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CompAir C30 User Manual

CompAir C30
59 pages
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C30, C35-10, C38, C42, C50
Deutz M1011F
Powered Compressor
Id. Nr. 100 002 755 / 02 - März 2003
Operating Manual
GB
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CompAir C30 Specifications

General IconGeneral
BrandCompAir
ModelC30
CategoryAir Compressor
LanguageEnglish

Summary

1. Foreword

1.1 Information on the Compressor

Details CompAir screw compressor development, standards compliance, and environmental protection.

1.2 Normal Use Guidelines

Covers intended use, potential risks, and necessary precautions for safe compressor operation.

1. Foreword

1.3 Specifications for DLT 0404 Models

Lists technical specifications for DLT 0404 series compressors, including performance and dimensions.

1. Foreword

1.4 Maintenance and Care Importance

Stresses the critical role of regular maintenance and care for compressor reliability and longevity.

1.5 General Operating Information

Explains the manual's purpose and provides general guidelines for safe, cost-effective compressor use.

3. Security Regulations

3.1 Safety Instruction Identification

Defines safety symbols (Danger, Attention, Note) and clarifies manufacturer liability for non-compliance.

3.2 General Safety Instructions

Covers organizational measures, personnel qualifications, and general safety practices for machine operation.

3.3 Machine Modifications and Alterations

Prohibits unauthorized modifications, requiring manufacturer approval for safety and compliance.

3. Security Regulations

3.4 Loading, Relocation, and Transport Safety

Provides detailed safety instructions and procedures for loading, relocating, and transporting the compressor unit.

3.5 On-Site Installation, Starting, and Operation Safety

Outlines essential guidelines for safe installation, startup procedures, and normal operation at the site.

3. Security Regulations

3.7 Specific Hazard Instructions: Gas, Noise, Hydraulics

Details specific hazards related to gas, dust, steam, smoke, hydraulics, pneumatics, and noise.

3. Security Regulations

3.6 Special Jobs and Maintenance Safety Procedures

Covers safety procedures for maintenance, repairs, and special jobs, emphasizing qualified personnel and clean environments.

3. Security Regulations

3.7 Electrical, Battery, and Maintenance Safety Precautions

Focuses on electrical safety, battery handling, and general precautions during maintenance and inspections.

3. Security Regulations

3.7 Hazard Instructions: Electrical, Gas, and Noise Exposure

Addresses specific hazards including electrical energy, gas/dust/steam/smoke, hydraulics/pneumatics, and noise exposure.

3. Security Regulations

3.8 Symbols and Definitions Overview

Explains various symbols used throughout the manual for safe operation and maintenance.

3. Security Regulations

3.8 Warning Symbols Explained

Continues the explanation of warning symbols related to exhaust gas, electric shock, pressurized parts, and noise levels.

3. Security Regulations

3.8 Operational Safety Symbols

Illustrates symbols for hot surfaces, fuel drain, parking brake, oil filler plug, condensation drain, and stop/emergency stop devices.

3. Security Regulations

3.8 Towing and Manual Consultation Symbols

Shows symbols related to transportation braces and the necessity of consulting the manual before towing.

4. Construction and Functional Description

4.1 Construction Overview

Describes the overall construction of the mobile compressor system, including the engine and screw compressor.

4.2 Functional Description: Oil & Air Circuits

Explains the operational principles of the oil and air circuits within the compressor system.

4. Construction and Functional Description

Engine Speed and Air Volume Regulation

Details the regulation mechanism for engine speed and air volume control.

4. Construction and Functional Description

4.3 System Component Description

Lists and describes components of the compressor system, including optional features.

4. Construction and Functional Description

4.4 Electrical Wiring Diagram

Presents the electrical wiring diagram for the compressor and optional generator with a component key.

4. Construction and Functional Description

4.5 Terminal Diagram DIN ISO 1724

Shows the terminal diagram for connecting external electrical components and lights.

5. Transport and Installation on Site

5.1 Transport Safety Procedures

Provides essential safety instructions and procedures for transporting the compressor unit.

5. Transport and Installation on Site

5.4 On-Site Installation Guidelines

Details site installation requirements, location considerations, and safe setup practices for the compressor.

5. Transport and Installation on Site

Altitude Considerations for Operation

Addresses operational requirements for the compressor at higher altitudes and fuel temperature considerations.

6. Preparing the Compressor for Operation

6.1 Checking Oil Levels

Explains how to check oil levels in the pressure tank and engine, including safety warnings.

6.2 Battery Safety Precautions

Provides safety precautions for handling batteries and battery acid.

6.3 Fuel Tank Filling Procedure

Details the safe procedure for filling the fuel tank, emphasizing cleanliness and correct fuel type.

6. Preparing the Compressor for Operation

6.4 Air Filter Maintenance Display Check

Describes how to check the air filter maintenance indicator and when to perform filter maintenance.

7. Putting the Compressor into Operation

7.1 Initial Operation Checks

Covers initial checks, transport safety, and observations during the first hours of operation.

7.2 Operating Elements Identification

Identifies and explains the functions of the control panel elements and indicators.

7.3 Compressor Start-Up Procedure

Provides step-by-step instructions for safely starting the compressor engine.

7. Putting the Compressor into Operation

7.3 Start-Up and Auxiliary Power

Continues start-up procedures, including using jumper cables and cold-starting with ether.

7.4 Setting Operating Pressure

Details how to correctly set the operating pressure, emphasizing specialist involvement.

7.5 Operation Monitoring and Fault Detection

Explains how to monitor the compressor during operation and identify fault conditions.

7. Putting the Compressor into Operation

7.5 Fault Tracing and Shutdown

Continues fault tracing and troubleshooting procedures for compressor shutdown.

7.6 Normal Operation Guidelines

Provides guidelines for normal operation, including safety, pressure, and temperature limits.

7.7 Safe Shutdown Procedure

Describes the correct procedure for shutting down the compressor safely.

7. Putting the Compressor into Operation

7.8 System Decommissioning Measures

Outlines preservation measures for closing down the system for extended periods.

8. Fuels and Lubricants

8.1 Recommended Compressor Lubricant

Specifies recommended lubricants for the compressor, detailing viscosity and compliance requirements.

8.2 Recommended Engine Oil

Refers to the engine manual for recommended engine oil specifications.

8.3 Tool Lubricant Recommendations

Recommends specific tool oils and their advantages for lubricating connected appliances.

8.4 Diesel Fuel Specifications

Specifies requirements for diesel fuel, including sulfur content and low-temperature considerations.

9. Maintenance

9.1 General Maintenance Tasks

Covers general cleaning and inspection tasks for the compressor and its components.

9.2 Engine Maintenance Requirements

Refers to the engine manual for specific engine maintenance tasks and intervals.

9. Maintenance

9.4 Compressor Maintenance Schedule

Provides a detailed maintenance schedule based on operating hours and intervals for various compressor components.

9. Maintenance

9.4.1 Compressor Oil Filter Replacement

Explains the procedure for replacing the compressor oil filter cartridge, including safety precautions.

9.4.2 Compressor Oil Change Procedure

Details the steps for changing the compressor oil, emphasizing safe draining and refilling.

9.4.3 Automatic Monitoring System Check

Describes checking the automatic monitoring system, with safety warnings for high voltage.

9.4.4 Fine Separator Inspection and Replacement

Outlines inspecting and replacing the fine separator, with safety warnings about pressure.

9. Maintenance

9.4.5 Air Filter Replacement (Compressor/Engine)

Provides instructions for replacing air filter elements for both compressor and engine.

9.4.6 Safety Valve Operation Check

Explains how to check the safety valve's operation and the importance of its functionality.

9. Maintenance

9.4.7 Control System Notes

Mentions control system components and checking battery acid levels.

9.4.8 Battery Maintenance Guidelines

Refers to manufacturer instructions for battery maintenance, with safety warnings about gases.

9.4.9 Torque Specifications List

Lists torque specifications for various screw connections on the compressor.

10. Troubleshooting

Insufficient or No Air Supply Issues

Lists common causes and corrections for problems related to insufficient or no air supply.

Low Air Pressure Causes and Solutions

Identifies potential causes and solutions for low air pressure issues.

Compressor Overheating and Shutdown

Details causes and corrections for compressor overheating and automatic shutdown.

Compressor Fails to Start

Provides troubleshooting steps for issues preventing the compressor from starting.

10. Troubleshooting

Oil in Air Line Diagnosis

Addresses oil presence in the air line, its causes, and remedies.

Safety Valve Blow-Off Troubleshooting

Explains why the safety valve might blow off and how to resolve the issue.

Post-Shutdown Oil Discharge from Air Filter

Describes troubleshooting for oil discharge from the air filter after shutdown.

Engine Starts and Shuts Down Issues

Lists causes and corrections for the engine starting and then shutting down unexpectedly.

11. Generator Option Overview

11.1 Introduction to Generator Option

Introduces the generator option, its operation, and maintenance aspects.

11.2 Generator Safety Precautions

Provides critical safety warnings and precautions for operating the generator, covering fuel, exhaust, and electrical safety.

11.3 Generator Operating Principle

Explains the basic operating principle of the synchronous generator and its components.

11. Generator Option Overview

11.4 Safe Generator Operation with Electrical Equipment

Details safe operating procedures for the generator, including device connection and electrical safety.

11. Generator Option Overview

11.4 Generator Operation and Electrical Safety Precautions

Continues safe operating procedures, including insulation monitoring tests and range switch settings.

11.5 Insulation Monitoring and Device Connection Testing

Provides a step-by-step guide for testing the insulation monitoring system and device connection.

11. Generator Option Overview

11.6 Technical Characteristics: 8 kVA 400/230 V Generator

Lists technical specifications, characteristics, and data for the 8 kVA generator.

11. Generator Option Overview

11.7 Technical Characteristics: 12 kVA 400/230 V Generator

Lists technical specifications, characteristics, and data for the 12 kVA generator.

11.8 Technical Characteristics: 7 kVA 110 V Generator

Lists technical specifications, characteristics, and data for the 7 kVA generator.

11. Generator Option Overview

11.8 7 kVA 110 V Generator Technical Data

Continues technical specifications for the 7 kVA generator, including regulator and switchbox data.

11. Generator Option Overview

11.9 Wiring Diagram: 8/12 kVA 400/230 V Generator Switchbox

Shows the wiring diagram for the switchbox of 8 kVA and 12 kVA generators.

11.10 Wiring Diagram: 7 kVA 110 V Generator Switchbox

Displays the wiring diagram for the switchbox of the 7 kVA generator.

11. Generator Option Overview

11.11 Generator Troubleshooting Flowchart

Provides a troubleshooting flowchart for generator issues like dead sockets and blown fuses.

11. Generator Option Overview

11.11 Generator Problem Causes and Corrections

Lists common generator problems, their causes, and corresponding solutions.

12. Heat Exchanger Option

12.1 Heat Exchanger Safety Regulations

Stresses observance of general compressor safety regulations when using the heat exchanger.

12.2 Heat Exchanger Design and Operation

Explains the function of the heat exchanger in controlling compressed air and engine oil temperatures.

12.3 Heat Exchanger Maintenance and Care

States that the heat exchanger system is maintenance-free.

12.4 Heat Exchanger Troubleshooting

Lists common issues with the heat exchanger, such as temperature problems, and their solutions.

13. Compressed Air Processing Option (After cooler / Filter)

13.1 Safety Regulations for Air Processing

Reminds users to follow general compressor safety regulations for this option.

13.2 Design and Operation of Air Processing

Describes the design and function of the aftercooler and filter options for compressed air.

13.3 Maintenance Instructions for Filters

Advises observing general safety regulations for maintenance and disposal of filters.

13.4 Air Processing Troubleshooting

Addresses troubleshooting for increased air humidity and oil in the discharge air line.

14. Breathing Air Connection Option

14.1 Safety and Function Notes

Refers to a separate manual for safety and functional details of the breathing air filter unit.

15. Oil Temperature Controller Option

15.1 Controller Safety Regulations

Emphasizes following general compressor safety regulations when operating the oil temperature controller.

15.2 Controller Design and Function

Explains how the oil temperature controller maintains optimal oil circuit temperature for the compressor.

15.3 Controller Maintenance and Care

States that this system is maintenance-free.

15.4 Controller Troubleshooting

Details troubleshooting for low compressed air temperature related to the oil temperature controller.

16. Undercarriage System

16.1 Undercarriage Introduction

States that only manufacturer parts should be used and design modifications are reserved.

16.2 Undercarriage Safety

Emphasizes compatibility of wheel/hub parts, torque figures, and restrictions on welding.

16.3 KHV13 Height-Adjustable Towing System

Describes the adjustable towing system, its serrated connections, and tightening torques.

16.4 Braking System Overview

Introduces KNOTT over-run brake systems and their components.

16. Undercarriage System

16.4 KNOTT Braking System Details

Continues braking system information, including autoreverse, spring axles, and safety for towing eyes.

16.5 Brake System Adjustment Procedures

Details preparations and preliminary requirements for adjusting the brake system.

16. Undercarriage System

16.5 Brake System Adjustment Steps

Continues adjustment procedures for the braking system, including brake linkage and wheel brakes.

16.5.5 Brake Linkage Adjustment

Provides specific steps for adjusting the brake linkage for proper operation.

16.6 Brake System Readjustment

Explains how to readjust the braking system, typically to compensate for brake lining wear.

16. Undercarriage System

16.6 Brake System Readjustment Steps

Continues readjustment procedures and includes a final check and test run recommendation.

16.7 Undercarriage Maintenance and Care

Outlines maintenance and lubrication intervals for KNOTT overrun systems and vertical drawbars.

16. Undercarriage System

16.8 Undercarriage Malfunctions and Remedies

Lists common malfunctions of the undercarriage and braking system, with their causes and remedies.

16. Undercarriage System

16.8 Braking System Malfunctions and Remedies

Continues malfunction and remedy list, including issues with ball coupling and general brake system works.

17. Tool Oiler Option

Tool Oiler Operation and Maintenance

Details how to operate the tool oiler, adjust oil dosage, and check oil levels.

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