Rotair MDVN 71 AP Operating, Maintenance & Parts Manual
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Rotair MDVN 71 AP Operating, Maintenance & Parts Manual

Mobile motor compressor
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MANUALE DI USO E MANUTENZIONE - RICAMBI
MANUEL D'ENTRETIEN - PIECES DE RECHANGE
OPERATING MAINTENANCE
- PARTS MANUAL
BEDIENUNG
UND
WARTUNGSANLEITUNGEN
MANUAL DE USO Y MANTENIMIENTO - RECAMBIOS
MOBILE MOTOR COMPRESSOR
MDVN
71 AP
Via Bernezzo 67 – 12023 CARAGLIO (CN) –ITALIA
TLF: +39 0171 619676 – FAX: +39 0171 619677
E-MAIL: info@rotairspa.com
http://www.rotairspa.com

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Summary of Contents for Rotair MDVN 71 AP

  • Page 1 MANUALE DI USO E MANUTENZIONE - RICAMBI MANUEL D’ENTRETIEN - PIECES DE RECHANGE OPERATING MAINTENANCE - PARTS MANUAL BEDIENUNG WARTUNGSANLEITUNGEN MANUAL DE USO Y MANTENIMIENTO - RECAMBIOS MOBILE MOTOR COMPRESSOR MDVN 71 AP Via Bernezzo 67 – 12023 CARAGLIO (CN) –ITALIA TLF: +39 0171 619676 –...

  • Page 3: Table Of Contents

    SUBJECT INDEX Identification data _ Technical data _ Manual use and consultation _ Envisaged machine use _ Technical description of machine and its function _ 5.1) Chassis and axle _ 5.2) Bodywork _ 5.3) Motor _ 5.4) Compression unit _ 5.5) Oil separator tank _ 5.6)
  • Page 4 (*)Measured in accordance with ISO 1217 standards (±5%). (**)Measured in accordance with directive CEE 84/533, technical adaptation 85/406/CEE. CAUTION: The use of non-original ROTAIR spares will result in the immediate cancellation of the guarantee. On requesting assistance or ordering of parts always cite the model number and...
  • Page 5 -- 2) TECHNICAL DATA -- COMPRESSOR: -- WORKING PRESSURE: 7 bar -- MAXIMUM FINAL PRESSURE: 8 bar -- MINIMUM WORKING PRESSURE: 5 bar -- AIR YIELD AT MAX SPEED 7100 litres/1’ AND ON WORKING PRESSURE: -- COOLING: hydraulic oil (*) -- OIL SYSTEM CAPACITY: 13 litres (*) Q8 SCHUBERT 46 oil is recommended.
  • Page 6 It is important to ensure that the special maintenance operations in particular are undertaken by specialized personnel. In the event of loss or damage of this manual, ROTAIR must be asked for a copy, citing the relative machine identification details as shown on the plate on the machine.
  • Page 7 “Conforming use" presupposes the observance of the following regulations concerning the use, maintenance and transport of the unit itself. It is also necessary to ensure that all the accident prevention regulations hereby described are followed, also in accordance with general safety regulations as indicated in the current legislation.
  • Page 8 Any parts or accessories which fail to guarantee safe function are to be replaced. ROTAIR S.p.A. Use only the oils and lubricants recommended or approved by the engine manufacturer. Ensure that the selected lubricants comply with all current safety provisions, particularly as regards explosion or fire risks, and the hazard of the decomposition or production of harmful gases.
  • Page 9 14. The precision of the pressure and temperature indicators should be regularly checked in order to ensure rapid replacement should the tolerance values be irregular. ROTAIR S.p.A. 15. The parts should be replaced solely using original spares. 16. The safety instruments are to be tested as described in the maintenance table in the instructions manual in order to ensure that they are in good operating conditions.
  • Page 10 Position the unit on flat ground and lock the parking brake before releasing the unit from the towing vehicle. Should the compressor not feature a parking brake, immobilise the compressor by placing some wedges in front or behind the wheels. The operator should avoid getting in the way of any released compressed air as the force of the air speed may cause injury to those directly in its path.
  • Page 11 personal injury. Before disconnecting any piping, always make sure that there is no internal pressure. 14. Never fill up with fuel with compressor in action. Keep the fuel away from hot parts. Never smoke during fuel filling operations. Never spread or leave any oil, fuel, coolant liquids or detergent substances on the compressor or near it.

  • Page 12: Chassis And Axle

    -- 5) TECHNICAL DESCRIPTION -- This unit, like the entire MDVN range is an oil injection screw mobile motorized compressor, single-stage and silenced. The motor is of internal combustion type, and runs on gas oil, and transmits power to the compressor by means of an elastic joint positioned co-axially between the two.

  • Page 13: Compression Unit

    -- 5.4) COMPRESSION UNIT -- It is completely manufactured in the ROTAIR factory and consists of a central body (cylinder) inside which are fitted two screw rotors with asymmetric section, a male one with 5 lobes and female one with 6 lobes.
  • Page 14 -- 5.7) CONTROL INSTRUMENTATION AND DEVICES (FIG.1 -- The control panel layout, near the air exit cocks was specifically designed so as to have all the controls within reach of a single person. All the necessary instruments to control the unit are located on the control panel.
  • Page 15 -- 5.8 WIRING SISTEM AND ITS FUNCTION -- This motor-driven compressor is fitted with a 12V wiring system with continuos current: the wiring diagram is as follow (table 1): Table 1 Details wiring diagram Starter motor Low pressure stop bulb (3,5bar) Mass ignition Fuel solenoid (hold)
  • Page 16 CAUTION: All operations on the wiring system must be carried out by specialized personnel. 1) WIRING SYSTEM FUNCTION 1.1) By turning the starting block key (part. 4 fig. 1) to the right in the position “ON”, the panel is powered and the following warning lights come on: Engine oil pressure warning light This indicates whether the engine oil circuit is in pressure (warning light off) or not (warning light on).
  • Page 17 2) In machines approved for road use the electrical system is completed by lighting wiring (TABLE 2). In the table, the wire connections inside the 7-pole socket are given and their connection to the rear light apparatus. This system is connected directly to the towing machine via an extension lead which is supplied with the engine-compressor.

  • Page 18: Safety Devices

    -- 5.8.1) SAFETY DEVICES -- These devices protect the machine from all malfunctions which could cause serious damage to the machine, if they are not promptly eliminated.  6b Minimum oil pressure gauge: This device prevents the starting up if the machine until the pressure inside the oil separator tank has not fallen to under 1.5 Bar.
  • Page 19 - 5.9) OLEOPNEUMATIC PLANT (Fig. 3) -- -- 5-9-1) COMPRESSOR LUBRICATION SYSTEM -- The system includes the oil separator tank (Z), the thermostatic valve (U) on which, at the entrance, the oil filter (V) and the oil cooling radiator (M) are mounted. As shown in fig.
  • Page 20 When the oil temperature reaches 75C, the thermostatic valve (U9 closed completely and from then on all the oil in circulation goes through the radiator and is thereby cooled (M). From the radiator (M) the oil is injected into the compressor (O). The filter (V) has an internal "by-pass"...
  • Page 21 -- 5-9-3) AUTOMATIC MOTOR SPEED REGULATION (Fig. 3) -- The system controls the speed of the diesel motor according to the compressed air taken in and consists of: maximum pressure valve (G), suction regulator (B), accelerator control piston (E), contrast spring (H). ...
  • Page 22 -- 6) MACHINE HANDLING AND PARKING -- -- 6.1) LIFTING INSTRUCTIONS (Fig. 4) -- The bodywork has a special opening protected by a rubber covering, making it possible to easily reach the lifting hook, without lifting the bonnet. A lifting clevis is supplied for this purpose together with the compressor. a) Check that the lifting parts (crane, hoist etc) have the capacity to move the weight of the unit (see par.

  • Page 23: Towing Instructions

    -- 6.2) TOWING INSTRUCTIONS (Fig. 5) -- This paragraph concerns machines suited to road circulation and thereby complete with regular homologation certificate. For correct towing of the motor-drive compressor please follow these instructions: a) Ensure that the towing eyelet or the ball attachment is compatible with the towing device fitted on the towing vehicle.

  • Page 24: Transport Instructions

    -- 6.3) TRANSPORT INSTRUCTIONS (Fig. 6) -- The unit is despatched by Rotair fixed to a support suitable for movement by means of lift trucks; this wooden platform, facilitates the fastening to the flatbed of the transport vehicle and prevents this load from sliding.

  • Page 25: Starting Up

    It is only necessary to use specialized personnel for special maintenance operations, and those with the necessary technical know-how as provided by the "Rotair" assistance service. -- 7.1) BEFORE STARTING UP THE MACHINE -- Before starting up the machine carefully proceed according to the following instructions: -7.1.1) Make sure that the machine is level;...
  • Page 26 -7.1.5 Check the level of the cooler liquid in the radiator (Fig.9). ATTENTION: The radiator cap (part T) must never be removed while the engine is hot, as this would cause a sudden escape of liquid that could cause serious burns. Any top-ups must be made using a mixture of water and anti-freeze liquid,...

  • Page 27: During The Working Stage

    -- 7.2) STARTING UP -- Proceed as indicated in the illustrations of chap. 5.7 1) Fully close the air delivery taps 2) Position switch (4) to ON position, which will switch on the spark-plug pre-heating alternator and oil pressure indicators. 3) Wait for the spark-plug pre-heating indicator to go off.

  • Page 28: After Machine Stop

    -- 7.5) AFTER MACHINE STOP 1) After machine operation in very dusty conditions, it will be necessary to clean and replace the air filter and check that the cooling radiator is clean, should it be clogged proceed as indicated in paragraph (10.4) 2) Check that there has been no oil or fuel leakage during operations.
  • Page 29 -- 8) MACHINE SETTING AND TUNING -- -- 8.1) CHECK ON MOTOR RPM MAXIMUM SPEED -- The calibration of the maximum rpm is set and sealed by the constructor. It cannot be altered for any reason. Any tampering with the sealing and consequent variation in the max. rpm, will result in the immediate cancellation of the guarantee terms, both in relation to the motor and compressor parts.
  • Page 30 If, after increasing the spring (M) pulling potential as described above, the piston (C) continues to impede the rod (P) it is necessary to check the correct function of the acceleration device by checking the maximum pressure regulation valve (fig. 16, page 26) proceeding as follows: Dismantle and clean the various components, carefully checking to make sure that there are no foreign bodies that may impede the perfect sealing of the housing of the...
  • Page 31 Should the minimum rpm need to be regulated proceed as follows (fig. 12): 4.1) Using a 13 mm wrench loosen the lock-nut (D) and use a screwdriver tighten regulation screw (V) (to increase revs) or to loosen it (to reduce the revs), re-securing it using the lock-nut (D).
  • Page 32 WARNING: Should the gauge have a jerky discontinuous function, it must be replaced. Therefore before undertaking any calibration of the maximum and minimum pressure valves, make sure that the gauge itself is efficient and reliable. -- 8.3) MINIMUM PRESSURE CHECKING AND SETTING (Fig. 14) -- The purpose of this valve is to ensure that during operation the pressure in the oil separator tank does not drop under the minimum value, in order to ensure the necessary oil circulation.

  • Page 33: Safety Valve Check

    ROTAIR SPA citing the machine serial number. ROTAIR will not accept any responsibility in the event of the use of non-original and non- conforming valves.
  • Page 34 -- 9) MAINTENANCE PROGRAMME -- This programme indicates all the necessary periodic operations to be undertaken in the machine and which are essential to ensure its efficient function and long life. ORDINARY MAINTENANCE Can be undertaken by the personnel who operate on the machine and includes all those periodic programmed maintenance operations such as checks on the oil level, air filters, refuelling, cleaning operations and checks to isolate any eventual leakage of lubricant or fuel inside the machine.
  • Page 35 Every 3000 HOURS: General check on the various components by the "Authorized Rotair" assistance service. WARNING: during the various maintenance operations it is necessary to carefully examine the rubber piping and should it be found to be excessively hardened and rigid, they must be replaced with materials having equivalent technical features.

  • Page 36: Battery Check

    10) PERIODIC MAINTENANCE -- -- 10.1) AIR FILTER CHECKING (Fig. 16) --  This check must undertaken periodically after every 1oo working hours, however should the machine operate particularly dusty environments it may be necessary even daily.  The filter consists of two filtering cartridges (1 stage): to check them Fig.

  • Page 37: Cooling Radiator Cleaning

    -- 10.4) COOLING RADIATOR CLEANING -- The cooling liquids of the compressor and motor are cooled by a radiator which must therefore be kept clean to ensure that the ventilation air can easily pass through its honeycomb flaps. Should the flaps become clogged with dust of other particles, there is a risk of harmful overheating of the mechanical parts of the screw compressor, seriously jeopardizing its function and duration.

  • Page 38: Braking Device Check

    -- 10.7) BRAKING DEVICE CHECK -- As concerns this operation consult the use and maintenance manual relative to the axial - brake - overrun, compiled by the manufacturer and which forms part of the documentation supplied together with the machine. -- 10.8) WHEEL BLOCKING SCREW CHECK -- Using a special spanner ensure that there are no loose screws.

  • Page 39: Compressor Oil Replacement

    -- 10.10) COMPRESSOR OIL REPLACEMENT (Fig. 20) -- Compressor oil replacement must also be undertaken taking into account the working conditions under which the machine operates (dusty conditions, very high temperatures etc) and in any event at intervals which must never exceed 1500 working hours, or at least once a year.
  • Page 40 10.11) OIL SEPARATOR ELEMENT (Fig. 21) -- -- 10.11.1) CHECKING OF OIL SEPARATOR ELEMENT -- This operation is reserved for specialized and qualified personnel. The frequency is usually estimated as being of about every 2000 working hours, but it strictly depends on the observance of all the maintenance regulations indicated in this manual.
  • Page 41 9. Tighten the bolts,(A), with a tightening torque of 80 Nm. 10.Re-connect all the pipes to the respective fittings. 11.Start up the machine ensuring there is no leakage between the cap and the tank. 12.Allow the machine to operate for 10-15 minutes with closed cocks 13.Stop the machine with tank depressurized to 0 bar, re-check the screw tightening (A).
  • Page 42 ANOMALY CAUSES SOLUTIONS Recharge or replace if Flat or defective battery. necessary. Clean and tighten them. Battery wire cables either oxidized or loose. Fill the tank. Lack of fuel. Request intervention of the Defective fuel solenoid valve. customer assistance service of the motor constructor;...
  • Page 43 ANOMALY CAUSES SOLUTIONS On opening the cocks the Defective maximum pressure Dismantle carefully motor fails to accelerate. regulation valve. check the spring and the conical housing. If the defect cannot be repaired the valve must replaced. position maximum pressure according to the instructions of paragraph ***************************** *****************************...
  • Page 44 check the cooler liquid level. If it is found to be the probe positioned compressor check the oil level in the tank and top up as necessary; check the cooler fan and clean the radiator; replace compressor oil filter. If it is found to be the probe positioned separator tank, check the oil separator filter according to...
  • Page 45 ANOMALY CAUSES SOLUTIONS Adjust according Minimum work pressure too instructions of par. 8.3. low. Restore correct level (par. Excessive oil in the tank. 7.1.4). Position the machine so it is The machine works in a non- Oil leakage from cocks. level.

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