CompAir C125-7 Operating And Service Manual
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CompAir C125-7 Operating And Service Manual

CompAir C125-7 Operating And Service Manual

Cummins qsb4.5 powered compressor
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Original Operating and Service Manual
C125-7, C110-9, C95-12, C85-14
C140-9, C115-12, C105-14
Cummins QSB4.5
Powered Compressor
●
GB
Id. no. 100 011 421 / 08 - December 2013

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Summary of Contents for CompAir C125-7

  • Page 1 Original Operating and Service Manual C125-7, C110-9, C95-12, C85-14 C140-9, C115-12, C105-14 Cummins QSB4.5 Powered Compressor ● Id. no. 100 011 421 / 08 - December 2013...

  • Page 2: Proposition 65 Warning

    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.
  • Page 3 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.
  • Page 4 ☎ 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 (≤...
  • Page 5 Time required for service work Date Maintenance – Inspection – Repair...
  • Page 6 Cause of malfunction – Remarks...
  • Page 7 Original Operating and Service Manual C125-7, C110-9, C95-12, C85-14 C140-9, C115-12, C105-14 Cummins QSB4.5 Powered Compressor...
  • Page 8 1. Index Index Index ........................................2 Foreword ......................................4 Information on the compressor..............................4 Normal use....................................4 Specifications type DLT 1303..............................5 Declaration of conformity................................7 Maintenance and care................................8 General information..................................8 Security Regulations ..................................9 Identification of safety instructions.............................. 9 General safety instructions.................................
  • Page 9 1. Index 10 Troubleshooting....................................37 11 Electronic system ................................... 39 11.1 Overview ....................................39 11.2 Operation ....................................40 11.3 Menu navigation..................................40 11.4 Troubleshooting ..................................41 12 Compressed air processing option (after cooler / filter / bypass line) ..................43 12.1 Safety regulations for alternate compressed air processing .....................

  • Page 10: Normal Use

    The compressor is designed for providing 2.1 Information on the compressed air: compressor * For operating compressed-air CompAir screw compressors are the appliances product of many years' research and * For conveying bulk material development. These preconditions, together with high quality standards,...
  • Page 11 1300 C95-12 5.0 - 12.0 3000 QSB4.5 Water 2300 1300 C110-9 11.3 5.0 - 8.6 3000 QSB4.5 Water 2300 1300 C125-7 12.5 5.0 - 7.0 3000 QSB4.5 Water 2300 1300 C105-14 10.5 5.0 - 14.0 3000 QSB4.5 Water 2200 1300 C115-12 11.5...
  • Page 12 2. Foreword Fig. 1...

  • Page 13: Declaration Of Conformity

    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 ;...

  • Page 14: 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. In case of damage, the trained technical...

  • Page 15: Security Regulations

    3. Security Regulations Security Re gulati ons Personnel delegated to work with the Only trained or specially instructed 3.1 Identification of safety 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 particularly the chapter on safety operating, setting up, maintaining and...
  • Page 16 3. Security Regulations Parts to be removed for transport On descents, always adapt speed to the 3.4 Loading/Relocation/Transport purposes must be carefully refitted and circumstances! Never change into low fixed again before putting the machine / gear during the descent, but always Loading / Relocation installation back into operation.
  • Page 17 3. Security Regulations 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.
  • Page 18 3. Security Regulations 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.
  • Page 19 3. Security Regulations 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.
  • Page 20 3. Security Regulations Gas, dust, steam, smoke Noise 3.7 Instructions concerning 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, as there may be for example risk of fire Only use original fuses with the...

  • Page 21: Symbols And Definitions

    3. Security Regulations 3.8 Symbols and definitions Carefully read the Operating Manual Attention: Hot and dangerous exhaust Attention: Hot surfaces before machine set-up and fumes maintenance. Never attempt to operate the machine Attention: Pressurized part or system. Attention: Danger of electric shock. without the safety device mounted.
  • Page 22 3. Security Regulations 0,5h Protect the generator from moisture. Warning: Hot surfaces. Do not clean with a water/vapour jet. Open the body lids no earlier than 30 minutes after the safety warning has switched off. Attention: Do not use an ether aerosol A.
  • Page 23 3. Security Regulations Before connecting the tow bar or commencing to tow consult the operating Fuel drain manual System radiator/coolant recovery Oil filler plug reservoir may be under pressure. Fuel Combined stop and emergency stop device...
  • Page 24 4 Combined cooler compressor system is a single-stage, oil- coated and burnt at 220 °C. The sound 5 Oil filter (compressor) flooded screw compressor. The CompAir absorbing mats are inserted and easy to 6 Air filter (compressor) screw profile represents the state-of-the- be cleaned.

  • Page 25: Functional Description

    4. Construction and functional description Rising air bleed: 4.2 Functional description Tank pressure (15) drops. Valve Y1 (22) The numbers in brackets refer to the closes. Suction controller (8) opens. functional plan (see Fig. 4). Engine speed increases. Oil circuit The oil required for sealing and cooling Falling air bleed: the rotors as well as for lubricating the...

  • Page 26: System Description

    4. Construction and functional description 4.3 System description ECM Dieselmotor CONTROLLER ECM Diesel Engine Controller (Electronic Control Module) Kompressor (electronic control module compressor 10 11 Fig. 4 A13528674 Air filter 16 Fine separator OPTIONS Diesel engine 17 Safety valve 40 Tool oiler Water cooler 18 Pressure retaining non-return valve 41 Oiler valve...

  • Page 27: Wiring Diagram

    4. Construction and functional description 4.4 Wiring diagram Fig. 5 A13528774 Starter Solenoid valve emergency tripping SO Main switch control panel Generator Tank pressure (4...20 mA) S1 Ignition switch Relay for voltage supply 10 Control pressure (4...20 mA) Relay for starter 11 Cooling water level Solenoid valve for volume flow 12 Pressure gland temperature...
  • Page 28 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 tail lamp yellow green (R) right indicator lamp red (54) right stop lamp left stop lamp green...
  • Page 29 5. Transport and installation on site Tra nspo rt a nd ins tallatio n o n site Never exceed the maximum towing 5.2 Attachment of the contact- 5.1 Transport speed! Danger! Observe national breaker cable on braked regulations! chassis Please also observe the safety If the towing connection becomes instructions in Chapter 3 on the subject uncoupled, the trailer is braked by the...

  • Page 30: Installation On Site

    * When hoisting the compressor, set up (see operating instructions) please consult specially-made compressors with the the hoisting gear in such a way that the CompAir. necessary technical modifications for compressor, which must be set up use in such areas) Set up the machine in such a way that horizontally, is lifted vertically.
  • Page 31 5. Transport and installation on site Attention No force may be exerted on the dis- charge valves, for example by pulling the hoses or fitting additional equipment (e.g. a water separator, compressed air oiler, etc.) directly at the discharge valve. Temperatures/air humidity Install the compressor in a location with maximum possible frost protection.
  • Page 32 6. Preparing the compressor for operation Prepari ng t he c omp ress or f or o per ation Checking the oil level in 6.1.2 6.2 Battery Danger the engine Check the machine / installation for external damage and faults at least once per shift.

  • Page 33: Filling Up The Fuel Tank

    6. Preparing the compressor for operation 6.4 Checking the air filter 6.3 Filling up the fuel tank maintenance displays Fig. 16 Fig. 15 When the red service sector in the Danger transparent part is fully visible, the air filter is due for maintenance. (See Chapter Only fill up with fuel when the screw Maintenance, air filter replacement.) compressor is at a standstill.

  • Page 34: Initial Operation

    * 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...

  • Page 35: Operation

    7. Putting the compressor into operation 7.4 Setting the operating pressure 7.6 Operation Note In the case of emergency (!) the system Danger Danger can be closed down via an emergency- stop switch. The system comes to an The setting of the operating pressure Only operate the compressor at the immediate standstill.
  • Page 36 CompAir oilers or dusty environment. If necessary, automatic pipe oilers, using the special For relubrication use only lithium analyse the oil.

  • Page 37: General Maintenance

    9. Maintenance Mainte nan ce The idling speed must not be changed Changing the condensation water 9.1 General maintenance either, as this might cause serious Water is heavier than diesel fuel. It damage to the screw compressor, e.g. Danger separates out on the floor of the fuel pre- damage to the coupling! filter.

  • Page 38: Maintenance And Inspection Schedule

    9. Maintenance 9.4 Maintenance and inspection schedule 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)
  • Page 39 9. Maintenance 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 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■...
  • Page 40 9. Maintenance * Switch off screw compressor Oil filter replacement Oil change (compressor) 9.4.1 9.4.2 (compressor) * Check oil level, add oil if necessary Inspecting / Replacing the 9.4.3 fine separator Fig. 22 Fig. 23 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...

  • Page 41: Checking The Safety Valve

    9. Maintenance If the differential pressure is > 1 bar, the Checking the safety valve 9.4.5 Attention fine separator cartridge must be replaced. Replace the safety cartridge at the * Remove all hexagon screws around the latest every third time the air filter circumference of the lid.
  • Page 42 9. Maintenance 9.6 Inspection intervals for Control Torque specifications 9.4.6 9.4.8 pressure vessels and The control system takes the form of a The following tightening torques apply to electrical installations stepless speed/volumetric flow regulation screwed connections: system. It consists of: Pressure vessels Wheel screws 325 Nm...

  • Page 43: Troubleshooting

    10. Troubleshooting Tro ublesh ootin g 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 Spring and plunger inside the intake control...
  • Page 44 10. Troubleshooting Problem Possible cause(s) Correction Engine starts but switches off again V-belt defective Replace immediately, or the system switches off Oil pressure switch/engine defective Replace while running Check and replace where necessary Engine coolant temperature switch defective or coolant temperature too high Compressor temperature switch defective Check and replace where necessary Replace or plug onto sensor...

  • Page 45: Electronic System

    11. Electronic system Electronic syste m Operating pressure in bar and psi 11.1 Overview Individual fault type Engine speed (min ) and working hours (h) LED green (ok) LED red (fault) Start button Ignition key, Stop (shut down compressor) Reset button, Enter Choice of menu 10 = Decrease working pressure 11 = Increase working pressure...

  • Page 46: Menu Navigation

    11. Electronic system Menu 3: Errors with detailed 11.2 Operation information 1. Starting the compressor ____________- 3 -____________________ see chapter 7.3 Qty: Error ------------------------------------- 2. Changing the operating pressure Engine Oil Pressure see chapter 7.4 Engine Water Temp. 3. Troubleshooting Intercooler Temp.
  • Page 47 11. Electronic system 11.4 Troubleshooting Error information according to CAN-bus, J1939: = Suspect Parameter Number = Failure Mode Identifier = Fault Code SPN FMI FC Problem Possible cause(s) Correction 110 0 Engine water temperature Radiator dirty Check, clean too high Cooling air intake blocked Check, correct Ventilator defective...
  • Page 48 11. Electronic system Further error information according to CompAir: SPN FMI FC Problem Possible cause(s) Correction Interruption to K1 or F2 defective Check, replace engine electronics Loose cable on K1, F2, G1, X3, ... Check, correct Broken belt drive systems (G1)

  • Page 49: Design And Operation

    12. Compressed air processing option (after cooler / filter / bypass line) Compr esse d air pr ocessin g op tion (aft er c oole r / filte r / bypas s line ) 12.3 Maintenance instructions 12.1 Safety regulations for Attention alternate compressed air The oil-containing condensate has to...
  • Page 50 13. Oil temperature controller option Oil tem per atur e co ntroll er o ption 13.1 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.

  • Page 51: Braking System

    14. Undercarriage Underc ar riage action. Instead the rubber is stretched 14.1 Introduction Danger in accordance with its characteristics. Care must be taken without fail to Danger With the rubber spring axles the axle ensure that the overrun or towing tube bears the axle by pretensioned system is always aligned parallel with The user forfeits all rights to claim if...

  • Page 52: Adjusting The Braking System

    14. Undercarriage 14.5.3 Adjusting the brake * Preadjust the length of the brake 14.5 Adjusting the braking system linkage [6] (slight play permitted). 14.5.1 Preparations * Operate the handbrake lever [3] and check the position of the compensating * Jack up the trailer balances [9 and 10].

  • Page 53: Malfunctions And Remedies

    14. Undercarriage Information regarding dual-row angular 14.6 Readjusting the braking 14.7 Maintenance and care bail bearings: system KNOTT – overrun systems * These bearings are maintenance-free, In general, readjusting the wheel brakes have been provided with a lifetime * The overrun system must be lubricated adequately serves to readjust the braking lubrication.
  • Page 54 14. 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...
  • Page 55 Only refill the tool oiler, when the reservoir; refill, if necessary (oil to be screw compressor is out of operation used: CompAir AES 82). and depressurized! * Check the seal of the screw plug, Only screw off the oiler reservoir, when replace if required.
  • Page 60 Gardner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Deutschland Tel. ++49 (0)6761 832-0 www.compair.com e-mail: sales@compair.com...

This manual is also suitable for:

C110-9C95-12C85-14C140-9C115-12C105-14

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