Denyo DU-190 Instruction Manual
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Denyo DU-190 Instruction Manual

Portable compressors
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Summary of Contents for Denyo DU-190

  • Page 1 Instruction Manual English...
  • Page 3 Instruction Manual for Portable Compressors DU-190 Original instructions Printed matter No 2950 8360 01 05/2019...
  • Page 4 Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk. While every effort has been made to ensure that the information in this manual is correct, Denyo Co., Ltd does not assume responsibility for possible errors.

  • Page 5: Table Of Contents

    Table of contents Preface Service kits..........29 Storage ............29 Please read the following instructions carefully Safety precautions ........7 before starting to use your compressor. Oil specifications........33 Introduction ..........7 Oil level check ........... 35 It is a solid, safe and reliable machine, built according to the latest technology.
  • Page 6 Air filter engine/compressor....... 46 7.2.1 Servicing ..........46 7.2.2 Main parts ..........46 7.2.3 Cleaning the dust trap ......46 7.2.4 Cleaning instructions filter element ..46 7.2.5 Replacing the air filter element ....47 7.2.6 Air receiver..........48 Safety valve ..........48 Fuel system..........

  • Page 7: Safety Precautions

    It is the responsibility of management to appoint Take necessary steps to keep unauthorized persons The policy of Denyo is to provide the users of their equipment with safe, reliable and efficient products. operators with the appropriate training and skill for...

  • Page 8: General Safety Precautions

    The manufacturer does not accept any liability for any GENERAL SAFETY PRECAUTIONS Care shall be taken to avoid damage to safety valves other pressure-relief devices, damage arising from the use of non-original parts and The owner is responsible for maintaining the unit for modifications, additions or conversions made especially to avoid plugging by paint, oil coke or in a safe operating condition.

  • Page 9: Safety During Transport And Installation

    13 If the warning light on the ABS module or in the Place the unit on level ground and apply the bends in lifting cables, chains or ropes. vehicle lights up, please contact Denyo. parking brake before disconnecting the unit from Helicopter lifting is not allowed.
  • Page 10 Close the compressor air outlet valve before 11 Before removing the oil filler plug, ensure that the - below 85 dB(A): no action needs to be taken for occasional visitors staying a limited time connecting or disconnecting a hose. Ascertain pressure is released by opening an air outlet that a hose is fully depressurized before valve.

  • Page 11: Safety During Maintenance And Repair

    Keep away dirt, cover falling objects, wearing of a safety helmet should Parts shall only be replaced by genuine Denyo the parts and exposed openings with a clean cloth, be included.

  • Page 12: Tool Applications Safety

    15 Protect the engine, alternator, air intake filter, 23 Make sure that oil, solvents and other substances electrical and regulating components, etc., to likely to pollute the environment are properly prevent moisture ingress, e.g. when steam- disposed of. cleaning. 24 Before clearing the unit for use after maintenance 16 When performing any operation involving heat, or overhaul, check that operating pressures, temperatures and speeds are correct and that the...

  • Page 13: Specific Safety Precautions

    If the set pressure must be altered then use only When batteries are being charged, an explosive correct parts supplied by Denyo and in accordance - the minimum working temperature Tmin in °C gas mixture forms in the cells and might escape with the instructions available for the valve type.

  • Page 14: Leading Particulars

    Leading particulars GENERAL DESCRIPTION Engine Regulation The compressors DU-190 are driven by a 4 cylinder The compressor is provided with a continuous The DU-190 are silenced, single-stage, oil-injected in-line liquid-cooled diesel engine. pneumatic regulating system and a blow-off valve screw compressors, built for a nominal effective which is integrated in the unloader assembly.
  • Page 15 Frame and axles Serial number The compressor/engine unit is supported by rubber buffers in the frame. Bodywork The bodywork has openings at the shaped front and rear end for the intake and outlet of cooling air and hinged doors for maintenance and service operations. The bodywork is internally lined with sound- absorbing material.

  • Page 16: Main Parts

    Main Parts - 16 -...
  • Page 17 Reference Name Reference Name Alternator Regulating valve Serial number AFce Air filter (compressor element) Air filter (engine) Safety valve Air outlet valves Vacuum indicator Air receiver Battery Compressor element Control panel DPar Drain plug air receiver DPcv Drain plug compressor element DPoc Drain plug compressor oil cooler DPosv...

  • Page 18: Compressor Regulating System

    COMPRESSOR REGULATING SYSTEM - 18 -...
  • Page 19 Reference Name AFce Air filter (compressor element) Air filter (engine) Air filter Element Air receiver/Oil separator Air outlet valve Bypass valve Coupling housing Compressor element Control panel Cooling fan Drain plug Engine Oil cooler Oil separator element Oil stop valve Oil filter compressor Regulating valve Safety cartridge...

  • Page 20: Air Flow

    AIR FLOW Air drawn through the airfilter (AFce) into the compressor element (CE) is compressed. At the element outlet, compressed air and oil pass into the air receiver/oil separator (AR/OS). The check valve (CV) prevents blow-back of compressed air when the compressor is stopped. In the air receiver/oil separator (AR/OS), most of the oil is removed from the air/oil mixture.

  • Page 21: Oil System

    OIL SYSTEM The lower part of the air receiver (AR) serves as an oil tank. Air pressure forces the oil from the air receiver/oil separator (AR/OS) through the oil cooler (OC), the oil filter (OFc) and the oil stop valve (OSV) to the compressor element (CE).

  • Page 22: Continuous Pneumatic Regulating System

    CONTINUOUS PNEUMATIC REGULATING SYSTEM - 22 -...
  • Page 23 The compressor is provided with a continuous If the air consumption is less than the maximum air pneumatic regulating system and a blow-off valve, output, air receiver pressure increases and the which is integrated in the unloader assembly (UA). regulating valve supplies control air to throttle valve The blow-off valve is kept closed by receiver pressure to reduce the air output and holds air receiver pressure and opens by compressor element outlet pressure...

  • Page 24: Markings And Information Labels

    MARKINGS AND INFORMATION LABELS Read the instruction manual before Filler cap coolant. Dangerous outlet gases. starting. Read the instruction manual before Warning! Part under pressure. Danger, hot surface. topping up with coolant. Do not stand on outlet valves. Service point. Electrocution hazard.

  • Page 25: Operating Instructions

    Operating instructions LIFTING INSTRUCTIONS Safety precautions The operator is expected to apply all relevant Safety precautions. When lifting transporting compressor in any way, the battery switch must always be in the “OFF” position. Locate the rear-end of the compressor upwind, away When lifting the compressor, the hoist has to be placed in such a way that the compressor, which must from contaminated wind-streams and walls.

  • Page 26: Starting / Stopping

    STARTING / STOPPING 8. Attach the air line(s) to the closed air outlet valve(s). Connect the safety chain. BEFORE STARTING No external force may be applied to the air outlet valve(s), e.g. by pulling hoses 1. Before initial start-up, prepare battery for or by connecting equipment directly to operation if not already done.

  • Page 27: Controller Panel

    Controller Panel CONTROL PANEL DESCRIPTION STARTING/STOPPING 1. The engine ignition key port (1) is used to start the SAFETY PRECAUTION engine. 1. Before starting the machine, make sure that the 2. The fuel level low indicator (2) glows if the fuel fuel tank is full.

  • Page 28: Emergency Stop

    EMERGENCY STOP   The emergency stop button is only to be used in emergency situations not for stopping procedures. When an emergency stop button (1) is pressed, power to all outputs is terminated, by the emergency stop itself (hardware) as well as by the software. When the emergency stop button (1) is pressed the operator can unlock the emergency stop by turning it counterclockwise...

  • Page 29: Maintenance

    If the compressor is going to be stored Service Paks minimize downtime and keep your without running from time to time, maintenance budget low. protective measures must be taken. Order Service Paks at your local Denyo dealer. - 29 -...
  • Page 30 3002 6085 50 For the most important subassemblies, Denyo has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts, save administration costs and are offered at a reduced price, compared to individual components. Refer to the parts list for more information on the contents of the service kits.
  • Page 31 3002 6085 30 3002 6085 40 3002 6085 50 Clean oil cooler(s)/radiator Inspection by Denyo service technician Check engine & compressor anti-vibration pads Check functioning of regulating valve Check electrical system cables for wear Check engine (minimum and maximum) speed...
  • Page 32 5. Gummed or clogged filters mean fuel starvation and reduced engine performance. 6. See section Oil specifications. 7. The following part numbers can be ordered from Denyo to check on inhibitors and freezing point:  2913 0028 00 Refractometer  2913 0029 00 pH meter.

  • Page 33: Oil Specifications

    OIL SPECIFICATIONS Paroil from Denyo is the ONLY oil tested and Paroil releases excess heat efficiently, whilst It is strongly recommended to use Denyo approved for use in all engines built into Denyo maintaining excellent bore-polish protection to limit branded lubrication oils both compressors and generators.
  • Page 34 COMPRESSOR OIL ENGINE OIL Synthetic Compressor oil Paroil S Use specified engine oil, It greatly affects Liter US gal Order number the startup operation and life of the 1630 0160 00 engine. 1630 0161 00 Barrel 55.2 1630 0162 00 Only use oil, CF class or higher, Container 1000 265 1630 0163 00...

  • Page 35: Oil Level Check

    The oil level should be shown in the sight glass or above the sight glass. Add oil if necessary. In this case, contact Denyo. Before removing the oil filler plug (2), ensure that the pressure is released by opening an air outlet valve (3).

  • Page 36: Topping Up The Compressor Oil

    1. Run the compressor until warm. Close the outlet TOPPING UP THE COMPRESSOR OIL valve(s) (1) and stop the compressor. Wait until the pressure is released through the automatic blow-down valve. Unscrew the oil filler plug (2) by a single turn. This uncovers a vent hole, which permits any pressure in the system to escape.

  • Page 37: Compressor Oil Flushing Procedure

    10. Check the oil level and top up if necessary. Whenever aged oil is discovered, e.g. when changing 11. Collect all waste lubricant used during the the oil separator, contact Denyo Service dept. to have flushing process and dispose of it in accordance your compressor cleaned and flushed.

  • Page 38: Coolant Specifications

    The use of the correct coolant is important for proper Mixing rate of LLC should be selected within the heat transfer and protection of liquid-cooled engines. Denyo's COOLANT EG extended life coolant is the range of 30-50%. Coolants used in these engines must be mixtures of...

  • Page 39: Handling Coolant Eg

     A refractometer can be ordered from Denyo with the benefits of 5 years protection when its used on its part number 2913 0028 00.

  • Page 40: Topping Up Without Draining From The Cooling System

    TOPPING UP WITHOUT DRAINING FROM THE COOLING SYSTEM The quantity of COOLANT EG Concentrate to be topped up can be estimated with the following formula and/or graph: Corrections concentrate in measured system towards 50% volume by using COOLANT EG Concentrate Example: PN: 1604 8159 00 Liter...

  • Page 41: Topping Up After Limited Quantity Draining From The Cooling System

    TOPPING UP AFTER LIMITED QUANTITY DRAINING FROM THE COOLING SYSTEM The quantity of COOLANT EG Concentrate to be topped up after draining a calculated volume from the cooling system, can be estimated with the following formula and/or graph: Corrections concentrate in measured system towards 50% volume by using COOLANT Concentrate Example: PN: 1604 8159 00 Liter...

  • Page 42: Replacing The Coolant

    Protect the electrical and controlling equipment, air filters, etc. against  Using the Denyo Instruction book, determine the penetration of moisture. amount of COOLANT EG required and pour into the radiator top tank.

  • Page 43: Battery Care

    BATTERY CARE ACTIVATING A DRY-CHARGED BATTERY MAKE-UP DISTILLED WATER  Take out the battery. The amount of water evaporating from batteries is Before handling batteries, read the largely dependant on the operating conditions, i.e. relevant safety precautions and act  Battery and electrolyte must be at equal temperatures, number of starts, running time between accordingly.

  • Page 44: Periodic Battery Service

    When a compressor element is due for overhaul, it  Keep the battery clean and dry. needs to be done by Denyo. This guarantees the use of  Keep the electrolyte level at 10 to 15 mm above genuine parts and correct tools with care and the plates or at the indicated level;...

  • Page 45: Adjustments And Servicing Procedures

    Adjustments and servicing procedures ADJUSTMENT OF THE CONTINUOUS PNEUMATIC REGULATING SYSTEM The working pressure is determined by the tension of the spring in the regulating valve (RV). This tension can be increased to raise the pressure and decreased by turning the adjusting wheel clockwise and anti- clockwise respectively.

  • Page 46: Air Filter Engine/Compressor

    AIR FILTER ENGINE/COMPRESSOR MAIN PARTS CLEANING THE DUST TRAP Remove dust daily. The Denyo air filters are specially To remove dust from the dust trap squeeze the designed for the application. The use of vacuator valve (6) several times. non-originals air filters may lead to...

  • Page 47: Replacing The Air Filter Element

    REPLACING THE AIR FILTER ELEMENT New elements must also be inspected for tears or punctures before installation. Discard the element (4) when damaged. A dirty safety cartridge (3) is an indication of a mal- functioning air filter element. In that case replace the element and safety cartridge.

  • Page 48: Air Receiver

    AIR RECEIVER SAFETY VALVE FUEL SYSTEM PRIMING INSTRUCTIONS All adjustments or repairs are to be done by an authorized representative of the valve supplier, see section Specific safety Fuel leaked or spilled onto hot surfaces precautions. or electrical components can cause a fire. To help prevent possible injury, turn the “ON/OFF”...

  • Page 49: Problem Solving

    Choked air filter elements (AF). Remove and inspect elements. Clean or replace, if necessary. Regulating valve (RV) defective. Have regulating valve removed and inspected by an Denyo Service representative. Blow down valve stuck in open position. Check and correct as necessary.
  • Page 50 Possible faults Corrective actions Regulating valve (RV) opens too late or its ball valve spring is broken. Have regulating valve removed and inspected by an Denyo Service representative. Air leaks in regulating system. Check hoses and their fittings. Stop leaks; replace leaking hoses.
  • Page 51 Oil stop valve malfunctioning. Remove and inspect valve. Oil separator element (OS) clogged. Have element removed and inspected by an Denyo Service representative. Alternator precautions 1. Never reverse the polarity of the battery or the alternator. 2. Never break any alternator or battery connections while the engine is running.

  • Page 52: Available Options

    Available options Cold start (-20 °C) Aftercooler + water separator + bypass Generator 15kVA Inlet shut down + spark arrestor Tool box Non-return valve Additional fuel filter Lubricator Additional fuel tank Undercarriage - 52 -...

  • Page 53: Technical Specifications

    Technical specifications TORQUE VALUES GENERAL TORQUE VALUES CRITICAL TORQUE VALUES The following tables list the recommended torques applied for general applications Assemblies Torque value, Nm (lbf.ft) during assembly of the compressor. Compressor to frame: Bolts, elements/gear casing 46 (33.95) For hexagon screws and nuts with strength grade 8.8 Bolts, elements/support 80 (59.04) Bolts, support/buffer...

  • Page 54: Compressor / Engine Specifications

    COMPRESSOR / ENGINE SPECIFICATIONS REFERENCE CONDITIONS DU-190 Designation Unit 7 bar Absolute inlet pressure 14.5 Relative air humidity Air inlet temperature °C °F Normal effective working pressure 101.52 The inlet conditions are specified at the air inlet grating outside the canopy.

  • Page 55: Limitations

    LIMITATIONS DU-190 Designation Unit 7 bar Minimum effective receiver pressure Maximum effective receiver pressure, compressor unloaded 126.18 Maximum ambient temperature at sea level °C °F Minimum starting temperature °C °F Minimum starting temperature, with coldstart equipment °C °F Altitude capability...

  • Page 56: Performance Data

    PERFORMANCE DATA DU-190 Designation Unit 7 bar Engine shaft speed, normal and maximum 3000 Engine shaft speed, compressor unloaded 1600 2) 6) Free air delivery Fuel consumption - at 100% FAD kg/h 8.52 lb/h 18.78 - at 75% FAD kg/h lb/h 15.43...
  • Page 57 DU-190 Designation Unit 7 bar Noise level - Sound pressure level (Lp), measured according to ISO 2151 under free field conditions at 7 m dB(A) distance - Sound power level (Lw) complies with 2000/14/EC dB(A) - 57 -...

  • Page 58: Design Data

    DESIGN DATA Compressor Designation Unit DU-190 Capacity of cooling system Designation DU-190 us gallon 2.24 Number of compression stages With filter change. Engine Unit Designation Unit DU-190 Designation Unit DU-190 Make Kubota Capacity of compressor oil system Type V1505T us gallon 2.37...
  • Page 59 1) At reference conditions, if applicable, and at normal shaft speed unless otherwise stated 2) Free air delivery is measured according to ISO 1217 ed.3 1996 annex D Tolerance: +/- 5% 25l/s<FAD<250l/s +/- 4% 250l/s <FAD The international standard ISO British BSI 1571 part 1 1217 corresponds to following German DIN 1945 Part 1...

  • Page 60: Electric System

    ELECTRIC SYSTEM Circuit diagram - 9829 3801 10 - 60 -...
  • Page 61 Circuit diagram - 9829 3801 10 - 61 -...

  • Page 62: Electric System

    ELECTRIC SYSTEM Wire harness - 1094 3133 02 - 62 -...

  • Page 63: Data Plate

    Data plate 1. Weight 2. Model 3. Serial number 4. Maximum working pressure 5. Free air delivery 6. Engine power 7. Speed 8. Year of manufacturing - 63 -...

  • Page 64: Disposal

    Remove spilled fluid mechanically; pick up the rest non-recyclable materials. with absorbing agent (for example sand, sawdust) and Your Denyo compressor consists for the most part of dispose of it in accordance with applicable local metallic materials, that can be remelted in steelworks disposal regulations.

  • Page 65: Maintenance Log

    Maintenance Log Compressor ..................Customer ....................Serial number........................................Service hours Maintenance action Date By: initials - 65 -...

  • Page 66: Dimension Drawing - 9829380226-01

    Dimension drawing - 9829380226-01 If non service side placed near wall, please keep more than mm distance 2744 1080 Hot Air Out Air Inlet R756,3 1080 1135 567,5 567,5 1280 2642 Air Inlet Air Inlet - 66 -...

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