ADE ADE015759 Operation & Maintenance Manual

Compressor welder generator unit

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ADE018327
REV00
Operation &
Maintenance
Manual
Compressor Welder
Generator Unit
ADE015759
Truck-based CWG
Ph: +61 7 3863 5800
www.ade.net.au

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Summary of Contents for ADE ADE015759

  • Page 1 ADE018327 REV00 Operation & Maintenance Manual Compressor Welder Generator Unit ADE015759 Truck-based CWG Ph: +61 7 3863 5800 www.ade.net.au...
  • Page 2: Table Of Contents

    Table of Contents TABLE OF CONTENTS ............1 GENERAL INFORMATION .........1 SAFETY ..............2 .......2 MPORTANT AFETY NFORMATION & L ........3 AFETY IGNS ABELS PRODUCT ID INFORMATION ......4 ID P ............4 LATE CWG EQUIPMENT ..........5 ......5 ATERPILLAR ERKINS NGINE ............5 LTERNATOR ........5 OMPRESSOR YSTEM ............5...
  • Page 3: Table Of Contents

    Whenever a question arises regarding the information contained within this manual please consult Australian Diversified Engineering Pty Ltd for the latest available information. Selected manuals may be found at www.ade.net.au containing the most up to date information for the product. General Information Compressor Welder Generator...
  • Page 4: Safety

    do not contain a safety alert or symbol such as Danger 2 Safety or Warning) are to indicate that an instruction must be Important Safety Information carried out. The label will contain black text on a white background. Read and obey the information contained Safety precautions and warnings may be listed in this on these labels.
  • Page 5: Safety Signs & Labels

    Safety Signs & Labels There are several specific safety signs specific to the service vehicle. Their exact location and description of the hazard are reviewed in this section. Make sure that you can read all safety signs. You must replace a label if it is damaged, missing or cannot be read.
  • Page 6: Product Id Information

    3 Product ID Information Unit ID Plate An ID plate has been fitted to each machine to indicate information such as the date of manufacture and serial number. Refer to the fitted ID plate for further information. ID plate affixed near the oil separator tank Product Identification Section Compressor Welder Generator...
  • Page 7: Cwg Equipment

    Air Compressor System 4 CWG Equipment The CWG is equiped with a 40 CFM air compressor system, which is controlled and monitored at the Caterpillar/Perkins Engine control cabinet. The system consists of the following components: The CWG is driven by a Perkins 403D-11G engine. The engine is a inline 3 piston diesel engine, governed 1.
  • Page 8: Control Cabinet

    Control Cabinet All CWG functions are controlled and monitored from the control cabinet, fitted in the rear driver’s side cabinet. Functionality available includes:  Start and stop the engine  Monitor the engine’s oil pressure, RPM and operating hours.  Monitor the alternator’s voltage, frequency and output current.
  • Page 9: Operation Of Cwg

    5 Operation of CWG Ensure you are familiar with the functionality, operation and all warnings associated with this equipment before attempting any form of operation. Basic CWG Operation and Monitoring To start the CWG: 1. Check all personnel are clear of the CWG unit. 2.
  • Page 10: Air Compressor Operation And Monitoring

    Air Compressor Operation and Compressor Overtemperature Monitoring compressor protected over To start the air compressor: temperature switch. If the compressor outlet reaches 1. Check all personnel are clear of the CWG unit. 105 °C the switch will shut down the compressor and 2.
  • Page 11: Maintenance Section

    6 Maintenance Section 6.1.2 Crushing & Cutting Prevention Disconnection of hoses and removal of supporting pins and bolts of the service Unintended machine movement may result in vehicle may result in unintended machine personal injury or death. Before performing movement and/or release of stored energy. maintenance on this machine ensure it has Personal injury or death may result.
  • Page 12: Cwg Maintenance Schedule

    CWG Maintenance Schedule 6.2.5 Every 500 Hours (or 1 year) This schedule is based on the CWG operation  Fuel system filter – Replace hours, which displayed Engine  Engine air cleaner Element – Clean/Replace Monitoring screen of the CWG control panel. ...
  • Page 13: Cwg Maintenance Tasks

    CWG Maintenance Tasks Maintenance tasks not described here are detailed in Section 9 of the Olympian Operator and Maintenance Instruction Manual, and page 60 of the Perkins Operation and Maintenance Manual. 6.3.1 Checking the Gearbox Oil Level 1. Remove oil level inspection plug (1). 2.
  • Page 14: Air Compressor Maintenance Schedule

    Air Compressor Maintenance Schedule This schedule is based on the air compressor operation hours, which are displayed on the Compressor Hours gauge on the CWG control cabinet. Note – This maintenance schedule has been adapted from Section 15 of the Compressor Unit OEM documentation, which should be referred to for further instructions.
  • Page 15: Air Compressor Maintenance Tasks

    Air Compressor Maintenance Tasks 6.5.2 Draining Condensate from Separator Tank Maintenance tasks not described here are detailed in Section Compressor Unit 1. Ensure CWG and truck are shut down and documentation. isolated. 2. Wait for the machine to cool down. 6.5.1 Checking Compressor Oil Level 3.
  • Page 16 6.5.3 Cleaning the Air Suction Filter 6.5.4 Belt Tension 1. Ensure CWG and truck are shut down and 1. Ensure CWG and truck are shut down and isolated. isolated. 2. Remove filter cover (2). 2. Remove the belt guard. 3. Remove the filter. 3.
  • Page 17 6.5.5 Changing the Oil 1. Ensure CWG and truck are shut down and isolated. 2. Oil should be changed while machine is warm (i.e. right after operation) 3. Drain oil from oil separator tank via the tap (see Section 1.1.1). Close tap. 4.
  • Page 18 6.5.6 Replacing the Oil Filter and Separator 6.5.7 Cleaning the Filtering Panel Filter 1. Ensure CWG and truck are shut down and 1. Ensure CWG and truck are shut down and isolated. isolated. 2. Remove filtering panel (11) from cowling via 2.
  • Page 19: Consumables For Maintenance

    Consumables for Maintenance The following consumables required by the CWG are available for order from ADE. Part Part Number Gearbox oil ADE018575 Air compressor oil ADE018547 Air compressor oil filter ADE018548 Air compressor oil ADE018549 separator filter Pre-cooler filtering panel...
  • Page 20: Literature Reference Materials

    7 Literature Reference Materials Olympian Generator Documentation The Olympian generator documentation has been provided with the CWG. Air Compressor System Documentation The CSA 10 air compressor documentation has been provided with the CWG. Reference Information Compressor Welder Generator...

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