Original Operating Manual

C270TS-9, C260TS-10, C250TS-12,

C240TS-14, C230TS-9, C220TS-10,
C210TS-12, C200TS-14
Cummins QSB6.7
Powered Compressor

●
GB Id. No. ZS1059027 / 07 - May 2014
 1. Index
1 Index

1 Index .................................................................................................................................................................................................. 1

2 Foreword ........................................................................................................................................................................................... 2
2.1 Normal use................................................................................................................................................................................. 2
2.2 Maintenance and care................................................................................................................................................................ 2
2.3 General information.................................................................................................................................................................... 2
2.4 Specifications............................................................................................................................................................................. 3
2.5 Declaration of conformity ........................................................................................................................................................... 5
3 Security Regulations ........................................................................................................................................................................ 6
3.1 Identification of safety instructions.............................................................................................................................................. 6
3.2 General safety regulations ......................................................................................................................................................... 6
3.3 Particular dangers associated with compressed air.................................................................................................................... 6
3.4 Particular dangers associated with machines with combustion engines..................................................................................... 7
3.5 Dangers present when loading/moving machines ...................................................................................................................... 8
3.6 Particular dangers associated with mobile machines ................................................................................................................. 8
3.7 General workplace dangers ....................................................................................................................................................... 8
3.8 Dangers resulting from neglecting to perform maintenance ....................................................................................................... 9
3.9 Dangers during maintenance and repairs .................................................................................................................................. 9
3.10 Dangers resulting from conversion work/modifications on the machine ................................................................................... 10
3.11 Symbols and definitions ........................................................................................................................................................... 11
4 Construction and functional description ...................................................................................................................................... 13
4.1 Construction............................................................................................................................................................................. 13
4.2 Functional description .............................................................................................................................................................. 14
4.3 System description................................................................................................................................................................... 14
4.4 Wiring diagram ......................................................................................................................................................................... 15
4.5 Terminal Diagram DIN EN ISO 11446...................................................................................................................................... 16
5 Transport and installation on site.................................................................................................................................................. 17
5.1 Transport ................................................................................................................................................................................. 17
5.2 Setting tow bar with height adjustment..................................................................................................................................... 17
5.3 Attachment of the contact-breaker cable on braked chassis .................................................................................................... 18
5.4 Loading/Relocation .................................................................................................................................................................. 18
5.5 Installation on site .................................................................................................................................................................... 18
6 Preparing the compressor for operation....................................................................................................................................... 20
6.1 Checking oil levels ................................................................................................................................................................... 20
6.1.1 Checking the oil level in the pressure tank ................................................................................................................... 20
6.1.2 Checking the oil level in the engine .............................................................................................................................. 20
6.2 Filling up the fuel tank .............................................................................................................................................................. 20
7 Putting the compressor into operation ......................................................................................................................................... 21
7.1 Initial operation......................................................................................................................................................................... 21
7.2 Operating elements.................................................................................................................................................................. 21
7.3 Start-up .................................................................................................................................................................................... 21
7.4 Monitoring / fault ...................................................................................................................................................................... 22
7.5 Operation ................................................................................................................................................................................. 22
7.6 Menu assistance ...................................................................................................................................................................... 22
7.7 Shutdown ................................................................................................................................................................................. 23
7.8 Decommissioning..................................................................................................................................................................... 23
8 Fuels ................................................................................................................................................................................................ 24
8.1 Recommended lubricant for compressor.................................................................................................................................. 24
8.2 Recommended engine oil ........................................................................................................................................................ 24
8.3 Diesel fuel ................................................................................................................................................................................ 24
8.4 Coolant .................................................................................................................................................................................... 24
9 Maintenance .................................................................................................................................................................................... 25
9.1 General maintenance information ............................................................................................................................................ 25
9.2 Cleaning................................................................................................................................................................................... 25
9.3 Daily maintenance.................................................................................................................................................................... 25
9.4 Torque specifications ............................................................................................................................................................... 25
9.5 Inspection intervals for pressure vessels and electrical installations ........................................................................................ 25
9.6 Maintenance and inspection schedule ..................................................................................................................................... 26
10 Troubleshooting.............................................................................................................................................................................. 28
10.1 General fault rectification information ....................................................................................................................................... 28
10.2 Faults, causes and remedy ...................................................................................................................................................... 28
10.3 Warning lights .......................................................................................................................................................................... 28
10.4 Individual error display ............................................................................................................................................................. 29

1
 2. Foreword
2 For ewor d

2.1 Normal use 2.2 Maintenance and care 2.3 General information

The compressors have been built using Care and maintenance are all-important This operating manual is to help you to
the latest techniques in design and in if the screw compressor is to meet the get to know the compressor and to use it
accordance with recognized safety demands placed upon it. Compliance with for its intended applications. It must
regulations. the prescribed maintenance intervals and always be available at the site of the
careful execution of care and maintenance compressor. The operating manual is to
The compressor is intended for the work are therefore essential, especially be read and used by all persons in charge
production of compressed air: under difficult working conditions. of work with the compressor.
* for driving compressed air units Besides the operating instructions and
Service the current regulations applicable in the
* for transporting bulky materials
Contact your CompAir representative in user's country and at the sites of operation
* for transporting screed the event of problems, for maintenance, concerning accident prevention, the
* for sand blasting and paint spraying servicing and your spare parts recognized technical rules for safe and
work requirements. Genuine spare parts from proper working are also to be complied
Gardner Denver ensure product with.
* for cleaning work on machines, conformity and high levels of availability.
boarding material
Warranty
* for blowing out drilled holes. In the event of serious queries Only use the compressor for its intended
Special designs for the customer’s purpose and follow this operating manual.
particular form of intended use can be Gardner Denver assumes no liability in the
determined in the customer’s order event of changes to the declared
specifications. conformity.
Warranty claims cannot be made in the
event of deviations from this operating
manual.
The Guarantee and Liability terms of
Gardner Denver's General Terms and
Conditions are not extended through the
above instructions.

Safety regulations

Danger

It is important that you follow the

safety regulations in Chapter 3 of the
operating manual.

Technical modifications
Fig. 1
We reserve the right to undertake
Please enter the data from the identifi-
modifications without notice in the
cation plate for your compressor, in the
interests of technical progress.
spaces above. In case of questions or
orders for spare parts, please give us the
compressor type, compressor number and
the year of construction as given on the
identification plate.

2
 2. Foreword

2.4 Specifications

water filled into engine

Oil fill (compressor)
Operating pressure

Volume of cooling

Fuel tank capacity

Filling volume of
max. installation
Delivery volume

Type of cooling
Pressure range

Engine rating
Trade name

engine oil
Ambient Engine

Engine
height
temperature speed

min. max. min. max.

3 [m above
[m /min] [barg] [barg] [°C] [°C] [l] [kw] [rpm] [rpm] [l] [l] [l]
sea level]

C 200TS-14 20.00 14.0 5-14 -10 +50 3000 65 water 180 1000 2400 55 17 370
C 210TS-12 21.00 12.00 5-12 -10 +50 3000 65 water 180 1000 2400 55 17 370

Cummins QSB6,7
C 220TS-10 22.00 10.00 5-10 -10 +50 3000 65 water 180 1000 2400 55 17 370
C 230TS-9 23.00 8.60 5-8,6 -10 +50 3000 65 water 180 1000 2400 55 17 370
C 240TS-14 24.00 14.0 5-14 -10 +50 3000 70 water 228 1000 2400 60 17 370
C 250TS-12 25.00 12.00 5-12 -10 +50 3000 70 water 228 1000 2400 60 17 370
C 260TS-10 26.00 10.00 5-10 -10 +50 3000 70 water 228 1000 2400 60 17 370
C 270TS-9 27.00 8.60 5-8,6 -10 +50 3000 70 water 228 1000 2400 60 17 370

Compressed air connections

PN8NTC 2.2 at the operators

max. sound intensity acc. to

max. sound intensity acc. to

Height without exhaust pipe

Height without exhaust pipe

Gross vehicle weight rating

PN8NTC 2.2, distance 7m

level, acc. to 2000/14/EC
max. permissible noise

location,distance 1m
standard model*)
Operating weight

Tyre pressure
Overall width
Length, max.
Trade name

Tyres
Rim

[kg] [kg] [mm] [mm] [mm] [mm] [barg] [dB/1pW] [dB(A)] [dB(A)]

C 200TS-14 3500 3340 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 210TS-12 3500 3340 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
1 x 2” + 3 x 3/4"

C 220TS-10 3500 3340 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 230TS-9 3500 3340 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 240TS-14 3500 3360 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 250TS-12 3500 3360 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C 260TS-10 3500 3360 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72
C270TS-9 3500 3360 5500 1960 2304 2444 5,5 J x 14 205 R 14 C 3.75 100 81 72

* with optional features maximum 3,500 kg

3
 2. Foreword

Fig. 2

4
2. Foreword

2.5 Declaration of conformity

1. Declaration of conformity
in accordance with the EC Machinery Directive 2006/42/EC, Supplement II A

2. We, hereby declare Gardner Denver Deutschland GmbH

Argenthaler Str.11
D-55469 Simmern

that the product: Kompressor

type: DLT0206 ; DLT0408 ; DLT0704 ; DLT1303 ; DLT2701 ; DLT2702

trade mark: 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 ;
C220TS-10 ; C230TS-9 ; C240TS-14 ; C250TS-12 ; C260TS-10 ; C270TS-9 ; C200TS-24 ;
C210TS-21 ; C203TS-17

manufacturer no.:

in the form as shipped by us complies with the following relevant provisions:

2006/ 42/ EG 2009/ 105/ EG 2004/ 108/ EG

2007/ 46/ EG 2006/ 95/ EG

This machine is exempt from 97/23/EC the Pressure Equipment Directive, reference Article 1
clauses 3.3 and 3.6

3. If the machine is modified in a way not agreed upon with us, this statement will be void.

4. Harmonized standards applied, particularly

EN 1012-1 EN ISO 12100 EN 61000-6-2

EN 29001 EN 60034-1 EN 60204-1 EN 61000-6-4

5. National engineering standards and specifications applied

AD-S1/2000 VDE 0100 DIN 3230

BetrSichV

6. Recording agency: CompAir Drucklufttechnik -

Zweigniederlassung der
Gardner Denver Deutschland GmbH

Simmern,
Date Signature

5
 3. Security Regulations
3 Security R egula tions

3.1 Identification of safety of this compressor, even if not expressly Attention

stated in this operating manual.
instructions
Places thus marked refer to possible
Gardner Denver accepts no Danger dangers for machines or parts of
responsibility for any damage or injury machines.
Places thus marked refer to possible
caused by non-compliance with these
dangers for persons. Note
safety measures or non-observance of
normal care and caution during the Places thus marked give general and
handling, operation, maintenance or repair technical information for optimum, cost-
effective machine use.

3.2 General safety regulations

Danger Safety measure required

Working with compressors involves Everyone working with the machine must have first read and understood the operating
dangers that are not immediately manual. Don’t leave this until you start work – it’s too late.
apparent. Please keep this operating manual handy at all times on the site of the machine /
installation, in the bag provided.
Pay attention to all safety and danger warnings on the machine/ installation!
Deploy trained staff only. The responsibility of the personnel for operating, setting up and
maintaining the machine / installation must be clearly defined.
Make sure that only authorized personnel use the machine.
Define who is responsible for operating the machine, and authorize him to ignore
instructions from third parties if these instructions could compromise safety.
Symbols on the machine indicating Ensure that all safety and danger notices on the machine/system stay fully legible.
dangers may become dirty.
Faults and modifications to the machine In case of malfunction, shut down and secure the machine / installation immediately. Have
may jeopardise safety. malfunctions corrected immediately.
Check the machine / installation for external damage and faults at least once per shift.
Any changes noticed (including changes in operating performance) must be reported
immediately to the authority or person in charge. If necessary, shut down and secure the
machine immediately.

3.3 Particular dangers associated with compressed air

Danger Safety measure required

Compressed air is very powerful. It can be Never play about with compressed air.
used for example to break open concrete
but can also put lives at risk.
Small parts propelled at high speed by When using compressed air to clean equipment, work with extreme caution and always
compressed air can penetrate the skin or wear suitable eye protection.
destroy an eye. Never direct compressed air onto the skin or towards another person.
Never use compressed air for cleaning clothing.
Compressed air connections may split and All connected components must be of the correct size and be suitable for the specified
put people at risk. operating pressure and temperature.
A hose connected to an air valve must be fitted with a safety wire for operating pressures
above 7 bars; it is in fact recommended that this safety device should be used for
pressures above 4 bars. The steel wire has a diameter of 8 mm and is firmly clamped to
the hose at least every 500 mm. Both ends are fitted with cable lugs.
Only use the correct type and size of hose coupling and connection.
The compressed air line connected at the air exit of the unit must not be under strain.
No force may be exerted on the discharge valves, for example by pulling the hoses or
fitting additional equipment (e.g. a water separator, compressed air oiler, etc.) directly to
the discharge valve.
Compressed air lines may be breached by Compressed-air lines have to be marked distinctly according to local regulations.
accident.
Compressed air lines get hot and expand. Make sure that the compressed air line from the compressor to the air network can expand
as a result of heat and cannot come into contact with inflammable materials.

6
 3. Security Regulations

Danger Safety measure required

Pipes and other parts with a surface temperature of more than 80 °C must be suitably
secured against contact and suitably marked.
Loose hose ends may flog and result in Before blowing through a hose or air line, it is essential to hold the open end firmly.
injury. Before connecting or disconnecting hoses, always close the compressor air outlet valves.
Before disconnecting a hose, always make sure that it is not under pressure.
Compression results in high temperatures. The system should be set up such that hazardous mixtures (inflammable solvent vapours
Risk of explosion from drawn in materials. etc. but also dusts and other dangerous or toxic materials) cannot be drawn in. The same
applies to flying sparks.
Never use the machine in environments where the possibility cannot be ruled out that
inflammable or toxic vapours may be taken in.
The installation is to be set up in such a way that it is adequately accessible and that the
necessary cooling is ensured. Never block the admission of air.
There is strong suction at the air inlet. The air intake is to be designed in such a way that no loose clothing can be drawn in.
There is a risk of injury, e.g. from getting The personnel must not have long, loose hair, or wear loose clothing or jewellery, including
stuck or being drawn in. rings, due to risk of injury through catching. Personal protective equipment should be worn
if necessary.
Connected compressed air tools may start Before switching on the machine / installation, or starting it up, make sure that nobody can
up unexpectedly when switching on. be injured by the machine / installation as it starts up.
Compressed air may contain oil and other The compressed air produced by these compressors must not be used as breathable air,
substances that may damage your health unless it has been processed specially for such an application in accordance with the
if inhaled. “Safety requirements for breathable air.”
When breathing apparatus with cartridges is used, make sure that the correct cartridge has
been inserted and that its service life has not expired.
As a rule: If several compressors are arranged in a system, manually operated valves have to be
installed so that each machine may be shut off individually. For the purpose of shutting off
pressurized systems, you should never rely on the effectiveness of return valves alone.
All pressure tanks located outside the unit with an approved operating pressure higher than
atmospheric pressure and fitted with two or more pressure feed lines must be equipped
with an additional safety device to automatically prevent the approved operating pressure
from being exceeded by more than 10%.
Never operate the system at temperatures and/or pressures below or above the values
indicated in the technical data sheet.

3.4 Particular dangers associated with machines with combustion engines

Danger Safety measure required

The exhaust emissions of combustion If a machine with such an engine has to work in an enclosed room, the exhaust gases must
engines contain carbon monoxide - a therefore be conducted out of doors by means of a hose or pipe with an internal diameter
lethal gas. of at least 150 mm. The use of extraction systems is highly recommended in test rooms for
mobile machines.
Fuel can easily ignite. Make sure that fuel does not come into contact with hot machine parts.
Do not smoke while filling up with fuel.
Never fill up with fuel while the engine is running.
Filling up at a pump can cause static In order to avoid this, a ground cable must be connected to the system while it is being
electricity and possibly sparks. filled up.
In water-cooled combustion engines, The cap of the coolant recovery bottle must not be removed before the system has cooled
water vapour is produced in the cooling down to ambient temperature.
circuit under high pressure.
Sparks from the exhaust may cause fires The operation of the compressor in areas where there is a risk of explosion is strictly
and explosions in environments with fire forbidden! (Exception: specially-made compressors with the necessary technical
hazards. modifications for use in such areas)
If a machine with a combustion engine has to work in a fire-risk environment, the unit must
be fitted with a spark catcher.
Make sure that the engine exhaust system is operationally safe and that no inflammable
material is in the vicinity.

7
 3. Security Regulations

Danger Safety measure required

Noise, even when it is not very loud, can Persons must be protected against any risks caused by noise in accordance with EC
make us nervous and irritated, and after a Guideline 2003/10/EG. Wearing ear muffs may impair communication between
longer period of time our nervous system persons.Warnings may not be heard. Inform supervisor.
can suffer serious damage. Shielding and doors must be closed during operation so that the flow of cool air within the
housing is not deflected and the efficiency of the sound insulating is not reduced.

3.5 Dangers present when loading/moving machines

Danger Safety measure required

Loose parts may fall off when lifting. All loose parts must first be removed or secured; parts fitted so that they can turn like
doors etc. must be secured and made immobile.
Parts to be removed for transport purposes must be carefully refitted and fixed again
before putting the machine / installation back into operation.
The compressor may fall if mistakes are Only use lifting tackle approved for the weight in question.
made when lifting.
Observe the operating manual for the lifting tackle.
When heavy loads are being conveyed by means of hoisting gear, it is imperative to keep
well clear of the load in order to avoid accidents.
Raise the compressor by its lifting lug only, using a hook or shackle that satisfies local
safety regulations. Cables, chains or ropes must never be fitted directly to or through
lifting lugs.
The compressor may be damaged if lifted Machines may only be hoisted correctly using hoisting gear in accordance with the
incorrectly. information in the operating manual (lifting spots for heavy-lift facilities etc.)
Never relocate the machine if external lines or hoses are connected to the discharge
valves, in order to avoid damage to the valves and/or collecting pipe and hoses.

3.6 Particular dangers associated with mobile machines

Danger Safety measure required

As a rule: Observe all the relevant traffic regulations and before starting to move, ensure that the
machine is in a suitable condition with regard to traffic laws.
Pressurised parts may be overloaded Switch off the compressor at least 10 min. before travel and allow the pressure in the lines
during travel. to drop by opening a pressure cock.
Wheels may come loose during travel. Make sure that the wheel nuts are properly tightened; never exceed the specified torque.
Machine may tip over if positioned at too Install the machine so that it is as horizontal as possible; a slight inclination is permissible
great an angle. (see information in Chapter 5.5 "Installation on site").
Always keep a safe distance from the edges of foundation ditches and embankments.
Do not travel across slopes transversely.
Unsecured machines may roll away. Before disconnecting the machine from the towing vehicle, apply the handbrake.
Disconnect the rapid-emergency brake cable and lighting cable, disconnect the lines of
the air brakes, use chocks to ensure that the machine does not roll away.
Ensure that the compressor system is stable before starting work and do not permit any
work that impairs this!

3.7 General workplace dangers

Danger Safety measure required

This manual only describes how to work Please note and pass on general statutory and other binding regulations that may
safely with the compressor itself. But other supplement the operating manual for the prevention of accidents and the protection of the
dangers will arise during work. environment. Such obligations may be for example the handling of hazardous materials, or
the provision and/or wearing of personal protective equipment, or traffic regulations.
Instructions, including supervisory responsibility and duty of notification for taking account
of special in-plant factors, for example regarding work organization, sequences of
operations, personnel assigned to certain tasks, are to be added to the operating manual.

8
 3. Security Regulations

Danger Safety measure required

Before starting work, make yourself familiar with the working environment at the installation
site. The working environment includes, for example, obstacles in the working and
transport areas, the carrying capacity of the ground, and any necessary cordoning off of
the building site from public traffic areas.
The location and operation of fire extinguishers must be made known. Observe the
instructions concerning fire alarm and fire fighting.
Set up the machine in such a way that no inlets, outlets or gates are blocked.
Keep an adequate distance between the machine/unit and overhead power lines! When
working near overhead power lines, equipment must not come near the power lines!
Danger! Find out about the safe distance to be observed!
When handling oils, greases and other chemical substances, observe the safety
regulations applicable for the product.
Caution when handling process materials (risk of burning / scalding).

3.8 Dangers resulting from neglecting to perform maintenance

Danger Safety measure required

Components of importance to safety wear Observe the setting, maintenance, and inspection work and intervals stipulated in the
over time. operating manual, including information about the replacement of parts / partial sections.
This work may only be carried out by specialists.
Observe the intervals stipulated or those given in the operating manual for routine checks
and inspections.
Verify regularly that safety valves and other pressure-relief devices are in perfect condition
and are not blocked, for example by dirt or paint
Lines perish. Replace hydraulic hose lines at the stated or at reasonable intervals even if no defects of
relevance to safety are apparent! (DIN 20066, part 5)
Spurting oil can result in injuries and fire. Check all lines, hoses, and bolted connections regularly for leaks and visible damage.
Repair damage immediately and always arrange for damaged parts to be replaced!
Risk of electric shock. Have the electrical equipment on a machine/system checked regularly. Have defects like
loose connections or charred cables rectified immediately.

3.9 Dangers during maintenance and repairs

Danger Safety measure required

During maintenance and repairs, parts The compressor can only be maintained by specially trained technicians. Contact your
that may be pressurised must be CompAir agent.
removed. If you maintain the compressor
Only persons with special knowledge and experience of hydraulics may work on system
and have not been trained by CompAir,
elements, for example components under pressure.
you will put yourself and others at risk.
Incorrectly configured spare parts may Spare parts must meet the technical requirements laid down by the manufacturer. This is
jeopardise safety, e.g. tear when loaded. always guaranteed when original spare parts are used.
Risk of electric shock. Work on the electrical systems of the machine / installation may only be carried out by a
trained electrician in accordance with electrical regulations.
Risk of injury from pressurised or moving Only carry out inspection, maintenance, and repair work when the screw compressor
parts. system is at a standstill and is not under pressure. Make sure that the system cannot be
switched on by accident.
Modifications to the machine impair safety. After completing repair work, always check to see whether any tools, loose parts or cloths
have been left in or on the machine, driving engine or driving equipment.
After the work has been completed, replace any protective devices that have been
removed. Operation without protective devices is not permissible.

9
 3. Security Regulations

3.10 Dangers resulting from conversion work/modifications on the machine

Danger Safety measure required

Genuine parts are designed especially for No alterations, additions, or modifications to the machine may be carried out without the
the machine. Modifications may interfere approval of the manufacturer. Unauthorized modifications to the machine are prohibited for
with safety equipment or give rise to new reasons of safety.
dangers for which protection is not Original parts are specially designed for our machines. We must explicitly point out that
provided. parts and special accessories not supplied by us are not approved by us. Installing or using
such products may thus adversely affect active and/or passive safety.
The manufacturer accepts no liability whatsoever for damage resulting from the use of non-
original parts or special accessories.
This also applies to the installation and adjustment of safety devices and valves as well as
to welding on bearing and pressurized parts.
If protective equipment is not functioning, Only operate the machine when all protective devices, shutdown devices, sound-insulating
operating the system may put lives at risk. equipment and extraction equipment are in place and working.
Safety devices, protective covers, or insulations mounted on the system must not be
removed or modified in any way.
Note
The General Type Approval becomes invalid in case of modifications or alterations which
change or infringe upon the external geometry as well as the gross axle weight rating.

10
3. Security Regulations

3.11 Symbols and definitions

Carefully read the Operating Manual Check cooling water level, engine oil level Tie down point
before machine set-up and and compressor oil level before starting
maintenance. up.

Never attempt to operate the machine Attention: Hot surfaces Attention: Hot and dangerous exhaust
without the safety device mounted. fumes

Do not inhale any compressed air from Attention: Pressurized part or system. Do not step/stand on maintenance
the system. valve or other parts of the pressurized
system.

3,75 BAR

Never attempt to operate the machine Lifting spot Attention: Maintain specified tyre
with open or loose shielding. pressure! (See Chapter
Foreword, specifications.)

11
 3. Security Regulations

Condensate discharge (oil/water) Emergency stop device

System radiator/coolant
Attention: Do not use an ether aerosol
recoveryreservoir may be under
pressure.

Do not remove the Operating and

Maintenance manual and manual
holder from this machine.

Attention: Prior to starting any

maintenance work consult
the operating and
maintenance instructions

100
Attention: Max. permissible noise level
(See Chapter Foreword,
specifications.)

12
 4. Construction and functional description
4 Constr uction and fun ction al desc riptio n

Fig. 3
1 Screw compressor 4.1 Construction Frame and chassis
2 Diesel engine
3 turbo charger 1 for engine The complete compressor unit is
Compressor and engine
mounted on an easily movable tandem
4 turbo charger 2 for compressor
5 air filter (compressor and engine) The machine owes the increase in support. The chassis is equipped with
6 pre-compressed air heat exchanger supplied air to the "TurboScrew" system. automatic overrun brakes and parking
7 water heat exchanger A turbocharger, driven by the waste gas of brakes, as well as a jockey wheel
8 oil heat exchanger the engine, supplies the oil flooded adjustable in height.
9 oil filter (compressor) CompAir screw compressor with pre-
10 pressure reservoir compressed air.
11 air outlet cock Air channelling
The drive unit is a water cooled charged
12 control panel diesel engine with pre-compressed air Fresh air is sucked in via a air inlet
13 battery heat exchanger. It drives the compressor cover at the rear end of the roof. The fresh
14 suspension screw rotor via an elastic flange coupling air is used for cooling the compressor and
15 vehicle identification number and a set of spur gears. The sizes of the engine pre-compressed air. Under this
(type plate) gears are chosen depending on the cover the air supply for the engine is also
16 chassis desired operating pressure of the taken up. In addition, fresh air flows into
17 fuel tank installation (8.6, 10, 12 or 14 bar). the engine chamber through exactly
18 exhaust muffler matched inlet openings near the rear in
the side walls, and is mixed with the air
Housing (casing) coming from the air inlet cover over the
engine unit. In the front part of the
The body consists of a floor panel machine, the complete air flow is
mounted on a base-frame. On this floor conducted through the engine cooling
panel, all body components are screwed water heat exchanger and the compressor
onto or screwed to one another in form of oil heat exchanger.
individual panels. Large flaps on all four
sides allow easy access for service and
maintenance work. The eye for attaching
lifting tackle can be easily reached
through a flap in the roof.

13
 4. Construction and functional description

4.2 Functional description operating pressure. The warm-up phase is * Lack of cooling liquid (level switch 29)
automatically shortened to 20 sec if the
* Temperature of cooling water above
The numbers in brackets relate to the system has already reached operating
temperature. When the operating pressure 107 °C speed reduction or switching off
function diagram (see Fig. 4).
has been reached the suction control above 113 °C
A combined throttle / rotational speed valve (6) is loaded with control air by the * Oil pressure under 0.9 bar
control allows a continuous air quantity electronic proportional controller (17) and
between 1 % and 100 % to be drawn. the engine regulated to idling speed by the * Compressor oil temperature over
electronic control. This in turn regulates 120 °C (temperature sensor)
When started up the engine (27) initially
runs at a low gentle speed. The suction the machine down depending on * Pre-compressed air temperature over
control valve (6) opens due to the intake consumption until idling speed is reached 95 °C
vacuum pressure created and the again. When the machine is switched off
compressor begins to transport air. Once the relief valve (14) opens and the * Pressure sensors with cable break or
a low operating pressure has been built compressor is automatically bled. outside the permissible value range
up, the suction control (6) closes and the In any of the following situations the * Water in fuel
engine stays at the gentle rotating speed. machine is automatically switched off or
After a warm-up phase of around 60 sec the engine speed reduced:
the compressor system automatically
increases the pressure to achieve * No charge voltage

4.3 System description

Fig. 4 A13534774
1 air filter 14 relief valve 29 compensation tank with level switch
2 differential pressure switch 15 air outlet cocks 30 water heat exchanger
3 exhaust turbo charger for engine 16 Pressure limiter 31 diesel tank with level switch
4 exhaust turbo charger for compressor 17 Electronic proportional regulator 32 bypass valve
5 pre-compressed air heat exchanger 18 non-return valve 33 nozzle for venting mechanism
for compressor and engine 19 Quick-acting valve 34 aperture for venting mechanism
6 suction control valve 20 oil filter 35 venting mechanism
7 compressor 21 oil temperature regulator
8 temperature switch 22 oil heat exchanger
9 pressure tank 23 orifice plate in suction pipe
10 fine oil separator 24 non-return valve
11 safety valve 25 Pressure sensor
12 Pressure sensor 27 diesel engine
13 pressure maintenance valve 28 non-return valve

14
 4. Construction and functional description

4.4 Wiring diagram

Fig. 5 A13534874
1 Starter 8 Solenoid valve emergency tripping F1 Fuse 10 A
2 Generator 9 Tank pressure (4...20 mA) F2 Fuse 30 A
3 Relay for voltage supply 10 Control pressure (4...20 mA)
4 Relay for starter 11 Cooling water level
5 Solenoid valve for volume flow 12 Pressure gland temperature
6 Solenoid valve pressure relief 13 Fuel level low
7 Option

15
 4. Construction and functional description

4.5 Terminal Diagram DIN EN ISO 11446

Fig. 6 A13533874
The terminal diagram is designed for a voltage of 12 Volts!

1. Indicator left 11. Not assigned R. Brake light right

2. Fog tail lamp 12. Not assigned Brake light left
3. Mass for contacts 1- 8 13. Mass for contacts 9 - 12 S. Number plate light
4. Indicator right GE. Indicator left Tail light left
5. Tail light right BL. Fog tail lamp Outline and/or side lights
6. Brake lights W. Mass for contacts 1- 8 G. Reversing light
7. Tail light left GN. Indicator right X. Socket on the vehicle
8. Reversing light B. Outline and/or side lights Y. Plugs on the attachment
9. Permanent positive Tail light right
10. Charging + for battery Number plate light

16
 5. Transport and installation on site
5 Tra nspo rt a nd ins tallatio n o n site

5.1 Transport Danger Before disconnecting the machine from

the tractor:
The screw compressor may only be * Apply the hand brake.
transported on public roads if
* Adjust the rear wheel so that the
* The machine group (engine) is not compressor is horizontal.
running,
* Release safety cable and cable for
* The pressure tank is not under lights.
pressure,
* Secure wheels with wheel chocks.
* The shielding is closed,
* The blocks are firmly hooked in
place, 5.2 Setting tow bar with height
* Hoisted and secured tail wheel, adjustment
* The tyres and brakes are 1 2
operationally safe and roadworthy,
Fig. 7 * The lighting is fully functional.
Always keep a safe distance from the
edges of foundation ditches and
embankments! Do not travel across
slopes transversely.
Never exceed the maximum towing
speed! Danger of accidents! Observe
national regulations! 4 3

Please also observe the safety Fig. 9

instructions in Chapter 3 on the subject
1 overrun device
of transporting.
2 drawbar
Before transporting the compressor,
check to make sure that the draw gear of Danger
the towing vehicle and the drawbar eye or
trailer hitch ball connection are aligned Care must be taken without fail to
Fig. 8 exactly to each other. ensure that the overrun or towing
system (Fig. 9, Pos. 1) is always
Danger When transporting the screw compressor aligned parallel with the drawbar (Fig.
with a vehicle, the following points must 9, Pos. 2).
Make sure to check the torque after be observed:
50 kilometers following wheel The vehicle must not be driven unless
* Switch off the compressor at least the overrun system is parallel with the
mounting and at regular intervals.
10 min. before travel and allow the drawbar!
Tighten wheel nuts or screws evenly in pressure in the lines to drop by opening
a diagonal sequence to the specified a pressure cock. The toggle nut must be tightened to the
torque using a torque wrench. specified torque to keep it in place.
* Stow accessories in a safe place.
Replacing the trailer coupling ring The teeth of the swivel arm (Fig. 9,
* Firmly seal cover. pos. 3) and the drawbar are clamped
The coupling arrangements which can be * Connect up coupling device to vehicle together with an M36x1.5 bolt. The towing
used: and connection ropes to trailer. torque then depends on the permissible
gross weight of the trailer, and the length
* Trailer coupling ring DIA 40 in * Hook up wheel chocks. of the swivel arm.
accordance with DIN 74054 - 40A
* Adjust the height of the tow bar to the Torque setting = 650 Nm
* ball coupling Ø 50 towing vehicle (see 0 and chapter 5.2).
The teeth of the swivel arm and the
* coupling ring DIA 76.2 VG 74059 * Attach and secure clevis or coupling.
overrun device are clamped (Fig. 9,
A different coupling unit in the form of a * Raise and secure support fixtures. pos. 4) together with an M28x1.5 bolt.
complete kit may be ordered, if necessary.
* Connect the safety cable to the towing The nut must be tightened to a torque
The clevis may only be replaced by a vehicle (see chapter 5.3). setting of T = 400 Nm.
monitoring body working on behalf of the
* Connect electric connection cable After the teeth have been clamped,
Road Traffic Licensing Regulations (e.g.
between vehicle and screw compressor. to prevent it working loose the nut must
TÜV, DEKRA…). The testing body
* Check the lights (tail lights, brake lights, secured to the bolt with the cotter pin.
produces a certificate that should be kept
The cotter pin is attached to the drawbar
with the vehicle’s papers. indicator lights, and rear fog lamp).
with a chain.
* Release handbrake.
* Check to make sure that the wheels
are properly tightened, the tyres are in
a roadworthy condition and the tyre
pressure is correct (danger of
accidents).

17
 5. Transport and installation on site

5.3 Attachment of the contact- Attention 5.5 Installation on site

breaker cable on braked
Do not attempt to use a crane hook or
chassis
similar load suspension devices direct
If the towing connection becomes on the lifting device to avoid damages
uncoupled, the trailer is braked by the to the lifting device!
breakaway cable. Put the breakaway Use proper hoisting gears only such as
cable in the eye provided or wind it around hoisting straps in compliance with DIN
the towing collar and hitch it up to the standard 61360 with proper lifting ca-
cable with the snap link. pacity for connecting the load
The breakaway cable must be attached suspension device (e.g. crane) and the A = 1m
in a way that ensures that even on lifting device. B = 1m
extremely sharp bends there is no danger Only deploy load bearing equipment
of activating the locking brake. which corresponds to the safety
instructions for lifting gear. Fig. 12

Use a transport harness compliant with Danger

local regulations for transporting by
helicopter. The eyes provided may not The air intake must be positioned in
be used for this purpose. such a way that loose clothing cannot
be drawn in.
Never lift up or lash down the unit
using the shielding! Make sure that the pressure pipe from
the compressor to the aftercooler or
Never relocate the machine if external the air system can expand as a result
lines or hoses are connected to the of heat, and that it does not come into
discharge valves, in order to avoid contact with inflammable materials.
damage to the valves and/or collecting
pipe and hoses. The air intake is to be designed in such
Fig. 10
a way that no dangerous admixtures
When loading, the following points must (inflammable solvent vapours etc., but
be observed: also other dangerous or toxic
5.4 Loading/Relocation * When hoisting the compressor, set up substances) can be taken in. This also
the hoisting gear in such a way that the applies to flying sparks.
compressor, which must be set up Pipes and other parts with a surface
horizontally, is lifted vertically. temperature of more than 80 °C must
* Only relocate the compressor by itself. be suitably secured against contact
and suitably marked.
* Raise and lower the compressor
carefully. The operation of the compressor in
areas where there is a risk of explosion
* After relocating, remove the load is strictly forbidden! (Exception:
suspension device or the hoisting gear specially-made compressors with the
from the lifting device. necessary technical modifications for
use in such areas)
* Tie down the compressor on the cargo
area. Please also note the safety instructions
in Chapter 3 on the subject of
Fig. 11 * Only clamp to tie rod and wheel axles,
installation on site.
or to the apertures provided in the
Danger vehicle frame.

Only use hoisting gear (e.g. crane) with * When disassembling the chassis, the Location
appropriate lifting capacity for the cover and machine unit may only be
supported under the main frame. The complete system is to be set up in
loads occurring! such a way that it is easily accessible and
Only use the correct suspension gear! that the required cooling is guaranteed.
Never block the air intake. Ensure that the
Keep clear of the swiveling range of the entering of moisture and dirt together with
hoisting gear! the intake air is kept to a minimum.
Keep clear of suspended loads! The compressor is to be set up away
All loose parts that could fall down from walls.
during hoisting must first be removed
Attention
or secured; pivoting parts, like doors,
towbars, etc. must be secured in such The screw compressor should be
a way that they cannot move. positioned such that neither waste air
Never leave the load suspended on the nor waste gases are drawn in as this
hoisting gear. Acceleration or braking would result in overheating and a
of the means of transport must remain reduction in engine performance.
within the approved limits. The compressor must be set up in as
Please also observe the safety horizontal a position as possible.
instructions in Chapter 3 on the subject Maximum permissible inclination during
of loading. operation:

18
 5. Transport and installation on site

* In direction of pull: 15 degrees Temperatures/air humidity

* Backwards: 15 degrees
Install the compressor in a location with
* To the right and to the left: 15 degrees
maximum possible frost protection. The
suction air temperature must be within the
range specified on the data.

Note
Particularly in case of installation out of
doors and at night, observe fuel tempera-
ture. At temperatures below 0 °C, summer
15° 15° diesel fuel tends to precipitate and block
the fuel filter. In this case use winter diesel
fuel.

15° 15°
Fig. 13

Attention
Greater inclinations endanger the
operating reliability of the screw
compressor.
When setting up the unit on ground that
is not horizontal, or with a variable angle
(see operating instructions) please consult
CompAir.

Note
In dusty environments, set up the machine
in such a way that the wind does not blow
the dust in the direction of the machine.
During operation in clean environments,
the intervals for cleaning the air intake
filter and the cooler elements are much
longer.

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.

19
 6. Preparing the compressor for operation
6 Prepa ring t he c omp ress or f or o per ation

6.1 Checking oil levels 6.1.2 Checking the oil level in 6.2 Filling up the fuel tank
the engine
6.1.1 Checking the oil level in
the pressure tank

Fig. 16
Fig. 15
Danger
Fig. 14 Danger
Only fill up with fuel when the screw
Danger Only check the oil level when the compressor is at a standstill.
compressor engine is at a standstill. Cleanliness is essential! Spill no fuel!
Only check the oil level when the Spill no oil! The oil may be hot. Risk of
scalding! Filling up at a pump can cause static
engine is at a standstill and the
electricity and possibly sparks.
compressor is not under pressure. Check for leaks.
Proceed as follows:
The pressure tank may be under Proceed as follows:
pressure and the oil may be hot. * Open tank lid
* Shut the compressor down. Wait for
Risk of scalding! Spill no oil! 5 minutes. * Fill up tank with diesel fuel, using a
sieve (use summer or winter diesel fuel
Check for leaks. * Ensure that the screw compressor is depending on outside temperatures)
Proceed as follows: standing horizontally.
* Close tank tight with tank lid
* Shut the compressor down and wait * Pull the dipstick out.
* Close the covering.
until the system is depressurized, in no * The oil level should be as near as
case less than 5 minutes. possible to the upper dipstick mark. Note
* Before checking the oil level ensure * Correct as required. The fuel tank should always be filled up in
that the vehicle is standing horizontally.
* Put the dipstick back. good time. The fuel gauge displays the
* Unscrew dipstick. fuel level.
* Close oil filler.
* The oil level should be within the marks For outside temperatures below 0 °C, use
on the dipstick. Attention only winter diesel fuel.
* Correct as required. After a short test run, the oil level For outside temperatures below 0 °C,
should be between the markings on the observe the operating manual of the
* Check the seal on the dipstick and
dip stick. engine manufacturer for winter operation.
replace if required.
For oil specifications, see engine You can reduce the occurrence of
* Screw in dipstick and tighten firmly.
instruction manual. condensation in the fuel tank considerably
by filling it up in good time. This also
Attention
prevents downtimes and starting problems
After a short test run, the oil level that can occur when the fuel tank is run
should be between the markings on the dry.
dip stick. For oil specifications, see
recommended lubricants, Chapter 8.1.
With a system which has been out of
operation for some time, run the
machine for an approx. 1 minute warm-
up period and then check the oil level.

20
 7. Putting the compressor into operation
7 Putting t he co mp resso r int o o per ation

7.1 Initial operation 7.3 Start-up * The system is now ready for operation.
Check that the hoses / tools are
Transport inspection Danger correctly connected and open the
requisite air bleed cocks.
Every CompAir screw compressor
Before starting up, make sure that no
has already run in the factory and has Note
one is in the danger area of the engine /
already undergone a thorough test before
screw compressor. If the system also fails to start after the
shipment. This test ensures that the
compressor complies with the given data Compressors may not be operated in third attempt at starting, you must wait
and works perfectly. Independent of hazardous environments unless they until the tank pressure has dropped. The
the care taken in the factory, it is still have been specially designed for this symbol "9" (see Fig. 17) shows when the
possible for the compressor to be purpose (e.g. exhaust protected tank pressure has dropped enough to
damaged during transport. For this reason against emission of flying sparks etc.). permit a start release.
it is recommended that the unit should be
examined for possible damage during Never, under any circumstances, use
transport. "Startpilot" (Spray-can starting aid),
ether or other starting aids. As the air Start-up using jumper cables /
Remove any transport seals (dummy supply goes to both the engine and auxiliary batteries
flange, plugs, etc.) and dehydrating compressor, cold starting with a
agents before start-up. Distribution tubes starting aid may result in a dangerous
and connection lines must have the explosion.
specified dimensions and must be suitable
for use with the max. operating pressure After service work has been
and the media to be taken up. completed: Make sure that all
protective devices have been refitted
During the first hours of operation, the and that all tools have been removed.
compressor should be observed in order
to be able to ascertain any possible The exhaust from the system contains
malfunctions. carbon monoxide, a lethal gas.
The exhaust must be routed to the
outside via a pipe or a hose with an
7.2 Operating elements internal diameter of not less than
Operating panel: 150 mm if the compressor is used
indoors. Fig. 18

Adequate ventilation must be assured. Danger

The use of an exhauster system is Longer operation with an auxiliary
urgently recommended. battery or jumper cables connected
Only operate the compressor with the can lead to sudden emissions of gas.
hood closed. Danger posed by rotating An inflammable air / gas mixture is
and hot parts on the inside. formed. Explosion hazard!

Attention Attention

Check the oil levels in the pressure Serious damage can be caused to the
tank and in the engine of the electrical system if wrongly connected.
compressor each time before start-up. * Ignition key in position “0” (Off-Aus)
Fig. 17
Do not start the compressor unless the * First connect positive terminals then
1 Operating pressure in bar and psi air tapping cocks are closed.
2 Individual fault type negative terminals (ground).
1 = Engine oil pressure * Start as described in section “Starting
2 = Engine water temperature Starting up the compressor: up the compressor.”
3 = Intercooler temperature
* Close air tapping cocks.
4 = Airend temperature Note
5 = Engine water level * Turn ignition key to position "I" (on).
6 = Fuel level Symbols 1 and 8 light up. After the engine has started, first
7 = Water in fuel disconnect the negative cables (ground)
8 = Battery voltage * Press start button and then the positive cables.
9 = Cable break, Start against pressure * The system starts for 15 seconds. Follow the instructions for operating the
10 = Other errors from CAN-Bus (engine) compressor at an ambient temperature of
3 Engine speed, operating hours Danger less than 0 °C, in Chapter 5, Transport
4 LED green (ok) and Installation on Site, in this operating
5 LED red (fault) If the start is not successful, the manual.
6 Start button system attempts to start for a
7 Ignition key, Stop (shut down second and third time after a short
compressor) waiting period.
8 Reset button, Enter
* After starting the engine runs in idle
9 Choice of menu
and the compressor at reduced
10 Decrease working pressure
pressure.
11 Increase working pressure
* Depending on ambient temperature
this will be followed by a warm-up
phase of the engine.

21
 7. Putting the compressor into operation

7.4 Monitoring / fault 7.5 Operation 7.6 Menu assistance

Danger Danger 1 11 10 9

Interference with the automatic Only operate the compressor at the

monitoring system is not permitted. permissible operating pressure and at
the permissible temperature.
When the “Fault” indicator lamp lights up,
the screw compressor is automatically Only use the compressor for its
shut down when the following faults occur: intended purpose (see Chapter 2.1 of
this operating manual) in order to avoid
* engine oil pressure too low residual risk for persons and assets.
* cooling water temperature too high
* charge air temperature too high Only operate the compressor in a safe, 2 6 7
3 4 5 8
* engine oil temperature too high functioning condition.
* cooling water level too low Fig. 19
* fuel shortage All components, hoses etc. fitted must
* Water present in fuel pre-filter be of the correct size and designed for Fig. 19 is the main window and shows the
* charge control (e.g. V-belt tear, the specified operating pressure and current operating status of the system.
defective generator, ...) temperature. Additional information can be displayed by
* hardware fault (e.g. cable break) When working with compressed air, pressing button 9. The number of the
* other fault in the engine electronics wear suitable protective clothing (e.g. menu window appears in the top line.
protective suit, safety goggles, etc.).
The system can first be started up after
these faults once the cause leading to Wearing ear muffs may impair Menu 1: General information and
shut-down has been eliminated and the communication between persons. settings
fault has been confirmed with the reset Warnings may not be heard. Inform - 1 -________________________________
button "8" (see Fig. 17). supervisor. Date : 01.03.07
All other operating states are Check the compressor regularly. Time : 15:00:00
represented using the system electronics Version : V010307
Check the machine / installation for
menu. Compressor type : DLT1303
external damage and faults at least
WCA-No. : (17 characters)
once per shift. Any changes noticed
Switch the system off if an oil mist is Engine-No. : (8 characters)
entrained in the compressed air or if (including changes in operating
Next service : h
excessive oil consumption is apparent performance) must be reported
(see "Trouble-shooting") immediately to the authority or person Display Contrast : 140 (preset)
in charge. If necessary, shut down and
Display Lighting : On/Off (preset)
secure the machine immediately.
Language : English (preset)

Set display contrast (bright), display

lighting (on / off) and language:
* select with arrow button (10, 11)
* move to entry field with reset button (8)
* change value with arrow button (10, 11)
* actuate with reset button (8).

Menu 2: Operating data of the

compressor

______- 2 -______________________
Compressor Operating Data
1) Rated Eng. Speed : RPM
2) Actual Eng. Speed : RPM
3) Load @ Act. Speed : %
4) Fuel Consumption : L/h
5) Engine Oil Press. : bar
6) Engine Water Temp. : C
7) Engine Oil Temp. : C
8) Intercooler Temp : C
9) Charge Air Press : bar
10) Battery Voltage : V
11) Airend Temp. : C

22
 7. Putting the compressor into operation

Menu 3: Errors with detailed 7.7 Shutdown 7.8 Decommissioning

information
In order to shut down the compressor:
____________- 3 -____________________
Qty: No: Error * Close air discharge valves. The screw
------------------------------------- compressor reduces the speed of the
0 01 Engine Oil Pressure engine back to idling speed after the
0 02 Engine Water Temp. preset final pressure has been
0 03 Intercooler Temp. reached.
0 04 Airend Temperature
0 05 Engine Water Level * Allow the screw compressor to idle for
0 06 Fuel Level a few minutes.
0 07 Water in Fuel
0 08 Alternator Voltage * Turn ignition key to position "0" (off).
0 09 Hardware The system switches off after a defined
0 10 CAN-SPN overtravel time.
0 11 Emergency Stop
* Withdraw the ignition key. Fig. 20
Qty. = Number of errors, i.e. how often The screw compressor is automatically If the system is to be closed down for a
has this error occurred depressurized to atmospheric pressure. longer period of time (approx. 3 months or
A re-start is only then possible once the longer) the following preservation
No. = Error number
container pressure has fallen below measures must be taken:
Error = Error name 1.5 bar.
* Engine preservation (see separate
Using this menu point additional Note engine operating manual).
information on the individual errors can be
viewed with the arrow buttons (10, 11). In the case of emergency (!) the system * Disconnect battery cables.
The individual error display provides can be closed down via an emergency- * No special measures are required at
operating data of an error. The last error is stop switch. The system comes to an the compressor.
displayed. Previous errors can be selected immediate standstill. This type of
with the arrow button 11. shutdown is stored in the electronics. * Relieve the strain on tyres by jacking
up the vehicle.
Attention
Individual error display under menu * Check tyre pressure every 2 months.
option 3: The pressure line between the pressure
* Release the handbrake.
tank and the outlet valves will remain
E 1 (= continuous Error number) pressurised because of the pressure
Attention
Error .... at .... h maintenance valve with its non-return
------------------------------------- function. In order to allow the When putting back into operation,
Date : remaining pressure to be released carry out the maintenance work
Time : open an outlet valve while outlet pipes in accordance with Chapter 9
Eng. Oil Press. : bar are connected. “Maintenance.”
Eng. Water Temp. : C
Intercooler Temp : C Danger
Airend Temp. : C
Working Pressure : bar
It is important that you ensure that the
Actual Eng. Speed : RPM
pressure is completely blown off via
AirCtrl. Pressure : bar
Ambient Temp. : C the blow-off valve.
SPN / FMI : Should this not be the case, open the
Start OK / K.O. : / air outlet valves, identify the fault and
correct it.
SPN and FMI are error codes according to
J1939 which are sent by the engine
electronic system.

Return to menu option 3 with button 9.

Pressing button 9 again returns the
display to the original state (see Figure
Fig. 19).

23
 8. Fuels
8 Fuels

8.1 Recommended lubricant for 8.2 Recommended engine oil 8.4 Coolant
compressor
Lubricant specifications for the driving Attention
engine can be found in the enclosed
Note
engine operating manual. Only operate the engine with coolant!
In these screw compressors, circulating oil Pure water may cause damage to the
has not only a lubricating function, but in engine and to connected components.
particular it also has cooling and sealing The coolant consists of 50% water and
functions. It is therefore exposed to more 8.3 Diesel fuel
50% corrosion protection/antifreeze
difficult conditions. In particular the tempe- fluid. Use drinking water only.
Use common diesel fuel (EN590).
rature conditions at the installation site
and the consistency of the air (dust, dirt, Do not use sea, brackish, industrial,
Attention
and humidity content, as well as chemical rain or distilled water.
influences) must be taken into account See engine instruction manual.
Only use corrosion inhibitors and
when selecting a suitable lubricant.
antifreezes recommended and
Attention
Attention approved by the engine manufacturer!
The compressor must not be fuelled
Products of differing product groups
Do not mix oils of different with bio-diesel (DIN 51606) or vegetable
must not be mixed!
specifications. oil.
The maintenance intervals and the Note
maximum and minimum operating
Please observe the engine manufacturer's
temperatures given in this operating
operating instructions and coolant
manual only apply when high-quality
specifications.
multi-grade oils are used.
Use of the wrong oil leads to
impairment of function.
Out of consideration for the high loads
imposed on the lubricant in screw
compressors with oil injection cooling, we
recommend the use of suitable, non
ageing, non foaming, corrosion-protective
oils. They must meet the following
requirements for hydraulic fluids:
H-LP 32 and H-LP 46 in accordance with
DIN 51524, Part 2, June 1985.
The viscosity of the lubricants should
comply with viscosity class ISO VG 32
DIN 51519, July 1976, with 28 - 35
mm2/s(cSt) / 40 °C, or if the ambient
temperature is constantly above 25 °C,
with viscosity class ISO VG 46 DIN 51519,
July 1976, with 41 - 50 mm2/s(cSt)/40 °C.

Attention
Conventional engine oils marked HD
must not be used.
When using oils with the “Brief De-
scription HYD 10/HYD 20" in accordance
with the ‘Standard Lubricants for Building
Machinery and Vehicles’ published by the
‘Hauptverband der Deutschen Bauindustrie
e.V.’ (Principal Association of the German
Building Industry), only the given hydraulic
fluids may be used in accordance with
ISO VG 32 and ISO VG 46.
If other lubricants are to be used, please
contact your authorized dealer or your
local branch.

24
 9. Maintenance
9 Maint enan ce

9.1 General maintenance 9.3 Daily maintenance 9.4 Torque specifications

information
Drain water out of upstream fuel filter The following tightening torques apply to
screwed connections:
Danger
Wheel screws 90 Nm
Have the compressor maintained on a
regular basis. The maintenance Pressure vessel cover 100 Nm
schedule (see chapter 9.6) must be Safety valve 80 Nm
observed. Important parts wear over
time. They must be checked and Engine bearing
replaced if necessary. on engine 169 Nm
on spring element 180 Nm
The compressor can only be
maintained by specially trained Compressor bearing
technicians. Contact your CompAir on compressor 90 Nm
agent. Your agent will be able to on spring element 180 Nm
maintain the compressor for you, or
Chassis mounting screw 180 Nm
train you so that you can maintain it
yourself. Suspension device 180 Nm
If you maintain the compressor and
have not been trained by CompAir, you
will put yourself and safe compressor
9.5 Inspection intervals for
operations at risk.
pressure vessels and
The ‘Warning, maintenance work electrical installations
underway’ sign must be put up before Fig. 21
the following work is undertaken. Pressure vessels
1 Conveying pump
Cordon off the area around the
2 Vent plug As per the requirements of the 97/23/EC
workplace as required.
3 Filter element Pressure Equipment Directive, a qualified
Carry out all checks and work only 4 Water sensor person must inspect the pressure vessel
when the engine is stationary and the 5 Water drain from inside every five years.
screw compressor depressurised.
Danger As per the requirements of the 97/23/EC
During inspection, adjustment, or Pressure Equipment Directive, an
maintenance work, remember that the Drain water only with the engine off. appointed body must perform a strength
surfaces of machine parts can be hot, test on the pressure vessel after ten
particularly the exhaust system (risk of Water is heavier than diesel fuel. It years.
burning). separates out on the floor of the fuel pre-
filter. The water must be emptied on a
daily basis (via water drain 5). The water Electrical installation
sensor monitors the water content in the
fuel and switches off the system if the The electrical installation must be
9.2 Cleaning inspected by a qualified electrician after
water content is too high.
four years and also each time work has
Clean the screw compressor at regular,
been performed on it.
not too long intervals: Checking oil levels
Should stricter inspection intervals apply
* Blow-clean all valves, controllers, Check the oil levels as described in in your country, these must be observed.
fittings, pressure tank, oil cooler, chapter 6.1 on p. 20.
radiator, screw compressor, and
engine with compressed air or a steam
jet appliance.
* Inspect the cooling ribs of the radiator
to make sure that air can pass through.
* Clean the body at regular intervals.
Then grease or oil the hinges of the
body hood with multi-purpose grease.
If sound-absorbing matting has to be
replaced, remove the retaining brackets,
replace the old sound-absorbing matting
with new matting, replace the retaining
brackets.

25
 9. Maintenance

9.6 Maintenance and inspection schedule

1,500 h
2,000 h

2,500 h
3,000 h

3,500 h
4,000 h

4,500 h
5,000 h

5,500 h
6,000 h
60 h
500 h
1,000 h
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)
Drain off water in the fuel pre-filter
Clean air filter (screw compressor/engine) between times
or renew if the red field appears
Engine maintenance
Every 500 h, although at least every 6 months:
Check tyre pressure and wheel nuts,
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
retighten if necessary
Have the brake system checked/adjusted ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Lubricate chassis / draw gear ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Have the safety valve checked ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Lubricate hood hinges ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Clean cooler (more frequently if used in a dusty environment) ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
Every 1000 h, although at least each year:
Have the air filters replaced (screw compressor/motor) ■ ■ ■ ■ ■ ■
Have the screw compressor oil filter replaced ■ ■ ■ ■ ■ ■
Oil change (screw compressor) ■ ■ ■ ■ ■ ■
Have the automatic status monitoring checked ■ ■ ■ ■ ■ ■
Have the fine separator replaced: annually or in the event of a difference in
■ ■ ■ ■ ■ ■
pressure > 1 bar
Have the orifice of the exhaust line cleaned ■ ■ ■ ■ ■ ■
Have the closed-loop control checked ■ ■ ■ ■ ■ ■
Have the solenoid valves checked ■ ■ ■ ■ ■ ■
Have the acid level in the batteries checked ■ ■ ■ ■ ■ ■
Have the retaining bolts and/or nuts checked and tightened if necessary
■ ■ ■ ■ ■ ■
(chassis, frame and body)
Have the suspension device checked ■ ■ ■ ■ ■ ■
Unscrew optional vessel for tool oil and check inside for any corrosion.
■ ■ ■ ■ ■ ■
If rust is found, replace the vessel with new, original spare part.
Inspection every 4 years:
Inspection of the electrical installation by a qualified electrician ■
Inspection every 5 years:
Internal inspection of the pressure vessel by a qualified person ■
Inspection every 10 years:
Strength test of the pressure vessel by the appointed body
X For your own benefit, put a cross on the servicing schedule against maintenance work when performed.
■

26
9. Maintenance
6,500 h
7,000 h

7,500 h
8,000 h

8,500 h
9,000 h

9,500 h
10,000 h

10,500 h
11,000 h

11,500 h
12,000 h

12,500 h
13,000 h

13,500 h
14,000 h

14,500 h
15,000 h

15,500 h
16,000 h

16,500 h
17,000 h

17,500 h
18,000 h

18,500 h
19,000 h

19,500 h
20,000 h
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

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

■ ■ ■ ■

■ ■ ■

■ ■

27
 10. Troubleshooting
10 Tro ubles hooti ng

10.1 General fault rectification The compressor can only be repaired

by specially trained technicians.
information
If you attempt to repair the compressor
Danger and have not been trained by CompAir,
you will put yourself and safe
Whenever you encounter problems for compressor operations at risk.
which no remedy is provided in this
manual, contact your CompAir agent.

10.2 Faults, causes and remedy

Problem Possible cause(s) Correction

Insufficient or no air supply Clogged air filter Clean air filter
Other problems Switch off system, inform Service
Compressor becomes excessively hot Compressor oil level too low Fill up with oil
(automatic shutdown)
Oil cooler dirty (outside) Clean
Other problems Switch off system, inform Service
Screw compressor will not start No fuel Fill up with fuel
Water in fuel filter Drain off water from fuel pre-filter
(see Chapter 9.3)
Air in system Vent fuel system
Other problems Inform Service
Engine starts but switches off again Refer to instrument panel for cause of fault See chapter 10.4.
immediately, or the system switches off
while running

10.3 Warning lights

OK Fault Description

1 = Engine oil pressure

2 = Engine water temperature

3 = Intercooler temperature

4 = Airend temperature

5 = Engine water level

6 = Fuel level

7 = Water in fuel

8 = Battery voltage

9 = Hardware, Cable break, Start against pressure

10 = Other errors from CAN-Bus (engine)

28
 10. Troubleshooting

10.4 Individual error display

SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
FC = Fault Code

SPN FMI FC Problem Possible cause(s) Correction

110 0 151 Engine water temperature Radiator dirty Check, clean
too high
Cooling air intake blocked Check, correct
Other problems Contact Service
105 0 155 Intercooler temperature Loss of pressure charge air cooler Check, clean
too high too high
Outlet temperature turbocharger Contact Service
too high
System operated with open cladding Close cladding
100 1/18 415 Engine oil pressure too low Wrong oil level Check, fill up oil
Wrong oil grade Check, change oil if necessary
Other problems Contact Service
97 0/15 418 Water in fuel Water content too high in fuel Check, drain off water from fuel pre-
filter (see Chapter 9.3), improve fuel
quality
627 0 434 Battery supply interrupted System stopped via EMERGENCY Engine electronics system could not
STOP shut down properly
Restart system and switch off correctly,
acknowledge error
Other problems Contact Service
157 1/18 559 Pressure fuel pump too low No fuel (with external fuelling) Check, fill up
Other problems Contact Service
522 1 Resonance Compressor oil level too low Check, fill up oil
Wrong oil grade Check, change oil if necessary
Drag load too high Contact Service

If an error cannot be eliminated according to the instructions and in the case of any other errors, contact the Service department.

29
Gardner Denver Deutschland GmbH
Argenthaler Str. 11
55469 Simmern
Deutschland

Tel. ++49 (0)6761 832-0

www.compair.com
e-mail: [email protected]