C76, C62HS, C65-10, C60-12, C55-14

C62, C53-9, C50, C38, C35-10, C30

Deutz M2011

Powered Compressor

Operating Manual

GB Id. Nr. 100 006 932 / 02 - September 2006

CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some of itsconstituents are known to the State of

California to cause cancer, birth defects,and other reproductive harm.

Maintenance and Inspection Manualfor CompAir Compressors

This Maintenance and Inspection Manualis intended only as a supplement to theoperating instructions and parts list for yourCompAir compressor.

It does not replace these technicaldocuments.

This Maintenance and Inspection Manualis intended for you, the machine attendant.It is provided to facilitate the requiredmaintenance and inspection work andallow this work to be reviewed at any time.When this Maintenance and InspectionManual is kept carefully it can contribute toreduction of the maintenance costs andincreasing the operating reliability andservice life of your compressor.

Attention

When starting up your compressor forthe first time, observe the operatinginstructions under all circumstances.

Proper operation, care and continuoussupervision of the compressor system aredecisive for the operating reliability,performance and service life.

We cannot assume any liability fordamage resulting from failure to observethe operating instructions, improper repairsor use of other than genuine parts.

Questions/Parts ordersAlways indicate:- Machine number (rating plate)- Machine model.

We request you to present thisMaintenance and Inspection Manualto our service personnel on request.Thank you.

Danger

Please observe the maintenanceinstructions (service intervals andpoints) given in the operatinginstructions.Perform inspection, maintenance andrepair work only when the machine isstanding still, not under voltage and notunder pressure.Safety devices such as guards must notbe removed during operation.

Service Contact Partner, name: ________________________________________________________________%

____________________________

Plant Maintenance Personnel, Name: ___________________________________________________________%

____________________________

Number of associated Parts List: _______________________________________________________________________________________________

Machine model: _____________________________________________________________________________________________________________

Machine serial number: _______________________________________________________________________________________________________

Year of production: __________________________________________________________________________________________________________

Data acc. to compressor rating plate: ____________________________________________________________________________________________

_________________________________________________________________________________________________________________________

_________________________________________________________________________________________________________________________

_________________________________________________________________________________________________________________________

Operating pressure ( max. operating pressure): ___________________________________________________________________________________

Remarks: __________________________________________________________________________________________________________________

_________________________________________________________________________________________________________________________

_________________________________________________________________________________________________________________________

_________________________________________________________________________________________________________________________

_________________________________________________________________________________________________________________________

Date Maintenance Inspection RepairTo

tal o

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ting

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s

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rs

Time required for service work

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Type

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C76, C62HS, C65-10, C60-12, C55-14

C62, C53-9, C50, C38, C35-10, C30

Deutz M2011

Powered Compressor

Operating Manual

GB Id. Nr. 100 006 932 / 02 - September 2006

31.1 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 accessories

conform 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 its

intended purpose* The compressor is not operated by

trained personnel* Unauthorized changes or modifications

are carried out on the compressor* You are not wearing the prescribed

protective clothing* You do not comply with the safety

instructions

* 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 prevention

regulations* Generally recognized safety and traffic

regulations* Particular national regulationsThe compressor is designed for providingcompressed air:* For operating compressed-air

appliances* For conveying bulk material* For sandblasting and paint-spraying

operations* For cleaning machines and shuttering

material - 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

41. Foreword

1.3 Specifications type DLT 0406

* 7 kVA, one-phase 110 V AC, 50 Hz or8 kVA, 400/230 V AC, 50 Hz

** 7 kVA, one-phase 110 V AC, 50 Hz or8 kVA, 400/230 V AC, 50 Hz or12 kVA 400/230 V AC, 50 Hz

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

C30 1025.0 767 807 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C30 G * 1025.0 834 874 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C35-10 1025.0 805 845 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C35-10 G** 1025.0 889 929 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C38 1025.0 805 845 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C38 G ** 1025.0 889 929 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C42 1025.0 805 845 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C42 G ** 1025.0 889 929 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C50 1025.0 868 908 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C50 G * 1025.0 935 975 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

Ambient Enginetemperature speed

min. max. No-load On-load

[m3/min] [barg] [barg] [C] [C] [m above [l] [kW] [rpm] [rpm] [l] [l]sea level]

C30 3.0 7.0 5-8 -10 50 1000 9.0 F2M2011 Oil 23.0 1700 2600 7.5 60

C30 G * 3.0 7.0 5-8 -10 50 1000 9.0 F2M2011 Oil 23.0 1700 2600 7.5 60

C35-10 3.5 10.0 5-10 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C35-10 G ** 3.5 10.0 5-10 -10 45 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C38 3.8 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C38 G ** 3.8 7.0 5-8 -10 45 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C42 4.2 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C42 G ** 4.2 7.0 5-8 -10 45 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C50 5.0 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C50 G * 5.0 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

51. Foreword

1.4 Specifications type DLT 0703

** 7 kVA, one-phase 110 V AC, 50 Hz or8 kVA, 400/230 V AC, 50 Hz or12 kVA 400/230 V AC, 50 Hz

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

C53-9 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 98 81 69

C53-9 G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 98 81 69

C55-14 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70

C60-12 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70

C62 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 98 81 69

C62 G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 98 81 69

C62HS 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70

C62HS G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70

C65-10 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70

C65-10 G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70

C76 1300 1069 1100 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70

C76 G** 1300 1153 1184 3790 1580 1390 5 1/2 J x 14 185 R 14 2.8 99 82 70

Ambient Enginetemperature speed

min. max. No-load On-load

[m3/min] [barg] [barg] [C] [C] [m above [l] [kW] [rpm] [rpm] [l] [l]sea level]

C53-9 5.3 8.6 5-9 -10 50 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120

C53-9 G ** 5.3 8.6 5-9 -10 45 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120

C55-14 5.5 14.0 5-14 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120

C60-12 6.0 12.0 5-12 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120

C62 6.2 7.0 5-8 -10 50 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120

C62 G ** 6.2 7.0 5-8 -10 45 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120

C62HS 6.2 7.0 5-8 -1050 1000

14.0 BF4M2011 Oil 61.0 1550 2600 10.0 12040 3000C62HS G ** 6.2 7.0 5-8 -10 50 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120

40 3000C65-10 6.5 10.0 5-10 -10 50 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120

C65-10 G ** 6.5 10.0 5-10 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120

C76 7.6 7.0 5-8 -10 50 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120

C76 G ** 7.6 7.0 5-8 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 1202

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61. Foreword

Fig. 2

DLT0406

DLT0703

71.5 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.

ServiceIn case of faults, or should you require

spare 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. 3Please 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,numro de commande, numero d'ordine

Typ, type, modle, tipo

Volumenstrom, flow rateflux volumique, flusso volumetrico

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

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

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

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

m3/min

bar

min-1

kW

bar

max. Sttzlast an Kupplung, max. tongue load at

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

Baujahr, year,anne, anno

N

Handelsbezeichnung, trade name, dnominationcommerciale, denominazione commerciale

7

9

10

11

8

6

4

5

2

3

1

CompAir Drucklufttechnik GmbHWerk 55469 Simmern

1.6 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.

WarrantyOnly use this compressor with accurate

knowledge 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 of

CompAir'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

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

Technical modificationsWe reserve the right to undertake

modifications without notice in the interestsof technical progress.

82. Index

1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 Information on the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 Normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 Specifications type DLT 0406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4 Specifications type DLT 0703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.5 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.6 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3. Security regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.1 Identification of safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.3 Modifications and alterations to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.4 Loading / Relocation / Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.5 Installation on site / Starting / Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.6 Special jobs / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.7 Instructions concerning particular hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.8 Symbols and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4. Construction and functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214.4 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.5 Terminal Diagram DIN ISO 1724 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5. Transport and installation on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.2 Link up breakaway cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.3 Loading / Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.4 Installation on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6. Preparing the compressor for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276.1 Checking oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.1.1 Checking pressure tank oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276.1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276.3 Filling up the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276.4 Checking the air filter maintenance display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7. Putting the compressor into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297.1 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297.4 Setting the operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307.5 Monitoring / fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317.7 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317.8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8. Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.1 Recommended lubricant for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.2 Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.3 Tool lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.5 Recommended lubricants for the bogies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

99. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339.2 Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339.3 Maintenance of chassis and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339.4 Compressor maintenance / Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9.4.1 Oil filter replacement (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359.4.2 Oil change (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359.4.3 Checking the automatic monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359.4.4 Inspecting / Replacing the fine separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359.4.5 Air filter replacement (compressor / engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369.4.6 Checking the safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369.4.7 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379.4.8 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379.4.9 Torque specifications DLT 0406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379.4.10 Torque specifications DLT 0703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9.5 Spare parts for maintenance purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

11. Generator option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4011.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4011.2 Generator safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4011.3 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4011.4 Operating the generator (Working safely with electrical equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4111.5 Testing insulation monitoring/startup/device connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4211.6 Technical characteristics of 8 kVA 400/230 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4311.7 Technical characteristics of 12 kVA 400/230 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4311.8 Technical characteristics of 7 kVA 110 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4411.9 Generator switchbox wiring diagram of 8 kVA and 12 kVA 400/230 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4511.10 Generator switchbox wiring diagram of 7 kVA 110 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4511.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

12. Heat exchanger option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4812.1 Safety regulations for the use of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4812.2 Design and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4812.3 Maintenance / Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4812.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

13. Compressed air processing option (After cooler / Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4913.1 Safety regulations for alternate compressed air processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4913.2 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4913.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4913.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

14. Breathing air connection option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5014.1 Notes on safety and description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

15. Oil temperature controller option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5115.1 Safety regulations for the use of an oil temperature controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5115.2 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5115.3 Maintenance / care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5115.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

16. Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5216.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5216.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5216.3 KHV13 height-adjustable towing system, model B 3.5.13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5216.4 Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5216.5 Adjusting the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5316.6 Readjusting the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5416.7 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5416.8 Malfunctions and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

17. Tool oiler option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2. Index

10

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.

DangerPlaces 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 measuresPlease keep this operating manual handy

at 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

11

3.4 Loading / Relocation / Transport

Loading / RelocationAll loose parts that could fall down when

the 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 unitMake sure that the air vessel is not under

pressure.Lift and secure supporting gear.Make sure that the drawbar eye can

move freely in the tow bar.Check to make sure that the drawbar is

adjusted 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, always

check 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

12

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.

Normal operationBefore starting work, make yourself

familiar 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 properly

positioned and fixed in place* All hoses and/or pipes within the system

are 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 properlyAll connected components must be of

the 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 skin

or towards another person.Never use compressed air for cleaning

clothing. 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.

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 static

electricity and possibly sparks. In order toavoid this, a ground cable must beconnected to the system while it is beingfilled up.

3. Security Regulations

13

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 / MaintenanceCare

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.* Switch off battery master switch and/or

detach connector.* Put up a warning sign on the main

switch Attention! Maintenance work.Close off the complete maintenancearea, if required.

* Disconnect the starter battery.Individual parts and larger subassemblies

must 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 may

only 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.

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.* Switch off battery master switch and/or

detach connector.* Put up a warning sign on the main

switch Attention! Maintenance work.Close off the complete maintenancearea, if required.

* Disconnect the starter battery.Before removing or opening any part

under pressure, separate the equipmenteffectively from all sources of pressure andrelease the pressure from the completesystem.

3. Security Regulations

14

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.

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.

3. Security Regulations

15

* 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 EnergyOnly use original fuses with the specified

amperage.In case of faults in the electrical power

supply, 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 the

machine/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, smokeOnly carry out welding, burning, and

grinding 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 systemsWork on hydraulic equipment may only

be 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.

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.

3. Security Regulations

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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 environmentsThe operation of the compressor in areas

where 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.

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17

3.8 Symbols and definitions

Emergency stop

Do not operatewith the hoodopen

Do not step onpressure-conducting parts

Do not removethe compressordocumentation

Do not inhalecompressed air

Caution: Hotsurfaces

Caution: Hot anddangerousexhaust fumes

Caution: Underpressure

Only operate withprotective grating

Only start with the bleed cocksclosed

Caution: Caution: VesselPressure vessel is pressurised

Check filling Observe thelevel operating

instructions

Bleed water from the pressurevessel after every 24 operatinghours or if the water ratio is toohigh

Caution: Do not use ether spray

100 9898381/5083 A93614780

Sound level data

3. Security Regulations

Hoisting point

Tie down point

Caution: Do not move with thetransport safety locking

Caution: Remember the handbrake

Note tyre pressure

18

3. Security Regulations

Options

Condensationdrain from after-cooler or fromafter-cooler withsubsequentfiltering

Caution: Protect from wetness.Do not direct a water jet at thegenerator.

Danger of electric shock

19

4. Construction and functional description

Fig. 41 Instrument panel2 Tool oiler3 Pressure tank4 Battery5 Oil filter (compressor)6 Hood7 Vehicle and chassis type identification

number8 Chassis9 Oil cooler

10 Engine11 Diesel engine12 Fuel line filter13 Proportional controller14 Fuel tank15 Air filter (compressor)16 Suction controller17 Main battery switch18 Oil filter (compressor)19 Compressor20 Taps

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.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.

4.1 Construction

Compressor and engineThe DLT 0406 and DLT 0703 series is a

sound proofed mobile compressor system.The core is a single-stage, oil-floodedscrew compressor. The CompAir screwprofile represents the state-of-the-art. Theair is delivered pulsation-free.

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 box

mounted 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.

20

4.2 Functional description (see fig.5)Oil circuit

The oil required for sealing and coolingthe rotors as well as for lubricating theroller bearings is injected into thecompressor (10) from the pressure tank(17), 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 (16) and the oil filter (13). Theintake control valve (11) is fitted with a non-return function, so that when the system isswitched off, flooding of the air filter (9) isprevented.

Air circuit

The intake air flows through the air filter(9) and the suction control valve (11) intothe compressor (10). During compression,oil is injected in order to lubricate, cool andseal the screw rotors. The compressed air-oil mixture flows into the pressure tank(17). Centrifugal preseparation of the oil isensured through tangential entry into thetank.

Any remaining oil is separated from theair in the fine separator (18).

The compressed air is fed via the Venturinozzle (20) / the pressure retention valve(option) to the compressed air discharge(21). The venturi nozzle (20) effectivelyprevents the system pressure from fallingbelow the minimum operating pressurerequired for the system to work properly.A temperature monitoring device (14) aswell as an operational pressure manometer(22) are integral parts of the air circuit.

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 (11) closed. Once thediesel engine (2) has warmed up, thethrottle/speed control is activated pressingthe load button.

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

The control valve (11) is connected to theengine speed control lever over a secondset cylinder. When starting, the engine isset to full load and the control valve (11) isopen. The compressor (10) starts toproduce and pressure builds up inside the

4. Construction and functional description

pressure tank (17). When exceeding theoperating pressure the P-controller (23)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 cylinders(11,4). Over the calibrated openings of theexhaust air nozzles (5,12) the control airgets partly into the atmosphere and anycondensate will be let off. The throttle valve(11) closes (throttle-type governor) and theengine speed will be lowered (speedcontrol). That way the air volume will beadjusted variable to the required air. If theair output drops down to zero, the throttlevalve (11) is completely closed and theengine runs under idle running speed. Overthe exhaust air nozzles (5,12) the sucked inair will be let off over a leakage cleft. Whenthe pressure of the container drops downthe control pressure of the controller dropsdown too; the throttle valve opens and theengine speed will increase.

When turning off the engine the backlashflap inside the controller will be closedthrough the system pressure. The releasevalve (25), which closes parallel to theengine lifting magnet, looses power andopens. The container pressure drops downto zero.

21

4. Construction and functional description

4.3 System description

1. Air filter - diesel engine2. Diesel engine3. Oil cooler - diesel engine4. Engine actuating cylinder5, Nozzle - engine servo cylinder6. Engine temperature transmitter7. Engine oil pressure8. Fuel level switch9. Air filter - compressor

10. Compressor11. Suction controller12. Nozzle suction controller13. Oil filter compressor oil14. Temperature switch15. Orifice, evacuation line16. Oil cooler compressor oil17. Pressure tank

18. Fine separator19. Safety valve20. Venturi nozzle21. Air bleed component 2 x 3/4" (3 x 3/4")22. Pressure gauge23. Controller unit / proportional controller24. Controller unit / load switching valve25. Controller unit / relief valveOption26. Chalwyn valveOption27. Compressor oil temperature controllerOption oiler28. Oiler reservoir29. Oiler valveOption heat exchanger/after-cooler/subsequent filter30. Cooler31. Condensation run-off

32. Filter combination33. Heat exchanger34. Oil temperature controller -

heat exchangerOption35. Extraction lever oil-free compressed air36. Backlash valveOption37. Extraction lever 1 1/2"Option38. Backlash valveOption39. Solenoid valve - generator optionOption clean air40. Pressure control41. Activated carbon filter42. One-hand coupling43. Pressure gauge44. Fuel cooler

Fig. 5 135 101 74

22

4. Construction and functional description

4.4 Wiring diagram

D1-D8 Semi-conductor diodeD10 Battery charge pilot lampD11 Fault pilot lampD12 Option lamp "Pre-heating running"D13 Lamp " Warn run ended"D14 OptionD15 Option lamp "Engine temperature

too high"D16 Option lamp "Compressed air

temperature too high"D17 Lamp "Fuel shortage switch off"

F1 FuseF2 FuseF3 Fuse (option)

G1 GeneratorG2 Battery

K1-K8 Small relay 12 V

M1 Starter

P1 Hours of operation counter

R1.1 Option heating flange

S1 Main switchS1.1 Main battery switchS2 Load buttonS3 Oil pressureS4 Engine temperatureS5 Compressed air temperatureS6 Fuel shortage

X1 Plug connector (pin/socket)X2 Generator plug

Y1 Lifting magnet - fuelY2 Solenoid valve ressure reliefY3 Solenoid valve generator idling

automaticY5 Solenoid valve load switch valve

Fig. 6 135 100 74

23

105 580 74

rear fog lamp

right taillamp

right indicator lamp

right stoplamp

left stoplampleft 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. 7

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

24

5.1 Transport

Fig. 8

DangerMake 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 ringThe 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 for

France)A different coupling unit in the form of a

complete 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 TV -Technical Inspectorate, DEKRA - GermanMotor Vehicle Monitoring Association, etc.).The inspection station provides a fittingcertificate to be kept with the vehicledocuments.

DangerThe screw compressor may only betransported on public roads if* The machine group (engine) is not

running,* The pressure tank is not under

pressure,* The shieldings are closed,* The blocks are firmly hooked in

place,* Hoisted and secured tail wheel,* The tyres and brakes are

operationally 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 and

locked in position (jockey wheel).* Drawbar is connected to the towing

vehicle.

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

* The contact-breaking cable is connectedto the towing vehicle. Safety chains areattached on towing vehicle.

* The electrical cable (option) isconnected to the vehicle and to thescrew compressor .

* Check the lights (tail lights, brake lights,indicator lights, and rear fog lamp)(option).

* 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 theed