Operating and Service Manual

Original operating and service manual
C270TS-9, C260TS-10, C250TS-12,

C240TS-14, C230TS-9, C220TS-10,
C210TS-12, C200TS-14
Cummins QSB6.7
Powered Compressor
●
GB Id. no. 100 013 403 / 06 - November 2013
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Maintenance and Inspection
Manual for CompAir Compressors
This Maintenance and Inspection

Manual is intended only as a supplement
to the operating instructions and parts list
for your CompAir compressor.
It does not replace these technical
documents.
This Maintenance and Inspection
Manual is intended for you, the machine
attendant. It is provided to facilitate the
required maintenance and inspection work
and allow this work to be reviewed at any
time. When this Maintenance and
Inspection Manual is kept carefully it can
contribute to reduction of the maintenance
costs and increasing the operating
reliability and service life of your
compressor.
Attention
When starting up your compressor for
the first time, observe the operating
instructions under all circumstances.
Proper operation, care and continuous
supervision of the compressor system are
decisive for the operating reliability,
performance and service life.
We cannot assume any liability for
damage resulting from failure to observe
the operating instructions, improper
repairs or use of other than genuine parts.
Questions/Parts orders
Always indicate:
- Machine number (rating plate)
- Machine model.
We request you to present this

Maintenance and Inspection Manual to our
service personnel on request.
Thank you.
Danger
Please observe the maintenance

instructions (service intervals and
points) given in the operating
instructions.
Perform inspection, maintenance and
repair work only when the machine is
standing still, not under voltage and
not under pressure.
Operation of the system without
protective equipment (e.g. fan safety
grills) is not permitted.
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:
______________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
Total operating hours
Time required for service work
Date Maintenance – Inspection – Repair
Hours
Start
End
Oil change (date/hours)
Type of oil Cause of malfunction – Remarks
Temperature (°C) compressor

(outlet-pressure fitting oil inlet)
Mechanic's signature
Original operating and service manual
C270TS-9, C260TS-10, C250TS-12,

C240TS-14, C230TS-9, C220TS-10,
C210TS-12, C200TS-14
Cummins QSB6.7
Powered Compressor
1. Index
1 Index
1 Index .................................................................................................................................................................................................. 2
2 Foreword ........................................................................................................................................................................................... 4
2.1 Information on the compressor................................................................................................................................................... 4
2.2 Normal use................................................................................................................................................................................. 4
2.3 Specifications ............................................................................................................................................................................. 5
2.4 Declaration of conformity............................................................................................................................................................ 7
2.5 Maintenance and care................................................................................................................................................................ 8
2.6 General information.................................................................................................................................................................... 8
3 Security Regulations ........................................................................................................................................................................ 9
3.1 Identification of safety instructions.............................................................................................................................................. 9
3.2 General safety instructions ......................................................................................................................................................... 9
3.3 Modifications and alterations to the machine............................................................................................................................. 9
3.4 Loading/Relocation/Transport .................................................................................................................................................. 10
3.5 Installation on site / Starting / Normal operation ....................................................................................................................... 10
3.6 Special jobs / Maintenance ...................................................................................................................................................... 12
3.7 Instructions concerning particular hazards ............................................................................................................................... 14
3.8 Symbols and definitions ........................................................................................................................................................... 15
4 Construction and functional description ...................................................................................................................................... 17
4.1 Construction ............................................................................................................................................................................. 17
4.2 Functional description .............................................................................................................................................................. 18
4.3 System description................................................................................................................................................................... 19
4.4 Wiring diagram ......................................................................................................................................................................... 20
4.5 Terminal Diagram DIN ISO 1724.............................................................................................................................................. 21
5 Transport and installation on site.................................................................................................................................................. 22
5.1 Transport ................................................................................................................................................................................. 22
5.2 Attachment of the contact-breaker cable on braked chassis .................................................................................................... 22
5.3 Loading/Relocation .................................................................................................................................................................. 23
5.4 Installation on site .................................................................................................................................................................... 23
6 Preparing the compressor for operation ...................................................................................................................................... 25
6.1 Checking oil levels ................................................................................................................................................................... 25
6.1.1 Checking the oil level in the pressure tank ................................................................................................................... 25
6.1.2 Checking the oil level in the engine .............................................................................................................................. 25
6.2 Battery ..................................................................................................................................................................................... 25
6.3 Filling up the fuel tank .............................................................................................................................................................. 26
7 Putting the compressor into operation ......................................................................................................................................... 27
7.1 Initial operation......................................................................................................................................................................... 27
7.2 Operating elements .................................................................................................................................................................. 27
7.3 Start-up .................................................................................................................................................................................... 27
7.4 Setting the operating pressure ................................................................................................................................................. 28
7.5 Monitoring / fault....................................................................................................................................................................... 28
7.6 Operation ................................................................................................................................................................................. 28
7.7 Shutdown ................................................................................................................................................................................. 29
7.8 Decommissioning..................................................................................................................................................................... 29
8 Fuels ................................................................................................................................................................................................ 30
8.1 Recommended lubricant for compressor.................................................................................................................................. 30
8.2 Recommended engine oil......................................................................................................................................................... 30
8.3 Diesel fuel ................................................................................................................................................................................ 30
8.4 Coolant .................................................................................................................................................................................... 30
8.5 Recommended lubricants for the bogies .................................................................................................................................. 30
9 Maintenance .................................................................................................................................................................................... 31
9.1 General maintenance ............................................................................................................................................................... 31
9.2 Engine maintenance ................................................................................................................................................................ 31
9.3 Maintenance of chassis and brakes ......................................................................................................................................... 31
9.4 Maintenance and inspection schedule ..................................................................................................................................... 32
9.4.1 Oil filter replacement (compressor)............................................................................................................................... 34
9.4.2 Oil change (compressor) .............................................................................................................................................. 34
9.4.3 Inspecting / Replacing the fine separator...................................................................................................................... 34
9.4.4 Air filter replacement (compressor / engine) ................................................................................................................. 35
9.4.5 Checking the safety valve............................................................................................................................................. 35
9.4.6 Control ......................................................................................................................................................................... 36
9.4.7 Battery maintenance .................................................................................................................................................... 36
9.4.8 Torque specifications ................................................................................................................................................... 36
9.5 Spare parts for maintenance purposes .................................................................................................................................... 36
9.6 Inspection intervals for pressure vessels and electrical installations ........................................................................................ 36
2
1. Index
10 Troubleshooting.............................................................................................................................................................................. 37
11 Electronic system ........................................................................................................................................................................... 38

11.1 Overview .................................................................................................................................................................................. 38
11.2 Operation ................................................................................................................................................................................. 39
11.3 Menu navigation....................................................................................................................................................................... 39
11.4 Troubleshooting ....................................................................................................................................................................... 40
12 Undercarriage ................................................................................................................................................................................. 42
12.1 Introduction .............................................................................................................................................................................. 42
12.2 Safety....................................................................................................................................................................................... 42
12.3 Height-adjustable towing system.............................................................................................................................................. 42
12.4 Braking system ........................................................................................................................................................................ 43
12.5 Adjusting the braking system ................................................................................................................................................... 43
12.5.1 Preparations................................................................................................................................................................. 43
12.5.2 Preliminary requirements:............................................................................................................................................. 44
12.5.3 Adjusting the brake....................................................................................................................................................... 44
12.5.4 Adjusting the brake compensating system .................................................................................................................. 44
12.5.5 Adjusting the brake linkage [6] ..................................................................................................................................... 44
12.6 Readjusting the braking system ............................................................................................................................................... 45
12.7 Maintenance and care.............................................................................................................................................................. 45
12.8 Malfunctions and remedies ...................................................................................................................................................... 46
13 Compressed air processing option (after cooler / filter / bypass line) ....................................................................................... 48
13.1 Safety regulations for alternate compressed air processing ..................................................................................................... 48
13.2 Design and operation ............................................................................................................................................................... 48
13.3 Maintenance instructions.......................................................................................................................................................... 48
13.4 Troubleshooting ....................................................................................................................................................................... 48
3
2. Foreword
2 Foreword
2.1 Information on the The compressor is designed for providing

compressed air:
compressor
* For operating compressed-air
CompAir screw compressors are the appliances
product of many years' research and
development. These preconditions, * For conveying bulk material
together with high quality standards, * For the supply of floor pavement
guarantee the manufacture of screw
compressors with a long service life, a * For sandblasting and paint-spraying
high degree of reliability and cost-effective operations
operation. The strict environmental
* For cleaning machines and shuttering
protection standards have of course been
material - do not direct towards
complied with.
persons!
* For blow-cleaning drilled holes.
2.2 Normal use Any other use, or any additional use,

for example as respiratory air, is regarded
The compressors have been built using as not being for the originally intended
the latest techniques in design and in purpose. The manufacturer / supplier
accordance with recognized safety accepts no liability for any resulting
regulations. damage. The risk is assumed by the user
alone.
Nevertheless, the operator or third
parties may be exposed to risk to life and The compressor may only be used in
limb in the course of the use of the a technically perfect condition, for its
compressor (e.g. through flying pieces of intended purpose, with appropriate
building material, swirling particles of dirt awareness of safety regulations and
or dust, electrical current, thermal hazards, subject to compliance with the
vibrations, noise or mechanical hazards), operating manual. In particular, faults
and the machine or other tangible assets representing safety hazards are to be
may be impaired, for reasons that could corrected at once.
not have been avoided through preventive
constructional safety 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 in
the operating manual
For this reason every person involved in
the operation, maintenance and repair of
the compressor must read and observe
the operation manual and the safety
regulations. This is to be confirmed by
signature as required.
Furthermore, the following naturally apply:
* The relevant accident prevention
regulations
* Generally recognized safety and traffic
regulations
* Particular national regulations
4
2. Foreword
2.3 Specifications
Volume of cooling water

max. installation height
Oil fill (compressor)

Operating pressure
Fuel tank capacity

filled into engine
Filling volume of
Delivery volume
Type of cooling
Pressure range
Engine rating
Trade name
engine oil
Ambient Engine
Engine
temperature speed
min. max. min. max.

3 [m above
[m /min] [barg] [barg] [°C] [°C] [l] [kw] [rpm] [rpm] [l] [l] [l]
sea level]
Cummins
C 200TS-14 20.00 14.0 5-14 -10 +50 3000 65 water 180 1000 2400 55 17 370
QSB6,7
Cummins
C 210TS-12 21.00 12.00 5-12 -10 +50 3000 65 water 180 1000 2400 55 17 370
QSB6,7
Cummins
C 220TS-10 22.00 10.00 5-10 -10 +50 3000 65 water 180 1000 2400 55 17 370
QSB6,7
Cummins
C 230TS-9 23.00 8.60 5-8,6 -10 +50 3000 65 water 180 1000 2400 55 17 370
QSB6,7
Cummins
C 240TS-14 24.00 14.0 5-14 -10 +50 3000 70 water 228 1000 2400 60 17 370
QSB6,7
Cummins
C 250TS-12 25.00 12.00 5-12 -10 +50 3000 70 water 228 1000 2400 60 17 370
QSB6,7
Cummins
C 260TS-10 26.00 10.00 5-10 -10 +50 3000 70 water 228 1000 2400 60 17 370
QSB6,7
Cummins
C 270TS-9 27.00 8.60 5-8,6 -10 +50 3000 70 water 228 1000 2400 60 17 370
QSB6,7
max. permissible noise level,

Compressed air connections
PN8NTC 2.2 at the operators

max. sound intensity acc. to
max. sound intensity acc. to

Height without exhaust pipe
Height without exhaust pipe

Gross vehicle weight rating
PN8NTC 2.2, distance 7m

location,distance 1m
acc. to 2000/14/EC
Operating weight
standard model*)
Tyre pressure
Overall width
Length, max.
Trade name
Tyres
Rim
[kg] [kg] [mm] [mm] [mm] [mm] [bar] [dB/1pW] [dB(A)] [dB(A)]
C 200TS-14 3500 3340 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 210TS-12 3500 3340 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
1 x 2” + 3 x 3/4"
C 220TS-10 3500 3340 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 230TS-9 3500 3340 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 240TS-14 3500 3360 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 250TS-12 3500 3360 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 260TS-10 3500 3360 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C270TS-9 3500 3360 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
* with optional features maximum 3,500 kg
5
2. Foreword
Fig. 1
6
2. Foreword
2.4 Declaration of conformity
1. Declaration of conformity
in accordance with the EC Machinery Directive 2006/42/EC, Supplement II A
2. We, hereby declare Gardner Denver Deutschland GmbH

Argenthaler Str.11
D-55469 Simmern
that the product: Kompressor
type: DLT0206 ; DLT0408 ; DLT0704 ; DLT1303 ; DLT2701
trade mark: C20 ; C25 ; C25-10; C30 ; C35-10 ; C38 ; C42 ; C50 ; C55-14 ; C60-12 ; C65-10 ; C65HS ; C76 ;
C85-14 ; C95-12 ; C105-14 ; C110-9 ; C115-12 ; C125-7 ; C140-9 ; C200TS-14 ; C210TS-12 ;
C220TS-10 ; C230TS-9 ; C240TS-14 ; C250TS-12 ; C260TS-10 ; C270TS-9 ; C200TS-24 ;
C210TS-21 ; C203TS-17
manufacturer no.:
in the form as shipped by us complies with the following relevant provisions:
2006/ 42/ EG 2009/ 105/ EG 2004/ 108/ EG

2007/ 46/ EG 2006/ 95/ EG
This machine is exempt from 97/23/EC the Pressure Equipment Directive, reference Article 1
clauses 3.3 and 3.6
3. If the machine is modified in a way not agreed upon with us, this statement will be void.
4. Harmonized standards applied, particularly
EN 1012-1 EN ISO 12100 EN 61000-6-2

EN 29001 EN 60034-1 EN 60204-1 EN 61000-6-4
5. National engineering standards and specifications applied
AD-S1/2000 VDE 0100 DIN 3230

BetrSichV
6. Recording agency: CompAir Drucklufttechnik -

Zweigniederlassung der
Gardner Denver Deutschland GmbH
Qualitätsmanagement: Christian Mair
Simmern,
Date Signature
7
2. Foreword
2.5 Maintenance and care 2.6 General information This fact results in the termination/
expiration of the guarantee and warranty
Care and maintenance are all-important This operating manual is to help you to claims against the manufacturer.
if the screw compressor is to meet the get to know the compressor and to use it
demands placed upon it. Compliance with for its intended applications. It contains
the prescribed maintenance intervals and important information about how to Safety regulations
careful execution of care and maintenance operate the compressor safely, cost-
work are therefore essential, especially effectively and with due care. Compliance Danger
under difficult working conditions. with the instructions in this manual will
help to avoid danger, reduce repair costs It is important that you follow the
and downtime, and increase the reliability safety regulations in Chapter 3 of the
Service and service life of the compressor. operating manual.
In case of faults, or should you require This operating manual is to be

spare parts for the screw compressor, supplemented by instructions concerning Technical modifications
please contact your local CompAir agent. current national regulations for accident
prevention and environmental protection. We reserve the right to undertake
In case of damage, the trained technical It must always be available at the site of modifications without notice in the
staff will guarantee a fast, expert repair the compressor. The operating manual is interests of technical progress.
using CompAir spare parts. Original to be read and used by all persons in
CompAir spare parts are manufactured charge of work with the compressor, for
according to the state of the art and example operation, including setting up,
guarantee continued reliable operation. correcting faults during operation, disposal
of waste products from production, care,
If you have important questions, disposal of process materials, upkeep
(maintenance, inspection, repair) and
transport.
Besides the operating instructions and
the current regulations applicable in the
user's country and at the sites of operation
concerning accident prevention, the
recognized technical rules for safe and
proper working are also to be complied
with.
Warranty
Only use this compressor with accurate
knowledge of and in compliance with this
manual.
Gardner Denver do not accept
responsibility for safe functioning of the
compressor for actions that do not
correspond to normal use or for purposes
not mentioned in the manual.
Warranty claims cannot be entertained for:
Fig. 2 * Operating errors
Please enter the data from the identifi- * Inadequate maintenance
cation plate for your compressor, in the
spaces above. In case of questions or * Incorrect fuels
orders for spare parts, please give us the * Damage caused by non-use of original
compressor type, compressor number CompAir parts
and the year of construction as given on
the identification plate. * Modification of the system.
If you give us this data you can be sure The Guarantee and Liability terms of
that you will be given the correct Gardner Denver's General Terms and
information or sent the spare parts you Conditions are not extended through the
require. above instructions.
Any unauthorized modification of the
compressor system/station or the
installation of components (e.g. fine
separators) not released by the
manufacturer result in the loss of the
CE symbol.
8
3. Security Regulations
3 Security Regulations
3.1 Identification of safety Personnel delegated to work with the Only trained or specially instructed
machine must have read the operating personnel may be assigned to this work.
instructions
manual before beginning this work, The responsibility of the personnel for
Gardner Denver accepts no particularly the chapter on safety operating, setting up, maintaining and
responsibility for any damage or injury instructions. It is too late to do this while repairing the machine / installation must
caused by non-compliance with these working. This applies particularly to be clearly defined.
safety measures or non-observance of personnel only using the machine
Make sure that only authorized
normal care and caution during the occasionally, e.g. for setting up and
personnel use the machine.
handling, operation, maintenance or repair maintaining the machine.
of this compressor, even if not expressly Define who is responsible for operating
Safety and danger-conscious working
stated in this operating manual. the machine, and authorize him to ignore
by the personnel in compliance with the
instructions from third parties if these
If any of the regulations contained in operating manual should be checked at
instructions could compromise safety.
this manual do not correspond to local least occasionally.
statutory provisions, particularly with Only allow personnel that are training,
The personnel must not have long, loose
reference to safety, then the stricter of that are under instruction or are attending
hair, or wear loose clothing or jewellery,
the two applies. a course of general training to use the
including rings, due to risk of injury
machine / installation under the constant
These safety instructions are of a through catching. Personal protective
supervision of an experienced person.
general nature and are applicable to equipment should be worn if necessary or
various types of machine and equipment. as required by regulations. Work on the electrical systems of the
For this reason it is possible that some machine / installation may only be carried
Pay attention to all safety and danger
information may not apply to the out by a trained electrician in accordance
warnings on the machine/ installation!
aggregate(s) described in this manual. with electrical regulations.
Make sure that all safety and danger
Only persons with special knowledge
Danger warnings on the machine / installation can
and experience of hydraulics may work on
be read.
Places thus marked refer to possible system elements, for example
dangers for persons. For all safety-relevant modifications to components under pressure.
the machine / installation or its operating
Attention behaviour, stop the machine / installation
immediately and report the fault to the 3.3 Modifications and alterations
Places thus marked refer to possible competent authority / person.
dangers for machines or parts of to the machine
machines. Spare parts must meet the technical
requirements laid down by the No alterations, additions, or
manufacturer. This is always guaranteed modifications to the machine may be
Note
when original spare parts are used. carried out without the approval of the
Places thus marked give general and manufacturer. This is also true for the
technical information for optimum, cost- Replace hydraulic hoses at the given installation and the adjustment of safety
effective machine use. intervals, or at suitable intervals, even if devices and valves as well as for welding
no safety-relevant defects are visible at supporting and pressurized parts.
(DIN 20066, Part 5). Unauthorized modifications to the machine
3.2 General safety instructions Observe the intervals stipulated or those are prohibited for reasons of safety.
given in the operating manual for routine Original parts are specially designed for
Organizational measures checks and inspections. our machines. We must explicitly point out
Please keep this operating manual Workshop equipment suitable for that parts and special accessories not
handy at all times on the site of the carrying out maintenance work is supplied by us are not approved by us.
machine / installation, in the bag provided. essential. Installing or using such products may thus
adversely affect active and/or passive
Please note and pass on general The location and operation of fire safety.
statutory and other binding regulations extinguishers must be made known.
that may supplement the operating Observe the instructions concerning fire The manufacturer accepts no liability
manual for the prevention of accidents alarm and fire fighting. whatsoever for damage resulting from the
and the protection of the environment. use of non-original parts or special
Such obligations may be for example the Limiting values (pressure, temperature, accessories. This also applies to the
handling of hazardous materials, or the time settings etc.) must be permanently installation and adjustment of safety
provision and/or wearing of personal marked. devices and valves as well as to welding
protective equipment, or traffic regulations. on bearing and pressurized parts.
Instructions, including supervisory Personnel selection and qualification; Note

responsibility and duty of notification for basic tasks
taking account of special in-plant factors, The General Type Approval becomes
Work on or with the machine /
for example regarding work organization, invalid in case of modifications or
installation may only be carried out by
sequences of operations, personnel alterations which change or infringe upon
reliable personnel. Observe the minimum
assigned to certain tasks, are to be added the external geometry as well as the gross
statutory age.
to the operating manual. axle weight rating.
9
3.4 Loading/Relocation/Transport Parts to be removed for transport On descents, always adapt speed to the
purposes must be carefully refitted and circumstances! Never change into low
Loading / Relocation fixed again before putting the machine / gear during the descent, but always
installation back into operation. beforehand. When leaving the driver's
All loose parts that could fall down when seat, always secure the unit to make sure
the machine is lifted must first be removed When putting the machine / installation
that it cannot roll away or be used without
or secured; pivoting parts like doors, etc. back into operation again, only proceed in
authorization!
must be immobilized. accordance with the operating manual.
Avoid all operations that adversely affect
For lifting heavy parts, hoisting gear and the stability of the unit.
heavy-lift facilities with the appropriate Transporting the complete unit
capacities, which have been checked and
Make sure that the air vessel is not
approved in accordance with local safety
under pressure. 3.5 Installation on site / Starting /
regulations, must be used.
Lift and secure supporting gear. Normal operation
For lifting machines or parts of machines
with one or more lifting eyes, only hooks Make sure that the drawbar eye can Installation on site
or shackles complying with local safety move freely in the tow bar.
regulations may be used. Never fasten Besides the general technical operation
cables, chains or ropes to or through lifting Check to make sure that the drawbar is in accordance with the regulations of the
eyes. adjusted to the bar height of the towing local authorities, it is essential that the
vehicle. following guidelines be observed.
Lifting hooks, lifting eyes, shackles etc.
must never be bent and must always be Check to make sure that the body is Before switching on the machine /
stressed in alignment with the load- closed and locked, and that the cable for installation, or starting it up, make sure
carrying axis. The load capacity of the the rapid-emergency brake is connected that nobody can be injured by the
hoisting gear is reduced if the lifting force to the towing vehicle. machine / installation as it starts up.
is applied at an angle to the axis. Join up the connections of the air brake, The installation is to be set up in such a
All bearing parts must be stressed if present. way that it is adequately accessible and
vertically, as far as possible, for maximum that the necessary cooling is ensured.
Check to make sure that the wheels are
safety and optimum performance of the Never block the admission of air.
properly tightened, that the tyres are in a
hoisting gear. If required, a support is to roadworthy condition, that the tyre The air intake is to be designed in such
be installed between the hoisting gear and pressure is correct and that the brakes a way that no dangerous admixtures
the load. Secure the load properly. function properly. (inflammable solvent vapours etc., but
When heavy loads are being conveyed also dust and other dangerous or toxic
Connect the cable for the signalling
by means of hoisting gear, it is imperative substances) can be taken in. This also
and lighting fittings. Check the proper
to keep well clear of the load in order to applies to flying sparks.
functioning of the lighting.
avoid accidents. The air intake is to be designed in such
Release the handbrake.
Never leave the load suspended on the a way that no loose personal clothing can
hoisting gear. Before transporting the unit, always be drawn in.
check to make sure that the accessories
Acceleration or braking of the means of Make sure that the compressed air line
are firmly attached so that they can cause
transport must remain within the approved from the compressor to the air network
no accidents!
limits. can expand as a result of heat and cannot
When using public roads, tracks and come into contact with inflammable
The hoisting gear is to be set up in such spaces, observe the current traffic materials.
a way that the object is lifted vertically. regulations, and if necessary make the
Should this not be possible, precautions The compressed air line connected at
unit roadworthy first!
must be taken to prevent the load from the air exit of the unit must not be under
swinging. Thus it is possible to use two Never exceed the maximum towing strain.
sets of hoisting gear, both with an angle of speed. Observe national regulations!
Compressed-air lines have to be marked
inclination of not more than 30° to the Always switch on lights if visibility is poor distinctly according to local regulations.
vertical. and during lighting-up time!
If several compressors are arranged in a
Nominate experienced supervisors for When going through underpasses, system, manually operated valves have to
the lifting process. bridges, tunnels, overhead power lines, be installed so that each machine may be
Machines may only be hoisted correctly etc., always make sure that you have shut off individually. For the purpose of
using hoisting gear in accordance with the enough clearance! shutting off pressurized systems, you
information in the operating manual (limit should never rely on the effectiveness of
Always keep a safe distance from the return valves alone.
stop points for heavy-lift facilities etc.) edges of foundation ditches and
Only use a suitable transport vehicle embankments! Safety devices, protective covers, or
with sufficient carrying capacity. insulations mounted on the system must
Do not travel across slopes transversely: not be removed or modified in any way.
Before or immediately after completion always keep equipment and loads near
of loading, secure the machine / ground level (for example, do not place
installation to prevent accidental shifting. them on the bodywork).
Display an appropriate warning. Before
putting the machine / installation back into
operation, the securing devices must be
duly removed.
10
All pressure tanks located outside the Make sure that: Never play about with compressed air.
unit with an approved operating pressure
* All bolted connections have been Never direct compressed air onto the
higher than atmospheric pressure and
tightened skin or towards another person.
fitted with two or more pressure feed lines
must be equipped with an additional * All electrical wiring has been connected Never use compressed air for cleaning
safety device to automatically prevent the correctly and is in good condition clothing. When using compressed air to
approved operating pressure from being clean equipment, work with extreme
exceeded by more than 10%. * The engine exhaust system is
caution and always wear suitable eye
operationally safe and that no
protection.
Pipes and other parts with a surface inflammable material is in the vicinity
temperature of more than 80 °C must be The compressed air produced by these
suitably secured against contact and * The wheel nuts are properly tightened;
compressors must not be used as breath-
suitably marked. never exceed the specified torque.
able air, unless it has been processed
specially for such an application in
Electrical connections must comply with
accordance with the “Safety requirements
local regulations. Normal operation
for breathable air.”
With compressors fitted with generators, Before starting work, make yourself
When breathing apparatus with
use equipotential bonding systems for the familiar with the working environment at
cartridges is used, make sure that the
protection of persons. the installation site. The working
correct cartridge has been inserted and
environment includes, for example,
Install the machine so that it is as that its service life has not expired.
obstacles in the working and transport
horizontal as possible; a slight inclination
areas, the carrying capacity of the ground, Never use the machine in environments
is permissible (see information in Chapter
and any necessary cordoning off of the where the possibility cannot be ruled out
"Installation").
building site from public traffic areas. that inflammable or toxic vapours may be
Set up the machine in such a way that taken in.
Take the necessary precautions to make
no inlets, outlets or gates are blocked,
sure that the machine / installation is only Never operate the system at
even when the doors are open.
operated in a safe, functional condition. temperatures and/or pressures below or
Before disconnecting the machine from above the values indicated in the technical
Only operate the machine when all
the towing vehicle, apply the handbrake. data sheet.
protective devices, shutdown devices,
Disconnect the rapid-emergency brake
sound-insulating equipment and extraction Persons working in environments or
cable and lighting cable, disconnect the
equipment are in place and working. rooms in which the acoustic pressure is
lines of the air brakes, use chocks to
85 dB(A) or higher must wear earmuffs.
ensure that the machine does not roll Be careful: loose articles of clothing, hair
Caution: this may impair communication
away. or limbs can still be drawn in by revolving
between persons. Warnings may not be
parts.
If a machine with a combustion engine heard. Inform supervisor.
has to work in a fire-risk environment, the Verify regularly that:
Shielding and doors must be closed
unit must be fitted with a spark catcher.
* All protective equipment is properly during operation so that the flow of cool air
In dusty environments, set up the positioned and fixed in place within the housing is not deflected and the
machine in such a way that the wind does efficiency of the sound insulating is not
not blow dust in its direction. During * All hoses and/or pipes within the reduced. Doors and hoods may only be
operation in clean environments, the system are in good condition, are opened briefly.
intervals for cleaning the air intake filter properly fixed in place and do not chafe
With water-cooled combustion engines
and the cooler elements are much longer. * There are no leaks (fuel, oil or coolant with a closed cooling circuit, the cap of the
Do not install the machine directly in leaks) coolant recovery bottle must not be
front of walls. Make sure that the warm air * All bolted connections have been removed before the system has cooled
coming from the engine and cooling tightened down to ambient temperature.
systems is not drawn into the air intake
* All electrical wiring is properly Never fill up with fuel while the engine is
under any circumstances. Drawing this
connected and is in perfect condition running. Make sure that fuel does not
warm air in through the engine or cooler
come into contact with hot machine parts.
fan could lead to overheating; if it is * Safety valves and other pressure-relief
drawn into the combustion chamber, this devices are in perfect condition and are Do not smoke while filling up with fuel.
will result in a loss of power. not blocked, for example by dirt or paint Filling up at a pump can cause static
Never relocate the machine if external * The safety devices all work properly electricity and possibly sparks. In order to
lines or hoses are connected to the avoid this, a ground cable must be
discharge valves, in order to avoid All connected components must be of connected to the system while it is being
damage to the valves and/or collecting the correct size and be suitable for the filled up.
pipe and hoses. specified operating pressure and
temperature. The exhaust emissions of combustion
No force may be exerted on the engines contain carbon monoxide - a
discharge valves, for example by pulling Only use the correct type and size of lethal gas. If a machine with such an
the hoses or fitting additional equipment hose coupling and connection. engine has to work in an enclosed room,
(e.g. a water separator, compressed air the exhaust gases must therefore be
Before blowing through a hose or air
oiler, etc.) directly to the discharge valve. conducted out of doors by means of a
line, it is essential to hold the open end
firmly. If the open end is not held firmly, it hose or pipe with an internal diameter of
can whiplash and cause damage or injury. at least 150 mm. The use of extraction
systems is highly recommended in test
Avoid any working methods that could rooms for mobile machines.
be considered risky!
11
Before connecting or disconnecting For all work concerning the operation, After the work has been completed,
hoses, always close the compressor air production adjustment, conversion, or replace any protective devices that have
outlet valves. Before disconnecting a settings of the machine / installation and been removed. Operation without
hose, always make sure that it is not its safety-relevant equipment, as well as protective devices is not permissible.
under pressure. servicing, maintenance, and repair,
Working clothing should be close-fitting
observe the operating manual for start-up
A hose connected to an air valve must during work on running screw compressor
and shutdown procedures and the
be fitted with a safety wire for operating systems.
instructions for maintenance work.
pressures above 7 bars; it is in fact
recommended that this safety device All maintenance and repair work may
Maintenance
should be used for pressures above only be carried out when the system is
4 bars. The steel wire has a diameter of shut down, or, with electrical systems, During maintenance and repair work, the
8 mm and is firmly clamped to the hose at when the mains power supply is switched contractor has to inform the personnel
least every 500 mm. Both ends are fitted off. Make sure that the equipment cannot about the dangers that can occur during
with cable lugs. be switched on by accident. their work and about measures to avert
such dangers.
Check the machine / installation for Whenever the machine/system is com-
external damage and faults at least once pletely powered down for maintenance The personnel have to support all
per shift. Any changes noticed (including and repair procedures, it has to be measures to improve safety at work.
changes in operating performance) must secured against unintentional power-on
be reported immediately to the authority or or the mains supply has to be cut off Safety devices for preventing or
person in charge. If necessary, shut down with electrical systems. eliminating dangers must be serviced
and secure the machine immediately. regularly and their functioning tested at
* Switch off battery master switch and/or least once per year. Faults discovered
In case of malfunction, shut down and detach connector. must be corrected at once or reported
secure the machine / installation to the supervisor.
* Put up a warning sign on the main
immediately. Have malfunctions corrected
switch “Attention! Maintenance work.” Only use the correct tools for
immediately.
Close off the complete maintenance maintenance and repair work.
Observe the operating manual for start- area, if required.
up and shutdown procedures as well as Only use original spare parts.
* Disconnect the starter battery.
inspection displays. All maintenance and repair work may
Individual parts and larger subassem- only be carried out when the system is
blies must be carefully attached to the shut down, or, with electrical systems,
3.6 Special jobs / Maintenance hoisting gear and secured in case of when the mains power supply is switched
replacement. off. Make sure that the aggregate cannot
Care be switched on by accident.
Only use suitable, technically perfect
Observe the setting, maintenance, and hoisting gear and load suspension devices Whenever the machine/system is com-
inspection work and intervals stipulated with adequate carrying capacity. Keep pletely powered down for maintenance
in the operating manual, including clear of suspended loads. and repair procedures, it has to be
information about the replacement of secured against unintentional power-on
Before removing any part under
parts / partial sections. This work may or the mains supply has to be cut off
pressure, separate the aggregate
only be carried out by specialists. with electrical systems.
effectively from all sources of pressure
Maintenance work, tests and repairs and release the pressure from the * Switch off battery master switch and/or
should be carried out in a well ventilated complete system. detach connector.
room, away from heat, open flames, or
Never use inflammable solvents or * Put up a warning sign on the main
sparks. Appropriate prohibition signs (fire,
carbon tetrachloride to clean parts. switch “Attention! Maintenance work.”
open flames, no smoking) must be put up.
Close off the complete maintenance
Take precautions to avoid toxic vapours
Loss of oil leads to a very slippery floor. area, if required.
from cleaning fluids.
Statistics have shown that many accidents
can be attributed to the installation or * Disconnect the starter battery.
Absolute cleanliness is essential during
maintenance of machines on oily floors or maintenance and when carrying out Before removing or opening any part
machine components. For this reason, repairs. under pressure, separate the equipment
always start maintenance work by effectively from all sources of pressure
cleaning the floor and the machine Only carry out maintenance and repair
and release the pressure from the
exterior. work when the machine is located on an
complete system.
even, stable base and is secured against
Inform operating personnel before running away and against buckling. For moveable machines support the
beginning to carry out special work or towing mechanism and axle with
maintenance. Nominate a supervisor. Only carry out inspection, maintenance,
appropriate means if work is to be carried
and repair work when the screw com-
After completing repair work, always out underneath the units (a jack is not
pressor system is at a standstill and is not
check to see whether any tools, loose sufficient).
under pressure.
parts or cloths have been left in or on Observe the safety precautions for work
the machine, driving engine or driving Protective devices, i. e. protective grids,
on batteries.
equipment. may not be removed during operation.
Pay attention to cleanliness. Prevent
Maintenance and repair work is only to Caution while the screw compressor is
dirt from entering by sealing the parts and
be carried out under the supervision of or in operation.
exposed openings with a clean cloth,
by a person qualified for this work. paper, or tape.
12
Before the aggregate is approved for The insulation or protective shielding of Always tighten bolted connections
operation after maintenance or an parts whose temperature may exceed loosened during maintenance and repair
overhaul, make sure that operating 80 °C and which personnel may work.
pressures, temperatures, and time accidentally touch may not be removed
If it is necessary to dismantle safety
settings are correct and that the control before these parts have cooled down to
devices during machine set-up, mainte-
and shutdown devices are working room temperature.
nance, and repair work, the safety devices
properly.
Check the accuracy of the pressure must be reassembled and checked imme-
The electric motor, generator, air filter, and temperature displays regularly. If the diately after completing the maintenance
electrical components and control permissible tolerance limits have been and repair work.
equipment are to be protected against exceeded, then they must be replaced.
Ensure safe, environment-friendly
the penetration of dampness - for
Never carry out welding work or any disposal of process materials as well as
example when cleaning with a steam
other work that produces heat in the replaced parts. Oil containing
jet - by covering or sealing them.
vicinity of fuel or oil systems. Systems, components, such as fine separators and
Under no circumstances should the which could contain fuel or oil, have to be oils, must be disposed of in accordance
sound-insulating material be removed or completely drained and cleaned, e.g. by with the relevant legal provisions. Oil must
modified. means of a steam jet, before proceeding not enter the soil!
with the work to be carried out.
Never use solvents with dangerous
properties for cleaning parts. Never carry out any welding work on any
Safety precautions for work with
pressure tank or components under
Maintenance work, tests, and repairs batteries
pressure, or modify them in any way.
should be carried out in a well ventilated
The fluid contained in batteries is diluted
room, away from heat, open flames, or If work causing heat, flames, or sparks
sulphuric acid which can cause blindness
sparks. Appropriate prohibition signs (fire, has to be carried out on a machine, the
if brought into contact with the eyes, or
open flames, no smoking) must be put up. surrounding components must be
serious burns if brought into contact with
protected with non-flammable material.
Wear suitable eye protection when the skin. For this reason it is essential to
inspecting the system. Make sure that the Before dismantling or overhauling a work with the greatest of care when
openings of spray containers, valves, compressor, engine, or any other servicing batteries, e.g. when checking
pipes, or atomizers are never directed at machine, make sure that no movable battery charge, and to take all necessary
yourself or at any other person during the part with a weight of more than 15 kg safety precautions.
inspection. can move or roll away.
Always wear long-sleeved overalls, acid-
The fuel used in these systems is highly Machines whose main movement is resistant gloves and safety goggles.
inflammable, toxic and poisonous. Avoid back and forth must be moved at least
On charging a battery, an explosive gas
contact with eyes and skin, and never once, rotating machines several times,
mixture is formed in the cells, which can
inhale vapours. Should you accidentally in order to make sure that there is no
escape through the vent holes in the
swallow fuel, do not induce vomiting, but mechanical malfunction in the machine
sealing caps. If ventilation is poor, a highly
seek medical attention. or in the driving part.
explosive atmosphere can form around
Should fuel come into contact with the Only experienced persons may be the battery, and can persist for several
eyes, or in case of eye irritation by charged with slinging loads and instructing hours after charging.
vapours, flush eyes with plenty of clean crane drivers. These instructors must
Thus:
water and seek medical attention. remain within sight of the operator or be in
touch with him via walkie-talkie or similar * Never smoke in the vicinity of batteries
Every time a message is displayed or
device. that are being charged or have just
there is a suspicion that an internal part
been charged.
of the machine has overheated, the During assembly work above body
machine must be shut down. Never open height, use appropriate or otherwise * Put up prohibition signs for fire, open
the inspection cover, however, before the safety-relevant climbing aids and working flames and smoking in workshops
machine has cooled down sufficiently to platforms. Do not use machine parts as where batteries are charged.
rule out the possibility of the oil vapours climbing aids! Wear safety belts when
igniting spontaneously when mixed with carrying out maintenance work at greater * Never interrupt a current-carrying
air. heights. circuit at battery terminals because
of the danger of spark formation.
In order to avoid an increase in Keep all steps, handles, railings,
operating temperature, inspect and clean platforms, scaffolds, and ladders free of * Proceed particularly cautiously when
the heat transfer surfaces (cooling ribs dirt, snow, and ice. connecting or disconnecting rein-
etc.) regularly. Draw up a schedule for the forcement cables or quick-charge
Before beginning maintenance and cable clamps.
most suitable cleaning intervals for each
repair, clean the machine, particularly
machine. When starting up using jumper cables
couplings and bolted connections, of oil,
Avoid damaging the safety valves and fuel, and special care products. Do not or auxiliary batteries, first connect the
other pressure-reducing devices. In use aggressive detergents. Use lint free positive terminals and then the negative
particular, make sure that they are not cloths for cleaning. terminals. After starting the engine, first
blocked through paint, oil carbon, or disconnect the negative terminal (ground
After cleaning, remove all covers and cable) and only then the positive terminal.
dust accumulation, which could impair
seals. Disconnect the auxiliary battery after the
the effect of these devices.
starting procedure in order to avoid the
After cleaning, check all fuel, engine oil,
risk of the release of gas (explosion
and hydraulic fluid lines for leaks, loose
hazard).
connections, chafing and damage. Correct
any faults immediately.
13
3.7 Instructions concerning Gas, dust, steam, smoke Noise

particular hazards Only carry out welding, burning, and Protect personnel at risk from noise, in
grinding work on the machine / installation accordance with EU Directive 2003/10/EU.
Electrical Energy when this has been explicitly permitted,
Only use original fuses with the as there may be for example risk of fire
and/or explosion. Oils, Greases and Other Chemical
specified amperage.
Substances
In case of faults in the electrical Prior to welding, burning and grinding
remove any dirt and inflammable sub- When handling oils, greases and other
power supply, shut down the machine /
stances from the machine/system and its chemical substances, observe the safety
installation immediately!
environment and ensure proper ventilation regulations applicable for the product.
Work on electrical systems or equipment (danger of explosion)! Caution when handling process
may only be carried out by a trained
Only operate combustion engines in materials (risk of burning / scalding).
electrician or by trained persons under
the leadership and supervision of a trained properly ventilated rooms. Ensure ventila-
electrician in accordance with the tion is adequate before starting up in
standards of electrical engineering. closed rooms. Potentially-explosive environments
Machine and system parts where Always adhere to the legal provisions The operation of the compressor in
service, maintenance, and repair work is applicable to the particular location! areas where there is a risk of explosion is
being carried out must be switched off strictly forbidden! (Exception: specially-
Follow the local regulations applicable made compressors with the necessary
load, if required by regulations. First check at the respective site of installation.
the deenergized parts to make sure they technical modifications for use in such
are off load, then connect to ground and areas)
short-circuit, and insulate neighbouring Hydraulic and pneumatic systems
parts that are under tension.
Work on hydraulic equipment may
Note
The electrical equipment of a machine / only be carried out by persons with
installation must be inspected / tested special knowledge of and experience Gardner Denver accepts no responsibility
regularly. Faults, such as loose con- in hydraulics. for any damage or injury caused by non-
nections or overheated cables, must be compliance with these safety measures or
Check all lines, hoses, and bolted
corrected immediately. non-compliance with normal care and
connections regularly for leaks and visible
caution during the handling, operation,
If work has to be carried out on live damage. Repair any damage immediately.
maintenance or repair of this compressor,
parts, then call in a second person to It is essential that damaged parts should
even if not expressly stated in this
operate the emergency stop switch or be replaced! Spurting fluid can lead to
operating manual.
master switch with over voltage release. injuries and fires.
Cordon off the working area with a red-
Before beginning repair work, relieve
and-white safety chain and a warning
the pressure in system sections to be
sign.
opened and in pressure lines (hydraulic
Only use insulated tools. and compressed-air lines) in accordance
with the descriptions of the
Keep an adequate distance between subassemblies.
the machine/unit and overhead power
lines! When working near overhead power Hydraulic and compressed-air lines
lines, equipment must not come near the must be routed and fitted in accordance
power lines! Danger! Find out about the with the regulations. Do not confuse the
safe distance to be observed! connections!
After touching high-voltage lines: The fittings, length, and quality of
hoses must be in accordance with the
* Do not leave the machine. requirements.
* Move the machine away from the
danger area.
* Warn outsiders not to come closer or
touch the machine.
* Make sure that the voltage is switched
off.
* Do not leave the machine until the line
which has been touched or damaged,
has been switched off load!
When working with high-voltage
assemblies, ground the supply cable
after voltage has been isolated, and
short-circuit the components, e.g.
capacitors, with a ground rod!
14
3.8 Symbols and definitions
Carefully read the Operating Manual Check cooling water level, engine oil Tie down point
before machine set-up and level and compressor oil level before
maintenance. starting up.
Never attempt to operate the machine Attention: Hot surfaces Attention: Hot and dangerous exhaust
without the safety device mounted. fumes
Do not inhale any compressed air from Attention: Pressurized part or system. Do not step/stand on maintenance
the system. valve or other parts of the pressurized
system.
3,75 BAR
Lifting spot Attention: Maintain specified tyre

Never attempt to operate the machine
pressure! (See Chapter
with open or loose shielding.
Foreword, specifications.)
15
Condensate discharge (oil/water) Emergency stop device
System radiator/coolant recovery

Attention: Do not use an ether aerosol
reservoir may be under pressure.
Do not remove the Operating and

Maintenance manual and manual
holder from this machine.
Attention: Prior to starting any

maintenance work consult
the operating and
maintenance instructions
100
Attention: Max. permissible noise level
(See Chapter Foreword,
specifications.)
16
4. Construction and functional description
4 Construction and functional description
Fig. 3 4.1 Construction The drive unit is a water cooled charged

diesel engine with pre-compressed air
1 Screw compressor Compressor and engine heat exchanger. It drives the compressor
2 Diesel engine screw rotor via an elastic flange coupling
3 turbo charger 1 for engine The machine owes the increase in and a set of spur gears. The sizes of the
4 turbo charger 2 for compressor supplied air to the "TurboScrew" system. gears are chosen depending on the
5 air filter (compressor and engine) Here a turbo charger driven by the desired operating pressure of the
6 pre-compressed air heat exchanger exhaust of the engine supplies the oil- installation (8.6, 10, 12 or 14 bar).
7 water heat exchanger flooded CompAir screw compressor with
8 oil heat exchanger pre-compressed air. The machine
9 oil filter (compressor) provides a two-step compression with
Housing (casing)
10 pressure reservoir intermediate cooling. This thermo-
11 air outlet cock dynamically sensible compression The body consists of a floor panel
12 control panel principle allows a considerable increase in mounted on a base-frame. On this floor
13 battery the effeciency. In conjunction with the panel, all body components are screwed
14 suspension CompAir screw shape this compression onto or screwed to one another in form of
15 vehicle identification number system is at the latest state of technology. individual panels. Large flaps on all four
(type plate) sides allow easy access for service and
The machine components and the
16 chassis maintenance work. Their opening action is
pressure reservoir with the outlet element
17 fuel tank effectively supported by gas springs. The
are held on insulating elements which
18 exhaust muffler eye for attaching lifting tackle can be
prevent structure-born noise and dampen
easily reached through a flap in the roof.
down vibrations.
For convenient assembly, all individual
parts of the body are bolted together using
machine bolts. For effective corrosion
prevention, the individual parts are zinc-
phosphate coated, electrostatically
powder coated, and stove-enamelled at
220 °C.
17
All current noise regulations (15. Blm 4.2 Functional description circuit. The pressure sensor (12) only
SchV, ISO, EC directives) are complied allows the machine to be restarted when
with. The sound absorbing mats are (compare Fig. 4) the operating pressure has fallen below
inserted and may be cleaned easily. 1,5 bar.
Oil circuit
The oil needed for sealing and cooling
Frame and chassis the rotor and for lubricating the roller Control
bearings is injected from the pressure tank
The complete compressor unit is A combined throttle / rotational speed
(9) which is under system pressure into the
mounted on an easily movable tandem control allows a continuous air quantity
compressor (7). The pressure differential
support. The chassis is equipped with between 1 % and 100 % to be drawn.
between the pressure tank and the oil
automatic overrun brakes and parking
injection point is used to regulate oil When started up the engine (27) initially
brakes, as well as a jockey wheel
volume. The oil passes through the oil filter runs at a low gentle speed. The suction
adjustable in height.
(20), the oil temperature regulator (21), control valve (6) opens due to the intake
which depending on its temperature sends vacuum pressure created and the
the oil through the oil heat exchanger (22). compressor begins to transport air. Once
Air channelling Downstream of the compressor a a low operating pressure has been built
Fresh air is sucked in via a air inlet temperature sensor (8) is located which up, the suction control (6) closes and the
cover at the rear end of the roof. The fresh switches off the machine in the event of engine stays at the gentle rotating speed.
air is used for cooling the compressor and excess temperature. After a warm-up phase of around 60 sec
engine pre-compressed air. Under this the compressor system automatically
The oil collecting in the fine oil separator
cover the air supply for the engine is also increases the pressure to achieve
(10) is also transported back by the
taken up. In addition, fresh air flows into operating pressure. The warm-up phase
system pressure via an orifice plate (23).
the engine chamber through exactly is automatically shortened to 20 sec if the
matched inlet openings near the rear in The suction valve (6) is equipped with a system has already reached operating
the side walls, and is mixed with the air stop function which protects the air inlet temperature. When the operating pressure
coming from the air inlet cover over the tubes from flooding when the machine is has been reached the suction control
engine unit. In the front part of the switched off. valve (6) is loaded with control air by the
machine, the complete air flow is electronic proportional controller (17) and
conducted through the engine cooling the engine regulated to idling speed by the
water heat exchanger and the compressor Air circuit electronic control. This in turn regulates
oil heat exchanger. the machine down depending on
Two turbo chargers (3 and 4) are consumption until idling speed is reached
A bulkhead wall in the compressor connected in series in the exhaust gas again. When the machine is switched off
separates the cold and hot zones so that flow of the diesel engine (27) which take in the relief valve (14) opens and the
a thermal short between the engine fresh air via two air filters (1). The pre- compressor is automatically bled.
compartment and the cooling air compressed air is than cooled down in the
discharge area is excluded. pre-compressed air heat exchanger (5) In any of the following situations the
and then entered into the diesel engine machine is automatically switched off or
(27) or the screw compressor (7). When the engine speed reduced:
the suction regulator (6) is set to the * No charge voltage
closed position the pre-compressed air
transported to it is blown out of the * Lack of cooling liquid (level switch 29)
machine in order to prevent damage to the
* Temperature of cooling water
turbo charger (6). When the suction
above 107 °C speed reduction or
regulator is open the pre-compressed air
switching off above 113 °C
passes into the screw compressor (7).
During the compression process oil is * Oil pressure under 0.9 bar
injected here for lubricating, cooling and
sealing the screw rotor. The compressed * Compressor oil temperature over
air / oil mixture flows into the pressure 120 °C (temperature sensor)
tank (9). Here a preliminary centrifugal * Pre-compressed air temperature over
separation of the oil is achieved when the 95 °C
mixture enters the tank in a tangential
direction. The remaining oil is separated * Pressure sensors with cable break or
from the air in the fine oil separator (10). outside the permissible value range
After this the nearly oil-free compressed air * Water in fuel
reaches the compressed air outlet cocks
(15) via the pressure maintenance valve
(13) with integrated stop valve (13). The
pressure maintenance valve (13) reliably
prevents the system pressure from
dropping below the minimum operating
pressure required for the machine. The
differential pressure switch (2) for the air
filters, a temperature switch (24) for the
engine pre-compressed air, a temperature
switch (8) for the compressor oil, a system
pressure manometer (16) and a tempera-
ture sensor (12) are integrated into the air
18
4.3 System description
Fig. 4 A13534774
1 air filter 12 Pressure sensor 24 non-return valve
2 differential pressure switch 13 pressure maintenance valve 25 Pressure sensor
3 exhaust turbo charger for engine 14 relief valve 27 diesel engine
4 exhaust turbo charger for compressor 15 air outlet cocks 28 non-return valve
5 pre-compressed air heat exchanger 16 Pressure limiter 29 compensation tank with level switch
for compressor and engine 17 Electronic proportional regulator 30 water heat exchanger
6 suction control valve 18 non-return valve 31 diesel tank with level switch
7 compressor 19 Quick-acting valve 32 bypass valve
8 temperature switch 20 oil filter 33 nozzle for venting mechanism
9 pressure tank 21 oil temperature regulator 34 aperture for venting mechanism
10 fine oil separator 22 oil heat exchanger 35 venting mechanism
11 safety valve 23 orifice plate in suction pipe
19
4.4 Wiring diagram
Fig. 5 A13534874
1 Starter 8 Solenoid valve emergency tripping F1 Fuse 10 A
2 Generator 9 Tank pressure (4...20 mA) F2 Fuse 30 A
3 Relay for voltage supply 10 Control pressure (4...20 mA)
4 Relay for starter 11 Cooling water level SO Main switch control panel
5 Solenoid valve for volume flow 12 Pressure gland temperature S1 Ignition switch
6 Solenoid valve pressure relief 13 Fuel level low
7 Option
20
4.5 Terminal Diagram DIN ISO 1724
Circuit connector
blue (54 G) rear fog lamp
right side marker lamp

Connector
white right licence plate lamp
black brown (58 R) right tail lamp
yellow green (R) right indicator lamp
red red (54) right stop lamp

left stop lamp
green yellow (L) left indicator lamp
brown black (58 L) left tail lamp
blue
left licence plate lamp
left side marker lamp

white (31) ground
Fig. 6 105 580 74

The terminal diagram is designed for a voltage of 12 Volts!
21
5. Transport and installation on site
5 Transport and installation on si te
5.1 Transport Danger Attention
The screw compressor may only Always keep a safe distance from the
be transported on public roads if edges of foundation ditches and
embankments! Do not travel across
* The machine group (engine) is slopes transversely.
not running,
* The pressure tank is not under
pressure,
* The shielding is closed, 5.2 Attachment of the contact-
* The blocks are firmly hooked in breaker cable on braked
place, chassis
* Hoisted and secured tail wheel,
If the towing connection becomes
* The tyres and brakes are uncoupled, the trailer is braked by the
operationally safe and roadworthy, breakaway cable. Put the breakaway
cable in the eye provided or wind it
Fig. 7 * The lighting is fully functional.
around the towing collar and hitch it up
Never exceed the maximum towing to the cable with the snap link.
speed! Danger! Observe national
The breakaway cable must be attached
regulations!
in a way that ensures that even on
Please also observe the safety extremely sharp bends there is no danger
instructions in Chapter 3 on the of activating the locking brake.
subject of transporting.
Before transporting the compressor,
check to make sure that the draw gear of
the towing vehicle and the drawbar eye
or trailer hitch ball connection are aligned
exactly to each other.
When transporting the screw compressor
with a vehicle, the following points must
Fig. 8 be observed:
* The shielding is closed.
Danger
* The blocks are firmly hooked in place.
Fig. 9
Make sure to check the torque after
* The support(s) is(are) retracted and
50 kilometers following wheel
locked in position (jockey wheel).
mounting and at regular intervals.
Tighten wheel nuts or screws evenly * Drawbar is connected to the towing
in a diagonal sequence to the specified vehicle.
torque using a torque wrench. * The drawbar is adjusted to the height
of the towing vehicle (option).
Replacing the trailer coupling ring * The contact-breaking cable is
The coupling arrangements which can connected to the towing vehicle. Safety
be used: chains are attached on towing vehicle.
* Trailer coupling ring DIA 40 in * The electrical cable (option) is

accordance with DIN 74054 - 40A connected to the vehicle and to the
screw compressor.
* ball coupling Ø 50
* Check the lights (tail lights, brake
* coupling ring DIA 76.2 VG 74059 lights, indicator lights, and rear fog
lamp) (option).
A different coupling unit in the form of a
complete kit may be ordered, if necessary. * Check to make sure that the wheels
Replacing the trailer coupling ring is are properly tightened, the tyres are
permitted only if proper fitting is carried out in a roadworthy condition and the tyre
by an inspectorate for the sector covered pressure is correct (danger of
by the Regulations Authorizing the Use of accidents).
Vehicles for Road Traffic (e.G. the TÜV -
Technical Inspectorate, DEKRA - German * When parking the compressor prior to
Motor Vehicle Monitoring Association, uncoupling from the towing vehicle
etc.). The inspection station provides a actuate the handbrake, detach the
fitting certificate to be kept with the vehicle contact-breaker cable and the lighting
documents. cable, and secure the compressor
against rolling using chocks. Then
adjust to the horizontal position by
means of a support or support wheel.
22
5.3 Loading/Relocation Never relocate the machine if external 5.4 Installation on site
lines or hoses are connected to the
discharge valves, in order to avoid
damage to the valves and/or collecting
pipe and hoses.
When loading, the following points must
be observed:
* Secure the load suspension device or
the hoisting gear in the lifting device of
the screw compressor.
A = 1m
* When hoisting the compressor, set up B = 1m
the hoisting gear in such a way that the
compressor, which must be set up
Fig. 10 Fig. 11
horizontally, is lifted vertically.
Danger * Only relocate the compressor by itself. Danger
* Raise and lower the compressor The air intake must be positioned in
Only use hoisting gear (e.g. crane) with
carefully. such a way that loose personal
appropriate lifting capacity for the
loads occurring! clothing cannot be drawn in.
* After relocating, remove the load
suspension device or the hoisting gear Make sure that the pressure pipe from
Only use the correct suspension gear!
from the lifting device. the compressor to the aftercooler or
Keep clear of the swiveling range of the the air system can expand as a result
* Tie down the compressor on the cargo
hoisting gear! of heat, and that it does not come into
area of the means of transport.
contact with inflammable materials.
Keep clear of suspended loads!
* Only tie to the pull tube or to the wheel
The air intake is to be designed in such
All loose parts that could fall down axles, or use the openings provided in
a way that no dangerous admixtures
during hoisting must first be removed the frame
(inflammable solvent vapours etc.,
or secured; pivoting parts, like doors,
* When the chassis is being dismantled, but also other dangerous or toxic
towbars, etc. must be secured in such
the shielding with machine group may substances) can be taken in. This also
a way that they cannot move.
only be supported under the base applies to flying sparks.
Never leave the load suspended on the frame.
Pipes and other parts with a surface
hoisting gear. Acceleration or braking
temperature of more than 80 °C must
of the means of transport must remain
be suitably secured against contact
within the approved limits.
and suitably marked.
Please also observe the safety
The operation of the compressor in
instructions in Chapter 3 on the subject
areas where there is a risk of explosion
of loading.
is strictly forbidden! (Exception:
Attention specially-made compressors with the
necessary technical modifications for
Do not attempt to use a crane hook or use in such areas)
similar load suspension devices direct
Please also note the safety instructions
on the lifting device to avoid damages
in Chapter 3 on the subject of
to the lifting device!
installation on site.
Use proper hoisting gears only such as
hoisting straps in compliance with DIN
standard 61360 with proper lifting ca- Location
pacity for connecting the load
suspension device (e.g. crane) and the The complete system is to be set up in
lifting device. such a way that it is easily accessible and
that the required cooling is guaranteed.
Only deploy load bearing equipment Never block the air intake. Ensure that the
which corresponds to the safety entering of moisture and dirt together with
instructions for lifting gear. the intake air is kept to a minimum.
Use a transport harness compliant The compressor is to be set up away
with local regulations for transporting from walls.
by helicopter. The eyes provided may
not be used for this purpose (max.
acceleration if the eyes are used =
2 x g)
Never lift up or lash down the unit
using the shielding!
23
Attention Attention
The screw compressor is to be set up No force may be exerted on the dis-
in such a way that no air reflection can charge valves, for example by pulling
take place, i.e. neither waste air nor the hoses or fitting additional
exhaust emissions may be drawn in; equipment (e.g. a water separator,
the same applies to dangerous compressed air oiler, etc.) directly at
admixtures to the air. Drawing this the discharge valve.
waste air in could lead to overheating
and a loss of power.
Temperatures/air humidity
The compressor must be set up in as
horizontal a position as possible. Install the compressor in a location with
Maximum permissible inclination during maximum possible frost protection. The
operation: suction air temperature must be within the
range specified on the data
* In direction of pull: 15 degrees
* Backwards: 15 degrees
Note
* To the right and to the left: 15 degrees
Particularly in case of installation out of
doors and at night, observe fuel tempera-
ture. At temperatures below 0 °C, summer
diesel fuel tends to precipitate and block
the fuel filter. In this case use winter diesel
fuel.
15° 15°
15° 15°
Fig. 12
Attention
Greater inclinations endanger the

operating reliability of the screw
compressor.
When setting up the unit on ground that
is not horizontal, or with a variable angle
(see operating instructions) please consult
CompAir.
Set up the machine in such a way that
no inlets, outlets or gates are blocked,
even when the doors are open. Prior to
uncoupling from the tow vehicle, apply the
handbrake. Disconnect contact-breaking
cable and lighting cable, uncouple air
brake lines. Secure wheels with chocks.
Note
In dusty environments, set up the machine
in such a way that the wind does not blow
the dust in the direction of the machine.
During operation in clean environments,
the intervals for cleaning the air intake
filter and the cooler elements are much
longer.
24
6. Preparing the compressor for operation
6 Preparing the compressor for opera tion
6.1 Checking oil levels 6.1.2 Checking the oil level in 6.2 Battery
the engine
6.1.1 Checking the oil level in
the pressure tank
Fig. 15
Fig. 14
Danger
Fig. 13 Danger
When working with battery acid
Danger Only check the oil level when the (electrolyte), wear acid-resistant
compressor engine is at a standstill. goggles, gloves and apron.
Only check the oil level when the Spill no oil! The oil may be hot. Risk
of scalding! The gases released by the battery are
engine is at a standstill and the
explosive. Avoid sparks and open fires
compressor is not under pressure. Check for leaks. in the vicinity of the battery.
The pressure tank may be under Proceed as follows: Do not allow acids to come into contact
pressure and the oil may be hot.
* Ensure that the screw compressor is with skin or clothing. Wear safety
Risk of scalding! Spill no oil! standing horizontally. goggles.
Check for leaks. * Ensure that the screw compressor has Place no tools on the battery.
Proceed as follows: been out of operation for some time. The battery is filled and charged in
* Unscrew dipstick. accordance with DIN 43539. The battery is
* Before checking the oil level in the fastened with clamping strips.
engine and in the compressor ensure * The oil level should be as near as
that the vehicle is standing horizontally. possible to the upper dipstick mark. The batteries used are ready to be
installed and ready for service. Replace-
* Ensure that the screw compressor has * Correct as required. ment batteries should be of the same type
been out of operation for some time.
* Screw in dipstick. as the batteries installed (low gassing).
* Unscrew dipstick. The replacement battery should be unfilled
* Close oil filler. and only be preloaded so that it has to be
* The oil level should be within the marks
* For oil specifications, see “Engine filled with battery acid. The battery and the
on the dipstick.
Operating Manual”. acid should have a temperature of at least
* Correct as required. +10 °C.
* Check the seal on the dipstick and Attention Proceed as follows:
replace if required. After a short test run, the oil level * Fill up with battery acid as far as the
* Screw in dipstick and tighten firmly. should be between the markings on base of the control insert
the dip stick.
Attention * Leave the battery to stand for some
For oil specifications, see engine time
After a short test run, the oil level instruction manual.
* Then shake it gently
should be between the markings on
the dip stick. For oil specifications, see * If required, top up with acid
recommended lubricants, Chapter 8.1.
* Tighten sealing caps
With a system which has been out of
operation for some time, run the * Leave for 1 hour
machine for an approx. 1 minute warm- * The battery is ready for use
up period and then check the oil level.
25
6. Preparing the compressor for operation
6.3 Filling up the fuel tank
Fig. 16
Danger
Only fill up with fuel when the screw

compressor is at a standstill.
Cleanliness is essential! Spill no fuel!
Filling up at a pump can cause static
electricity and possibly sparks.
Proceed as follows:
* Open tank lid
* Fill up tank with commercially available
branded diesel fuel, using a sieve (use
summer or winter diesel fuel depending
on outside temperatures)
* Close tank tight with tank lid
* Close the covering.
Note
The fuel tank should always be filled up
in good time. The fuel gauge displays the
fuel level.
For outside temperatures below 0 °C, use
only winter diesel fuel.
More information on fuel quality, see
engine operating manual.
For outside temperatures below 0 °C,
observe the operating manual of the
engine manufacturer for winter operation.
You can reduce the occurrence of
condensation in the fuel tank considerably
by filling it up in good time. This also
prevents downtimes and starting problems
that can occur when the fuel tank is run
dry.
26
7. Putting the compressor into operation
7 Putting the co mpressor into opera tion
7.1 Initial operation 7.3 Start-up Starting up the compressor:

* Close air tapping cocks.
Transport inspection Danger
* Turn ignition key to position "I" (on).
Every CompAir screw compressor Symbols 1 and 8 light up.
Before starting up, make sure that no
has already run in the factory and has
one is in the danger area of the engine /
already undergone a thorough test before * Press start button
screw compressor.
shipment. This test ensures that the
* The system starts for 15 seconds.
compressor complies with the given data Compressors may not be operated in
and works perfectly. Independent of hazardous environments unless they Danger
the care taken in the factory, it is still have been specially designed for this
possible for the compressor to be purpose (e.g. exhaust protected If the start is not successful, the
damaged during transport. For this reason against emission of flying sparks etc.). system attempts to start for a
it is recommended that the unit should be second and third time after a short
examined for possible damage during Never, under any circumstances, use
"Startpilot" (Spray-can starting aid), waiting period.
transport.
ether or other starting aids - Danger of * After starting the engine runs in idle
Remove any transport seals (dummy explosion! and the compressor at reduced
flange, plugs, etc.) and dehydrating pressure.
After service work has been
agents before start-up. Distribution tubes
and connection lines must have the completed: Make sure that all * Depending on ambient temperature this
protective devices have been refitted will be followed by a warm-up phase of
specified dimensions and must be suitable
for use with the max. operating pressure and that all tools have been removed. the engine.
and the media to be taken up. The exhaust from the system contains * The system is now ready for operation.
During the first hours of operation, the carbon monoxide, a lethal gas. Check that the hoses / tools are
compressor should be observed in order The exhaust must be routed to the correctly connected and open the
to be able to ascertain any possible outside via a pipe or a hose with an requisite air bleed cocks.
malfunctions. internal diameter of not less than
Note
150 mm if the compressor is used
indoors. If the system also fails to start after the
7.2 Operating elements
third attempt at starting, you must wait
Adequate ventilation must be assured.
Operating panel: until the tank pressure has dropped. The
The use of an exhauster system is symbol "9" (see Fig. 17) shows when the
urgently recommended. tank pressure has dropped enough to
permit a start release.
Only operate the compressor with the
hood closed. The hood may only be
opened briefly for minor adjustments
while the compressor is running. Start-up using jumper cables /
Skilled personnel only are authorized auxiliary batteries
to work with the hood open.
When working with the screw
compressor in operation and with the
shielding/hood open, wear ear
protection.
Fig. 17
Caution: this may impair
1 Operating pressure in bar and psi communication between persons.
2 Individual fault type Warnings may not be heard. Inform
1 = Engine oil pressure supervisor.
2 = Engine water temperature
3 = Intercooler temperature Attention
4 = Airend temperature
5 = Engine water level Opening the covering interferes with
6 = Fuel level the flow of cool air in the compressor Fig. 18
7 = Water in fuel section. For this reason, the machine
8 = Battery voltage will switch off after a short time. Danger
9 = Cable break, Start against Full sound-insulating is only achieved Longer operation with an auxiliary
pressure when the covering is closed. battery or jumper cables connected
10 = Other errors from CAN-Bus (engine)
Check the oil levels in the pressure can lead to sudden emissions of gas.
3 Engine speed, operating hours
tank and in the engine of the An inflammable air / gas mixture is
4 LED green (ok)
compressor each time before start-up. formed. Explosion hazard!
5 LED red (fault)
6 Start button
Do not start the compressor unless the Attention
7 Ignition key, Stop (shut down
air tapping cocks are closed.
compressor) Serious damage can be caused to the
8 Reset button, Enter electrical system if wrongly connected.
9 Choice of menu
10 Decrease working pressure
11 Increase working pressure
27
* Ignition key in position “0” (Off-Aus) 7.5 Monitoring / fault 7.6 Operation
* First connect positive terminals then
negative terminals (ground). Danger Danger
* Start as described in section “Starting Interference with the automatic Only operate the compressor at the
up the compressor.” monitoring system is not permitted. permissible operating pressure and at
the permissible temperature.
Note When the “Fault” indicator lamp lights up,
the screw compressor is automatically Only use the compressor for its
After the engine has started, first shut down when the following faults occur: intended purpose (see Chapter 2.2 of
disconnect the negative cables (ground) this operating manual) in order to avoid
and then the positive cables. * engine oil pressure too low
residual risk for persons and assets.
* cooling water temperature too high
Follow the instructions for operating the * charge air temperature too high Only operate the compressor in a safe,
compressor at an ambient temperature of * engine oil temperature too high functioning condition.
less than 0 °C, in Chapter 5, Transport * cooling water level too low
and Installation on Site, in this operating All components, hoses etc. fitted must
* fuel shortage
manual. be of the correct size and designed for
* Water present in fuel pre-filter
the specified operating pressure and
* charge control (e.g. V-belt tear,
temperature.
defective generator, ...)
* hardware fault (e.g. cable break) When working with compressed air,
7.4 Setting the operating pressure * other fault in the engine electronics wear suitable protective clothing (e.g.
protective suit, safety goggles, etc.).
The system can first be started up after
Danger these faults once the cause leading to Wearing ear muffs may impair
shut-down has been eliminated and the communication between persons.
The setting of the operating pressure fault has been confirmed with the reset Warnings may not be heard. Inform
may only be carried out by a specialist. button "8" (see Fig. 17). supervisor.
The operating pressure is set via the All other operating states are Check the compressor regularly. Check
operating panel (see Fig. 17). represented using the system electronics the machine / installation for external
* pressing the arrow button obtains the menu. damage and faults at least once per
menu to set the operating pressure shift. Any changes noticed (including
Attention changes in operating performance)
* set the requisite operating pressure must be reported immediately to the
using the arrow buttons Disconnect the battery or generator
authority or person in charge. If
only when the engine is not running.
* confirm the new operating pressure necessary, shut down and secure the
with the reset button Switch the system off if an oil mist is machine immediately.
entrained in the compressed air or if
Leaking condensation contains a
Note excessive oil consumption is apparent
(see "Trouble-shooting") proportion of oil and must be collected
The operating pressure can be set in the and disposed of under safe conditions.
range of 5.0 bar to a max. operating Condensation must not enter the
pressure (depending on the system soil or the rivers. Major quantities of
version). The maximum admissible condensation accumulate particularly
operating pressure is noted on the type in versions with aftercoolers for
plate! processing compressed air. Provide a
collecting basin.
28
7.7 Shutdown 7.8 Decommissioning

In order to shut down the compressor:
* Close air discharge valves. The screw
compressor reduces the speed of the
engine back to idling speed after the
preset final pressure has been
reached.
* Allow the screw compressor to idle for
a few minutes.
* Turn ignition key to position "0" (off).
The system switches off after a defined
overtravel time.
* Withdraw the ignition key. Fig. 19
The screw compressor is automatically If the system is to be closed down for a

depressurized to atmospheric pressure. longer period of time (approx. 3 months
A re-start is only then possible once the or longer) the following preservation
container pressure has fallen below measures must be taken:
1.5 bar. * Engine preservation (see separate
engine operating manual).
Note
* Disconnect battery cables.
In the case of emergency (!) the system
can be closed down via an emergency- * No special measures are required at
stop switch. The system comes to an the compressor.
immediate standstill. This type of
* Relieve the strain on tyres by jacking
shutdown is stored in the electronics.
up the vehicle.
Attention * Check tyre pressure every 2 months.
The pressure line between the * Release the handbrake.
pressure tank and the outlet valves will
remain pressurised because of the Attention
pressure maintenance valve with its
non-return function. In order to allow When putting back into operation,
the remaining pressure to be released carry out the maintenance work
open an outlet valve while outlet pipes in accordance with Chapter 9
are connected. “Maintenance.”
Danger
It is important that you ensure that the

pressure is completely blown off via
the blow-off valve.
Should this not be the case, open the
air outlet valves, identify the fault and
correct it.
29
8. Fuels
8 Fuels
8.1 Recommended lubricant for 8.2 Recommended engine oil 8.5 Recommended lubricants for
compressor the bogies
Lubricant specifications for the driving
engine can be found in the enclosed For relubrication use only lithium
Note
engine operating manual. saponified grease which fulfils the
In these screw compressors, circulating oil following specifications:
has not only a lubricating function, but in
* consistency groups (NLGI) 2
particular it also has cooling and sealing
DIN 51818
functions. It is therefore exposed to more
difficult conditions. In particular the tempe- 8.3 Diesel fuel * worked penetration 265-295
rature conditions at the installation site and DIN ISO 2137
Use common diesel fuel (EN590).
the consistency of the air (dust, dirt, and
humidity content, as well as chemical * dripping point > 180 °C
Attention DIN ISO 2176
influences) must be taken into account
when selecting a suitable lubricant. See engine instruction manual. * operational temperature
– 40 °C … +140 °C
Attention Attention
This corresponds to a DIN 51502
Do not mix oils of different The compressor must not be fuelled lubrication grease, designation KP2N-4U.
specifications. with bio-diesel (DIN 51606) or
vegetable oil. Greases with different thickeners
The maintenance intervals and the (soap base) must not be mixed.
maximum and minimum operating
temperatures given in this operating Recommended grease: Fuchs Renolit
manual only apply when high-quality LZR 2.
8.4 Coolant
multi-grade oils are used.
Use of the wrong oil leads to Attention
impairment of function.
Only operate the engine with coolant!
Out of consideration for the high loads Pure water may cause damage to the
imposed on the lubricant in screw engine and to connected components.
compressors with oil injection cooling, we
recommend the use of suitable, non The coolant consists of 50% water and
ageing, non foaming, corrosion-protective 50% corrosion protection/antifreeze
oils. They must meet the following fluid. Use soft water only; drinking
water usually meets this requirement.
requirements for hydraulic fluids:
H-LP 32 and H-LP 46 in accordance with Do not use sea, brackish, industrial,
DIN 51524, Part 2, June 1985. rain or distilled water.
The viscosity of the lubricants should Use released corrosion protection/
comply with viscosity class ISO VG 32 antifreeze fluid only. The use of anti-
DIN 51519, July 1976, with 28 - 35 corrosion oil as cooling-system anti-
mm2/s(cSt) / 40 °C, or if the ambient freeze is not permitted.
temperature is constantly above 25 °C,
with viscosity class ISO VG 46 DIN 51519, Products of differing product groups
July 1976, with 41 - 50 mm2/s(cSt)/40 °C. must not be mixed!
Attention Note
Conventional engine oils marked HD Please observe the engine

must not be used. manufacturer's operating instructions and
fuel specifications.
When using oils with the “Brief De-
scription HYD 10/HYD 20" in accordance
with the ʻStandard Lubricants for Building
Machinery and Vehiclesʼ published by the
ʻHauptverband der Deutschen Bauindustrie
e.V.ʼ (Principal Association of the German
Building Industry), only the given hydraulic
fluids may be used in accordance with
ISO VG 32 and ISO VG 46.
If other lubricants are to be used, please
contact:
Argenthaler Straße 11
D-55469 Simmern/Hunsrück
Telephone 06761 / 832-339
Telefax 06761 / 832-421
or your authorized dealer or your local
branch.
30
9. Maintenance
9 Maintenance
9.1 General maintenance Advance fuel filter Draining the condensation water
Water is heavier than diesel fuel. It
Danger separates out on the floor of the fuel pre-
filter. The water must be emptied on a
Install a "Caution maintenance work" daily basis (via water drain 5). The water
warning sign and cordon off a wide sensor monitors the water content in the
area around the workplace before fuel and switches off the system if the
starting any work. water content is too high.
During inspection, adjustment, or
maintenance work, remember that the Changing the filter element
surfaces of machine parts can be hot,
particularly the exhaust system (risk The intervals for changing the filter
of burning) and that the control device element will depend on the quality of the
may move during operation (risk of fuel. A clogged filter will lead to a reduced
crushing). fuel supply and to a loss of performance
and start difficulties. The filter element
Clean the screw compressor at regular, must be replaced if the performance drops
not too long intervals: noticeably.
* Blow-clean all valves, controllers, * Drain off a little fuel. To do this open
fittings, pressure tank, oil cooler, the water drain (5).
radiator, screw compressor, and
engine with compressed air or a steam Fig. 20 * Unscrew the filter element (3) from the
jet appliance. filter head. Remove the filter element
1 Conveying pump and clean the sealing surfaces.
* Inspect the cooling ribs of the radiator 2 Vent plug
to make sure that air can pass through. 3 Filter element * Coat the filter seal with fresh fuel or a
4 Water sensor little grease. Tightly screw on the new
* Clean the body at regular intervals. filter element to the filter head. Do not
Then grease or oil the hinges of the 5 Water drain
use tools to tighten!
body hood with multi-purpose grease.
Danger * Actuate the fuel conveying pump with
If sound-absorbing matting has to be open bleed screw until fuel exits from
replaced, remove the retaining brackets, Change filters only with the engine off
the bleed screw. Close the bleed
replace the old sound-absorbing matting and in cool condition.
screw, start the engine and observe
with new matting, replace the retaining Do not spill fuel. leakages. Make any necessary
brackets. corrections with machine switched off.
Attention
Frequency of water draining or element
9.2 Engine maintenance 9.3 Maintenance of chassis
replacement is determined by the
The maintenance of the engine is to be contamination levels present in diesel and brakes
carried out in accordance with the engine fuel.
The maintenance of the chassis and the
operating manual. brakes must be carried out in accordance
Note
with the chassis instruction manual.
Attention Ensure the system is free from leakage.
Check the hoses for cracks and replace Work on the brakes may only be carried
Full load speed is factory-set by the
if necessary. out by trained technical staff or by
manufacturer and must not be
specialist brake services!
modified. Dispose of contaminated filters in
The idling speed must not be changed accordance with the regulations. Danger
either, as this might cause serious
During inspection, adjustment, or
damage to the screw compressor,
maintenance work, remember that the
e.g. damage to the coupling!
surfaces of machine parts can be hot,
particularly the exhaust system (risk
of burning) and that the control device
may move during operation (risk of
crushing).
31
9. Maintenance
9.4 Maintenance and inspection schedule
1,500 h
2,000 h
2,500 h
3,000 h
3,500 h
4,000 h
4,500 h
5,000 h
5,500 h
6,000 h
60 h
500 h
1,000 h
Due at x hours run
At the latest after x years 1 yr 2 yrs 3 yrs 4 yrs 5 yrs 6 yrs

Daily:
Visual checking for external damage, defects and leaks
Check the oil level in the diesel engine
Check the coolant level
Check the oil level in the compressor
(drain off any condensate from the oil tank)
Drain off water in the fuel pre-filter
Clean air filter (screw compressor/engine) between times or renew if the
red field appears
See the engine operating instructions for maintaining the engine
Maintenance every 500 h, although at least every 6 months
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) ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Maintenance every 1000 h, although at least each year
Change both air filters (screw compressor/engine) ■ ■ ■ ■ ■ ■
Change oil filter of the screw compressor ■ ■ ■ ■ ■ ■
Oil change (screw compressor) ■ ■ ■ ■ ■ ■
Inspect automatic operational monitoring ■ ■ ■ ■ ■ ■
Change fine separator every year or if differential pressure > 1bar ■ ■ ■ ■ ■ ■
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 ■ ■ ■ ■ ■ ■
Unscrew optional vessel for tool oil and check inside for any corrosion.
■ ■ ■ ■ ■ ■
If rust is found, replace the vessel with new, original spare part.
Inspection every 4 years:
Inspection of the electrical installation by a qualified electrician ■
Internal inspection of the pressure vessel by a qualified person ■
Strength test of the pressure vessel by the appointed body
■
X For your own benefit, put a cross on the servicing schedule against maintenance work when performed.
32
9. Maintenance
6,500 h
7,000 h
7,500 h
8,000 h
8,500 h
9,000 h
9,500 h
10,000 h
10,500 h
11,000 h
11,500 h
12,000 h
12,500 h
13,000 h
13,500 h
14,000 h
14,500 h
15,000 h
15,500 h
16,000 h
16,500 h
17,000 h
17,500 h
18,000 h
18,500 h
19,000 h
19,500 h
20,000 h
7 yrs 8 yrs 9 yrs 10 yrs 11 yrs 12 yrs 13 yrs 14 yrs 15 yrs 16 yrs 17 yrs 18 yrs 19 yrs 20 yrs
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■
■ ■ ■
■ ■
33
9. Maintenance
9.4.1 Oil filter replacement 9.4.2 Oil change (compressor) * Switch off screw compressor
(compressor) * Check oil level, add oil if necessary
9.4.3 Inspecting / Replacing the

fine separator
Fig. 21 Fig. 22
Danger Danger
Only replace the oil filter cartridge Only change the oil when the engine is
when the engine is at a standstill and at a standstill and the system is not
Fig. 23
the screw compressor is not under under pressure.
pressure. Danger
Caution when draining off hot oil:
Caution with hot oil: risk of scalding! risk of scalding! Spill no oil!
Pressure tank is under pressure. Only
Spill no oil! Attention work when the motor is at a standstill
and the screw compressor is not under
Attention Change the oil filter every 1,000 oper- pressure.
ating hours, but at least once per year.
Change the oil filter every 1,000 oper- Caution with hot oil: risk of scalding!
ating hours, but at least once per year. The screw compressor must not be Spill no oil!
under pressure during oil change.
Note Note
Drain the oil at operating temperature.
Dispose of oil filter cartridge in accordance Dispose of fine separator in accordance
with the relevant regulations - hazardous Do not mix oils of different
with the relevant regulations - hazardous
waste! specifications.
waste!
Check for leaks. Note Check for leaks.
Changing the oil filter: Collect used oil, do not allow it to enter the Replace the fine separator at least once
soil. Dispose of oil in accordance with the per year or measure the differential
* Unscrew the oil filter cartridge using
relevant regulations - hazardous waste! pressure as follows:
appropriate tools
Spill no oil! Check for leaks. * When the engine is at a standstill and
* Dispose of oil filter cartridge
the screw compressor is not under
Changing the oil:
* Apply a thin coat of oil to the seal of the pressure, unscrew the dipstick from the
new oil filter cartridge * Unscrew dipstick pressure tank.
* Screw on and tighten the new oil filter * Place oil drain pan under oil drain valve * Screw in the reducing adapter.
cartridge (follow the instructions on the
* Unscrew the sealing cap of the * Screw the pressure gauge into the
oil filter cartridge)
pressure vessel reducing adapter.
* Check for leaks
* Collect used oil in the oil drain pan * Start the screw compressor and let it
* Check oil level, add oil if necessary run at full operating pressure with the
* When the used oil has been drained
maximum air flow.
completely, use a new sealing ring on
the sealing screw of the pressure * The difference in pressure between
vessel, position and tighten screw or the pressure gauge on the pressure
close the oil drain valve tank and the pressure gauge on the
instrument panel must not exceed
* Fill up with new oil (see section
1 bar.
"Specifications" in chapter 2.3 for initial
oil capacity; use a little less oil when
performing an oil change).
* For lubricants see “Lubricant Table”
* Check sealing ring on dipstick, replace
if necessary
* Screw in and tighten dipstick
* Start screw compressor, run for approx.
two minutes, check for leaks
34
9. Maintenance
If the differential pressure is > 1 bar, the Note 9.4.5 Checking the safety valve
fine separator cartridge must be replaced.
The air filters should be checked weekly
* Disconnect all lines from the tank for dust contamination.
cover.
The maintenance interval of the air
* Remove all hexagon screws around the
filter depends on the dustiness of the
circumference of the lid. environment.
* Remove the lid and the old fine
separator. Replacing the safety cartridge
* Remove the used seals from the (at the latest with every third replacement
pressure tank, clean the sealing
of the air filter element):
surface and insert new seals.
* Open the clamps on the air filter cover
* Insert a new fine separator into the
pressure vessel and fit new seals. * Pull the air filter element out from the Fig. 25
casing
* Fit the lid. Insert the hexagon screws Check the operation of the safety valve
and tighten them across the diagonal * pull the safety cartridge out from the at least twice a year. The check is carried
(tightening torque see Chapter 9.4.8 casing out with the system pressurised. Carefully
"Torque specifications"). turn the knob anti-clockwise, until the
* insert the new safety cartridge internal pressure lifts the valve cone,
* Reconnect all lines to the tank cover. releasing a mixture of oil and air. Then
* push on air filter element
* Check for leakage. turn the knob fully clockwise again.
* reattach air filter cover as shown in
* Dispose of the old fine separator Fig. 24 In accordance with national standards,
cartridge in the specified manner. but at least once a year, carry out a
Attention suitable test to check whether the valve
blows down at the correct pressure.
The air filter cartridges are never
9.4.4 Air filter replacement cleaned! If the valve is not working properly,
(compressor / engine) replace it immediately with a new one
* clean the sealing area in the casing designed for the system. This type of
Danger * Insert filter cartridge and ensure that operation may only be carried out by
the seal is in the correct position trained personnel.
All inspections and servicing work
must be carried out when the engine is * push on the lid with the air filter and Danger
at a standstill and the screw click into the clamps
The screw compressor must not be
compressor is not under pressure.
operated with a faulty safety valve!
A mixture of oil and air will escape
when the valve is checked/tested.
Fig. 24
Note
Observe the fault indication unit display.
The air filter elements must be replaced at
least once a year. Do not clean and reuse
the air filter elements.
Replacement of air filter elements:

* open the clamps on the air filter cover
* pull the old air filter element out from
the casing
* insert the new air filter element
* reattach air filter cover as shown in
Fig. 24
35
9. Maintenance
9.4.6 Control Attention 9.6 Inspection intervals for

pressure vessels and
Check the acid level after a maximum
electrical installations
of 1,000 operating hours, or after
24 months, whichever occurs first, and Pressure vessels
fill up with distilled water if necessary.
As per the requirements of the 97/23/EC
For battery maintenance please also Pressure Equipment Directive, a qualified
refer to the manufacturerʼs instructions person must inspect the pressure vessel
and the engine operating manual. from inside every five years.
As per the requirements of the 97/23/EC
Pressure Equipment Directive, an
appointed body must perform a strength
9.4.8 Torque specifications test on the pressure vessel after ten
Fig. 26 years.
The following tightening torques apply to
The control system takes the form of a screwed connections:
stepless speed/volumetric flow regulation Electrical installation
system. It consists of: Wheel screws 90 Nm
The electrical installation must be
* The intake control valve on the air Pressure vessel cover 100 Nm inspected by a qualified electrician after
intake Safety valve 80 Nm four years and also each time work has
* Pressure transducer been performed on it.
* Proportional valve Engine bearing
on engine 169 Nm Should stricter inspection intervals apply
* Electronic unit
on spring element 180 Nm in your country, these must be observed.
The intake regulation valve contains a
cone, which changes the volume of the air Compressor bearing
intake and which has a non-return on compressor 90 Nm
function, in order to prevent the intake on spring element 180 Nm
regulation valve and the air filter from Chassis mounting screw 180 Nm
being flooded with oil when the screw
compressor is turned off. Suspension device 180 Nm
9.5 Spare parts for maintenance

9.4.7 Battery maintenance purposes
Designation Identification No.
Service package 1000 Bh A19052774

Service package A19008674
(fine separator)
Spare parts list 100013407
Service parts
Air filter element A13368674
Air filter safety element A13368774
Fig. 27
Fuel filter set 100011182
Danger
Oil filter cartridge (engine) 100011183
The gases released by the battery are Advance fuel filter (engine) 100011184
explosive.
Oil filter cartridge A04425274
Avoid sparks and open fires in the (compressor)
vicinity of the battery.
Air-oil separator element A13363674
Do not allow acids to come into contact
with skin or clothing. Wear safety Seal for air-oil separator A93182110
goggles. element
Place no tools on the battery.
The battery is maintenance-free in
accordance with DIN.
36
10. Troubleshooting
10 Troubleshooting
Further information on faults is provided in the section on the electronics system (see chapter 11.4).
Problem Possible cause(s) Correction

Insufficient or no air supply Clogged air filter Clean air filter
Clogged oil fine separator filter cartridge Replace compressor oil, oil filter and oil
fine separator filter cartridge
Coupling defective Replace
Wrong setting at controller To be adjusted by a specialist
Plunger inside the intake control valve is not Clean, replace parts if necessary, readjust
fully opened
Insufficient pressure Pressure control valve defective Repair or replace
Control line defective Repair or replace
Piston ring or spring in engine control Repair or replace
cylinder or controller defective
Compressor becomes excessively hot Wrong oil Replace
(automatic shutdown)
Compressor oil level too low Fill up with oil
Fan broken Replace
Oil cooler dirty (outside) Clean
Oil filter clogged Replace
Leak in oil line Repair or replace
Air short circuit Repair
Screw compressor will not start No fuel Fill up with fuel
Fuel filter clogged Replace fuel filter cartridge
Fuel line loose, broken, or jammed Repair line
Operating voltage low Charge battery or replace
Electrical connection loose, corroded, Replace
or broken
Air in system Vent fuel system
Lifter magnet not working Replace
Relay defective Replace
Starter defective Replace
Other engine problems See engine operating manual
Fuse defective Replace
Ignition switch defective Replace
Oil in air line Orifice in oil return line clogged Repair / clean
Oil fine separator defective Replace
Too much oil in pressure tank Correct
Safety valve blows off Controller set too high To be adjusted by a specialist
Pressure control valve defective Replace or repair
Intake control valve, control cylinder, Replace
engine, or connected control lines defective
Safety valve defective Replace
Oil comes out of the air filter of the Intake control valve defective Check and repair
compressor after the screw compressor
has been shut down
Engine starts but switches off again immedia- Refer to instrument panel for cause of fault Check and repair
tely, or the system switches off while running (refer also to Chapter 11. Electronic
system)
37
11. Electronic system
11 Electronic system
11.1 Overview 1= Operating pressure in bar and psi

2= Individual fault type
1 11 10 9 3= Engine speed (min-1) and working
hours (h)
4 = LED green (ok)
5 = LED red (fault)
6 = Start button
7 = Ignition key, Stop (shut down
compressor)
8 = Reset button, Enter
9 = Choice of menu
10 = Decrease working pressure
11 = Increase working pressure
2 3 4 5 6 8 7
Fig. 28
OK Fault Description
1 = Engine oil pressure
2 = Engine water temperature
3 = Intercooler temperature
4 = Airend temperature
5 = Engine water level
6 = Fuel level
7 = Water in fuel
8 = Battery voltage
9 = Hardware, Cable break, Start against pressure
10 = Other errors from CAN-Bus (engine)
38
11.2 Operation Menu 3: Errors with detailed

information
1. Starting the compressor
see chapter 7.3 ____________- 3 -____________________
Qty: No: Error
2. Changing the operating pressure -------------------------------------
see chapter 7.4 0 01 Engine Oil Pressure
0 02 Engine Water Temp.
3. Troubleshooting 0 03 Intercooler Temp.
see chapter 7.5 0 04 Airend Temperature
0 05 Engine Water Level
4. Switching off the compressor 0 06 Fuel Level
see chapter 7.7 0 07 Water in Fuel
0 08 Alternator Voltage
0 09 Hardware
0 10 CAN-SPN
11.3 Menu navigation 0 11 Emergency Stop
Fig. 28 is the main window and shows the

current operating status of the system. Qty. = Number of errors, i.e. how often
Additional information can be displayed by has this error occurred
pressing button 9.
No. = Error number
The number of the menu window appears
in the top line. Error = Error name
Using this menu point additional
Menu 1: General information and
information on the individual errors can be
settings
viewed with the arrow buttons (10, 11).
- 1 -________________________________ The individual error display provides
Date : 01.03.07 operating data of an error. The last error is
Time : 15:00:00 displayed. Previous errors can be selected
Version : V010307 with the arrow button 11.
Compressor type : DLT1303
WCA-No. : (17 characters)
Engine-No. : (8 characters) Individual error display under menu
Next service : h
option 3:
Display Contrast : 140 (preset)
E 1 (= continuous Error number)
Display Lighting : On/Off (preset) Error .... at .... h
Language : English (preset) -------------------------------------
Date :
Set display contrast (bright), display Time :
lighting (on / off) and language: Eng. Oil Press. : bar
Eng. Water Temp. : C
* select with arrow button (10, 11) Intercooler Temp : C
Airend Temp. : C
* move to entry field with reset button (8) Working Pressure : bar
* change value with arrow button (10, 11) Actual Eng. Speed : RPM
AirCtrl. Pressure : bar
* actuate with reset button (8). Ambient Temp. : C
SPN / FMI :
Start OK / K.O. : /
Menu 2: Operating data of the

compressor SPN and FMI are error codes according to
J1939 which are sent by the engine
______- 2 -______________________
electronic system.
Compressor Operating Data
1) Rated Eng. Speed : RPM
2) Actual Eng. Speed : RPM Return to menu option 3 with button 9.
3) Load @ Act. Speed : % Pressing button 9 again returns the
4) Fuel Consumption : L/h display to the original state (see Fig. 28).
5) Engine Oil Press. : bar
6) Engine Water Temp. : C
7) Engine Oil Temp. : C
8) Intercooler Temp : C
9) Charge Air Press : bar
10) Battery Voltage : V
11) Airend Temp. : C
12) Air Ctrl Pressure : bar
39
11.4 Troubleshooting
Error information according to CAN-bus, J1939:
SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
FC = Fault Code
SPN FMI FC Problem Possible cause(s) Correction

110 0 151 Engine water temperature Radiator dirty Check, clean
too high
Cooling air intake blocked Check, correct
Ventilator defective Check, replace
105 0 155 Intercooler temperature Loss of pressure charge air cooler Check, clean
too high too high
Outlet temperature turbocharger Check, correct
too high
Operation with open doors (TS...) Check, correct
100 1/18 415 Engine oil level too low Wrong oil level, incorrect grade of oil Check, fill up oil
Defective switch / cable harness Check, replace
97 0/15 418 Water in fuel Water content too high in fuel Check, drain off water from fuel pre-
filter, improve fuel quality
627 0 434 Battery supply interrupted System stopped via EMERGENCY Engine electronics system could not
STOP shut down properly
F1 failed in operation Restart system and switch off correctly,
acknowledge error
157 1/18 559 Pressure fuel pump too low Suction resistance too high Check, correct
Air content in fuel too high Examine fuel system for leakages
Clogged fuel filter/prefilter Check, replace filter
No fuel (with external fuelling) Check, fill up
Defective fuel hand pump Check, replace
G1 overvoltage (loose cable) Check, correct
Defective engine cable harness Check, replace
Contact engine manufacturer
Defective sensor Check, replace
40
Further error information according to CompAir:
SPN FMI FC Problem Possible cause(s) Correction

0 0 Interruption to K1 or F2 defective Check, replace
engine electronics
Loose cable on K1, F2, G1, X3, ... Check, correct
Broken belt drive systems (G1) Check, replace
Battery voltage too low Check, correct
1 3 Pressure transducer (DMU1) Defective / wrong pressure transducer Check, replace
(pressure tank)
outside measurement range
< 3 mA
1 21 Pressure transducer (DMU1) Defective / wrong transducer Check, replace
(pressure tank)
> 21 mA
(suction controller)
< 2 mA
(suction controller)
> 21 mA
2 0 Operating pressure constantly Intake regulator not closing Check, correct, replace
increasing (during standard
Control air to DMU2 interrupted
operation)
Pressure regulator or Y1 defective
5 5 Operating pressure constantly Intake regulator not closing Check, correct, replace
increasing (during warm-up
Control air to DMU2 interrupted
phase)
Pressure regulator or Y1 (Y3) defective
522 0 Torque required outside Coupling defective Check, replace
normal range
Operating pressure too low Check, correct
Intake controller remains closed Check, correct
522 1 Resonance Starter defective / no activation Check, correct
Drag load too high Check, correct
- Intake regulator remains open
- Oil level compressor too low
- Incorrect hydraulic oil
Problems with fuel system Check, correct
- Filter contaminated, frozen, ...
- Air in system
- Defective speed sensor
41
12. Undercarriage
12 Undercarriage
12.1 Introduction 12.3 Height-adjustable towing

system
Danger
The adjustable joint between the
The user forfeits all rights to claim if drawbar and intermediate arm, and
parts other than those of the between the overrun system and
manufacturer are used. intermediate arm, consists of toothed
heads or retainers with Hirth-type or radial
We reserve the right to modify design serrations.
and performance without prior notice.
Please quote axle number, model and To allow transmission of the towing
article number when contacting us with torque without any backlash, the nut must
queries or ordering spare parts. be tightened to the specified torque
setting.
The teeth of the swivel arm (Fig. 29,
pos. 1) and the drawbar are clamped
12.2 Safety together with an M36x1.5 bolt. The towing
torque then depends on the permissible
* It is most important that the wheel and gross weight of the trailer, and the length
the hub are compatible dimensionally. of the swivel arm.
This means that the P.C.D., wheel
bolts and inset must all be compatible Torque setting = 1200 Nm
both with the hub and the rim. The teeth of the swivel arm and the
Particular attention must be paid to the overrun device are clamped (Fig. 29,
recommended torque figures for the pos. 2) together with an M28x1.5 bolt.
wheel bolts.
The nut must be tightened to a torque
* Use torque wrench! setting of T = 500 Nm.
* No welding is permitted on the rubber After the teeth have been clamped,
suspension axle. to prevent it working loose the nut must
* Please note the swing arm movement. secured to the bolt with the cotter pin.
(See assembly instructions). The cotter pin is attached to the drawbar
with a chain.
* The wheel brakes are matched to the
overrun devices. Before using an
overrun from another manufacturer,
please check the compatibility with our
Technical Department.
Attention
Model details must not be obscured by
paint now concealed by components.
42
12. Undercarriage
12.4 Braking system
Before connection or disconnection of

braking system insert security bolt M10.
6
Fig. 29
Deviations from drawing possible
Danger
The handbrake lever is preloaded.

Remove the red security bolt only after
complete assembly of the braking
system including the connection of
the brake rod to the hitch. When any
servicing or disconnection of the
braking system takes place, reinsert
the security bolt. If attention to these
8 7 8 3 5 3 4
points is ignored, then the handbrake
lever can fly off, due the mechanics
of the preloaded system. Fig. 31 Over-run hitches
* Both the KNOTT torsional thrust spring The KNOTT overrun systems are
axles and the KNOTT rubber spring mechancal overrun systems with a
axles have superb springing and hydraulic shock absorber.
excellent dampening characteristics.
The torsional thrust spring elements
with their vulcanized rubber are 12.5 Adjusting the braking system
pretensioned before being pressed into
the axle tubes. There is no squashing 12.5.1 Preparations
of the rubber during spring action.
Instead the rubber is stretched in * Jack up the trailer
accordance with its characteristics. * Release the handbrake
Fig. 30 The results of this combination of
pretensioning and stretching are * Pull out the drawbar [5] of the overrun-
Attention exceptionally long life and zero system as far as it will go
maintenance.
Use the jack only under the fixing
brackets or at the chassis, never in the 3 4 5 2 1
Attention
centre.
* Towing eye and ball coupling may
only be changed by specialists.
Introduction
* Use a new safety nut every time one
* KNOTT over-run brake systems consist
of these items is changed.
of over-run hitches and wheel brakes
used in combination with KNOTT * Use specified torque setting:
torsional thrust spring axles. They are
approved in all countries of the EC and Towing eyes: M14 10.9: T = 180 Nm
in Switzerland. Ball coupling: M14 10.9: T = 125 Nm
* With the KNOTT autoreverse system * When using the ball coupling, Fig. 32 KNOTT overrun brake
ʻBackmatʼ there is no problem changing please follow the instructions given.
1 Contact-breaking cable
the direction of travel from forward to 2 Trailer coupling ring (varies by type)
reverse. The braking system is ready for 3 Handbrake lever
immediate operation again when 4 Transmission lever
changing from reverse to forward travel. 5 Drawbar and bellows
43
12. Undercarriage
Danger Ease off the adjusting screw [12] in the 12.5.5 Adjusting the brake linkage [6]
anticlockwise direction (approx. 1/2 turn)
until the wheel turns freely. Slight rubbing Adjust the brake linkage [6] so that it is
Always secure the handbrake lever
noises, which do not effect the free turning free of play longitudinally, without initial
using the lockscrew before
of the wheel, are permitted. tension.
dismounting the brake linkage.
When the brake is correctly adjusted, Readjustment
12.5.2 Preliminary requirements: the actuating travel of the control cable * Operate the handbrake lever [3]
[11] will be 5-8 mm. powerfully several times in order to
* When carrying out adjustments, always settle the braking system.
start with the wheel brakes. Carry out the adjustment procedure,
as described, on all the wheel brakes * Check the position of the brake
* When carrying out adjustments, turn in succession. compensating balances [9 and 10]
the wheel only in the direction of which should be at right angles to the
forward travel.
12.5.4 Adjusting the brake direction of towing
* Always make sure that the lockscrew compensating system * Check the play in the linkage [6]
has been mounted.
* Check that the wheels rotate freely with
* Do not pre-tension the expanding the brake released.
locking mechanism in the brake. If
necessary, loosen the brake linkage [6]
at the brake compensator [8]. Final check
* Check the expanding locking * Check fastenings for security (secure
mechanism and control cable [11] the hexagon locking nuts of the screw
for ease of movement. fastenings for the transmission system,
control cables, brake compensators,
Attention turnbuckle, linkage, etc.).
* The compression spring [7] may Fig. 34 KNOTT transmission system for * Check the compression spring [7] for
tandem axle chassis.
only be lightly pre-tensioned and initial tension.
must not become fully compressed
when activated!
Test run
* Never readjust the braking system
* If necessary, carry out 2-3 brake tests
or brakes by the brake linkage [6] or
turnbuckles (if fitted) in the linkage!
Brake test
* Recheck the play in the brake linkage
12.5.3 Adjusting the brake
[6] and, if necessary, readjust the
Wrench sizes for adjusting screws [12] linkage [6] for length free of play
Fig. 35 KNOTT transmission system for
Brake size Wrench size
single axle chassis.
160x35 / 200x50 SW 17
6 Brake linkage
250x40 SW 19
7 Compression spring
300x60 SW 22
8 Compensating balance assembly
9 Compensating balance (tandem) or
master compensator
10 Compensating balance (single axle)
11 Control cable
* Always make sure that the lockscrew
has been mounted.
* Preadjust the length of the brake
linkage [6] (slight play permitted).
* Remove lockscrew.
* Operate the handbrake lever [3] and
check the position of the compensating
Fig. 33 KNOTT wheel brake balances [9 and 10]. They should be at
12 Adjusting screw right angles to the direction of towing.
13 Cable entry * If necessary, adjust the position of the
Tighten the adjusting screw [12] (on the balance [10] and control cables [11]; in
outside of the brake plate, opposite the the case of tandem trailers, also adjust
cable entry [13]), turning clockwise until the master compensator [9] on the
the wheel can only be turned with difficulty linkage [6].
or not at all. * The compression spring [7] may only be
lightly pre-tensioned and must not
become fully compressed when
activated!
44
12. Undercarriage
12.6 Readjusting the braking 12.7 Maintenance and care Split lock Split lever always acts
system on the one-piece
Danger primary shoe
In general, readjusting the wheel brakes Check for smooth
adequately serves to readjust the braking These works may only be effected in operation
system, i.e. to compensate for brake lining specialized workshops.
wear. To readjust the wheel brakes, Replace corroded parts
proceed as described under 'Adjusting the
The split lever must
braking system'. Check the play in the Overrun hitches operate smoothly –
linkage [6] and readjust if necessary.
* After approximately 5000 km at least otherwise the brakes
Attention once a year the system should be may overheat
greased. The split lever must not
* Check the expanding locking
* Reaction test. Pull the handbrake lever be preloaded
mechanism and control cable [11]
as far as possible. Push the ball An important check
* The expanding lock compensator coupling as far back into the overrun- when servicing the
must not be pre-tensioned in the ning hitch as it will go. It should then braking system
brake. push itself out with a gas filled shock
absorber. Tension springs Replace corroded or
* Do not attempt to compensate for
over-stretched springs
ease of movement caused by brake * Grease the ball coupling.
lining wear by readjusting (shorten- Note installation position
ing) the brake linkage [6], e.g. by
way of the linkage screw fastenings Only attach springs on
Testing the brakes the tightening on the
* With the handbrake on, a braking effect brake shoe shield in the
of at least 18% of the permissible gross plate facing the brake
Readjustment
weight must be achieved. shield (tilting moment of
* Operate the handbrake lever [3] the backmat shoe to the
powerfully several times in order to * With the KH power lever, this braking brake shield)
settle the braking system effect must be achieved almost
immediately the slack has been taken Tightening Wedge tightening -
* Check the position of the brake up. comprising:
compensating balances [9 and 10] 1 tightening wedge
(which should be at right angles to the 2 tightening bolts
direction of towing). Toothing of height-adjustable drawbar 1 tightening screw
SW 19 brake 250x40
* Recheck the play in the linkage [6]; * To ensure they continue to engage with KHV35
if necessary, adjust the linkage [6] properly, clean rust and other dirt off SW 17 brake 200x50
again so that it is free of play, but the profiles of the toothed connections with KHV30
without initial tension. at least once a year.
Replace the coated
* Check the positions of the handbrake tightening screw (safety
lever [3], the play in the bowden cable Ball coupling effect) with a new one if
and compression spring [7] (only light * Follow the manufacturer (KNOTT) the safety effect is
initial tension) maintenance instructions. insufficient
General brake shoes
Final check
Wheel brake Check for wear:
* Check the screw fastenings for the every 5000 km, and at
transmission system (control cables, Brake hub Rusty, scored brake least once a year
brake compensators, linkage, etc.) surface – replace the
brake hub check permitted coating
* Check the tension of the compression thickness of 1.5 to 2 mm
spring [7] Do not unscrew or re-
turn the braking surface Coating wear: always
greater on the primary
Whenever possible (one-piece) brake shoe
replace the brake hubs
on both sides of the axle Brake coating surface:
to ensure equal braking 80% contact pattern
Friction carbon provides
Brake Versions mechanically optimum operating
activated split lever friction factor
Simplex brake with
automatic return New state: coatings
when new without
friction carbon: up to
30% less braking power
Pollution: brake
coatings polluted with oil
or grease – shoes must
be replaced
45
12. Undercarriage
Backmat shoe Components: Brake Brake balancing Ensure right-angled 12.8 Malfunctions and remedies
shoe shield, curve shoe position– Adjust using
and tension springs the hexagonal nuts on Danger
the cables
Smooth operation of the
curve shoe – clean Brake linkage Suspension of the Works on the brake system may only
sliding curves if linkage be carried out in specialized
necessary and lightly workshops.
Counter the screw
grease them with high- The brakes, transmission system,
connections
temperature grease stopping system and cable shaft are
Functional check: checked and approved to meet the
Smooth operation latest EU guidelines. Only components
Wheel bearings
and parts checked to this level may be
Cable holder Single parts: 2 half- General notes used.
liners, one loose
Attention Braking systems require regular
Installation: maintenance by accredited garages to
Attach and detach the Retighten wheel screws or nuts with maintain operational safety. When
cable from outside the specified torque after first loaded replacing braking shoes, make sure
journey or after 50 kilometres which- that all brake shoes of the axle are
Security: Secure the
ever occurs first. Retighten again after replaced.
half-liners by inserting
160 kilometres. In addition, check
cable grommets When working at the wheel brakes,
wheel bearing play. Wheel nuts should
make sure that the springs, the brake
Coupling ring Installation position: be tightened depending on conditions
shoes and the spreading lever are
oval opening facing of use, but at least once every six
correctly installed; observe the correct
outwards months.
sense of rotation.
Assembly Ensure correct
When adjusting the wheel brakes, turn
installation of the brake
Information regarding dual-row angular wheels in forward direction!
shoes – one-piece
bail bearings:
primary shoe must run Basically, a readjustment must be
in the forward drum * These bearings are maintenance-free, effected whenever works are carried
direction onto the shoe have been provided with a lifetime out at the brake system.
support (tightening lubrication. and have an extremely high
device) or rest on it If the wheel brakes or the brake drum
running performance.
have got very hot, continue to drive
Before inserting the * The bearings have been fixed in their carefully on, if possible, until they have
brake hub check again correct position using a safety flanged somewhat cooled down.
for completeness, nut. This flanged nut must be tightened
installation position and Use only genuine replacement parts so
with a torque of 280 +/- 10 Nm.
position of the parts that
* It is recommended to check this
* proper operation and safety is
tightening torque in the course of
ensured
service works.
Transmission system
* operating permission in national
* The flanged nut can only be unscrewed
Cable KNOTT patent – cable and international law is maintained
and re-used once. Afterwards. a new
can be attached and
nut must be used. When releasing or * guarantees remain valid.
detached from outside
tightening the flanged nut, grease the
Detaching: threads slightly, so as to avoid damage
Release cable to the fine thread.
connection
* Due to the high durability and the
Remove cable grommet
maintenance-free design of these dual-
from cable holder
row angular ball bearings, there will be
Fold out and remove the
no damage at the bearings under
outer liner
normal conditions.
Detach the nipple from
the coupling ring * If. due to exceptional circumstances.
problems were to occur with these
Attaching:
bearings, completely new brake drums
The same procedure in
with pressed-in bearings, circlips and
reverse
new locking nuts should be installed in
Smooth operation: principle.
The cable must operate
* Due to the design characteristics of the
smoothly – check on
bearings, the brake drums and the
every service
wheels may have a slight axial and
Replace cables which
tilting play; however, this is
do not operate smoothly
insignificant.
– they can cause the
brakes to overheat * Tighten wheel nuts at the
Cable - check corresponding tightening torque.
suspension
46
12. Undercarriage
Malfunction Cause Remedy

Insufficient braking effect Excessive backlash in brake system Re-adjust brake system
Brake linings not "run in" Actuate hand-brake lever slightly; drive 2-3
kilometers
Brake linings glazed, oily or damaged Replace brake shoes completely; clean
braking areas in the brake drums
Overrunning hitch hard to operate Grease overrunning hitch
Brake linkage is jammed or deformed Eliminate cause
Brake Bowden cables rusty or kinked Replace Bowden cables
Brake reacts by jerks Excessive backlash in brake system Re-adjust brake system
Shock absorber of overrunning hitch Replace shock absorber
defective
Backmat brake shoe is jammed in the Replace compl. brake shoes with brake shoe
brake shoe holder holders
Trailer is braked unilaterally Wheel brakes are actuated unilaterally Re-adjust brake system
Causes: possibly specified under see above
"Insufficient braking effect"
Trailer is already braked when the Shock absorber of overrunning hitch Replace shock absorber
accelerator pedal is released defective
Reverse driving had to accomplish, Brake system adjusted too tightly Re-adjust brake system
or even impossible
Bowden cables pre-loaded Re-adjust brake system
Braking action of hand-brake Incorrect setting Re-adjust brake system
insufficient
Hand brake not pulled tightly Actuate hand-brake lever as far as possible
Causes: possibly specified under idem
Wheel brakes get hot Brake system incorrectly set Re-adjust brake system
Causes: possibly specified under idem
Wheel brakes dirty Clean
Reversing lever of overrunning hitch is Remove reversing lever, clean it and grease it
jammed with Molykote
Handbrake lever not or only partially Set handbrake lever into zero- position
released
Ball coupling does not rest on ball Coupling dirty on the inside Clean and grease thoroughly
Ball of towing vehicle too big Check ball diameter: According to DIN 74058,
the ball on the car must not exceed 50 mm in
diameter when new. If the ball diameter
decreases to less than 49.5 mm, the ball has
to be replaced.
The ball must be perfectly spherical
47
13. Compressed air processing option (after cooler / filter / bypass line)
13 Compressed air processing option (a fter cooler / filter / bypass line)
13.1 Safety regulations for Filter option (ZTV-ING Part 3 Sec. 4) 13.3 Maintenance instructions
alternate compressed air A residual oil contents in the compres-
processing sed air of < 0.01 ppm is achieved by Danger
means of filtering. The filter assembly
consists of a fine filter and an extra-fine Prior to and when carrying out
Danger
filter. Both filters are equipped with a maintenance and repair procedures,
When operating the compressor, collecting receiver with an automatic please do observe the general safety
please observe the general safety condensate discharge. regulations in chapter 3 of the
regulations laid forth in the compressor operating manual.
compressor operating manual. The separated or filtered liquids are
brought together to a common drain. Attention
Attention The filters have to be disposed of.

13.2 Design and operation The after cooling system is mainte-
The oil-containing condensate has to
After cooler option be collected. Do not allow to enter into nance-free. For cleaning procedures,
the soil or into the drains! see 9.1 „General maintenance“ in the
In an air cooler (on the cooling air intake compressor operating manual.
side), the compressed air is cooled down
to a temperature close to the prevailing
Bypass line option
ambient air temperature downstream of Filter option
the pressure vessel. A condensate The bypass line bypasses the filters.
separator with automatic condensate When bypassing the filters the residual oil Filter change is required at latest when
evacuation is located downstream of the contents amounts to > 0.01 ppm. a differential pressure of 400 mbar has
air cooler. been reached or after approximately
500 operating hours - depending on the
The cooled-down compressed air is then degree of contamination. Pay attention to
piped to a heat exchanger for subsequent the filter maintenance display.
heating.
In this heat exchanger the energy of the
compressor oil is utilised. In cases where
the compressed air is not to be heated,
the 3-way ball cock located on the right-
hand side of the heat exchanger can be
used for redirecting it.
The vertical lever position means:
the heat exchanger is not operating Fig. 36 Bypassed filters:
Lever positioned in the direction of the line.
The horizontal lever position means:
the heat exchanger is operating
Attention
The 3-way ball cock should only be

switched over when the compressor is
not operating and the pressure is fully
released.
An intermediate position on the ball
cock is not allowed. Only the vertical
and the horizontal lever positions are
Fig. 37 Activated filters.
allowed because otherwise the ball
Lever positioned laterally to the line routing
cock would become damaged.
13.4 Troubleshooting
Problem Possible cause(s) Correction

Increased air humidity of the Contaminated air cooler. Clean
compressed air
Aperture or silencer in condensate Replace or clean
separator collecting tank clogged.
Oil in discharge air line See chapter 10 "Troubleshooting" in this
manual.
Filter clogged. Replace or clean
Faulty filter cartridges. Replace
48
Argenthaler Str. 11
55469 Simmern
Deutschland
Tel. ++49 (0)6761 832-0
www.compair.com
e-mail: sales@compair.com

Operating and Service Manual

Uploaded by

Operating and Service Manual

Uploaded by

Original operating and service manual

C270TS-9, C260TS-10, C250TS-12,

This Maintenance and Inspection

We request you to present this

Please observe the maintenance

Plant Maintenance Personnel, Name: _________________________________________________ ☎ __________________________________

Number of associated Parts List: ___________________________________________________________________________________________

Machine serial number: __________________________________________________________________________________________________

Year of production: ______________________________________________________________________________________________________

Data acc. to compressor rating plate: _______________________________________________________________________________________

Operating pressure (≤ max. operating pressure): ______________________________________________________________________________

Date Maintenance – Inspection – Repair

Type of oil Cause of malfunction – Remarks

Temperature (°C) compressor

C270TS-9, C260TS-10, C250TS-12,

11 Electronic system ........................................................................................................................................................................... 38

2.1 Information on the The compressor is designed for providing

2.2 Normal use Any other use, or any additional use,

Volume of cooling water

Oil fill (compressor)

Fuel tank capacity

min. max. min. max.

max. permissible noise level,

PN8NTC 2.2 at the operators

max. sound intensity acc. to

Height without exhaust pipe

PN8NTC 2.2, distance 7m

* with optional features maximum 3,500 kg

2.4 Declaration of conformity

2. We, hereby declare Gardner Denver Deutschland GmbH

that the product: Kompressor

type: DLT0206 ; DLT0408 ; DLT0704 ; DLT1303 ; DLT2701

in the form as shipped by us complies with the following relevant provisions:

2006/ 42/ EG 2009/ 105/ EG 2004/ 108/ EG

4. Harmonized standards applied, particularly

EN 1012-1 EN ISO 12100 EN 61000-6-2

5. National engineering standards and specifications applied

AD-S1/2000 VDE 0100 DIN 3230

6. Recording agency: CompAir Drucklufttechnik -

In case of faults, or should you require This operating manual is to be

Instructions, including supervisory Personnel selection and qualification; Note

3.7 Instructions concerning Gas, dust, steam, smoke Noise

3.8 Symbols and definitions

Lifting spot Attention: Maintain specified tyre

Condensate discharge (oil/water) Emergency stop device

System radiator/coolant recovery

Do not remove the Operating and

Attention: Prior to starting any

4 Construction and functional description

Fig. 3 4.1 Construction The drive unit is a water cooled charged

4.3 System description

4.4 Wiring diagram

4.5 Terminal Diagram DIN ISO 1724

blue (54 G) rear fog lamp

right side marker lamp

white right licence plate lamp

black brown (58 R) right tail lamp

yellow green (R) right indicator lamp

red red (54) right stop lamp

brown black (58 L) left tail lamp

left side marker lamp

Fig. 6 105 580 74

5.1 Transport Danger Attention

* Trailer coupling ring DIA 40 in * The electrical cable (option) is

Danger * Only relocate the compressor by itself. Danger

Greater inclinations endanger the

6.3 Filling up the fuel tank

Only fill up with fuel when the screw

7.1 Initial operation 7.3 Start-up Starting up the compressor:

7.7 Shutdown 7.8 Decommissioning

The screw compressor is automatically If the system is to be closed down for a

It is important that you ensure that the

Conventional engine oils marked HD Please observe the engine

9.4 Maintenance and inspection schedule

At the latest after x years 1 yr 2 yrs 3 yrs 4 yrs 5 yrs 6 yrs

9.4.3 Inspecting / Replacing the

Plant Maintenance Personnel, Name: _______________ ☎