 20,000 km (12,500 miles) orevery 3 years at the latest.

* Check the play at the coupling pointevery 20,000 km (12,500 miles). If theplay exceeds 3 mm, replace the guidebearing or drawbar.

* Check the tightening torques of thefastening screws at the guide bearingevery 5000 km (3000 miles);

Screws with grease nipple50 +5 NmScrews without grease nipple80 +5 Nm

* Check the tightening torques at theclamping block of the drawbar andclamping socket (drawbar tube - axlejoint) every 5000 km (3000 miles);

M12 screws 80 +5 NmM14 screws 90 +10 Nm

* Check that the braking system iscorrectly adjusted every 5000 km(3000 miles).

Vertically adjustable drawbars

Clean the faces of the tooth systems freeof fretting rust or other contamination atleast once a year in order to maintain agood fit.

Lubricate the threaded bolts and jointsonce a year or at any time if they becomestiff.

Attention

Do not grease the tooth system!

114

If desired, a lifting and adjusting systemcan be installed between the drawbarand the overrun system. The control armsof the adjusting system permit swivellingabout an angle of -10° to +49° in sixpositions. In every case, the overrunsystem or drawgear always remainshorizontal.

An integral gas-filled strut automaticallygenerates lifting force which reduces theforce required by the user. If the strutbecomes damaged or develops a leak, itmust be replaced.

Information regarding dual-row angular bailbearings:

* These bearings are maintenance-free,have been provided with a lifetimelubrication. and have an extremely highrunning performance.

* The bearings have been fixed in theircorrect position using a safety flangednut. This flanged nut must be tightenedwith a torque of 280 +/- 10 Nm.

* It is recommended to check thistightening torque in the course of serviceworks.

* The flanged nut can only be unscrewedand re-used once. Afterwards. a new nutmust be used. When releasing ortightening the flanged nut, grease thethreads slightly, so as to avoid damageto the fine thread.

* Due to the high durability and themaintenance-free design of these dual-row angular ball bearings, there will beno damage at the bearings undernormal conditions.

* If. due to exceptional circumstances.problems were to occur with thesebearings, completely new brake drumswith pressed-in bearings, circlips andnew locking nuts should be installed inprinciple.

* Due to the design characteristics of thebearings, the brake drums and thewheels may have a slight axial andtilting play; however, this is insignificant.

16. Undercarriage

115

16.8 Malfunctions and remedies

Cause

Excessive backlash in brake system

Brake linings not "run in"

Brake linings glazed, oily or damaged

Overrunning hitch hard to operate

Brake linkage is jammed or deformed

Brake Bowden cables rusty or kinked

Excessive backlash in brake system

Shock absorber of overrunning hitchdefective

Backmat brake shoe is jammed in thebrake shoe holder

Wheel brakes are actuated unilaterally

Causes: possibly specified under"Insufficient braking effect"

Shock absorber of overrunning hitchdefective

Brake system adjusted too tightly

Bowden cables pre-loaded

Backmat brake shoe is jammed in thebrake shoe holder

Incorrect setting

Causes: possibly specified under"Insufficient braking effect"

Backmat brake shoe is jammed in thebrake shoe holder

Brake system incorrectly set

Causes: possibly specified under"Insufficient braking effect"

Backmat brake shoe is jammed in thebrake shoe holder

Wheel brakes dirty

Reversing lever of overrunning hitch isjammed

Handbrake lever not or only partiallyreleased

Remedy

Re-adjust brake system

Actuate hand-brake lever slightly;drive 2-3 kilometers

Replace brake shoes completely; cleanbraking areas in the brake drums

Grease overrunning hitch

Eliminate cause

Replace Bowden cables

Re-adjust brake system

Replace shock absorber

Replace compl. brake shoes with brakeshoe holders

Re-adjust brake system

see above

Replace shock absorber

Re-adjust brake system

Re-adjust brake system

Replace compl. brake shoes with brakeshoe holders

Re-adjust brake system

Actuate hand-brake lever as far as possible

idem

Replace compl. brake shoes with brakeshoe holders

Re-adjust brake system

idem

Replace compl. brake shoes with brakeshoe holders

Clean

Remove reversing lever, clean it andgrease it with Molykote

Set handbrake lever into zero- position

16. Undercarriage

Malfunction

Insufficient braking effect

Brake reacts by jerks

Trailer is braked unilaterally

Trailer is already braked when theaccelerator pedal is released

Reverse driving had to accomplish, or evenimpossible

Braking action of hand-brake insufficient

Wheel brakes get hot

116

Malfunction

Coupling dirty on the inside

Ball of towing vehicle too big

Clean and grease thoroughly

Check ball diameter:According to DIN 74058, the ball on the carmust not exceed 50 mm in diameter whennew, and it must be 49.5 mm in diameter.If the ball diameter decreases to less than49.0 mm, the ball has to be replaced.The ball must be perfectly spherical

Cause Remedy

16. Undercarriage

Ball coupling does not rest on ball

Danger

Works on the brake system may only becarried out in specialized workshops.

When replacing braking shoes, makesure that all brake shoes of the axle arereplaced.

When working at the wheel brakes,make sure that the springs, the brakeshoes and the spreading lever arecorrectly installed; observe the correctsense of rotation.

When adjusting the wheel brakes, turnwheels in forward direction!

Basically, a readjustment according tochapter 17.5 "Fitting of the brakingsystem" must be effected wheneverworks are carried out at the brakesystem.

If the wheel brakes or the brake drumhave got very hot, continue to drivecarefully on, if possible, until they havesomewhat cooled down.

117

Fig. 45

Attention

Do not run the machine with an emptyoiler tank! The tank must alwayscontain a minimum of 0.2 l of tool oil.

Danger

Only refill the tool oiler, when the screwcompressor is out of operation anddepressurized!

Only screw off the oiler reservoir, whenthe screw compressor is out ofoperation and depressurized!

Do not spill any oil!

Watch out for leakage!

The oil dosage is continuously variable atthe adjusting knob.

* Turning the adjusting knob clockwise(symbol »–«) will reduce the oil flow upto 0-quantity (i.e. no oil for toollubrication in the compressed air).

* Turning the adjusting knob counterclock-wise (symbol »+«) will increase the oilflow.

Check the oil level in the depressurizedtool oiler

Fig. 46

* Shut down the screw compressor andwait until the compressor isdepressurized.

* Unscrew the screw plug.

* The oil must be visible in the oilerreservoir; refill, if necessary (oil to beused: CompAir AES 82).

17. Tool oiler option

* Check the seal of the screw plug,replace if required.

* Screw in the screw plug with the sealand tighten.

* Check for leaks after start-up of thescrew compressor.