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CompAir C30 Operating Manual
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CompAir C30 Operating Manual

Deutz m1011f powered compressor
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Operating Manual
C30, C35-10, C38, C42, C50
Deutz M1011F
Powered Compressor
GB
Id. Nr. 100 002 755 / 02 - März 2003

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Summary of Contents for CompAir C30

  • Page 1 Operating Manual C30, C35-10, C38, C42, C50 Deutz M1011F Powered Compressor Id. Nr. 100 002 755 / 02 - März 2003...
  • Page 2 * You do not observe the information in 1.1 Information on the compressor the operating manual CompAir screw compressors are the For this reason every person involved in product of many years' research and the operation, maintenance and repair of development.
  • Page 3 1. Foreword 1.3 Specifications type DLT 0404 Ambient Engine temperature speed min. max. No-load On-load /min] [bar] [bar] [°C] [°C] [kW] [rpm] [rpm] 5.0-8.0 1000 F2M1011 22.6 1850 3000 C30G 5.0-8.0 1000 F2M1011 22.6 1850 3000 5.0-8.0 1000 F3M1011F 34.0 1650 2800 6.75...

  • Page 4: Maintenance And Care

    Technical modifications current national regulations for accident please contact your local CompAir agent. We reserve the right to undertake prevention and environmental protection. It In case of damage, the trained technical...
  • Page 5 2. Index 1. Foreword ....................61 1.1 Information on the compressor .
  • Page 6 2. Index 9. Maintenance ................... . 91 9.1 General maintenance .

  • Page 7: Security Regulations

    The responsibility of the personnel for particularly the chapter on safety operating, setting up, maintaining and CompAir accepts no responsibility for instructions. It is too late to do this while repairing the machine / installation must any damage or injury caused by non- working.
  • Page 8 3. Security Regulations Before or immediately after completion Do not travel across slopes transversely: 3.4 Loading / Relocation / Transport of loading, secure the machine / installation always keep equipment and loads near to prevent accidental shifting. Display an ground level (for example, do not place Loading / Relocation appropriate warning.
  • Page 9 3. Security Regulations All pressure tanks located outside the unit Make sure that: * There are no leaks (fuel, oil or coolant with an approved operating pressure higher leaks) * All bolted connections have been than atmospheric pressure and fitted with tightened * All bolted connections have been two or more pressure feed lines must be...
  • Page 10 3. Security Regulations With water-cooled combustion engines Only use suitable, technically perfect 3.6 Special jobs / Maintenance with a closed cooling circuit, the cap of the hoisting gear and load suspension devices coolant recovery bottle must not be with adequate carrying capacity. Keep clear Care removed before the system has cooled of suspended loads.
  • Page 11 3. Security Regulations Whenever the machine/system is The fuel used in these systems is highly Machines whose main movement is back completely powered down for maintenance inflammable, toxic and poisonous. Avoid and forth must be moved at least once, and repair procedures, it has to be contact with eyes and skin, and never rotating machines several times, in order to secured against unintentional power-on...
  • Page 12 3. Security Regulations Always wear long-sleeved overalls, acid- The electrical equipment of a machine / Check all lines, hoses, and bolted resistant gloves and safety goggles. installation must be inspected / tested connections regularly for leaks and visible regularly. Faults, such as loose con- damage.
  • Page 13 (Exception: specially-made compressors with the necessary technical modifications for use in such areas) Note CompAir accepts no responsibility for any damage or injury caused by noncompliance with these safety measures or noncompliance with normal care and caution during the handling, operation,...
  • Page 14 3. Security Regulations Attention Hot and harmful exhaust Protect the generator from gas. moisture. Do not clean with a water/ vapor jet. Attention Danger of electric shock. Attention Do not use an ether aerosol Do not step/stand on maintenance Do not remove the Operating and valve or other parts of the Maintenance manual and manual pressurized system.
  • Page 15 3. Security Regulations Warning: Hot surfaces. Fuel drain Open the body lids no earlier than 30 minutes after the safety warning has switched off. A. Warning Oil filler plug B. Parking brake C. Correct position of the hand brake Condensation drain: Fuel Under very humid operating conditions the condensation should be drained from the pressure tank every 24 hours.
  • Page 16 3. Security Regulations Remove transportation braces before commissioning. Before connecting the tow bar or commencing to tow consult the operating manual...
  • Page 17 The DLT 0404 series is a sound proofed operational pressure manometer are mobile compressor system. The core is a integral parts of the air circuit. single-stage, oil-flooded screw compressor. The CompAir screw profile represents the state-of-the-art. The air is delivered pulsation-free.
  • Page 18 4. Construction and functional description Regulation Note It is not possible to start up the compressor if there is insufficient fuel is available. Starting up: The control function is inactive at start up, i.e. as the system rises, the engine speed is lowered to idling and the suction throttle closed.
  • Page 19 4. Construction and functional description 19. Oil filter Option oil temperature control 4.3 System description 20. Oil cooler compressor 30. Oil temperature control 21. Oil cooler engine Option After cooler 1. Air filter 22. Temperature switch 31. Cooler 2. Intake control valve 23.
  • Page 20 4. Construction and functional description Optional: K1 Relay - fault 4.4 Wiring diagram Y3 Solenoid valve generator automatic K2 Relay - fuel shortage idling control (optional) K3 Relay – start-up S1 Main switch Y4 Solenoid valve generator pressure K4 Relay – start lock S2 Start switch reduction (optional) S3 Signal interrupt switch...
  • Page 21 4. Construction and functional description 4.5 Terminal Diagram DIN ISO 1724 Terminal Diagram DIN ISO 1724 Connector Circuit connector white blue (54 G) rear fog lamp black brown (58 R) right taillamp yellow green (R) right indicator lamp red (54) right stoplamp left stoplamp green...
  • Page 22 5. Transport and installation on site * The lighting is fully functional. The breakaway cable must be attached in 5.1 Transport a way that ensures that even on extremely Never exceed the maximum towing sharp bends there is no danger of speed! Danger! Observe national activating the locking brake.
  • Page 23 The operation of the compressor in CompAir. areas where there is a risk of explosion When loading, the following points must be Set up the machine in such a way that...
  • Page 24 5. Transport and installation on site Altitude For operation at an altitude above 1,000 m, the compressor and engine must be adapted (modified design). Note Particularly in case of installation out of doors and at night, observe fuel tempera- ° ture.
  • Page 25 6. Preparing the compressor for operation The batteries used are ready to be Danger 6.1 Checking oil levels installed and ready for service. Only check the oil level when the Replacement batteries should be of the 6.1.1 Checking the oil level in the compressor engine is at a standstill.
  • Page 26 6. Preparing the compressor for operation Note It is not possible to start up the compressor if there is insufficient fuel is available. The fuel tank should always be filled up in good time. For outside temperatures below ° C, use only winter diesel fuel. More information on fuel quality, see engine operating manual.
  • Page 27 Transport inspection Operating panel: Only operate the compressor with the Every CompAir screw compressor hood closed. The hood may only be has already run in the factory and has opened briefly for minor adjustments already undergone a thorough test before while the compressor is running.
  • Page 28 7. Putting the compressor into operation * If the engine was started cold, let it Never use the ether cold-starting aid This readjusted operating pressure is to warm up for approximately 2 minutes while the engine is running, as this can be checked using the pressure gauge on and then press the START/RUN valve lead to serious damage.
  • Page 29 7. Putting the compressor into operation In order to trace the origin of the fault, Display for compressor temperature 7.7 Shutdown interrupt the engine oil temperature switch (with the engine oil pressure In order to shut down the compressor: switch still switched off). If the lamp now * Close air discharge valves.
  • Page 30 7. Putting the compressor into operation 7.8 Decommissioning Fig. 24 If the system is to be closed down for a longer period of time (approx. 3 months or longer) the following preservation measures must be taken: * Engine preservation (see separate engine operating manual).
  • Page 31 CompAir oilers or dusty environment. If necessary, (fuel additive). Consult your engine service automatic pipe oilers, using the special analyse the oil.

  • Page 32: Maintenance

    9. Maintenance Advance fuel filter 9.1 General maintenance Clean the screw compressor at regular, not too long intervals: * Blow-clean all valves, controllers, fittings, pressure tank, oil cooler, radiator, screw compressor, and engine with compressed air or a steam jet appliance.
  • Page 33 9. Maintenance 9.4 Compressor maintenance / Maintenance schedule Operating hours For 2 boxes per annum: Maintenance every 500 h, although at least every 6 months For 1 boxes per annum: Maintenance every 1000 h, although at least each year Install a "Caution maintenance work" warning sign and cordon off a wide area around the workplace before starting any work Check the oil level in the diesel engine...
  • Page 34 9. Maintenance * Start screw compressor, run for approx. 9.4.1 Oil filter replacement 9.4.2 Oil change (compressor) two minutes, check for leaks (compressor) * Switch off screw compressor * Check oil level, add oil if necessary 9.4.3 Checking the automatic monitoring system Danger Caution! High voltage! The sensors of...
  • Page 35 9. Maintenance Reassembling the air filter: Note 9.4.5 Air filter replacement (compressor / engine) * Clean the sealing surface in the filter Dispose of fine separator in accordance housing. with the relevant regulations - hazardous Danger * Insert safety cartridge (optional) and waste! ensure correct seating.
  • Page 36 9. Maintenance Attention 9.4.7 Control Check the acid level after a maximum of 1,000 operating hours, or after 24 months, whichever occurs first, and fill up with distilled water if necessary. For battery maintenance please also refer to the manufacturer’s instructions and the engine operating manual.

  • Page 37: Troubleshooting

    10. Troubleshooting Problem Possible cause(s) Correction Insufficient or no air supply Clogged air filter Clean air filter Screw compressor engine speed Set speed misadjusted Clogged oil fine separator filter cartridge Replace compressor oil, oil filter and oil fine separator filter cartridge Wrong setting at controller Adjust Spring and plunger inside the intake control...
  • Page 38 10. Troubleshooting Problem Possible cause(s) Correction 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 Pressure control valve defective Replace or repair Intake control valve, control cylinder, Replace...

  • Page 39: Generator Option

    11. Generator option * The IP 54 protection means the If the generator is overloaded briefly (for 11.1 Introduction generator is protected against less than the thermal response time of the splashes, spray and other foreign circuit breaker), or devices with excessive This manual describes the operation and bodies.
  • Page 40 11. Generator option The generator must not be used to inject The distribution systems (e.g. extension 11.4 Operating the generator power into a construction site distribution cables, device leads) must be carefully (Working safely with electrical system. chosen, laid and maintained. Check the equipment) electrical cables regularly, replacing rather To avoid unwanted interaction, do not...
  • Page 41 11. Generator option 3. Note that the starting consumption of 4th position (only for 8 kVA and 12 kVA) Attention devices driven by electric engines is As 3rd position, with the engine running generally a multiple of the specified The generator may only be used if the at constant speed rating.
  • Page 42 11. Generator option Connect the devices to the output Generator characteristics: Switchbox sockets one after the other, ensuring Extremely low dynamic internal resistance, Degree of protection . . . IP 54 that the current specified for each socket same output voltage whether hot or cold, Dimensions .
  • Page 43 11. Generator option Generator regulator Generator data 11.7 Technical characteristics of Model ....LCAR 3 BL Winding Colour Ins. class Resistance 12 kVA 400/230 V generator Connector assignment (at 20°C)/Ω...
  • Page 44 11. Generator option Efficiency at nominal output at 0.8 ind ... . 0.80 at 1.0 ....0.82 Distortion factor .
  • Page 45 11. Generator option 11.9 Generator switchbox wiring diagram 8 KVA and 12 KVA 400/230 V PROTECTIVE ISOLATION WITH INSULATION MONITORING K = OPERATING CURRENT CIRCUIT BREAKER AND FUSING/CIRCUIT BREAKING FOR ALL POLES H =INSULATION FAULT INDICATOR LAMP R = GMW/ISO INSULATION MONITOR YELLOW P = TEST BUTTON GREY...
  • Page 46 11. Generator option 11.11 Troubleshooting Sockets dead Has insulation Unplug Plug in devices Is insulation Press green monitor released? connected one after the monitoring still reset button (indicator lamp lit) devices other enabled? Connected devices are faulty Unplug Does fuse Has fuse blown? connected still blow?
  • Page 47 11. Generator option Problem Possible cause(s) Correction The generator supplies no or insufficient The generator circuit breaker has tripped Check electrical load output. voltage. due to overload or is defective. Check that all electrical terminals are properly seated. Check generator protective switch and replace if required.
  • Page 48 12. Heat exchanger option 12.1 Safety regulations for the use of the heat exchanger Danger When operating the compressor, please observe the general safety regulations laid forth in the compressor operating manual. The heat exchanger operates fully automatically. Operating errors at the heat exchanger are excluded.
  • Page 49 13. Compressed air processing option (After cooler / Filter) In an air cooler (on the cooling air intake 13.1 Safety regulations for alternate 13.3 Maintenance instructions side), the compressed air is cooled down compressed air processing to a temperature close to the prevailing Danger ambient air temperature downstream of the Danger...
  • Page 50 14. Breathing air connection option 14.1 Notes on safety and description of function Danger See the separate instruction manual for the filter unit for notes on safety and description of function! System function diagram: see page 78, fig. 4...
  • Page 51 15. Oil temperature controller option 15.1 Safety regulations for the use of an oil temperature controller Danger Please observe the general safety regulations in the compressor manual when operating the compressor. Operation of the oil temperature controller is fully automatic. Mal- operation of the oil temperature controller itself is impossible.
  • Page 52 16. Undercarriage 16.1 Introduction 16.3 KHV13 height-adjustable 16.4 Braking system towing system, model B 3.5.13 Introduction Attention The adjustable joint between the drawbar * KNOTT over-run brake systems consist and intermediate arm, and between the The user forfeits all rights to claim if of over-run hitches and wheel brakes overrun system and intermediate arm, parts other than those of the...
  • Page 53 16. Undercarriage Over-run hitches 16.5.2 Preliminary requirements: When the brake is correctly adjusted, the actuating travel of the control cable [11] will KNOTT over-run hitches are available for * When carrying out adjustments, always be 5-8 mm. both hydraulic and mechanical brakes. start with the wheel brakes.
  • Page 54 16. Undercarriage * Remove the security bolt [15]. Brake test * Check tthe bowden cable for slight play [14]; if neccessary, adjust the cable. * Operate the handbrake lever [3] and * Recheck the play in the brake linkage [6] check the position of the compensating and, if necessary, readjust the linkage * Check the tension of the compression...
  • Page 55 16. Undercarriage If desired, a lifting and adjusting system can be installed between the drawbar and the overrun system. The control arms of the adjusting system permit swivelling about an angle of -10° to +49° in six positions. In every case, the overrun system or drawgear always remains horizontal.
  • Page 56 16. Undercarriage 16.8 Malfunctions and remedies 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...
  • Page 57 16. Undercarriage Malfunction Remedy Cause 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, and it must be 49.5 mm in diameter.
  • Page 58 Fig. 46 * Shut down the screw compressor and wait until the compressor is depressurized. * Unscrew the screw plug. * The oil must be visible in the oiler reservoir; refill, if necessary (oil to be used: CompAir AES 82).

This manual is also suitable for:

C30gC35-10C38C42C50C42g