Operating Manual
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CALIFORNIA
Proposition 65 Warning

Diesel engine exhaust and some of its

constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.

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Maintenance and Inspection Manual

for CompAir Compressors

This Maintenance and Inspection Manual

is intended only as a supplement to the
operating instructions and parts list for your
CompAir compressor.
It does not replace these technical
documents.
This Maintenance and Inspection Manual
is intended for you, the machine attendant.
It is provided to facilitate the required
maintenance and inspection work and
allow this work to be reviewed at any time.
When this Maintenance and Inspection
Manual is kept carefully it can contribute to
reduction of the maintenance costs and
increasing the operating reliability and
service life of your compressor.
Attention

When starting up your compressor for

the first time, observe the operating
instructions under all circumstance
circumstances.s.
Proper operation, care and continuous
supervision of the compressor system are
decisive for the operating reliability,
performance and service life.
We cannot assume any liability for
damage resulting from failure to observe
the operating instructions, improper repairs
or use of other than genuine parts.

Questions/Parts
Questions/Parts orders
Always indicate:
- Machine
Machine num
number
ber (rat
(rating
ing pla
plate)
te)
- Ma
Mach
chin
inee mode
model.
l.

We request you to present this

Maintenance and Inspection Manual
to our service personnel on request.
Thank you.

Danger 
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instructions.
may change your settings at any time
Perform inspection, maintenance and 
or accept the default settings.
repair work only when the machine is 
standing still, not under voltage and not 
under pressure.
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Safety devices such as guards must not 
be removed during operation.
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Service
Service Contact Partne
Partner,
r, name: _________
__________________
___________________
___________________
__________________
__________________
__________________ 
_________    ________________
 ____________________________ 
____________ 

Plant Maintenance Personnel, Name: _________

__________________
__________________
___________________
___________________
__________________
_____________ 
____    ________________
 ____________________________ 
____________ 

Number of associ
associated
ated Parts List: __________
___________________
__________________
___________________
___________________
__________________
__________________
___________________
___________________
__________________
___________ 
__ 

Machine model: ________________

_________________________________
__________________________________
__________________________________
_________________________________
_________________________________
__________________________ 
_________ 

Machine serial number: _______________

________________________________
__________________________________
__________________________________
__________________________________
__________________________________
____________________ 
___ 

Year of product
production:
ion: _________
___________________
___________________
__________________
___________________
___________________
__________________
__________________
___________________
___________________
__________________
_____________ 
____ 

Data acc. to compressor rating plate: _________________

__________________________________
__________________________________
__________________________________
__________________________________
________________________ 
_______ 

 _________________________________
 ________________ __________________________________
__________________________________
__________________________________
__________________________________
__________________________________
____________________ 
___ 

 _________________________________
 ________________ __________________________________
__________________________________
__________________________________
__________________________________
__________________________________
____________________ 
___ 

 _________________________________
 ________________ __________________________________
__________________________________
__________________________________
__________________________________
__________________________________
____________________ 
___ 

Operating pressure (≤ max. operating pressure): _______________

________________________________
__________________________________
__________________________________
__________________________________ 
_________________ 
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____________________ 
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____________________ 
___ 
 

  s
  r
  u
  o
Time required for service work
   h
Date   g Maintenance – Inspection – Repair
  n
   i
   t
  a
  r
  e
  p
  o    t   s
   l   r   r
  a
   t   a    d   u
  o    t   n   o
   T    S    E    H

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  r   )
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   O    T    T   (    M

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Operating Manual
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cookies to enable essential site
functionality, as well as marketing,

C76, C62HS, C65-10, C60-12, C55-14

personalization, and analytics. You
may change your settings at any time
or accept the default settings.
C62, C53-9, C50, C38, C35-10, C30
Privacy Policy

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Deutz M2011
Powered Compressor 
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006 932 / All
02 - September 2006
This website stores data such as
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1. Foreword

1.1 Information on the compressor * You do not

not obser
observe
ve the
the inform
informati
ation
on in
the operating manual
CompAir screw compressors are the For this reason every person involved in
product of many years' research and the operation, maintenance and repair of
development. These preconditions, the compressor must read and observe
together with high quality standards, the operation manual and the safety
guarantee the manufacture of screw regulations. This is to be confirmed by
compressors with a long service life, a high signature as required.
degree of reliability
operation. The strictand cost-effective
environmental Furthermore, the following naturally apply:
protection standards have of course been * The rele
relevant
vant acc
accide
ident
nt preven
preventio
tionn
complied with. regulations
* General
Generallyly recogni
recognized
zed safet
safetyy and traff
traffic
ic
Confirmation of Conformity regulations
 The compressor and its accessories * Par
Partic
ticula
ularr nationa
nationall regula
regulatio
tions
ns
conform to the safety requirements laid
out in the EC Directives 89/392 and The compressor is designed for providing
95g368 EEC and in EN 474-1. compressed air:
* For oper
operati
ating
ng compr
compress
essed-
ed-air
air
appliances
* For conv
conveyin
eyingg bulk
bulk mat
materia
eriall
* For sandb
sandblas
lastin
tingg and paint-
paint-spr
sprayi
aying
ng
operations
* For clean
cleaning
ing mach
machines
ines and shutt
shutterin
eringg
material - do not direct towards persons!
* For blow
blow-cl
-cleani
eaning
ng drille
drilledd holes.
holes.
Any other use, or any additional use,
for example as respiratory air, is regarded
as not being for the originally intended
Fig. 1
purpose. The manufacturer / supplier
accepts no liability for any resulting
damage. The risk is assumed by the user
1.2 Normal use alone.
The compressor may only be used in
The compressors have been built using a technically perfect condition, for its
the latest techniques in design and in intended purpose, with appropriate
accordance with recognized safety awareness of safety regulations and
regulations. hazards, subject to compliance with the
Nevertheless, the operator or third parties operating manual. In particular, faults
may be exposed to risk to life and limb in representing safety hazards are to be
the course of the use of the compressor corrected at once.
(e.g. through flying pieces of building
material, swirling particles of dirt or dust,
electrical current, thermal vibrations, noise
or mechanical
This website storeshazards),
data suchandasthe machine
or other tangible assets may be impaired,
cookies
for to enable
reasons essential
that could notsite
have been
functionality,
avoided as well preventive
through as marketing,
constructional
personalization, and
safety measures. analytics. You
may change
Hazardsyouroccursettings at any
particularly when:time
or accept the default settings.
* The comp
compres
ressor
sor is
is not use
usedd for its
intended purpose
* Policy
Privacy The comp
compres
ressor
sor is
is not oper
operate
atedd by
trained personnel
* Marketing
Unauth
Una uthoriz
orized
ed changes
changes or modif
modificat
ications
ions
are carried out on the compressor
Personalization
* You are
are not weari
wearing
ng the
the prescr
prescribed
ibed
Analytics
protective clothing
* You do not comp
comply
ly with
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safetyy
instructions
Save Accept All
3
 

1. Foreword

1.3 Specifications type DLT 0406

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  a   o   n   r
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   l   s
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oad On
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oad    O
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  m
 [m above
[m  /min] [barg]
3
[barg] [°C] [°C] [l] [kW] [rpm] [rpm] [l] [l]
sea level]

C30 3.0 7.0 5-8 -10 50 1000 9.0 F2M2011 Oil 23.0 1700 2600 7.5 60

C30 G * 3.0 7.0 5-8 -10 50 1000 9.0 F2M2011 Oil 23.0 1700 2600 7.5 60

C35-10 3.5 10.0 5-10 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C35-10 G ** 3.5 10.0 5-10 -10 45 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C38 3.8 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C38 G ** 3.8 7.0 5-8 -10 45 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C42 4.2 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C42 G ** 4.2 7.0 5-8 -10 45 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C50 5.0 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

C50 G * 5.0 7.0 5-8 -10 50 1000 9.0 F3M2011 Oil 35.5 1700 2700 6.75 60

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C30 1025.0 767 807 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C30 G * 1025.0 834 874 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C35-10 1025.0 805 845 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

C35-10 G**
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C42 G ** 1025.0 889 929 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

Privacy
C50Policy 1025.0 868 908 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

Marketing
C50 G* 1025.0 935 975 3528 1490 1336 4 1/2 J x 13 165 SR 13 2.5 2 x 3/4" 98 82 69

* 7Personalization
kVA, one-ph
kVA, one-phase
ase 110
110 V AC,
AC, 50 Hz
Hz or
8 kVA, 400/230 V AC, 50 Hz
Analytics
** 7 kVA,
kVA, one-phase
one-phase 110
110 V AC, 50 Hz or
8 kVA, 400/230 V AC, 50 Hz or
Save
12 kVA 400/230 V Accept
AC, 50 HzAll
4
 

1. Foreword

1.4 Specifications type DLT 0703

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No-load
oad On
On-l
-load
oad    O
  m
 [m above
[m3 /min] [barg] [barg] [°C] [°C] [l ] [kW] [rpm] [rpm] [l] [l]
sea level]

C53-9 5.3 8.6 5-9 -10 50 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120
C53-9 G ** 5.3 8.6 5-9 -10 45 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120
C55-14 5.5 14.0 5-14 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C60-12 6.0 12.0 5-12 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C62 6.2 7.0 5-8 -10 50 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120
C62 G ** 6.2 7.0 5-8 -10 45 1000 14.0 F4M2011 Oil 46.5 1550 2600 10.0 120
50 1000
C62HS 6.2 7.0 5-8 -10 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
40 3000
C62HS G ** 6.2 7.0 5-8 -10 50 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
40 3000
C65-10 6.5 10.0 5-10 -10 50 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C65-10 G ** 6.5 10.0 5-10 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C76 7.6 7.0 5-8 -10 50 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120
C76 G ** 7.6 7.0 5-8 -10 45 1000 14.0 BF4M2011 Oil 61.0 1550 2600 10.0 120

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

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**Save
7 kVA,
kVA, one-phase
one-phaseAccept
110 V AC,
All50 Hz or
8 kVA, 400/230 V AC, 50 Hz or
12 kVA 400/230 V AC, 50 Hz 5
 

1. Foreword

DLT0406

DLT0703

This website stores data such as

cookies to enable essential site
functionality,
Fig. 2 as well as marketing,
personalization, and analytics. You
may change your settings at any time
or accept the default settings.

Privacy Policy

Marketing

Personalization

Analytics

Save Accept All

6
 

1.5 Maintenance and care 1.6 General information This fact results in the termination/ 
expiration of the guarantee and warranty
Care and maintenance are all-important This operating manual is to help you to claims against the manufacturer.
if the screw compressor is to meet the get to know the compressor and to use it
demands placed upon it. Compliance with for its intended applications. It contains
the prescribed maintenance intervals and important information about how to operate Safety regulations
careful execution of care and maintenance the compressor safely, cost-effectively
work are therefore essential, especially and with due care. Compliance with the Danger 

under difficult working conditions. instructions

danger, in this
reduce manual
repair costswill
and help to avoid
downtime, It is important that you follow the safety 
regulations in Chapter 3 of the operating 
and increase the reliability and service life
manual.
Service of the compressor.
In case of faults, or should you require This operating manual is to be
spare parts for the screw compressor, supplemented by instructions concerning Technical modifications
please contact your local CompAir agent. current national regulations for accident
prevention and environmental protection. It We reserve the right to undertake
In case of damage, the trained technical must always be available at the site of the modifications without notice in the interests
staff will guarantee a fast, expert repair compressor. The operating manual is to be of technical progress.
using CompAir spare parts. Original read and used by all persons in charge of
CompAir spare parts are manufactured work with the compressor, for example
according to the state of the art and operation, including setting up, correcting
guarantee continued reliable operation. faults during operation, disposal of waste
products from production, care, disposal of
If you have important questions, process materials, upkeep (maintenance,
inspection, repair) and transport.

CompAir Drucklufttechnik GmbH Besides the operating instructions and

Werk 55469 Simmern
the current regulations applicable in the
user's country and at the sites of operation
concerning accident prevention, the
recognized technical rules for safe and
proper working are also to be complied
with.
Typ, type, modèle, tipo

1 2

Handelsbezeichnung,trade name,dénomination
commerciale,denominazionecommerciale
Baujahr, year,
année, anno Warranty
3 4

Auftrags-Nr., order number,

5
Only use this compressor with accurate
knowledge of and in compliance with this
numéro de commande, numero d'ordine

max. Stützlast an Kupplung, max. tongue load at

coupling, charge d'appui à l'attelage,

carico di appoggio massimo sulla frizione
6 N
manual.
Volumenstrom, flow rate
flux volumique, flusso volumetrico 7 m3 /min

Ansaugdruck, intake pressure,

8 bar
CompAir Drucklufttechnik GmbH
do not accept responsibility for safe
pression d'aspiration, pressione d'aspirazione

Stufendrücke, stages pressures,

pression d'etages, pressioni degli stadi di compressione 9 bar
functioning of the compressor for actions
Drehzahl, revolutions per minute,
régime de rotation, numero dei giri 10 min-1
that do not correspond to normal use or for
Installierte Motorleistung, installed engine power,
puissance moteur installée, pressione di aspirazione
11 kW purposes not mentioned in the manual.
Warranty claims cannot be entertained for:
Fig. 3 * Op
Oper
erat
atin
ingg erro
errors
rs
Pleasestores
This website enter the datasuch
data fromas
the identifi- * In
Inad
adequ
equat
atee maint
maintena
enanc
ncee
cation plate for your compressor,
cookies to enable essential site in the
spaces above. In case of questions or * In
Inco
corr
rrec
ectt fue
fuels
ls
functionality,
orders forasspare
well parts,
as marketing,
please give us the * Damage
Damage caus
caused
ed by non-
non-use
use of
of origina
originall
personalization,
compressor type,analytics.
and compressorYou number CompAir parts
may change yourofsettings
and the year at any
construction as time
given on
* Mod
Modifi
ificat
cation
ion of the
the syst
system.
em.
or accept the default plate.
the identification settings.
If you give us this data you can be sure that The Guarantee and Liability terms of
you will be given the correct information or CompAir's General Terms and Conditions
sent the spare parts you require. are not extended through the above
Privacy Policy
instructions.
Marketing Any unauthorized modification of the
compressor system/station or the
Personalization installation of components (e.g. fine
separators) not released by the
Analytics manufacturer result in the loss of the
CE symbol.
Save Accept All

7
 

2. Index

1. Forew
Foreword
ord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information on the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Specifications type DLT 0406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Specifications type DLT 0703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7
1.6 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7

2. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Secu
Security
rity regul
regulation
ations s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Identification
Identification of safety
safety instructions
instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Modifications
Modifi cations and alterations
alterations toto the machine
machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Loading / Relocation / Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Installation on site / Starting / Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Special jobs / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 Instructions
Instru ctions concerni
concerning
ng particular
particular hazards
hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8 Symbols and definitions
definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. Const
Constructi
ruction
on and functi
functional
onal descr
descriptio
iption
n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4 Wiring diagram
diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5 Terminal Diagram
Diagram DINDIN ISO 1724 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5. Tr
Transp
ansport
ort and insta
installati
llation
on on site
site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport 24
5.2 Link up breakaway
breakaway cable
cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3 Loading / Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Installation on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6. Prep
Preparing
aring the compre
compressor
ssor for operatio
operation
n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Checking
Checking oil levels
levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1.1 Checki
Checkingng pressure
pressure tank oil oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1.2 Checki
Checkingng engine oil oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 Batter
Batteryy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3 Filling up the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.4 Checki
Checkingng the air filter
filter maintenan
maintenance ce display
display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. Putti
Putting
ng the compre
compressor
ssor into
into operation
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2 Operati
Operatingng elements
elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.4 Settin
Settingg the operating
operating pressure
pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.5 Monitoring / fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.6 Operati
Operationon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
This website storesndata
7.7 Shutdow
Shutdown . . . .such
. . . . as
.. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . 31
cookies7.8
to enable essential
Decommission
Decomm issioninging site
. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . 31
functionality, as well as marketing,
 8. Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
personalization, and analytics. You
8.1 Recomm
may change Recommendedended lubricant
your settings lub
atricant
any timefor compressor
for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2 Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
or accept
8.3the default
Tool settings.
lubricants .................... ..................... .......................... ..................... 32
8.4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.5 Recomm
Recommendedended lubricants
lubricants for the bogies bogies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Privacy Policy

Marketing
Personalization

Analytics

Save Accept All

8
 

2. Index

9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.1 General maintena
maintenance nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.2 Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.3 Maintenance
Maintenance of chassis
chassis and
and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.4 Compressor
Compres sor maintenance
maintenance / Maintena
Maintenance nce schedule
schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.4.1 Oil filter
filter replacement
replacement (compres
(compressor) sor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.4.2 Oil change
change (compressor)
(compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.4.3 Checki
Checking ng the automatic
automatic monitor
monitoring ing system
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.4.4
9.4.5 Inspec
Inspecting
filterting
Air filter / Replacing
Reement
replac placing(compres
replacement (cthe
tompressor
he fine sor separator
separator
engine). . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
/ engine) 35
36
9.4.6 Checki
Checking ng the safety
safety valve
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.4.7 Contro
Controll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.4.8 Batter
Batteryy maintenance
maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.4.9 Torque specific
specifications
ations DL DLT 0406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.4.10 Torque specifica
specifications
tions DLTDLT 0703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.5 Spare parts
parts for maintenanc
maintenancee purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10. Trouble
Troubleshooting
shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

11. Generator option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

11.1
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 40
11.2
11.2 Generator
Generat or safety
safety precautions
precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.3
11.3 Operating
Operating principle
principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.4
11.4 Operating
Operating the generator
generator (Working
(Working safely safely with
with electrical
electrical equipment
equipment)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.5
11.5 Testing insulat
insulation
ion monitoring/
monitoring/startu startup/devi
p/device ce connection
connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.6
11.6 Technic
echnical
al characterist
characteristicsics of 8 kVA kVA 400/230
400/230 V generator
generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.7
11.7 Technic
echnical
al characterist
characteristicsics of 12 kV kVA 400/230
400/230 V generator
generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.8
11.8 Technic
echnical
al characteristi
characteristics cs of 7 kVA kVA 110110 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11.9
11.9 Generator
Generat or switchbox
switchbox wiring
wiring diagram
diagram of 8 kVA kVA and 12 12 kVA
kVA 400/230
400/230 V generator
generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.10
11.10 Generator
Generat or switchbox
switchbox wiring
wiring diagram of 7 kVA kVA 110 110 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.111
11.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
12. Heat exchanger option
option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12.1 Safety regulatio
regulations
ns for the use of the the heat exchanger
exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12.2 Design and
and operation
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12.3 Maintenance
Mainten ance / Care
Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12.4 Troubleshoo
Troubleshooting
ting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
13. Compressed air
air processing option (After cooler / Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13.1 Safety regulati
regulations
ons for alternat
alternatee compressed
compressed air processi processing ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13.2 Design and
and function
function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13.3 Maintenance
Mainten ance instructi
instructions
ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13.4 Troubleshoo
Troubleshooting
ting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
14. Breathing air connection
connection option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

14.1 Notes on safety

safety and
and description
description of functi
function
on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15. Oil temperature controller option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
This website
15.1 stores
Safety data such
regulations
regulatio as the use of an oil
ns for oil temperature
temperature controller
controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
cookies to enable
15.2 essential
Design functsite
and function
and ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15.3 as
functionality, Maintenance / care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
well as marketing, 51
personalization, and analytics.. .You
15.4 Troubleshoo
Trou bleshootingting . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . 51
may change your settings
16. Undercarriage . . .at
. .any
. . . .time
. . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . 52
or accept16.1
the default settings.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
16.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
16.3 KHV13 height-adju
height-adjustablestable towing
towing system,
system, modelmodel B 3.5.133.5.13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
16.4 Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Privacy Policy 52
16.5 Adjusting the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
16.6 Readjus
MarketingReadjusting
ting the braking
braking system
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
16.7 Mainten
Maintenance
ance and care care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
16.8 Malfunc
Malfunctions
Personalization tions and remedies
remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Analytics
17. Tool oiler
oiler option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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9
 

3. Security Regulations

3.1 Identi
Identificatio
fication
n of safety
safety Personnel delegated to work with the Only trained or specially instructed
machine must have read the operating personnel may be assigned to this work.
instructions
manual before beginning this work, The responsibility of the personnel for
CompAir accepts no responsibility for particularly the chapter on safety operating, setting up, maintaining and
any dama
damage
ge or injur
injuryy caused
caused by
by non-
non- instructions. It is too late to do this while repairing the machine / installation must
compliance with these safety measures or working. This applies particularly to be clearly defined.
non-observance of normal care and personnel only using the machine
Make sure that only authorized personnel
caution
caution dur
during
ing the handlin
handling,
g, operati
operation,
on, occasionally, e.g. for setting up and
use the machine.
maintaining the machine.
maintenance or repairstated
even if not expressly of thisincompressor,
this Define who is responsible for operating
Safety and danger-conscious working
operating manual. the machine, and authorize him to ignore
by the personnel in compliance with the
instructions from third parties if these
If any of the regulations contained in operating manual should be checked at
instructions could compromise safety.
this manual do not correspond to local least occasionally.
statutory provisions, particularly with Only allow personnel that are training,
The personnel must not have long, loose
reference to safety, then the stricter of that are under instruction or are attending
hair, or wear loose clothing or jewellery,
the two applies. a course of general training to use the
including rings, due to risk of injury through
machine / installation under the constant
These safety instructions are of a general catching. Personal protective equipment
supervision of an experienced person.
nature and are applicable to various types should be worn if necessary or as required
of machine and equipment. For this reason by regulations. Work on the electrical systems of the
it is possible that some information may not machine / installation may only be carried
Pay attention to all safety and danger
apply to the aggregate(s) described in this out by a trained electrician in accordance
warnings on the machine/ installation!
manual. with electrical regulations.
Make sure that all safety and danger
Only persons with special knowledge and
Danger  warnings on the machine / installation can
experience of hydraulics may work on
be read.
Places thus marked refer to possible 
system elements, for example components
For all safety-relevant modifications to under pressure.
dangers for persons. the machine / installation or its operating
Attention behavior, stop the machine / installation
immediately and report the fault to the
Places thus marked refer to possible competent authority / person. 3.3 Modifi
Modification
cations
s and alterations
alterations
dangers for machines or parts of to the machine
Spare parts must meet the technical
machines. requirements laid down by the No alterations, additions, or modifications
manufacturer. This is always guaranteed to the machine may be carried out without
Note 
when original spare parts are used. the approval of the manufacturer. This
Places thus marked give general and  Replace hydraulic hoses at the given is also true for the installation and the
technical information for optimum, cost-  intervals, or at suitable intervals, even if adjustment of safety devices and valves
effective machine use. no safety-relevant defects are visible as well as for welding at supporting
(DIN
(D IN 20
20066
066,, Part
Part 5).
5). and pressurized parts. Unauthorized
modifications to the machine are prohibited
Observe the intervals stipulated or those for reasons of safety.
3.2 General safety instructions given in the operating manual for routine
checks and inspections. Original parts are specially designed for
Organizational measures our machines. We must explicitly point out
Workshop equipment suitable for carrying that parts and special accessories not
atPlease
all timeskeep thissite
on the operating manual handy
of the machine /  out maintenance work is essential. supplied by us are not approved by us.
Installing or using such products may thus
installation, in the bag provided. The location and operation of fire
extinguishers must be made known. adversely affect active and/or passive
This website
Please notestores
anddata
passsuch as
on general Observe the instructions concerning fire safety.
cookies to enable
statutory essential
and other bindingsiteregulations alarm and firefighting. The manufacturer accepts no liability
functionality, as well as marketing,
that may supplement the operating whatsoever for damage resulting from the
manual for theand prevention of accidents Limiting values (pressure, temperature,
personalization, analytics. You time settings etc.) must be permanently use of non-original parts or special
and the protection of the
may change your settings at any timeenvironment. accessories. This also applies to the
Such obligations may be for example the marked.
or accept theofdefault settings. installation and adjustment of safety
handling hazardous materials, or the devices and valves as well as to welding
provision and/or wearing of personal Personnel selection and qualification; on bearing and pressurized parts.
protective equipment, or traffic regulations. basic tasks
Privacy Policy including supervisory
Instructions, Work on or with the machine / installation
Note 
responsibility and duty of notification for may only be carried out by reliable The General Type Approval becomes inva- 
Marketing
taking account of special in-plant factors, personnel. Observe the minimum statutory lid in case of modification
modifications
s or alterations 
for example regarding work organization, age. which change or infringe upon the external 
Personalization
sequences of operations, personnel geometry as well as the gross axle weight 
assigned to certain tasks, are to be added
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to the operating manual. rating.

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10
 

3. Security Regulations

3.4 Loading / Relocation / Transport Before or immediately after completion Do not travel across slopes transversely:
of loading, secure the machine / installation always keep equipment and loads near
Loading / Relocation to prevent accidental shifting. Display an ground level (for example, do not place
appropriate warning. Before putting the them on the bodywork).
All loose parts that could fall down when machine / installation back into operation,
the machine is lifted must first be removed On descents, always adapt speed to the
the securing devices must be duly
or secured; pivoting parts like doors, etc. circumstances! Never change into low gear
removed.
must be immobilized. during the descent, but always beforehand.
Parts to be removed for transport When leaving the driver's seat, always
For lifting
heavy-lift heavy with
facilities parts,the
hoisting gear and
appropriate purposes must be carefully refitted and secure the unit to make sure that it cannot
fixed again before putting the machine /  roll away or be used without authorization!
capacities, which have been checked and installation back into operation.
approved in accordance with local safety Avoid all operations that adversely affect
regulations, must be used. When putting the machine / installation the stability of the unit.
back into operation again, only proceed in
For lifting machines or parts of machines accordance with the operating manual.
with one or more lifting eyes, only hooks
or shackles complying with local safety 3.5 Instal
Installation
lation on site
site / Starting /
regulations may be used. Never fasten Transporting the complete unit Normal operation
cables, chains or ropes to or through lifting Make sure that the air vessel is not under
eyes. pressure. Installation on site
Lifting hooks, lifting eyes, shackles etc. Lift and secure supporting gear. Besides the general technical operation
must never be bent and must always be in accordance with the regulations of the
stressed in alignment with the load-carrying Make sure that the drawbar eye can local authorities, it is essential that the
axis. The load capacity of the hoisting gear move freely in the tow bar. following guidelines be observed.
is reduced if the lifting force is applied at an Check to make sure that the drawbar is Before switching on the machine / 
angle to the axis. adjusted to the bar height of the towing installation, or starting it up, make sure
All bearing
vertically, parts
as far as must be stressed
possible, for maximum vehicle. that nobody
machine can be injured
/ installation by theup.
as it starts
Check to make sure that the body is
safety and optimum performance of the closed and locked, and that the cable for The installation is to be set up in such a
hoisting gear. If required, a support is to be the rapid-emergency brake is connected way that it is adequately accessible and
installed between the hoisting gear and the to the towing vehicle. that the necessary cooling is ensured.
load. Secure the load properly. Never block the admission of air.
Join up the connections of the air brake,
When heavy loads are being conveyed if present. The air intake is to be designed in such
by means of hoisting gear, it is imperative
Check to make sure that the wheels are a way that no dangerous admixtures
to keep well clear of the load in order to (inflammable solvent vapors etc., but
avoid accidents. properly tightened, that the tyres are in a
roadworthy condition, that the tyre pressure also dust and other dangerous or toxic
Never leave the load suspended on the is correct and that the brakes function substances) can be taken in. This also
hoisting gear. properly. applies to flying sparks.
Acceleration or braking of the means of Connect the cable for the signalling The air intake is to be designed in such a
transport must remain within the approved and lighting fittings. Check the proper way that no loose personal clothing can be
limits. functioning of the lighting. drawn in.
The hoisting gear is to be set up in such Release the handbrake. Make sure that the compressed air line
a way that the object is lifted vertically. from the compressor to the air network can
Should this not be possible, precautions Before transporting the unit, always expand as a result of heat and cannot
must be taken to prevent the load from check to make sure that the accessories come into contact with inflammable
swinging. Thus it is possible to use two are firmly attached so that they can cause materials.
This website storesgear,
sets of hoisting databoth
suchwithas an angle of no accidents!
The compressed air line connected at the
cookies to enable
inclination essential
of not more than site
30° to the When using public roads, tracks and air exit of the unit must not be under strain.
vertical.
functionality, as well as marketing, spaces, observe the current traffic
personalization, and analytics. You regulations, and if necessary make the Compressed-air lines have to be marked
Nominate experienced supervisors for the
unit roadworthy first! distinctly according to local regulations.
may change your settings at any time
lifting process.
or accept the default settings. Never exceed the maximum towing If several compressors are arranged in a
Machines may only be hoisted correctly
speed. Observe national regulations! system, manually operated valves have to
using hoisting gear in accordance with the
be installed so that each machine may be
information in the operating manual (limit Always switch on lights if visibility is poor shut off individually. For the purpose of
stop
Privacy points for heavy-lift facilities etc.)
Policy and during lighting-up time! shutting off pressurized systems, you
Only use a suitable transport vehicle with When going through underpasses, should never rely on the effectiveness of
Marketing
sufficient carrying capacity. return valves alone.
bridges, tunnels, overhead power lines,
Personalization etc., always make sure that you have Safety devices, protective covers, or
enough clearance! insulations mounted on the system must
Analytics
Always keep a safe distance from the not be removed or modified in any way.
edges of foundation ditches and
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11
 

3. Security Regulations

All pressure tanks located outside the unit Make sure that: Avoid any working methods that could be
with an approved operating pressure higher considered risky!
* All bol
bolted
ted con
connect
nections
ions have bee
beenn
than atmospheric pressure and fitted with
tightened Never play about with compressed air.
two or more pressure feed lines must be
equipped with an additional safety device * All elect
electric
rical
al wiring
wiring has
has been conne
connecte
ctedd Never direct compressed air onto the skin
to automatically prevent the approved correctly and is in good condition or towards another person.
operating pressure from being exceeded by
more than 10%. * The eng
engine
ine exh
exhaus
austt syst
system
em is
is Never use compressed air for cleaning
operationally safe and that no clothing. When using compressed air to
Pipes and other parts with a surface inflammable material is in the vicinity clean equipment, work with extreme
temperature of more than 80 °C must be caution and always wear suitable eye
suitably secured against contact and * The wheel
wheel nuts
nuts are
are proper
properlyly tight
tightened
ened;;
protection.
suitably marked. never exceed the specified torque.
The compressed air produced by these
Electrical connections must comply with compressors must not be used as breath-
local regulations. Normal operation able air, unless it has been processed
specially for such an application in
With compressors fitted with generators, Before starting work, make yourself
accordance with the “Safety requirements
use equipotential bonding systems for the familiar with the working environment at the for breathable air.”
protection of persons. installation site. The working environment
includes, for example, obstacles in the When breathing apparatus with cartridges
Install the machine so that it is as
working and transport areas, the carrying is used, make sure that the correct
horizontal as possible; a slight inclination is
capacity of the ground, and any necessary cartridge has been inserted and that its
permissible (see information in Chapter
cordoning off of the building site from public service life has not expired.
"Installation").
traffic areas.
Never use the machine in environments
Set up the machine in such a way that no
Take the necessary precautions
pre cautions to make where the possibility cannot be ruled out
inlets, outlets or gates are blocked, even
sure that the machine / installation is only that inflammable or toxic vapors may be
when the doors are open.
operated in a safe, functional condition. taken in.
Before disconnecting the machine from Only operate the machine when all Never operate the system at temperatures
the towing vehicle, apply the handbrake.
protective devices, shutdown devices, and/or pressures below or above the values
Disconnect the rapid-emergency brake
sound-insulating equipment and extraction indicated in the technical data sheet.
cable and lighting cable, disconnect the
equipment is in place and working.
lines of the air brakes, use chocks to Persons working in environments or
ensure that the machine does not roll away. Be careful: loose articles of clothing, hair rooms in which the acoustic pressure is
or limbs can still be drawn in by revolving 85 dB(
dB(A)
A) or higher
higher mus
mustt wear
wear ear muf
muffs.
If a machine with a combustion engine
parts. Caution: this may impair communication
has to work in a fire-risk environment, the
between persons. Warnings may not be
unit must be fitted with a spark catcher. Verify regularly that:
heard. Inform supervisor.
In dusty environments, set up the * All prot
protect
ective
ive equi
equipmen
pmentt is proper
properly
ly
Shieldings and doors must be closed
machine in such a way that the wind does positioned and fixed in place
during operation so that the flow of cool air
not blow dust in its direction. During
* All hoses
hoses and/o
and/orr pipes
pipes within
within the
the system
system within the housing is not deflected and the
operation in clean environments, the
are in good condition, are properly fixed efficiency of the sound-insulating is not
intervals for cleaning the air intake filter
in place and do not chafe reduced. Doors and hoods may only be
and the cooler elements are much longer.
opened briefly.
Do not install the machine directly in * There
There are
are no leaks
leaks (fuel,
(fuel, oil or
or coolant
coolant
leaks) With water-cooled combustion engines
front of walls. Make sure that the warm air
coming from the engine and cooling * All bol
bolted
ted con
connect
nections
ions have bee
beenn with a closed
coolant cooling
recovery circuit,
bottle must the
not cap
be of the
systems is not drawn into the air intake tightened removed before the system has cooled
under any circumstances. Drawing this
* All elect
electric
rical
al wiring
wiring is proper
properly
ly connect
connected
ed down to ambient temperature.
This warm
websiteair instores
throughdata
the such
engineasor cooler
and is in perfect condition
cookies to enable essential siteif it is
fan could lead to overheating; Never fill up with fuel while the engine is
drawn intoas
functionality, thewell
combustion chamber, this
as marketing, * Safety
Safety valve
valvess and other
other pressur
pressure-re
e-relie
lieff running. Make sure that fuel does not come
will result in a loss of power. devices are in perfect condition and are into contact with hot machine parts.
personalization, and analytics. You
Never relocate the machine if external not blocked, for example by dirt or paint Do not smoke while filling up with fuel.
may change your settings at any time
lines or hoses are connected
or accept the default settings. to the * The safe
safety
ty devic
devices
es all
all work
work properl
properlyy
discharge valves, in order to avoid damage Filling up at a pump can cause static
to the valves and/or collecting pipe and All connected components must be of electricity and possibly sparks. In order to
hoses. the correct size and be suitable for the avoid this, a ground cable must be
Privacy Policy specified operating pressure and connected to the system while it is being
No force may be exerted on the temperature. filled up.
discharge valves, for example by pulling
theMarketing
hoses or fitting additional equipment Only use the correct type and size of
(e.g. a water separator, compressed air hose coupling and connection.
Personalization
oiler, etc.) directly to the discharge valve. Before blowing through a hose or air line,
Analytics
Ifit is
theessential
open end to ishold
notthe
heldopen endit firmly.
firmly, can
whiplash and cause damage or injury.
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12
 

3. Security Regulations

The exhaust emissions of combustion Inform operating personnel before Only carry out inspection, maintenance,
engines contain carbon monoxide - a lethal beginning to carry out special work or and repair work when the screw
gas. If a machine with such an engine has maintenance. Nominate a supervisor. compressor system is at a standstill and is
to work in an enclosed room, the exhaust not under pressure.
gases must therefore be conducted out After completing repair work, always
check to see whether any tools, loose Protective devices, i. e. protective grids,
of doors by means of a hose or pipe with
parts or cloths have been left in or on the may not be removed during operation.
an internal diameter of at least 100 mm.
The use of extraction systems is highly machine, driving engine or driving
Caution while the screw compressor is in
equipment.
recommended in test rooms for mobile operation.
machines. Maintenance and repair work is only to be
After the work has been completed,
carried out under the supervision of or by a
Before connecting or disconnecting replace any protective devices that have
person qualified for this work.
hoses, always close the compressor air been removed. Operation without
outlet valves. Before disconnecting a hose, For all work concerning the operation, protective devices is not permissible.
always make sure that it is not under production adjustment, conversion, or
pressure. Working clothing should be close-fitting
settings of the machine / installation and its
during work on running screw compressor
safety-relevant equipment, as well as
A hose connected to an air valve must systems.
servicing, maintenance, and repair,
be fitted with a safety wire for operating
pressures above 7 bars; it is in fact observe the operating manual for startup
and shutdown procedures and the Maintenance
recommended that this safety device
instructions for maintenance work.
should be used
used for pressu
pressures
res above
above 4 bars. During maintenance and repair work, the
The stee
steell wire
wire has a diam
diamete
eterr of 8 mm All maintenance and repair work may contractor has to inform the personnel
and is firmly clamped to the hose at least only be carried out when the system is shut about the dangers that can occur during
every 500 mm. Both ends are fitted with down, or, with electrical systems, when the their work and about measures to avert
cable lugs. mains power supply is switched off. Make such dangers.
sure that the equipment cannot be
Check the machine / installation for The personnel have to support all
switched on by accident.
external damage and faults at least once
per shift. Any changes noticed (including Whenever the machine/system is measures to improve safety at work.
changes in operating performance) must completely powered down for maintenance Safety devices for preventing or
be reported immediately to the authority or and repair procedures, it has to be eliminating dangers must be serviced
person in charge. If necessary, shut down secured against unintentional power-on regularly and their functioning tested at
and secure the machine immediately. or the mains supply has to be cut off least once per year. Faults discovered must
with electrical systems. be corrected at once or reported to the
In case of malfunction, shut down and supervisor.
secure the machine / installation * Swi
Switch
tch off
off battery
battery maste
masterr switch
switch and/or
and/or
immediately. Have malfunctions corrected detach connector. Only use the correct tools for
immediately. maintenance and repair work.
* Put up a warni
warning
ng sign
sign on the
the main
main
Observe the operating manual for start- switch “Attention! Maintenance work.” Only use original spare parts.
up and shutdown procedures as well as Close off the complete maintenance All maintenance and repair work may
inspection displays. area, if required. only be carried out when the system is shut
* Dis
Discon
connect
nect the
the start
starter
er battery
battery.. down, or, with electrical systems, when the
mains power supply is switched off. Make
Individual parts and larger subassemblies sure that the aggregate cannot be switched
3.6 Special jobs / Maintenance must be carefully attached to the hoisting on by accident.
gear and secured in case of replacement.
Care
Only use suitable, technically perfect Wheneverpowered
completely the machine/system is
down for maintenance
Observe the setting, maintenance, and
hoisting gear and load suspension devices and repair procedures, it has to be
inspection work and intervals stipulated in
This website stores data such as information with adequate carrying capacity. Keep clear secured against unintentional power-on
the operating manual, including
of suspended loads. or the mains supply has to be cut off
cookies to enable essential site / partial
about the replacement of parts
with electrical systems.
sections.as
functionality, This work
well as may only be carried out
marketing, Before removing any part under pressure,
by specialists. separate the aggregate effectively from * Switch
Switch off
off battery
battery maste
masterr switch
switch and/or
and/or
personalization, and analytics. You
all sources of pressure and release the detach connector.
Maintenance
may change work, tests
your settings and repairs
at any time pressure from the complete system.
should be carried out in
or accept the default settings. a well ventilated * Put up a war
warning
ning sig
signn on the mai
mainn
room, away from heat, open flames, or Never use inflammable solvents or switch “Attention! Maintenance work.”
sparks. Appropriate prohibition signs (fire, carbon tetrachloride to clean parts. Close off the complete maintenance
open flames, no smoking) must be put up. area, if required.
Privacy Policy Take precautions to avoid toxic vapors
Loss of oil leads to a very slippery floor. from cleaning fluids. * Dis
Disconn
connect
ect the
the start
starter
er batter
batteryy.
Statistics have shown that many accidents
Marketing
can be attributed to the installation or Absolute cleanliness is essential during Before removing or opening any part
maintenance of machines on oily floors or maintenance and when carrying out under pressure, separate the equipment
Personalization repairs. effectively from all sources of pressure and
machine components. For this reason,
always start maintenance work by cleaning release the pressure from the complete
Analytics
the floor and the machine exterior. Onlywhen
work carrythe
outmachine
maintenance and repair
is located on an system.
even, stable base and is secured against
Save Accept All running away and against buckling.

13
 

3. Security Regulations

For moveable machines support the In order to avoid an increase in operating Keep all steps, handles, railings,
towing mechanism and axle with temperature, inspect and clean the heat platforms, scaffolds, and ladders free of
appropriate means if work is to be carried transfer surfaces (cooling ribs etc.) dirt, snow, and ice.
out underneath the units (a jack is not regularly. Draw up a schedule for the most
suitable cleaning intervals for each Before beginning maintenance and
sufficient).
repair, clean the machine, particularly
machine.
Observe the safety precautions for work couplings and bolted connections, of oil,
on batteries. Avoid damaging the safety valves and fuel, and special care products. Do not use
other pressure-reducing devices. In aggressive detergents. Use lintfree cloths
Payentering
from attentionbytosealing
cleanliness. Prevent
the parts and dirt particular, make sure that they are not for cleaning.
blocked through paint, oil carbon, or
exposed openings with a clean cloth, After cleaning, remove all covers and
dust accumulation, which could impair
paper, or tape. seals.
the effect of these devices.
Before the aggregate is approved for After cleaning, check all fuel, engine oil,
The insulation or protective shielding of
operation after maintenance or an and hydraulic fluid lines for leaks, loose
parts whose temperature may exceed
overhaul, make sure that operating connections, chafing and damage. Correct
80  ° C and which may accidentally be
pressures, temperatures, and time settings any faults immediately.
immed iately.
touched by personnel may not be removed
are correct and that the control and
before these parts have cooled down to Always tighten bolted connections
shutdown devices are working properly. room temperature. loosened during maintenance and repair
The electric motor, generator, air filter, work.
Check the accuracy of the pressure
electrical components and control
and temperature displays regularly. If the If it is necessary to dismantle safety
equipment are to be protected against the
permissible tolerance limits have been devices during machine set-up,
penetration of dampness - for example
exceeded, then they must be replaced. maintenance, and repair work, the safety
when cleaning with a steam jet - by
devices must be reassembled and checked
covering or sealing them. Never carry out welding work or any other
immediately after completing the
work that produces heat in the vicinity of
Under no circumstances should the maintenance and repair work.
fuel or oil systems. Systems, which could
sound-insulating
modified. material be removed or contain fuel or oil, have to be completely Ensure safe, environment-friendly
drained and cleaned, e.g. by means of a disposal of process materials as well as
Never use solvents with dangerous steam jet, before proceeding with the work replaced parts. Components containing oil,
properties for cleaning parts. to be carried out. for example fine separators, and oils must
be disposed of. Oil must not enter the soil!
Maintenance work, tests, and repairs Never carry out any welding work on any
should be carried out in a well ventilated pressure tank or components under
room, away from heat, open flames, or pressure, or modify them in any way.
Safety precautions for work with
sparks. Appropriate prohibition signs (fire,
If work causing heat, flames, or sparks batteries
open flames, no smoking) must be put up. has to be carried out on a machine, the
surrounding components must be protected The fluid contained in batteries is diluted
Wear suitable eye protection when
with nonflammable material. sulfuric acid which can cause blindness if
inspecting the system. Make sure that the
brought into contact with the eyes, or
openings of spray containers, valves, Before dismantling or overhauling a serious burns if brought into contact with
pipes, or atomizers are never directed at
compressor, engine, or any other machine, the skin. For this reason it is essential to
yourself or at any other person during the
make sure that no movable part with a work with the greatest of care when
inspection.
weight of more than 15 kg can move or roll servicing batteries, e.g. when checking
The fuel used in these systems is highly away. battery charge, and to take all necessary
inflammable, toxic and poisonous. Avoid safety precautions.
Machines whose main movement is back
contact with eyes and skin, and never and forth must be moved at least once, Always wear long-sleeved overalls, acid-
inhale vapors. Should you accidentally
rotating machines several times, in order to resistant gloves and safety goggles.
swallow fuel, do not induce vomiting, but
This seek
website stores data such as make sure that there is no mechanical
medical attention. On charging a battery, an explosive gas
malfunction in the machine or in the driving
cookies to enable
Should essential
fuel come site with the
into contact part. mixture is formed in the cells, which can
functionality, escape through the vent holes in the
eyes, or inas well
case of as
eyemarketing,
irritation by vapors, Only experienced persons may be
personalization, sealing caps. If ventilation is poor, a highly
flush eyes with plenty of clean You
and analytics. water and charged with slinging loads and instructing explosive atmosphere can form around the
may seek
changemedical
yourattention.
settings at any time crane drivers. These instructors must battery, and can persist for several hours
or accept
Everythe
timedefault settings.
a message is displayed or remain within sight of the operator or be in after charging.
there is a suspicion that an internal part touch with him via walkie-talkie or similar
device. Thus:
of the machine has overheated, the
machine
Privacy Policy must be shut down. Never open * Never
Never smoke
smoke in the
the vicini
vicinity
ty of batte
batteries
ries
During assembly work above body
the inspection cover, however, before the that are being charged or have just been
height, use appropriate or otherwise safety-
machine has cooled down sufficiently to charged.
Marketing relevant climbing aids and working
rule out the possibility of the oil vapors platforms. Do not use machine parts as
igniting spontaneously when mixed with air. * Put up
up prohibit
prohibition
ion signs
signs for fire
fire,, open
open
Personalization climbing aids! Wear safety belts when flames and smoking in workshops where
carrying out maintenance work at greater batteries are charged.
Analytics
heights. * Never
Never interrup
interruptt a current-c
current-carr
arryin
yingg circuit
circuit
at battery terminals because of the
Save Accept All danger of spark formation.

14
 

3. Security Regulations

* Proceed
Proceed partic
particular
ularly
ly cautio
cautiousl
uslyy when * Warn
Warn outside
outsiders
rs not
not to come
come clos
closer
er or Noise
connecting or disconnecting touch the machine.
Sound-insulating equipment on the
reinforcement cables or quick-charge
* Make
Make sure
sure that
that the volt
voltage
age is swi
switch
tched
ed machine / installation must be in operative
cable clamps.
off. position during operation.
When starting up using jumper cables or
* Do not
not leave
leave the
the machine
machine unti
untill the line
line Wear the prescribed personal ear muffs.
auxiliary batteries, first connect the positive
which has been touched or damaged, Caution: this may impair communication
terminals and then the negative terminals.
has been switched off load! between persons. Warnings may not be
After starting the engine, first disconnect
the negative terminal (ground cable) and When working with high-voltage heard. Inform supervisor.
only then the positive terminal. Disconnect assemblies, ground the supply cable after The power of perception may become
the auxiliary battery after the starting voltage has been isolated, and short- adversely affected by the noise and by
procedure in order to avoid the risk of the circuit the components, e.g. capacitors, carrying ear protection.
pro tection. Warnings may,
release of gas (explosion hazard). with a ground rod! therefore, not be heard. Circumspect
behaviour by all concerned is necessary.
Noise, even when it is not very loud, can
Gas, dust, steam, smoke
3.7 Instruc
Instructions
tions concerni
concerning
ng make us nervous and irritated, and after a
particular hazards Only carry out welding, burning, and longer period of time our nervous system
grinding work on the machine / installation can suffer serious damage. For this reason
Electrical Energy when this has been explicitly permitted, as a separate machine room is preferable, in
there may be for example risk of fire and/or order to keep the noise from the machines
Only use original fuses with the specified explosion. out of the workshop.
amperage.
Prior to welding, burning and grinding Depending on the number of machines in
In case of faults in the electrical power remove any dirt and inflammable a machine room, the noise generated can
supply, shut down the machine / installation substances from the machine/system be very loud. Depending on the level of
immediately! and its environment and ensure proper sound pressure in places where people are

Work
may onlyonbe
electrical
carried systems or equipment
out by a trained ventilation (danger of explosion)! present, the following precautions must be
taken:
Only operate combustion engines in
electrician or by trained persons under the properly ventilated rooms. Ensure Below
Below 70 dB(A):
dB(A): No specia
speciall measure
measuress
leadership and supervision of a trained ventilation is adequate before starting up required.
electrician in accordance with the in closed rooms.
standards of electrical engineering. Above 70 dB(A):
dB(A): Persons permanen
permanently
tly
Follow the local regulations applicable at present in the room must
Machine and system parts where service, the respective site of installation. wear ear muffs.
maintenance, and repair work is being
carried out must be switched off load, if Below 85 dB(A):
dB(A): For occasi
occasional
onal visito
visitors
rs
required by regulations. First check the Hydraulic and pneumatic systems who are only in the
deenergized parts to make sure they are room briefly, no special
Work on hydraulic equipment may only protective measures are
off load, then connect to ground and short- be carried out by persons with special
circuit, and insulate neighbouring parts that required.
knowledge of and experience in hydraulics.
are under tension. Above 85 dB(A): Noisy room. There must
must
Check all lines, hoses, and bolted be a warning sign at
The electrical equipment of a machine /  connections regularly for leaks and visible
installation must be inspected / tested every entrance pointing
damage. Repair any damage immediately. out that persons entering
regularly. Faults, such as loose con- It is essential that damaged parts should be
nections or overheated cables, must be the room - even if only
corrected immediately. replaced!
and fires. Spurting fluid can lead to injuries briefly - must wear ear
muffs.
If work has to be carried out on live parts, Before beginning repair work, relieve the
then
This website call stores
in a second
dataperson
such asto operate the Above 95 dB(A): The warning
warning signs
signs at the
the
pressure in system sections to be opened entrances must be
emergency
cookies to enable stop switch orsite
essential master switch and in pressure lines (hydraulic and
with overvoltage release. Cordon off the supplemented by the
functionality, compressed-air lines) in accordance with
working as areawell
withas marketing, safety
a red-and-white the descriptions of the subassemblies.
recommendation that
personalization,
chain and a warning sign. You
and analytics. even occasional visitors
may change your settings at any time Hydraulic and compressed-air lines must wear ear muffs.
Only use insulated tools. must be routed and fitted in accordance
or accept the default settings. Above 105 dB(A):Special ear protectors
Keep an adequate distance between the with the regulations. Do not confuse the adapted to the volume
machine/unit and overhead power lines! connections! and spectral composition
When working near overhead power lines, The fittings, length, and quality of of the noise must be
Privacy Policy must not come near the power
equipment hoses must be in accordance with the available. A warning sign
lines! Danger! Find out about the safe requirements. to this effect must be put
Marketing
distance to be observed! up at every entrance.
After touching high-voltage lines:
Personalization Make sure that sound propagated
* Do not
not lea
leave
ve the
the mac
machin
hine.
e. through walls and frames does not cause
Analytics
* Mov
Movee the
the machi
machine
ne away
away fro
from
m the
the an excessive sound level in the
surroundings.
danger area.
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15
 

3. Security Regulations

Oils, Greases and Other Chemical

Substances
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).

Potentially-explosive
Potentially-explosive environments
The operation of the compressor in areas
where there is a risk of explosion is strictly
forbidden! (Exception: specially-made
compressors with the necessary technical
modifications for use in such areas)

Note 

CompAir accepts no responsibility for any 

damage or injury caused by noncomplian
noncompliance 
ce 
with these safety measures or 
noncompliance with normal care and 
caution during the handling, operation,
maintenance or repair of this compressor,
even if not expressly stated in this 
operating manual.

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cookies to enable essential site
functionality, as well as marketing,
personalization, and analytics. You
may change your settings at any time
or accept the default settings.

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16
 

3. Security Regulations

3.8 Symbols and definitions Caution: Caution: Vessel

Pres
Pressur
sure
e ve
vesse
ssell is pre
press
ssuri
urised
sed

Hoisting point

Emergency stop

Do not operate
with the hood
open

Do not step on
pressure-
conducting parts Check fi
filling Observe ththe
level operating
instructions
Do not remove Tie down point
the compressor
documentation

Do not inhale
compressed air

Bleed water from the pressure

Caution: Hot vessel after every 24 operating
surfaces hours or if the water ratio is too
high

Caution: Hot and

dangerous
exhaust fumes Caution: Do not move with the
transport safety locking
Caution: Under
pressure

Caution: Do not use ether spray

Only operate with
This website stores data such as
protective grating
cookies to enable essential site
functionality, as well as marketing,
personalization, and analytics. You
may change your settings at any time
or accept the default settings.
Caution: Remember the handbrake

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Personalization 100 98
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98381/5083 A93614780
Only start with the bleed cocks Sound level data
Save
closed Accept All Note tyre pressure

17
 

3. Security Regulations

Options

Condensation
drain from after-
cooler or from
after-cooler with
subsequent
filtering

Caution: Protect from wetness.

Do not direct a water jet at the
generator.

This website stores data such as

cookies to enable essential site
functionality, as well as marketing,
personalization, and analytics. You
may Danger
change of your settings
electric at any time
shock
or accept the default settings.

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18
 

4. Construction and functional description

Fig. 4 4.1 Construction For convenient assembly, all individual

parts of the cover are screwed together
1Instrum
Instrumen entt pan panelel
Compressor and engine with machine screws. For the prevention of
2Too
ooll oil
oiler
er
corrosion, the compressor body is fully
3Pres
Pressusure re tatank nk The DLT 0406 and DLT 0703 series is a galvanised, electrostatically powder coated
4Battery sound proofed mobile compressor system. and burnt at °C 220. The sound absorbing
5Oil fil
filter
ter (co
(compr mpressessor)
or) The core is a single-stage, oil-flooded mats are inserted and easy to be cleaned.
6Hood screw compressor. The CompAir screw
7Vehicle
Veh icle and chassi chassiss type
type identif
identification
ication profile represents the state-of-the-art. The Frame and chassis
number air is delivered pulsation-free. The complete compressor unit is
8 Chassis
The drive assembly is a medium-cooled mounted on an easy-to-transport single-
9 Oil cocooler
diesel engine, which drives the screw axle chassis. The chassis is equipped
10 Engine
11 DiDies
eselel eng
engin inee rotors of the compressor by a flexible with automatic overrun brakes and
coupling. parking brakes, as well as a jockey wheel
12 FuFuel
el liline
ne fifiltlter
er
adjustable in height.
This website stores ldata
13 Proport
Prop ortiona
ional contro
con troller
ller as
such
14 toFuenable
cookies el ta
tank essential site
15 Air fil
filter
ter (co
(compr mpressessor)
or) Shielding (Body)
functionality,
16 Suc asonwell
Suctition control
cont asler
rollemarketing,
r Airflow
personalization, and The shielding consists of a low box
17 MaMain
in batbatte
teryry analytics.
switc
swi tchh You
mounted on a base-frame. A cover,
cover, which Fresh air is sucked in through the
may change
18 Oil filyour
filter
ter (co settings
(compr mpress at any time
essor)
or) can be opened wide for servicing is fixed to admission opening at the back of the
19 Comp
Co mpre res
s sor
so
or accept the default settings. r the base-frame. The opening of the cover compressor. The air intake volume is
20 Taps is effectively supported by pneumatic air for the engine and for the compressor
springs. The hook inside is for hanging up too, as well as cooling air for the engine
a load suspension device. The machine and for the oil cooler of the compressor.
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rests on rubber elements to prevent
vibrations and noise.
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19
 

4. Construction and functional description

4.2 Functional description (see fig.5) pressure tank (17). When exceeding the
operating pressure the P-controller (23)
Oil circuit feeds the set cylinder of the controller with
air. Each change of the pressure at the
The oil required for sealing and cooling admission opening causes a proportional
the rotors as well as for lubricating the pressure raise at the exit. This control
roller bearings is injected into the pressure operates the control cylinders
compressor (10) from the pressure tank (11,4). Over the calibrated openings of the
(17), which is under system pressure. The
difference in pressure between the exhaust
gets airinto
partly nozzles (5,12) the control
the atmosphere and anyair
pressure tank and the oil injection position condensate will be let off. The throttle valve
is approx. 1 bar. The oil hereby passes the (11) closes (throttle-type governor) and the
oil cooler (16) and the oil filter (13). The engine speed will be lowered (speed
intake control valve (11) is fitted with a non- control). That way the air volume will be
return function, so that when the system is adjusted variable to the required air. If the
switched off, flooding of the air filter (9) is air output drops down to zero, the throttle
prevented. valve (11) is completely closed and the
engine runs under idle running speed. Over
the exhaust air nozzles (5,12) the sucked in
Air circuit air will be let off over a leakage cleft. When
The intake air flows through the air filter the pressure of the container drops down
(9) and the suction control valve (11) into the control pressure of the controller drops
the compressor (10). During compression, down too; the throttle valve opens and the
oil is injected in order to lubricate, cool and engine speed will increase.
seal the screw rotors. The compressed air- When turning off the engine the backlash
oil mixture flows into the pressure tank flap inside the controller will be closed
(17). Centrifugal preseparation of the oil is through the system pressure. The release
ensured through tangential entry into the valve (25), which closes parallel to the
tank. engine lifting magnet, looses power and
Any remaining oil is separated from the opens. The container pressure drops down
air in the fine separator (18). to zero.
The compressed air is fed via the Venturi
nozzle (20) / the pressure retention valve
(option) to the compressed air discharge
(21). The venturi nozzle (20) effectively
prevents the system pressure from falling
below the minimum operating pressure
required for the system to work properly.
A temperature monitoring device (14) as
well as an operational pressure manometer
(22) are integral parts of the air circuit.

Regulation

Note 

This Itwebsite storestodata

is not possible startsuch
up theascompressor 
if there is i
insufficient
nsufficient fuel
cookies to enable essential site is available.
functionality,
Starting asup:well as marketing,
The control function is
inactive at start
personalization, andup,analytics.
i.e. as the system
You rises,
may change your settings at anyidling
the engine speed is lowered to timeand
the suction throttle (11) closed. Once the
or accept
diesel the
enginedefault
(2) hassettings.
warmed up, the
throttle/speed control is activated pressing
the load button.
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ThePolicy
throttle/speed control enables the
volume of air tapped (10) to be adjusted
Marketing
infinitely between 0% and 100%.
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The control valve (11) is connected to the
engine speed control lever over a second
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cylinder.
set to full loadWhen starting,
and the thevalve
control engine
(11)isis
open. The compressor (10) starts to
Save and pressureAccept
produce builds upAll
inside the

20
 

4. Construction and functional description

4.3 System description 18. Fine separa

separator
tor 32. Filter combin
combination
ation
19. Safe
Safety
ty valve
valve 33. Heat exchan
exchanger
ger
1. Air filter
filter - diesel
diesel engine 20. Vent
Venturi
uri nozzle 34. Oil temperature
temperature controller
controller -
2. Die
Diesel
sel engine
engine 21. Air bleed component
component 2 x 3/4" (3 x 3/4")
3/4") heat exchanger
3. Oil cooler
cooler - diesel engine
engine 22. Pressur
Pressuree gauge Option
4. Engine actuatin
actuatingg cylinder
cylinder 23. Control
Controller
ler unit / proport
proportional
ional controller
controller 35. Extrac
Extraction
tion lever oil-free
oil-free compressed air
5, Nozzle - engine
engine servo cylinder
cylinder 24. Control
Controller
ler unit / load switching
switching valve 36. Backla
Backlash
sh valve
6. Engine temperature
temperature transmitte
transmitterr 25. Control
Controller
ler unit / relief
relief valve Option

7.
8. Engine
Fuel leveloil switch
level spressure
pressure
witch Option
26. Chal
Chalwyn
wyn valve
valve 37. Extrac
Extraction
Option tion lever
lever 1 1/2"
9. Air filter
filter - compressor
compressor Option 38. Backla
Backlash
sh valve
10. Com
Compres
pressor
sor 27. Compres
Compressor
sor oil temperature
temperature controller Option
11.. Suctio
11 Suctionn controller
controller Option oiler 39. Solenoid valve
valve - generator
generator option
12. Nozzle – suction
suction controller
controller 28. Oiler reserv
reservoir
oir Option clean air
13. Oil filter
filter – compressor
compressor oil 29. Oile
Oilerr valve
valve 40. Pressu
Pressurere control
control
14. Temperat
emperature ure switch Option heat exchanger/a
exchanger/after-cooler/
fter-cooler/ 41. Activ
Activated
ated carbon
carbon filter
15. Orific
Orifice,
e, evacuation
evacuation line subsequent filter 42. One-hand coupli
coupling
ng
16. Oil cooler
cooler – compressor
compressor oil 30. Co
Coole
olerr 43. Pressu
Pressurere gauge
17. Pres
Pressur
suree tank 31. Condens
Condensation
ation run-off
run-off 44. Fue
Fuell cooler
cooler

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Fig. 5 and analytics. You 135 101 74
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21
 

4. Construction and functional description

4.4 Wiring diagram F1 Fuse S1 Main switch

F2 Fuse S1.1
S1.1 Main
Ma in batt
batter
eryy swit
switch
ch
D1-D8 Semi-c
Semi-conducto
onductorr diode F3 Fuse (option) S2 Load button
D100 Ba
D1 Batt
tter
eryy char
chargege pil
pilot
ot lam
lampp S3 Oil pressure
D111 Fa
D1 Faul
ultt pi
pilo
lott la
lamp
mp G1 Generator S4 Engine temperature
D12 Opt
Option
ion lam
lampp "Pre
"Pre-h
-heat
eatin
ingg runni
running
ng"" G2 Battery S5 Comp
Co mpreressse
sedd air
air te
temp
mper
erat
atur
uree
D133 La
D1 Lamp
mp " WarWarnn run
run en
ende
ded"
d" S6 Fuel sh
shortage
D14 Option K1-K8
K1-K8 Sma
Smallll relay
relay 12 V
D15 Opt
Option
too ion lamp
la
high" mp "Eng
"Engin
inee temp
tempera
eratu ture
re M1 Starter X1
X 2 Plug
Pl
Geug
necraon
onne
tonec
r pclto
tor
ugr (pi
(pin/
n/so
sock
cket
et))
D16 Option
Opt ion la
lamp
mp "C"Com
ompre
press
ssed
ed ai
airr
temperature too high" P1 Hour
Hourss of op
oper
erat
atio
ionn co
coun
unte
terr Y1 Lifting ma
magnet - fuel
D17 Lampp "Fue
Lam "Fuell shor
shorta
tage
ge – swi
switc
tchh off"
off" Y2 Sole
So leno
noid
id val
alvve res
ressu
sure
re re
relilief
ef
R1.1
R1.1 Op
Optition
on hea
heatiting
ng flflan
ange
ge Y3 Sole
So leno
noid
id va
valv
lvee ge
gene
nera
rato
torr id
idliling
ng
automatic
Y5 Sole
So leno
noid
id va
valv
lvee loa
loadd swi
switc
tchh va
valvlvee

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Fig. 6 135 100 74
22
 

4. Construction and functional description

4.5 Terminal Diagram DIN ISO 1724

Terminal Diagram DIN ISO 1724

Connector Circuit connector

white blue (54 G) rear fog lamp

black brown (58 R) right taillamp

yellow green (R) right indicator lamp

red red (54) right stoplamp

left stoplamp
green yellow (L) left indicator lamp

brown black (58 L) left taillamp

blue white (31) ground

Fig. 7 105 580 74

The terminal diagram is designed for a voltage of 12 Volts!

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23
 

5. Transport and installation on site

5.1 Transport * The ligh

lightin
ting
g is fully
fully funct
function
ional.
al. The breakaway cable must be attached in
a way that ensures that even on extremely
Never exceed the maximum towing 
sharp bends there is no danger of
speed! Danger! Observe national 
activating the locking brake.
regulations! 
Please also observe the safety 
instructions in Chapter 3 on the subject 
of transporting.

Before transporting the compressor,

check to make sure that the drawgear of
the towing vehicle and the drawbar eye or
trailer hitch ball connection are aligned
exactly to each other.
When transporting the screw compressor
Fig. 8 with a vehicle, the following points must be
observed: Fig. 9
Danger 
* The shi
shield
eldings
ings are clo
closed
sed..
Make sure to check the torque after 
* The bloc
blocks
ks are
are firmly
firmly hook
hooked
ed in place
place..
50 kilometers following wheel mounting 
and at regular intervals. * The suppo
support(
rt(s)
s) is(ar
is(are)
e) retrac
retracted
ted and
and 5.3 Loading/Relocation
locked in position (jockey wheel).
Tighten wheel nuts or screws evenly in 
a diagonal sequence to the specified  * Drawba
Drawbarr is conne
connecte
ctedd to the
the towing
towing
torque using a torque wrench. vehicle.
* The draw
drawbar
bar is
is adjust
adjusted
ed to the
the height
height of
of
Replacing the trailer coupling ring the towing vehicle (option).
The coupling arrangements which can be * The conta
contact-
ct-brea
breakin
kingg cable is conn
connect
ected
ed
used: to the towing vehicle. Safety chains are
attached on towing vehicle.
* Tr
Trail
ailer
er coup
couplin
lingg ring
ring RD 40
* The ele
electr
ctrica
icall cable
cable (op
(optio
tion)
n) is
* Co
Coup
upliling
ng 50 di
dia.
a. connected to the vehicle and to the
* Coup
Coupling
ling ring 2" dia.
dia. (only
(only for UK)
UK) screw compressor . Fig. 10
* Coupling
Coupling ring 68 x 25
25 dia.
dia. (only
(only for
for * Check the lights
lights (tail lights, brake lights
lights,,
indicator lights, and rear fog lamp) Danger 
France)
(option).
A different coupling unit in the form of a Only use hoisting gear (e.g. crane) with 
complete kit may be ordered, if necessary. * Check
Check to make
make sure
sure that
that the
the wheel
wheelss are appropriate lifting capacity for the loads 
Replacing the trailer coupling ring is properly tightened, the tyres are in a occurring! 
permitted only if proper fitting is carried out roadworthy condition and the tyre
Only use the correct suspension gear! 
by an inspectorate for the sector covered pressure is correct (danger of
by the Regulations Authorizing the Use of accidents). Keep clear of the swiveling range of the 
Vehicles for Road Traffic (e.G. the TÜV - hoisting gear! 
When parking the compressor, use the
Technical
Motor Inspectorate,
Vehicle MonitoringDEKRA - German
Association, etc.). support or the
compressor in jockey wheelposition.
a horizontal to secureApply
the Keep clear of suspended loads! 
The inspection station provides a fitting All loose parts that could fall down 
the parking brake. Use chocks to ensure
This certificate
website stores data
to be kept such
with as
the vehicle that the machine does not roll away. during hoisting must first be removed 
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documents. or secured; pivoting parts, like doors,
Attention towbars, etc. must be secured in such 
functionality, as well as marketing,
Danger  a way that they cannot move.
personalization, and analytics. You
Always keep a safe distance from the Never leave the load suspended on the 
may The
change
screw your settings at
compressor any
may onlytime
be 
edges of foundation ditches and
transported on public roads if  hoisting gear. Acceleration or braking 
or accept the default settings. embankments!! Do not travel across
embankments of the means of transport must remain 
* The mach
machine
ine grou
group
p (engin
(engine)
e) is not 
not  slopes transversely. within the approved limits.
running,
Please also observe the safety 
Privacy Policy
* The pressur
pressure
e tank
tank is
is not und
under 
er  instructions in Chapter 3 on the subject 
pressure, 5.2 Link up breakaway cable of loading.
Marketing
* The shield
shielding
ings
s are
are close
closed,
d,
If the towing connection becomes Attention
Personalization
* The blocks
blocks are
are firml
firmly
y hooke
hooked
d in  uncoupled, the trailer is braked by the
place, breakaway cable. Put the breakaway cable Do not attempt to use a crane hook or
Analytics
* Hoiste
Hoisted
d and secu
secured
red tail
tail whee
wheel,
l, in the eye
towing provided
collar or wind
and hitch it up ittoaround the
the cable similar load suspension
on the lifting devices
device to avoid direct
damages
* The tyres
tyres and bra
brakes
kes are  with the snaplink. to the lifting device!
Save
operationally safeAccept All
and roadworthy
roadworthy,
,

24
 

5. Transport and installation on site

Use proper hoisting gears only such as 5.4 Installation on site The compressor must be set up in as
hoisting straps in compliance with DIN horizontal a position as possible. Maximum
standard 61360 with proper lifting ca- permissible inclination during operation:
pacity for connecting the load
* In dire
directi
ction
on ofof pull:
pull: 15 degre
degrees es
suspension device (e.g. crane) and the
A A A * Bac
Backw
kwarards
ds:: 15 de
degre
grees
es
lifting device.
* To the righ
rightt and to
to the left
left:: 15 degree
degreess
Only deploy load bearing equipment
which corresponds to the safety B B B
instructions for lifting gear.
Use a transport harness compliant
with local regulations for transporting A = B = 1,5 m
by helicopter. The eyes provided may
not be used for this purpose (max.
acceleration if the eyes are used = 2 x g) Fig. 11
Never lift up or lash down the unit using Danger 
the shieldings!
The air intake must be positioned in 
Never relocate the machine if external
such a way that loose personal clothing 
lines or hoses are connected to the
cannot be drawn in. Fig. 12
discharge valves,
valves, in order to
t o avoid
damage to the valves and/or collecting Make sure that the pressure pipe from  Attention
pipe and hoses. the compressor to the aftercooler or the 
air system can expand as a result of  Greater inclinations endanger the
When loading, the following points must be
heat, and that it does not come into  operating reliability of the screw
observed:
contact with inflammable materials. compressor.
* Secure
Secure the
the load
load suspe
suspensi
nsion
on devic
devicee or
the hoisting gear in the lifting device of The
a wayairthat
intake is to be designed
no dangerous in such 
admixtures  When
not settingorupwith
horizontal, the aunit on ground
variable anglethat
(seeis
the screw compressor.
(inflammable solvent vapors etc., operating instructions) please consult
* When
When hoistin
hoistingg the compre
compressossorr, set up but also other dangerous or toxic  CompAir.
the hoisting gear in such a way that the substances) can be taken in. This also 
compressor, which must be set up applies to flying sparks. Set up the machine in such a way that
horizontally, is lifted vertically. no inlets, outlets or gates are blocked,
Pipes and other parts with a surface  even when the doors are open. Before
* Only reloc
relocate
ate the
the compres
compressor
sor by itse
itself.
lf. temperature of more than 80 ° C must be  disconnecting the machine from the towing
* Raise
Raise and
and lower
lower the com
compres
pressor
sor
suitably secured against contact and  vehicle, apply the handbrake. Disconnect
carefully.
suitably marked. contact-breaking cable and lighting cable,
The operation of the compressor in  uncouple air brake lines.
* After
After reloc
relocati
ating,
ng, remo
remove
ve the
the load
load
suspension device or the hoisting gear
areas where there is a risk of explosion  Secure wheels with chocks.
is strictly forbidden! (Exception: 
from the lifting device.
specially-made
specially-m ade compressors with the  Note 
* Tie
Tie down the
the compre
compresso
ssorr on the
the cargo
cargo necessary technical modifications for 
area of the means of transport. use in such areas)  In dusty environments, set up the machine 
in such a way that the wind does not blow 
* Only tie itit down
down at towba
towbarr and whee
wheell Please also note the safety instructions  the dust in the direction of the machine.
axles. in Chapter 3on
installation onsite.
the subject of  During operation in clean environments,
* Whe
Whenn the chas
chassis
sis is
is being
being disman
dismantle
tled,
d, the intervals for cleaning the air intake filter 
the shieldings
This website with machine
stores data such as group may and the cooler elements are much longer.
only be supported under
cookies to enable essential site the base frame.
Location Attention
functionality, as well as marketing, The complete system is to be set up in
personalization, and analytics. You such a way that it is easily accessible and No force may be exerted on the dis-
may change your settings at any time charge valves, for example by pulling
that the required cooling is guaranteed.
the hoses or fitting additional
or accept the default settings. Never block the air intake. Ensure that the
equipment (e.g. a water separator,
entering of moisture and dirt together with
compressed air oiler, etc.) directly at the
the intake air is kept to a minimum.
discharge valve.
Privacy Policy The compressor is to be set up away
from walls.
Marketing
Attention
Personalization
The screw compressor is to be set up in
Analytics such a way that no air reflection can
take place, i.e. neither waste air nor
exhaust emissions may be drawn in; the
Save Accept All same applies to dangerous admixtures
to the air. Drawing
Drawing this waste air in could
lead to overheating and a loss of power.
25
 

5. Transport and installation on site

Temperatures/air humidity
Install the compressor in a location with
maximum possible frost protection. The
suction air temperature must be within the
range specified on the data sheet.
Attention

An oil-temperature regulator (option) is

necessary for operation of the system at
(+40° C and above)
high temperatures (+40°
and/or high rel. air humidity (greater
than 90 %) or at temperatures below
0°C. For operation involving long
periods of idling and/or low partial loads
an oil temperature regulator is also
required.

Altitude
For operation at an altitude above
1,0000 m, the compr
1,00 compress
essor
or and engine
engine must
must
be adapted (modified design).
Note 

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

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26
 

6. Preparing the compressor for operation

6.1 Checking oil levels 6.1.2 Checking the oil level in the engine 6.2 Battery

6.1.1 Checking the oil level in the

pressure tank

Fig. 14
Fig. 15
Danger 
Only check the oil level when the  Danger 
Fig. 13
compressor engine is at a standstill. When working with battery acid (electro- 
Danger  Spill no oil! The oil may be hot. Risk  lyte), wear acid-resistant goggles,
of scalding!  gloves and apron.
Only check the oil level when the engine 
Check for leaks.
is at a standstill and the compressor is  The gases released by the battery are 
not under pressure. Proceed as follows: explosive. Avoid sparks and open fires 
* Ens
Ensure
ure that
that the
the screw
screw comp
compres
ressor
sor is
is in the vicinity of the battery.
The pressure tank may be under 
pressure and the oil may be hot. standing horizontally. Do not allow acids to come into contact 
* Ensure
Ensure that
that the
the screw
screw comp
compres
ressor
sor has
has with skin or clothing. Wear safety 
Risk of scalding! Spill no oil!  been out of operation for some time. goggles.
Check for leaks.
 * Uns
Unscrew
crew dips
dipstic
tick.
k. Place no tools on the battery.
Proceed as follows: The battery is filled and charged in
* The oil lev
level
el shoul
shouldd be as near
near as
as
* Before
Before chec
checking
king the oil
oil level
level in the
the possible to the upper dipstick mark. accordance with DIN 43539. The battery is
engine and in the compressor ensure fastened with clamping strips.
that the vehicle is standing horizontally. * Co
Corr
rrec
ectt as
as requ
requir
ired.
ed.
The batteries used are ready to be
* Ens
Ensure
ure that
that the
the screw
screw comp
compres
ressor
sor has
has * Sc
Scre
rew
w in dip
dipst
stic
ick.
k. installed and ready for service.
been out of operation for some time. Replacement batteries should be of the
* Cl
Clos
osee oil
oil fill
filler
er..
* Un
Unsc
screw
rew dip
dipst
stic
ick.
k. same type as the batteries installed
* For oil
oil speci
specific
ficati
ations
ons,, see “Eng
“Engine
ine (low gassing). The replacement battery
* The oil
oil level
level shoul
shouldd be withi
withinn the mark
markss Operating Manual”. should be unfilled and only be preloaded
on the dipstick. so that it has to be filled with battery
Attention acid. The battery and the acid should
* Co
Corr
rrec
ectt as
as requ
requir
ired.
ed.
have a temperature of at least +10 °C.
* Check
Check the
the seal
seal on the dipst
dipstick
ick and After a short test run, the oil level must
replace if required. not be above or below the upper or Proceed as follows:
lower dipstick marks. For oil specifi- * Fill
Fill up with
with batte
battery
ry acid
acid as far
far as the
the
* Scr
Screw
ew in dipst
dipstick
ick and
and tighten
tighten firm
firmly
ly..
cations, see engine instruction manual. base of the control insert
Attention * Leav
Leavee the batt
battery
ery to
to stand
stand for
for some
some time
time
This website stores data such as
After
cookies a short test
to enable run, the
essential oil level
site * Th
Then
en sh
shak
akee itit gen
gentltlyy
should be between the markings on the
functionality, as well as marketing, * If req
require
uired,
d, top
top up
up with
with aci
acidd
dip stick. For oil specifications, see
personalization,
recommended andlubricants,
analytics. Chapter
You 8.1. * Tigh
ighte
tenn seal
sealin
ingg caps
caps
may change your settings at any time
* The bat
batter
teryy is
is ready
ready for use
or accept the default settings.
* Le
Leav
avee for
for 1 hou
hourr

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27
 

6. Preparing the compressor for operation

6.3 Filling up the fuel tank 6.4 Checki

Checking
ng the air
air filter
filter
maintenance display

Fig. 16
Danger  Fig. 17
Only fill up with fuel when the screw  When the red service sector in the
compressor is at a standstill. transparent part is fully visible, the air filter
Cleanliness is essential! Spill no fuel!  is due for maintenance. (See Chapter
Maintenance, air filter replacement.)
Filling up at a pump can cause static 
electricity and possibly sparks. Empty the dust emission valve by
pressing together the emission slot in the
Proceed as follows: direction of the arrow.
* Op
Open
en ta
tank
nk lilidd
Note 
* Fill
Fill up tank
branded tandiesel
k with
withfuel,
comm
commercerciall
usingially
y availab
available
a sieve le
(use Clean the emission slot from time to time.
summer or winter diesel fuel depending
on outside temperatures)
* Clos
Closee tank
tank tight
tight wit
withh tank
tank lid
lid
* With
With the Deut
Deutzz engines
engines M201
M2011,1, the
the
injection pump is self-ventilating. When
the tank is empty, immediately fill in fuel
to ensure that the fuel pump is always
filled with fuel. This condition may result
in starting problems.
 * Cl
Clos
osee hoo
hood.
d.
Note 

It is not possible to start up the compressor 

if there is insufficient
i nsufficient fuel is available.

The fuel tank should always be filled up in 

good time. For outside temperatures below 
0 ° C,
C, use only winter diesel fuel.
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enable essential site see 
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engine operating manual.
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For outside temperatures belowYou0 ° C,
C,
may observe
changethe your settings
operating at any
manual of time
the engine 
manufacturer
manufacture
or accept r for winter
the default operation.
settings.
You can reduce the occurrence of  
condensation in the fuel tank considerably 
by filling
Privacy Policyit up in good time. This also 
 prevents downtimes
downtimes and starting problems 
problems 
that can occur when the fuel tank is run 
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28
 28

7. Putting the compressor into operation

7.1 Initial operation 7.2 Operating elements room, the exhaust gases must therefore 
be conducted out of doors by means of 
Transport
Transport inspection Operating panel: a pipe or hose with an internal diameter 
of at least 100 mm. The use of extraction 
Every CompAir screw compressor 1 2 3 4 5 systems is highly recommended in test 
has alre
already
ady run
run in the fact
factory
ory and
and has rooms for mobile machines.
already undergone a thorough test before
shipment. This test ensures that the Only operate the compressor with the 
compressor complies with the given data hood closed. The hood may only be 
and works perfectly. Independent of opened briefly for minor adjustments 
the car
caree taken
taken in the fact
factory
ory, it is still while the compressor is running.
possible for the compressor to be damaged Skilled personnel only are authorized to 
during transport. For this reason it is work with the hood open.
recommended that the unit should be
examined for possible damage during When working with the screw 
6 7
transport. compressor in operation and with the 
Fig. 19 shielding/hood open, wear ear 
Remove any transport seals (dummy protection.
flange, plugs, etc.) and dehydrating agents 1 Ignitition
Igni on sw
swititch
ch
before start-up. Distribution tubes and 2 Star
Startt / Ru
Runn valv
valvee Caution: this may impair 
connection lines must have the specified 3 "Batte
"Ba tteryry charg
charge"e" pilot
pilot lamp
lamp communication between persons.
dimensions and must be suitable for use 4 "Fau
"Faultlt"" pilo
pilott lamp
lamp Warnings may not be heard. Inform 
with the max. operating pressure and the 5 "Fuel
"Fuel short
shortage"
age" war
warning
ning lamp
lamp supervisor.
media to be taken up. 6 Operati
Oper ating
ng pres
pressur
suree gauge
gauge
7 Hours
Hou rs of
of opera
operatiotionn count
counter
er Attention
During the first hours of operation, the
compressor should be observed in order Opening the covering interferes with the
to be able to ascertain any possible flow of cool air in the compressor
malfunctions. section.
Full sound-insulating is only achieved
Transport safety locking of the towing
Transport when the covering is closed.
arrangement
Check the oil levels in the pressure tank
and in the engine of the compressor
each time before start-up.
Do not start the compressor unless the
air tapping cocks are closed.

Note 
Transport safety locking Fig. 20 Main battery switch
It is not possible to start up the compressor 
if there is insufficient fuel is available.

7.3 Start-up
Starting up the compressor:
Fig. 18 Danger 
* Cl
Clos
osee air
air tapp
tapping
ing coc
cocks
ks..
The towing
vertically arrangement
in accordance withis Figure
positioned
18. Before starting up, make sure that no  * Swi
Switch
tch on main
main batt
battery
ery swi
switch
tch..
The clamp must data
be released and the one is in the danger area of the engine / 
This website stores such as screw compressor. * Turn
Turn ingnit
ingnition
ion switc
switchh to positio
positionn "On" I;
spacer removed on initial use. The towing
cookies to enablecan
arrangement essential
then besite
adjusted the indicator lamps “Battery charge” and
Compressors may not be operated in  “Fault” come on.
functionality,
according astowell as marketing,
the required trailer height and hazardous environments unless they 
personalization, andclamp/ratchet
locked with the analytics. You(see here have been specially designed for this  * Turn
Turn the
the igniti
ignition
on switc
switchh furthe
furtherr to
Undercarriage Operating Instructions).
may change your settings at any time purpose (e.g. exhaust protected against  position .
or accept the default settings. emission of flying sparks etc.). * Hold
Hold the ignit
ignition
ion swit
switch
ch in posi
positio
tionn
Never, under any circumstances, use  until the engine starts running and the
"Startpilot" (Spray-can starting aid), “Battery charge” and “Fault” indicator
Privacy Policy ether or other starting aids - Danger of  lamps go off.
explosion!  * Rel
Releas
easee the
the ignit
ignition
ion swi
switch
tch..
Marketing After service work has been completed: 
* If the
the engine
engine has not
not star
started
ted afte
afterr
Make sure that all protective devices 
Personalization 15 seconds at the latest
latest,, turn the ignition
ignition
have been refitted and that all tools 
key back to position (Off-Aus). As
have been removed.
Analytics soon as the starter has reached a
The exhaust emissions of combustion  standstill and the pressure tank is no
engines contain carbon monoxide - a  longer under pressure, the engine can
Save Accept All lethal gas. If a machine with such an  be started again.
engine has to work in an enclosed 
 29

7. Putting the compressor into operation

* After
After the
the start,
start, the
the engine
engine runs
runs at the
the 7.4 Setting the
the operating
operating pressure 7.5 Monitoring / fault
idling speed and the compressor at
reduced pressure.
Danger 
* If the
the engine
engine was
was starte
startedd cold,
cold, let
let it
warm up for approximately 2 minutes Bridging the safety switch in the 
and then press the START/RUN valve automatic monitoring system is not 
permitted! 
(2). If the engine is warm, the START/ 
START/ 
RUN valve can be pressed immediately. When the “Fault” indicator lamp lights up,
* The insta
installat
llation
ion is now
now ready
ready to opera
operate.
te. the screw compressor is automatically shut
Check that all the hoses and tools have down when the following faults occur:
been connected correctly and open the * Fuel shortage
desired air outlet valves. * Compressor
Compres sor tem
tempera
peratur
turee too
too high
high
* Engine
Engine oil pre
press
ssur
uree too
too low
low
* Engine
Engine oil
oil tempe
temperat
rature
ure too high
Start-up using jumper cables / auxiliary Fig. 22
batteries
After one of these faults, it is only
Danger  possible to restart the machine after the
fault that caused the machine to be shut
The setting of the operating pressure  down has been corrected.
may only be carried out by a specialist.
The operating overpressure of the screw Attention
compressor is set by the manufacturer
Disconnect the battery or generator only
(seee the ident
(se identifi
ificat
cation
ion plate
plate on each
each
when the engine is not running.
compressor).
* Switch
Switch off
off the mac
machine
hine if the
the
Pressure values can be set between
compressed air transports oil spray or if
5 bar and
stated operating
on the rating overpressure
plate. Pressure values excessive
excess ive oil
oil is consumed
consumed.. (Refer
(Refer to the
the
trouble-shooting section)
higher than this are not permitted.
* Check
Check that
that the "bat
"batter
teryy charge"
charge" pilo
pilott
Fig. 21 Operating pressure is set by a specialist
lamp is not illuminated. If it glows, even
at the controller.
weakly, refer to the trouble-shooting
Danger  section.
* Remove
Remove count
countern
ernut
ut below
below the
the contr
control
ol
Longer operation with an auxiliary  knob of the regulator.
* Check
Check that
that the air
air pressu
pressure
re (7)
(7) assume
assumess
battery or jumper cables connected can  * Raise
Raise pressu
pressure re by turnin
turningg the adjust
adjusting
ing a value within the permissible pressure
lead to sudden emissions of gas. An  knob of the regulator clockwise range.
inflammable air / gas mixture is formed. (tow
(towar
ards
ds +)
+)..
Explosion hazard!  If the machine cuts out, before switching
* Lower
Lower the
the pres
pressure
sure by turni
turning
ng the
the off at the
the ignition
ignition switch
switch (1)
(1) carry
carry out the
Attention adjusting knob of the regulator following checks:
anticlockwise (towards -).
* Interr
Interrupt
upt the
the electri
electricc connect
connection
ion to the
the
Serious damage can be caused to the
* In order
order to
to lower
lower the
the pressu
pressure,
re, open
open an engine oil pressure switch immediately
electrical system if wrongly connected.
air discharge valve. after the engine has cut out and leave it
* Igni
Ignitio
tionn swi
switch
tch in pos
positi
ition
on (Off-A
(Off-Aus)
us) in the interrupted state.
 * After alterin
alteringg the pressure,
pressure, lock the
the
* First
First connec
connectt positiv
positivee termina
terminall then adjusting knob using the knurled nut. If the "fault" pilot lamp goes out
negative terminal (ground). immediately this indicates that either a
This readjusted operating pressure is to too low engine oil pressure or a lack of
This website stores data such as be checked using the pressure gauge on
* Star
Startt as descri
described
bed in sect
section
ion “Star
“Startin
tingg up fuel or a defective engine has led to the
cookiesthe
tocompressor.”
enable essential site the instrument panel at 100% air discharge cut-out.
functionality, as well as marketing, and maximum engine speed.
Note 
personalization, and analytics. You * If the
the light
light cont
continue
inuess glowin
glowingg this
this
may change your settings at any time indicates that an excessive engine
After the engine has started, first  temperature or compressor temperature
or accept the default
disconnect settings.
the negative cable (ground)  led to the cut-out.
and then the positive cable.
In order to trace the origin of the fault,
interrupt the engine oil temperature
Privacy Policy switch (with the engine oil pressure
switch still switched off).
off). If the lamp now
Marketing goes dark this indicates that the problem
is related to the oil temperature.
Personalization

Analytics

Save Accept All

 30

7. Putting the compressor into operation

* If the
the lamp
lamp contin
continues
ues glow
glowing
ing the
the fault
fault 7.6 Operation Danger 
is locate
locatedd somewhere
somewhere else. In this
this case
case
reconnect the engine oil temperature It is important that you ensure that the 
switch and interrupt the connection to Danger  pressure is completely blown off via the 
the compressor temperature switch. If Only operate the compressor at the  blow-off valve.
the lamp goes dark the compressor permissible operating pressure and at  Should this not be the case, open the air 
temperature has led to the cut-out. the permissible temperature. outlet valves, identify the fault and 
* Reconne
Reconnect ct all elect
electric
rical
al connect
connections
ions correct it.
once the fault has been identified in Only use purpose
intended the compressor for its 1.2 of 
(see Chapter
order to re-establish the function of the this operating manual) in order to avoid 
protective elements. Also reconnect residual risk for persons and assets. 7.8 Decommissioning
the engi
engine
ne oil
oil pressure
pressure swi
switch
tch..
Only operate the compressor in a safe,
* Switch
Switch the
the ignition
ignition switc
switchh to its positi
position
on functioning condition.
 (Off-Aus).
All components, hoses etc. fitted must 
Note  be of the correct size and designed for 
the specified operating pressure and 
These checks must be carried out  temperature.
immediately after the installation has 
cut out as the protective
protective circuits reset  When working with compressed air,
themselves after cooling down. wear suitable protective clothing (e.g.
protective suit, safety goggles, etc.).
If the ignition switch is pushed to the very
left while the machine is running it will be Wearing ear muffs may impair 
switched off. communication between persons.
Warnings may not be heard. Inform  Fig. 24
supervisor. If the system is to be closed down for a
Pressure gauge for display: “Operating Check the compressor regularly. longer period of time (approx. 3 months
pressure” or longer) the following preservation
Leaking condensation contains a  measures must be taken:
proportion of oil and must be collected 
and disposed of under safe conditions. * Engine
Engine prese
preserva
rvatio
tionn (see
(see separat
separatee
Condensation must not enter the  engine operating manual).
soil or the rivers. Major quantities of  * Dis
Discon
connec
nectt batt
battery
ery cab
cables
les..
condensation accumulate particularly 
in versions with aftercoolers for  * No speci
special
al measu
measures
res are
are requir
required
ed at the
the
processing compressed air. Provide a  compressor.
collecting basin.
* Reliev
Relievee the stra
strain
in on tyres
tyres by jacki
jacking
ng up
the vehicle.
* Che
Check
ck tyre
tyre press
pressure
ure every
every 2 months
months..
7.7 Shutdown
* Re
Rele
leas
asee the
the hand
handbr
brak
ake.
e.
Fig. 23 In order to shut down the compressor:
Attention
Danger  * Clo
Close
se air disc
discharg
hargee valves.
valves. The
The screw
screw

Do not operate the compressor at  compressor

engine back reduces
to idling the speed
speed afterofthe
the When putting back into operation,
carry out the maintenance work
pressures above the permissible  preset final pressure has been reached. in accordance with Chapter
Chapter 9
This website stores data such as
operating pressure.
* Allow
Allow the
the screw
screw compr
compress
essor
or to idle
idle for
for a “Maintenance.”
cookies to enable essential site
The pressure
functionality, as wellgauge shows the operating
as marketing, few minutes.
pressure of the compressor.
personalization, and analytics. You * Return
Return the
the igniti
ignition
on switc
switchh (1) to
to the
The permissible
may change operating
your settings pressure
at any time is position (Off-Aus).
indicated on the nameplate!
or accept the default settings.
Note 

This switch can also be used as an 

Privacy Policy emergency stop switch. No other 
switching off method is provided.
Marketing * Turn
Turn off
off power
power to the
the syste
system
m using
using the
the
main battery switch.
Personalization
After the installation has come to a
Analytics standstill all the air is automatically blown
out of the pressure tank via the blow-off
valve.
Save Accept All
 31

8. Fuels

8.1 Recomm
Recommended
ended lubrican
lubricantt for If other lubricants are to be used, please * Nato
Nato Cod
Codes
es F 54, F 75,
75, and
and F 76
contact: * BS 28
2869:
69: A1 and
and A2
A2 (obser
(observe
ve sulf
sulfur
ur
compressor
content with A2)
CompAir Drucklufttechnik GmbH
* AST
ASTMM D 975-
975-81
81 : 1-D and 2-D
Note  Argenthaler Straße 11 * VV
VV-F-
-F-800a
800a : DF-A,
DF-A, DF-1,
DF-1, and DF-2
DF-2..
D-55469 Simmern/Hunsrück
In these screw compressors, circulating oil  Telephone 06761 / 832-339 Note 
has not only a lubricating function, but in  Telefax 06761 / 832-421
 particular it also has cooling and
and sealing  See engine instruction manual.
functions. It is therefore exposed to more  or your authorized dealer or your local
branch.
difficult conditions. In particular the  At low temperatures,paraffin precipitation
temperature
temperatu re conditions at the installation  can cause blocks in the fuel system and
site and the consistency of the air (dust, disruptions in operation. Below outside
dirt, and humidity content, as well as  8.2 Recommended engine oil temperatures of 0 °C use winter diesel fuel
chemical influences) must be taken into  (to -15 °C). (This is usually available at gas
account when selecting a suitable lubricant. Lubricant specifications for the driving stations in good time before the winter
engine can be found in the enclosed season begins.) Diesel fuel with additives is
Attention engine operating manual. frequently offered for use at temperatures
as low as -20 °C („Superdiesel“).
Do not mix oils of different
specifications. Note 
8.3 Tool lubricants
The maintenance intervals and the Only mix in the tank. First put in the 
maximum and minimum operating required quantity of petroleum, then fill up.
Attention
temperatures given in this operating
manual only apply when high-quality See engine instruction manual.
Do not run the machine with an empty
multi-grade oils are used. oiler tank! The tank must
must always Below -15 °C or -20 °C, petroleum must
Use of the wrong oil leads to impairment contain a minimum of 0.2 l of tool oil. be added.
of function. The wrong tool lubricants lead to If it is necessary to use summer diesel
Change the compressor oil more deposits that cause malfunctions in the fuel below 0 °C, petroleum can also be
frequently than specified if the appliances connected! added up to 60 %.
equipment is operated under abnormal For the perfect lubrication of concrete In most cases, adequate resistance to
conditions, i.e. at a high ambient breakers and pneumatic spades, we low temperatures can be achieved by
temperature, high air humidity or in a recommend the use of CompAir oilers or adding a product to improve flow properties
dusty environment. If necessary, automatic pipe oilers, using the special (fuel additive). Consult your engine service
analyse the oil. synthet
synthetic
ic CompA
CompAirir oil
oil AES
AES 82. station.
Out of consideration for the high loads The special advantages of CompAir oil are Attention
imposed on the lubricant in screw as follows:
compressors with oil injection cooling, we The compressor must not be fuelled
recommend the use of suitable, non * Bi
Biod
odeg
egra
rada
dabl
ble,
e, with bio-diesel (DIN 51606) or vegetable
ageing, non foaming, corrosion-protective * Ice
Ice guar
guardd dow
downn to
to -50
-50 °C, for use with oil.
oils. They must meet the following sound absorbers,
requirements for hydraulic fluids:
H-LP 32 and H-LP 46 in accordance with * Ver
Veryy good
good lubricit
lubricityy, thus
thus wear-re
wear-reducing,
ducing,
DIN 5152
51524,
4, Part
Part 2, June
June 1985
1985.. * No irrit
irritati
ating
ng exhaus
exhaustt gases,
gases, work
work in
in
8.5 Recomm
Recommended
ended lubricants
lubricants for
for the
The viscosity of the lubricants should enclosed rooms possible, bogies
comply with viscosity class ISO VG 32 DIN * Good cle
cleani
aning
ng effec
effect,
t, no
no residue
residue For relubrication use only lithium saponified
This 51519,
websiteJulystores
1976,data such
with 28 - 35as
mm2 /s(cSt) / 
cookies to or
enable essential site formation grease which fulfils the following
40 °C, if the ambient temperature is specifications:
functionality,
constantlyas well25
above as°C,
marketing,
with viscosity class * Excelle
Excellent
nt preser
preservat
vation
ion propert
properties
ies,,
ISO VG 46 DIN
personalization, 51519,
and July 1976,
analytics. Youwith protects from corrosion. * consist
consistenc
encyy grou
groups
ps (NL
(NLGI)
GI) 2
41 - 50 mm 2 /s(cSt)/40 °C. DIN 51818
may change your settings at any time When using compressed air consumers
or accept the default settings.
Attention made by other manufacturers, then their * worked
worked pen
penetr
etrati
ation
on 265-
265-295
295
regulations must be observed. DIN ISO 2137
Conventional engine oils marked HD * dripp
dripping
ing po
point
int > 180
180 °C
must
Privacy not be used.
Policy DIN ISO 2176
When using oils with the “Brief De- 8.4 Diesel fuel * operat
operation
ional
al tempe
tempera
ratu
ture
re
Marketing
scription HYD 10/HYD 20" in accordance  – 40 °C … +140 °C
with the ‘Standard Lubricants for Building Use common diesel fuel with a sulfur
Personalization
Machinery and Vehicles’ published by the content of less than 0.5 %. If the sulfur This corresponds to a DIN 51502
‘Hauptverband der Deutschen Bauindustrie content is higher, oil has to be changed at lubrication grease, designation KP2N-4U.
Analytics
e.V.’ (Principal Association of the German
Germa n shorter intervals. Greases with different thickeners
Building Industry), only the given hydraulic The following fuel specifications are (soap
(soap bas
base)
e) must
must not
not be mix
mixed.
ed.
fluids
Savemay be used inAccept
accordanceAll with applicable:
ISO VG 32 and ISO VG 46. Recommended grease: Fuchs Renolit
* DIN 51 601 LZR 2.
 32

9. Maintenance

9.1 General maintenance Advance fuel filter

Clean the screw compressor at regular, not

too long intervals:
* Blow-cl
Blow-clean
ean all
all valves,
valves, cont
control
rollers
lers,,
fittings, pressure tank, oil cooler,
radiator, screw compressor, and engine
with compressed air or a steam jet
appliance.
* Inspec
Inspectt the cooli
cooling
ng ribs
ribs of the radia
radiator
tor to
to
make sure that air can pass through.
* Clean
Clean the
the body at regula
regularr interv
intervals
als..
Then grease or oil the hinges of the Fig. 25
body hood with multi-purpose grease.
Danger 
If sound-absorbing matting has to be
replaced, remove the retaining brackets, Only change filters when the engine is 
replace the old sound-absorbing matting at a standstill.
with new matting, replace the retaining Do not spill fuel.
brackets.
Attention

9.2 Engine maintenance The filter changing intervals are

specified in the engine manual.
The maintenance of the engine is to be
carried out in accordance with the engine Change the advance filter more often
operating manual. if there is considerable dirt.

Danger  Note 

During inspection, adjustment, or  Ensure the system is free from leakage.
maintenance work, remember that the  Check the hoses for cracks and replace 
surfaces of machine parts can be hot, if necessary.
particularly the exhaust system (risk  Dispose of contaminated filters in 
of burning) and that the control device  accordance with the regulations.
may move during operation (risk of 
crushing). Changing the advance fuel filter:
* Releas
Rele asee the
the cl
clam
amps ps..
Attention * Draw
Dra w the
the ends
ends of the hos hoses
es off
off..
In addition to the maintenace charts
* Inse
In sert
rt a new
new fifiltlter
er..
of the engine the following items of the
* Fitt the
Fi the hos
hosee end
ends. s.
* Fast
Fa sten
en the
the cla
clamp
mps. s.
engine operating instruction apply after
50 operating hours after the start-up of
new or overhauled engines:
9.3 Mainten
Maintenance
ance of chassis
chassis and
and
* Check
Check engi
engine
ne for
for leaks
leaks,, repair
repair if
if brakes
This website stores data such as
necessary
cookies to enable
* Ch
Chanange
ge en essential
engi
gine
ne oioill site The maintenance of the chassis and the
functionality, as well as marketing, brakes must be carried out in accordance
* Rep
Replac
lacee oil
oil filter
filter cart
cartrid
ridge
ge with the chassis instruction manual.
personalization, and analytics. You
* Chang
Changing
may change ing the
your fuel filte
settings filter
r cartrid
at anycartridge
timege and
and Work on the brakes may only be carried
advance fuel filter
or accept the default settings. out by trained technical staff or by
* Check
Check tappe
tappett clear
clearance
ance,, adjust
adjust if specialist brake services!
necessary
Danger 
Privacy
* Policy
Check
Check engi
engine
ne mount
mounts,
s, tight
tighten
en if
necessary During inspection, adjustment, or 
maintenance work, remember that the 
* Marketing
Check
Check V-belt
V-belt,, tensio
tension
n if nece
necessar
ssary
y surfaces of machine parts can be hot,
Personalization
Full load speed is factory-set by the particularly the exhaust system (risk 
manufacturer and must not be modified. of burning) and that the control device 
Analytics may move during operation (risk of 
The idling speed must not be changed
either, as this might cause serious crushing).
Save to the screw
damage Accept All
compressor, e.g.
damage to the coupling!
 33

9. Maintenance

9.4 Compre
Compressor
ssor maintenance
maintenance / Mainte
Maintenance
nance schedule
schedule

Operating hours    h    h    h    h    h    h    h    h    h    h    h    h    h    h    h    h    h
   0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0
   6    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0
   5    0    5    0    5    0    5    0    5    0    5    0    5    0    5    0
For 2 boxes per annum: Maintenance every 500 h,    1    1    2    2    3    3    4    4    5    5    6    6    7    7    8
although at least every 6 months   r
  a
  r
  a
  r
  a
  r
  a
  r
  a
  r
  a
  r
  a
  r
  a
For 1 boxes per annum: Maintenance every 1000 h,   e   e   e   e   e   e   e   e
  y   y   y   y   y   y   y   y
 .  .  .  .  .  .  .  .
although at least each year    1    2    3    4    5    6    7    8

Install a "Caution maintenance work" warning sign 

and
and cord
cordon on off
off a wid
wide
e area
area aro
aroun
und
d the
the work
workpl
plac
ace
e befo
before
re sta
start
rtin
ing
g any
any work 
work 

Check the oil level in the diesel engine daily

Check the oil level in the compressor daily
Empty fuel water separator (option) daily

Check tyre pressure and wheel nuts,

retighten if necessary                   

Adjust brake system (option) or have checked                   

Lubricate chassis / draw gear                  

Inspect safety valve                  

Lubricate hood hinges                  

Clean cooler                  
(more frequently if used in a dusty environment)

Change oil filter in the screw compressor          

Oil change (screw compressor)          

Inspect automatic operational monitoring          

Change fine separator

every year or if differential pressure > 1bar          

Clean air filter (screw compressor/engine)

bettwe
be ween
en ti
time
mess or re
rene
new
w if th
thee re
redd fie
ield
ld ap
appe
pear
arss Notte th
No thee ma
main
inte
tena
nanc
ncee in
indi
dica
cato
torr

Check hose lines for damage (leaks, formation of cracks)

and replace, if damaged          

Clean screen of the suction-off line          

Inspect control
This website stores(adjustment/function)
data such as          
cookies to enable essential site
Inspect solenoid valves          
functionality, as well as marketing,
personalization, and analytics.
Check the battery acid level You          
may change your settings at any time
Check
or accept clamping
the defaultbolts and nuts and retighten,
settings.
if necessary (chassis, frame and bodywork)          

Check suspension components          

Privacy Policy
Engine maintenance See the engine operating instructions for maintaining the engine
Marketing
Unscrew vessel for tool oil and check inside          
forPersonalization
any corrosion. If rust is found, replace the
vessel with a new, original spare part.
Analytics

These
Save
 maintenance
Accept intervals
All must be observed!
 For your own benefit, put a cross on the servicing schedule against maintenance work when performed.
 34

9. Maintenance

9.4.1 Oil filter

filter replacement
replacement 9.4.2
9.4.2 Oil chang
change
e (compress
(compressor)
or) * Start
Start screw
screw compre
compresso
ssor,r, run
run for approx
approx..
two minutes, check for leaks
(compressor)
* Swi
Switch
tch off scr
screw
ew comp
compres
ressor
sor
* Che
Check
ck oil
oil level,
level, add
add oil ifif necess
necessary
ary

9.4.3 Checki
Checking
ng the automati
automatic
c
monitoring system

Danger 
Caution! High voltage! The sensors of 
the automatic monitoring system must 
Fig. 27 not be short circuited.
Fig. 26
Danger  Check individually every 1000 operating
Danger  hours:
Only change the oil when the engine is 
1. Temperat
emperature
ure sensor - screw compressor
compressor
Only replace the oil filter cartridge when  at a standstill and the screw 
(pressure connection)
the engine is at a standstill and the  compressor is not under pressure.
screw compressor is not under  2. Oil pressure
pressure switch
switch - engine
Caution when draining off hot oil: 
pressure.
risk of scalding! Spill no oil!  3. Oil temperatur
temperaturee gauge - engine
Caution with hot oil: risk of scalding! 
Attention
Spill no oil!  Checking the automatic monitoring system:
Change the oil filter every 1,000 oper-
Attention ating hours, but at least once per year. * Discon
Disconnec
nectt conne
connecti
cting
ng cab
cable
le
* Con
Connect
nect to ground
ground at oil
oil tempera
temperatur
turee
Change the oil filter every 1,000 oper- The screw compressor must not be gauge.
ating hours, but at least once per year. under pressure during oil change.
* St
Star
artt scre
screw
w comp
compre
ress
ssor
or
Drain the oil at operating temperature.
Note  * The autom
automati
aticc monitor
monitoring
ing syste
system
m must
Do not mix oils of different switch off the screw compressor
Dispose of oil filter cartridge in accordance  specifications. immediately after starting, and the
with the relevant regulations - hazardous 
“Fault” indicator lamp must come on.
waste!  Note 
Check for leaks. Collect used oil, do not allow it to enter the 
Changing the oil filter: soil. Dispose of oil in accordance with
with the  9.4.4 Inspecting
Inspecting / Replacin
Replacing
g the fine
relevant regulations - hazardous waste! 
* Unscre
Unscrew
w the oil
oil filter
filter cartri
cartridge
dge using
using separator
appropriate tools Spill no oil! 

* Dis
Dispos
posee of oil fil
filter
ter car
cartri
tridge
dge Check for leaks. 2
* Appl
Applyy a thin
thin coat
coat of oil
oil to the
the seal
seal of the
the Changing the oil: 1

new oil filter cartridge * Unsc

Unscre
rew
w dips
dipsti
tick
ck 3
* Scr
Screw
ew on and and tight
tighten
en the
the new oil oil filter
filter * Pla
Place
ce oil
oil drain
drain pan under
under oil
oil drain
drain valve
valve
This website stores
cartridge data
(follow thesuch as
instructions on the
cookies oil
to filter
enable essential site
cartridge) * Unscrew
Unscrew the seal
sealing
ing cap
cap of the
the press
pressure
ure
functionality, vessel
* Ch
Chececkkasfo
forrwell as marketing,
leaks
leaks
personalization, and analytics. You * Col
Collec
lectt used
used oil
oil in the
the oil
oil drain
drain pan
pan
* Che
Check
may change ckyour
oil level,
oil lev el, add
add oil
settings at ifiany
f necess
nectime
essary
ary
* When
When the
the used
used oil
oil has
has been
been drai
drained
ned
or accept the default settings. completely, use a new sealing ring on Fig. 28
the sealing screw of the pressure
vessel, position and tighten screw or 1 Connect
Connection
ion for
for P cont
control
roller
ler
close the oil drain valve 2 Connect
Connection
ion for
for compress
compressoror suction
suction line
Privacy Policy 3 Oi
Oiler
ler conn
connec
ectition
on
* Fill
Fill up wit
withh new
new oil
oil (see
(see sect
section
ion
Marketing "Specifications" in chapter 1 for initial Danger 
oil capacity; use a little less oil when
Personalization performing an oil change). Pressure tank is under pressure. Only 
work when the motor is at a standstill 
Analytics  * For lubricants
lubricants see
see “Lubricant
“Lubricant Table”
Table” and the screw compressor is not under 
* Check
Check sealin
sealingg ring on
on dipstic
dipstick,
k, replac
replacee if pressure.
Save Accept All necessary Caution with hot oil: risk of scalding! 
* Scr
Screw
ew in
in and
and tight
tighten
en dips
dipstic
tickk Spill no oil! 
 35

9. Maintenance

Note  9.4.5 Air filter

filter replaceme
replacement
nt Reassembling the air filter:
(compressor / engine) * Clean
Clean the seali
sealing
ng surfa
surface
ce in the
the filte
filterr
Dispose of fine separator in accordance  housing.
with the relevant regulations - hazardous 
Danger  * Insert
Insert safet
safetyy cartridg
cartridgee (optiona
(optional)
l) and
waste! 
All inspections and servicing work must 
ensure correct seating.
Check for leaks.
be carried out when the engine is at a  * Insert
Insert the
the filter
filter cartr
cartridge
idge and
and make
make sure
Replace the fine separator at least once standstill and the screw compressor is  that the seal is properly seated.
per year or measure the differential not under pressure.
* Replace
Replace filt
filter
er hood
hood and fast
fasten
en using
using the
the
pressure as follows:
tensioning brackets (the tensioning
* When the engin
enginee is at
at a stands
standstil
tilll and brackets can only be closed if the filter
the screw compressor is not under cartridge with seal is seated properly on
pressure, unscrew the dipstick from the the sealing surface of the filter housing).
pressure tank.
* Reset
Reset the
the maint
maintenan
enancece indic
indicato
atorr by
* Scre
Screw
w in the redu
reducin
cingg adapte
adapter.
r. pressing the reset lever.
* Screw
Screw the
the pressu
pressure
re gauge
gauge int
intoo the
the
reducing adapter.
* Star
Startt the
the scre
screw
w comp
compres
ressor
sor.. 9.4.6 Checking the safety valve
* The diff
differen
erence
ce in press
pressure
ure betwe
between
en the
pressure gauge on the pressure tank Fig. 29
and the pressure gauge on the
instrument panel must not exceed 1 bar. Note 
If the differential pressure is > 1 bar, the Check the air filter every week for dust.
fine separator cartridge must be replaced. Every air filter is supplied with a 
* Rem
Remove
ove all
all hexago
hexagonn screws
screws arou
around
nd the
the maintenance indicator, which indicates 
circumference of the lid. the adding of the filter cartridge. The 
* Remove
Remove the lid and the old fin
finee maintenance
maintenan ce intervals of the air filter 
separator. depend on the air pollution.

* Remove
Remove thethe old
old seals
seals from
from the pres
pressur
suree If the red field of the maintenance indicator  Fig. 30
vessel, clean the sealing surface and fit is visible and stays engaged when the 
screw compressor is turned off, you must  Check the operation of the safety valve at
a new seal.
exchange the air filter cartridge (at least  least twice a year. The check is carried out
* Insert
Insert a new fine
fine separ
separato
atorr into
into the every 12 months). with the system pressurised. Carefully turn
pressure vessel and fit a new seal. the knob anti-clockwise, until the internal
Replace the air filters of the screw  pressure lifts the valve cone, releasing a
* Fit the
the lid.
lid. Insert
Insert the
the hexago
hexagonn screws
screws compressor and of the engine once yearly. mixture of oil and air. Then turn the knob
and tighten them across the diagonal fully clockwise again.
(tightening torque see Chapter 9.4.9 Do not clean or reuse the air filter.
"Torque
"T orque specifications"). In accordance with national standards,
Attention but at least once a year, carry out a
* Ch
Chec
eckk for
for leak
leakag
age.
e. suitable test to check whether the valve
Replace the safety cartridge (optional)
* Dispos
Disposee of
cartridge in the
the old finee separa
fin
specified semanner.
parator
tor at the latest every third time the air filter blows down at the correct pressure.
element is replaced. If the valve is not working properly,
This website stores data such as replace it immediately with a new one
cookies to enable essential site designed for the system. This type of
Replace air filter. operation may only be carried out by
functionality, as well as marketing,
personalization, and analytics. You * Loosen
Loosen the tens
tensioni
ioning
ng bracke
brackets
ts at the
the air trained personnel.
may change your settings at any time filter and fold away.
Danger 
or accept the default settings. * Re
Remo
move
ve fifiltlter
er hoo
hood.
d.
The screw compressor must not be 
* Remove
Remove filt
filter
er cartri
cartridge
dge from
from the filt
filter
er
operated with a faulty safety valve! 
hood.
Privacy Policy * Remove
Remove safe
safety
ty cartr
cartridge
idge (opt
(optiona
ional)
l)
A mixture of oil and air will escape when 
the valve is checked/tested.
from the housing.
Marketing
* Rep
Replac
lacee fil
filter
ter car
cartri
tridge
dge..
Personalization
Danger 
Analytics
Never clean the air filter cartridge with 
inflammable liquids.
Save Accept All
 36

9. Maintenance

9.4.7 Control For battery maintenance please also refer 9.5 Spare parts for maintenance
to the manufacturer’s instructions and the
purposes
engine operating manual.
Designation Identification No
No.
Service Package 1000 h
9.4.9 Torque specifications C30-C42 A19009474
DLT 0406
Service Package 1000 h
For the compressors C30, C30 G, C35-10, C50 A19009574
C35-10 G, C38, C38 G, C42, C42 G and Service Package 1000 h
C50, the following tightening torques apply C53-C76 A19009174
to screwed connections:
Service Package
Wheel screws 90 Nm air-
air-oi
oill se
sepa
para
rato
torr C30
30-C
-C50
50 A190
A19009
0967
6744
Fig. 31
Pressure vessel cover 40 Nm Service Package
The regulation is designed as continuous air-
air-oi
oill se
sepa
para
rato
torr C53
53-C
-C76
76 A190
A19009
0927
2744
speed control consisting of: Safety valve 50 Nm
Spare pa
parts lilist C3
C30-C50 100005900
* Th
Thee intak
intakee contr
control
ol valv
valve,
e, Engine bearing/  Spare pa
parts lilist C5
C53-C76 100005924
* The engi
engine
ne cont
control
rol cyl
cylinde
inder,
r, rubber metal element 90 Nm
* Th
Thee regul
regulat
ator
or its
itself
elf.. Compressor bearing/ 
rubber metal element 90 Nm Service parts
The intake control valve comprises:
Air filter insert C30-C50 A13306974
* the contr
control
ol pisto
pistonn for the
the volum
volumee flow-
flow- Chassis mounting screw 90 Nm
rate throttle control and acts as a check Safe
Safetty ca
cart
rtri
ridg
dgee C3
C30-
0-C5
C500 A133
A13308
0887
8744
suspension / frame
valve preventing
control valve andflooding of the
the air filter suction
with oil propertyy class 12.9 (Durlok screw)
propert screw) 169 Nm Air filter insert C53-C76 A13316774
when the screw compressor is switched property class 8.8 90 Nm Safe
Sa fetty ca
cartrtri
ridg
dgee C5
C53-
3-C7
C766 A133
A13316
1687
8744
off. suspension cross girder 90 Nm Hose to fuel filter A13238374
hose clip Spare
Spare car
cartr
tridg
idgee for
for fuel
fuel fil
filte
terr A05500
A05500174
174
9.4.8 Battery maintenance (engine
(engine,, compr
compress
essor/c
or/coole
ooler)
r) max
max.. 12 Nm Oill fi
Oi filt
lter
er ca
cart
rtri
ridg
dgee (M
(Mot
otor
or)) A104
A10458
5837
3744
hose clip (compressor/  Oill fil
Oi filte
terr car
cartr
trid
idge
ge C3
C30-
0-C4
C422 A048
A04819
1997
9744
pressure container) max. 30 Nm Oill fil
Oi filte
terr car
cartr
trid
idge
ge C5
C50-
0-C7
C766 A005
A00587
8737
3744
Air-oil separator element
C30-C50 A10012674
9.4.10 Torque specifications
Seal C30-C50 A93181360
DLT 0703
Air-oil separator element
For the compressors C53-9, C53-9 G, C53-C76 A13138274
C55-14, C60-12, C62, C62 G, C62HS,
C62 HS G, C65-10, C65-10 G, C76 and Seal C53-C76 A93181990

Fig. 32 C76
applyG,tothe following
screwed tightening torques
connections:
This website stores data such as
Danger  Wheel screws 90 Nm
cookies to enable essential site
functionality,
The gasesas released
well as marketing,
by the battery are  Pressure vessel cover 40 Nm
personalization,
explosive. and analytics. You
Safety valve 50 Nm
may change your settings
Avoid sparks and open atfires
any in
time
the 
or accept theof
vicinity default settings.
the battery. Engine bearing/ 
rubber metal element 90 Nm
Do not allow acids to come into contact 
with skin or clothing. Wear safety  Compressor bearing/ 
Privacy Policy
goggles. rubber metal element 90 Nm
Place no tools on the battery. Chassis mounting screw 90 Nm
Marketing
The battery is maintenance-free in
Personalization
accordance with DIN. suspension / frame
property class 8.8 90 Nm
Analytics
Attention
suspension cross girder 90 Nm
Check the acid level after a maximum
ofSave
1,000 operating Accept
hours, orAll
after
24 months, whichever
whichever occurs first,
first, and
fill up with distilled water if necessary.
 37

10. Troubleshooting

Problem Possible cause(s) Correction

Insufficient or no air supply Clogged air filter Clean air filter

Screw compressor engine speed Set speed

misadjusted

Clogged oil fine separator filter cartridge Replace compressor oil, oil filter and oil fine
separator filter cartridge
Wrong setting at controller Adjust

Spring and plunger inside the intake control Clean, replace parts if necessary, readjust
valve are not fully opened

Insufficient pressure Pressure control valve defective Repair or replace

Outflow valve dirty Clean

Control line defective Repair or replace

Intake control valve defective Repair or replace

Compressor becomes excessively hot Wrong oil Replace

(automatic shutdown)
Compressor oil level too low Fill up with oil

Fan broken Replace

Oil cooler dirty (outside) Clean

Oil filter clogged Replace

Leak in oil line Repair or replace

Air short circuit Repair

Screw compressor will not start No fuel Fill up with fuel

Fuel filter clogged Replace fuel filter cartridge

Fuel line loose, broken, or jammed Repair line

Operating voltage low Charge battery or replace

Electrical connection loose, corroded, or

broken Replace
This website stores data such as
cookies to enable essential site Air in system Extend starting operation (automatic
ventilation)
functionality, as well as marketing,
personalization, and analytics. You Solenoid valve out of order Replace
may change your settings at any time
or accept the default settings. Relay defective Replace

Starter defective Replace

Privacy Policy Other engine problems See engine operating manual
Marketing Fuse defective Replace (on the back of the instrument
panel).
Personalization
Switch defective Replace
Analytics

Save Accept All

 38

10. Troubleshooting

Problem Possible cause(s) Correction

Oil in air line Orifice in oil return line clogged Repair / clean

Oil fine separator defective Replace

Too much oil in pressure tank Correct

Safety valve blows off Controller set too high Set

Pressure control valve defective Replace or repair

Intake control valve, control cylinder, Replace

engine, or connected control lines defective

Valve for intake control valve is missing /  Repair or replace

is defective

Safety valve defective Replace

Oil comes out of the air filter of the Intake control valve defective Check and repair
compressor after the screw compressor (backlash flap, O-ring, spring)
has been shut down

Engine starts but switches off again V-belt defective Replace

immediately, or the system switches off
while running Oil pressure switch/engine defective Replace

Oil temperature switch defective Replace

Engine temperature switch defective Replace

Compressor defective Check

Cable defective or cable cover not plugged Replace or plug onto sensor
onto sensor

Relay defective Replace

Solenoid valve defective Replace

Generator defective Repair or replace

Generator controller defective Repair or replace

Other engine problems See engine operating manual

This website stores data such as
cookies to enable essential site
functionality, as well as marketing,
personalization, and analytics. You
may change your settings at any time
or accept the default settings.

Privacy Policy

Marketing

Personalization

Analytics

Save Accept All

 39

11. Generator option

11.1 Introduction * The IP 54

54 prote
protecti
ction
on mean
meanss the 
the  If the generator is overloaded briefly (for
generator is protected against  less than the thermal response time of the
This manual describes the operation and splashes, spray and other foreign  circuit breaker), or devices with excessive
maintenance of synchronous generators bodies. Do not, however, clean the  startup consumption levels are connected,
with switchboxes. generator with high-pressure  the regulator automatically limits the
equipment. output/startup consumption (through the
All information relates to data available at excitation current). This leads to a (desired)
the time of going to press. * Gener
Generato
ators
rs may
may only
only accept
accept up
up to 
withdrawal of the output voltage. Please
their nominal load if operated 
The manufacturer reserves the right to according to the standard  take account
devices of this when
simultaneously onoperating several
your generator.
make changes at any time, without prior temperature range and cooling 
notice or obligation. It is therefore always conditions specified. If installed 
advisable to check for updates. Note 
under different conditions, or if 
No part of this publication may be cooling of the engine or generator is  Switch devices (loads) on one after the 
reproduced or transmitted in any form or by impaired, for example in confined  other, starting with that with the least 
any means, without the prior written spaces or under unfavourable  favourable startup characteristics.
consent of the manufacturer. circumstances,
circumstance s, their output must be 
reduced. If the generator is extremely dirty,
Synchronous generators may only be insufficiently ventilated, or operating under
used as such. No other form of use is * Do not
not modi
modify
fy the
the gene
generat
rator/ 
or/  otherwise unacceptable conditions, to
permitted. switchbox. Such changes, or the use  prevent it or the regulator being damaged
of unsuitable parts, will invalidate  by overheating, the output voltage is
approval under machinery safety  reduced to about half its nominal value if
legislation and certification to  the temperature inside the switchbox
11.2 Generator safety precautions EU/EEC Directives. exceeds 80 °C. This compromises the
connected devices, which must be
Danger  switched off or unplugged immediately.
Always avoid operating the generator
Do not top up current-generating units  11.3 Operating principle under such conditions, and keep it clean
(generators) with fuel during operation!  (particularly fan cowl air inlets, cooling fins).
The generator is a self-excited brushless
Follow the additional fire and explosion  synchronous internal pole generator which The generator is fitted with a thermal-
protection regulations in the case of  is controlled electronically. It consists of magnetic circuit breaker, which not only
installation in enclosed spaces. the mai
mainn mach
machine,
ine, exc
excite
iter,r rotary rectifiers protects against overloads, but also
Attention! Exhaust gases are toxic! 
t oxic! 
and generator regulator assemblies, switches off in the event of an insulation
Do not operate generators in non- 
housed in a common enclosure. The main fault on a connected device. Interruption of
machin
mac hinee of the synch
synchrono
ronous us 3-phase
3-phase power distribution during operation may be
ventilated, enclosed spaces! 
generators
generat ors has variou
variouss design
design feature
features,s, caused by an insulation fault on a device
Check that electrical loads and their  including a damping cage and balancing (in which case an indicator lamp comes
connections are in perfect condition. system, which allow it to handle an on), or an overload (when it does not). If an
extremely asymmetrical load. All of the overload has occurred, eliminate its cause,
Synchronous generators operate safely 
other equipment required for safe electrical wait for a short time, then reset the circuit
and reliably. Before commissioning,
operation is accommodated in the directly breaker. On generators with a hinged glass
read through the safety precautions in 
mounted switchbox. cover over the circuit breaker, open the
this manual carefully.
The splashproof and dustproof generator cover, grasp the breaker’s operating
* Ensure
Ensure that
that chil
childre
dren
n under
under the age
age of 
is driven by the engine using V-belts. Over handle
hand le and push
push upward
upwardss (always
(always in
in the
fourteen and animals do not have  centre = yellow mark, not on one side!).
access to the generator while it is  the range from
the voltage no-loadistocontrolled
it supplies nominal output,
by a Then carefully close the cover again, and
running.
This website stores data such as highly integrated electronic regulator, tighten its knurled screws, without exerting
which is fully
fully encapsul
encapsulated
ated in the cover
cover of
of force. After the circuit breaker has released
cookies
* Totoavoi
aenable
void essential
d endang
end angeri ng site
ering people
peopl e or 
the switchbox, so that the output voltage due to an overload (indicator lamp off), wait
functionality, as well as marketing, or 
animals, or causing accidents
for a short time until it can be reset. The
damage to the machine, always  over this range complies with IEC 38
personalization, and analytics. You thermal-magnetic or thermal circuit breaker
carry out the usual
usual checks before  requirements. This standard is comparable
may change yourthe
switching settings at any
generator on. time with the public mains. is designed in accordance with the
or accept the default settings. machine specifications, particularly in
* There
There is alwa
always
ys a risk
risk of elec
electri
tric 
c  The stability of the output frequency is relation to shock and vibration resistance,
shock if a generator is used  entirely dependent on that of the speed of and ambient temperature. Only use an
improperly.. Never touch the 
improperly the combustion engine. You must therefore original part if replacements are needed.
Privacygenerator,
Policy or equipment connected  ensure that this engine is serviced,
to it, with
with wet hands.
hands. maintained and operated properly.
Marketing
* When usin
usingg severa
severall genera
generators,
tors, or if 
the public mains
Personalization is available, do not 
interconnect these systems.
Analytics
* Cauti
Caution!
on! Conne
Connecting
cting the gene
generator
rator to 
the public mains can damage it and 
severely endanger personnel.
Save Accept All
 40

11. Generator option

11.4 Operati
Operating
ng the
the generat
generator
or The generator must not be used to inject The distribution systems (e.g. extension
power into a construction site distribution cables, device leads) must be carefully
(Working safely with electrical
system. chosen, laid and maintained. Check the
equipment) electrical cables regularly, replacing rather
To avoid unwanted
unwan ted interaction, do not
This state-of-the-art synchronous than repairing any that are faulty.
connect distribution systems with additional
generator has been designed and built insulation monitors to the generator with its To cope with the greater mechanical
with maxim
maximumum safety
safety in
in mind.
mind. It will help built-in equivalent. strains and stresses on the generator’s
you get the most out of your work or leisure distribution system, use rubber-sheathed
activities. However, like all electrical Duringout
carried insulation and voltage
on the generator tests
by trained cables to the minimum standard of
equipment, it can represent a source of H07RN-F or A07RN-F in accordance with
danger (e.g. risk of electric shock) if the electricians, disconnect the insulation
DIN/VDE 0282 Part 810, or equivalent
operating instructions in this section are not monitor. designs, as moveable (extension) cables.
followed exactly. Please observe the Because the generator is not earthed, Where the cables may be under severe
instructions and the notes on dangers fault current circuit breakers used in stress, lay them in mechanical protection
affixed to your generator. distribution systems and equipment cannot systems, or with strong covers, or
Before starting the generator, all devices be relied upon to operate correctly when use NSSH
NSSHöü öü cables
cables in accor
accordanc
dancee with
must be unplugged and switched off. Only such units are connected to the generator, VDE 0250.
plug the devices in (one after the other) and, due to the Electrical isolation with
The lengths and conductor cross sections
and switch them on after the engine driving insulation monitoring and circuit breaking
of the extension cables must match the
the generator has reached its nominal protective measure, are not actually
type of equipment and the duty.
operating speed. required.
It is essential to ensure supply cables do
Keep the glass cover over the circuit The insulation monitor and circuit breaker
not exceed the maximum lengths specified!
breaker on the front panel closed at all should be checked daily when the
When using extension cables or moveable
times. Tighten the knurled screws by hand generator is in use, following the quick
distribution systems, the sum of the lengths
to maintain IP protection. reference instructions for Testing/insulation
Testing/insulation
of all extension cables connected to a
monitoring/starting/connecting equipment
Do not open the generator or the which are affixed to the generator. generator must
(for a copper
copp conot exceed
er conducto
nductor cro250
r cross smetres
ss section
ection of
switchbox. The brushless synchronous
design does not require maintenance. Attention 2.5 mm2 - for all sockets). The total length
of the extension cable, or the moveable
Do not modify the internal wiring. Devices connected the generator which distribution system, connected to any
cause the circuit breaker to release, and particular socket must not exceed 60 m
Repairs to electrical components and to
electrical operating equipment (supply the red indicator lamp for Insulation for a copper
copper conducto
conductorr cross
cross section
section of
fault to light up, must not be connected 1.5 mm, or 100
2 100 metre
metress for one of
of 2.5
2.5 mm2.
cables, loads) may only be carried out by
suitably trained electricians. to other generators (without insulation
monitoring), or to the public mains. Note 
The circuit breakers, control, alarm and Have equipment with insulation faults
release devices and the insulation monitors For defined releasing of the circuit breaker,
immediately replaced
replaced or repaired by the
are specially designed for the generator a loop resistance of 1.5  Ω 
 Ω  per
 per socket must 
manufacturer or a suitable electrical
and its sockets. Only use original spare not be exceeded.
specialist.
parts if replacements are needed. The circuit breaker must not be used for
When working in restricted conductive
The generator meets the requirements of routine switching on of the 3-phase
areas, i.e. as defined in DIN/VDE 0100 706
the Protective isolation with equipotential generator. If several devices, particularly
(e.g. in boilers), only one power tool or
bonding conductor and insulation those with different power consumption
mobile measuring instrument may
monitoring with circuit
in IEC 60364-5-551 andbreakers regulation
the German Gas be con
connect
nected
ed to the gener
generato
ator,r or for levels, are
different connected
voltage dropstocan
thearise,
AC sockets,
eachh suc
eac suchh load an additi
additional
onal isolat
isolating
ing depending on the turn-on time of the
This website stores
Installation data such
and Plumbing as
Association transformer, or one isolating transformer
(DVGW)
(DV
cookies toGW) regulat
regu
enable lation
ion GW site
essential 308.The
The system is neutral.
with several secondary windings, should
an IT type,
functionality, as with
wellneutral and PE
as marketing, be use
used.d. Handhel
Handheldd lights
lights may only
only ever Avoid overloading the generator. In
(equipotential bonding conductor). be use
usedd in restrict
restricted
ed conduct
conductive
ive areas
areas particular, to ensure user safety and
personalization, and analytics. You
The generator
may change does not
your settings at have to be
any time when operated off a SELV (safe extra low optimum performance, it is essential to
earthed (with a ground rod for example) to voltage) isolating transformer. observe the following rules:
or accept the default settings.
ensure adequate safety protection. Many portable power tools conform to 1. Only devices
devices whose
whose voltage
voltage and
However, if desired or required, defined German protection class II (i.e. they are frequency data on the load identification
earthing of the generator can also be double insulated, symbol     ). These plate conform to those on the generator
Privacy Policy
provided. devices should be used if possible. Use a identification plate may be connected.
Earthing of the neutral (N), or connecting cable and plug to connect any protection
Marketing 2. Only devices
devices whose power
power consumption
consumption
of the neutral to the equipotential bonding class I device (i.e. with metal housing parts
does not exceed the output specified on
conductor (PE), is prohibited on the that are not double insulated) to be used to
Personalization the generator identification plate may be
generator, the distribution system and all the PE (equipotential bonding) conductor.
used. The total power consumption of all
other devices. The use of so-called
Analytics Only connect devices and distribution of the loads connected to the generator
neutralised devices is not permitted, and
would lead to insulation monitoring being systems which
generator. The are in goodand
insulation, condition to the
plug and must not exceed its output.
Save automatically.
enabled Accept All socket combinations, must be in good
condition to ensure user safety. Do not use
any damp or dirty connectors.
 41

11. Generator option

3. Note that
that the starting
starting consumption
consumption of Attention * Ensure
Ensure that
that all
all the
the device
devicess on the
the
devices driven by electric engines is generator output sockets have been
generally a multiple of the specified The generator may only be used if the disconnected.
rating. If in doubt, it is advisable to circuit breaker released during the test
contact the equipment manufacturer and the indicator lamp came on until the Note 
directly. reset button was pressed.
All device switches must be in the 
The maximum current specified for each AUS / 0 / OFF position.
socket must not be exceeded.
Setting the range switch Danger 
If normal cooling cannot be maintained,
or the operating conditions are Turn the range switch to the required
position: Unchecked devices may endanger 
unacceptable in other respects, reduce personnel on startup, and may be 
the consump
consumption,
tion, rather than operati
operating
ng 1st position: damaged or cause damage.
the gene
generat
rator
or right
right up to its
its rating.
rating.
Compressed air and electrical power, * St
Start
art th
thee gener
generat
ator
or..
Ideal operating conditions are: variable engine speed.
1. Am
Ambi
bien
entt temp
temper
erat
atur
ure:
e: 25 °C Note 
* Compre
Compresse
ssedd air and
and electr
electrica
icall power
power
2. Air pressure: 100 kPa (1 bar) can be consumed up to maximum Do not load the generator until the 
engine speed. engine has warmed up.
3. Relative humidity: 30% Note that engine speed is reduced in the
Do not operate the generator at ambient event of an overload. * Check
Check that
that the
the circui
circuitt breake
breakerr is
temperatures above 40  ° C, below –10  ° C, engaged in the ON / I position
* Compre
Compresse
ssedd air
air mod
modee with
without
out (clo
(closse th
thee gl
glas
asss cove
cover)r)..
or in direct sunlight. consumption of electric power:
More detailed instructions for operation  –> engine speed matched to demand
under unfavourable conditions can be * Addi
Additio
tional
nal consu
consumpt
mption
ion of elect
electric
ric power
power
found in the combustion engine manual.
 –>
to variable
consumpt
cons engine
umption autspeed
ion automa isally
omatic matched
ticall ,y up to
maximum speed
11.5
11.5 Testing insula
insulation
tion monito
monitoring/
ring/ * Automa
Automatictic no-lo
no-load
ad operat
operation,
ion, i.e.
i.e. the
the
startup/device connection engine continues to run at maximum
speed for 100 seconds, if the electrical
Testing
Testing insulation monitoring power consumption is less than 75 VA
for a brief period.
Attention
2nd position:
Do not start the generator until you have As 1st position, but with the engine Figure 34
fully read and thoroughly understood running at constant speed
the safety precautions and operating Connect the devices to the output
instructions in this manual. * Same
Same functi
functions
ons as
as for 1st
1st posit
position,
ion, but sockets one after the other, ensuring
with the engine running at constant, that the current specified for each socket
During operation, check at least once a maximum speed is not exceeded, and the generator is
day that the protective measure for the not overloaded.
risk of electric shock through indirect
contact (in accordance with DIN and Switching on Note 
GW 308 requirement
requirement for Protective
Protective Turn the devices on, one after the other,
isolation with insulation monitoring and
This circuit
website stores data
breaking) such as
is working properly. using the device switches.
cookies to enable essential site If possible, plug in/switch on devices
functionality, as well
With the engine as marketing,
running, carry out the with high startup currents first. Only
personalization,
following test: and analytics. You connect suitable equipment in perfect
may change your settings at any time condition to the generator.
1. Unplug all
all devices
devices connected
connected to the
or accept the default
generator; open settings.
the glass cover and
switch the circuit breaker to ON/I. Switching off
2. Press the red test button. * Turn the devices
devices off, one after
after the
the other,
other,
Privacy Policy
3. Check whether
whether the
the circuit
circuit breaker
breaker using the device switches.
releases and red the INSULATION Figure 33
Marketing Note 
FAULT
FAUL T indicator lamp lights up.
Danger 
Personalization
4. Press and hold down thethe green reset
reset If possible, switch devices with the 
button for at least 2 seconds – the red Follow safety precautions!  highest current consumption off last.
Analytics
indicator lamp must go out.
* Carry
Carry out
out the
the usual
usual check
checkss (safe
(safety
ty * Switch
Switch the
the device
devicess off
off one afte
afterr the
5. Switch
Switch the circuit
circuit breaker to
to ON/I; close
close precautions, installation location, oil other.
Save Accept
the glass cover (tighten the All
knurled level, fuel, etc) before using the
screws by hand); the generator is now machine.
ready for use.
 42

11. Generator option

Note  Coolant
Coo lant . . . . . . . . . . . . . Air/ex
Air/exter
ternal
nally
ly Measurement reference
ventilated with poten
potentitial
al . . . . . . . . . . . . N
Ensure the covers of unused sockets  own fan, inde-
are closed again properly. pendent of Generator data
direction of Winding Colour Ins. class Resistance
rotation (at 20°C)/ Ω
Permis
Permissib
sible
le speed
speed rangerange 0 to 4000 rpm
Speed for nominal output 3000 to 4000 rpm U-N brown-blue F 0.59

Efficiency at nominal output V

W--NN w
blhaictek--bblluuee F
F 00..5599
at 0.8
0.8 ind
ind . . . . . . . . . . . . 0.8
0.800 1/2 U-N yellow-blue 0.65
at 1.0
1.0 . . . . . . . . . . . . . . . 0.8
0.822 1/2 V-N yellow-blue 0.65
1/2 W-N yellow-blue 0.65
Distortio
Distortionn factor
factor . . . . . . . < 5% 1F1-1F2 red-grey H 28
Weight
Wei ght . . . . . . . . . . . . . . 53 kg
Overal
Ove ralll size
size . . . . . . . . . . BG1322
BG13 (All resistances measured using the 4-wire
Over
Ov eral
alll leng
length
th . . . . . . . . 426 mm R method)
Figure 35
* Allow
Allow the
the engine
engine to conti
continue
nue runni
running
ng for
for Generator regulator
about 2 minutes, so that the generator Modell . . . . . . . . . . . . . .
Mode LCAR
LCAR3 11.7
11.7 Technic
echnical
al charact
characteristic
eristics
s of
cools down. Connector assignment 12 kV
kVA
A 400/230
400/230 V generator
Pin Colour Function
* St
Stop
op th
thee gene
genera
rato
torr. 1 red F1 Generat
Generator
or model
model . . . . . . DWG (BL4(BL4))
2 grey F2 13/7-2-ZE
3 violet 1/2 U Generat
Generator
or type
type . . . . . . . Syn
Synchr
chronou
onous,s,
4 violet 1/2 V internal pole,
11.6
11.6 Technic
echnical
al charact
characteristic
eristics
s of
5 violet 1/2 W brushless with
8 kV
kVA
A 400/230
400/230 V generator
generator exciter,
Switchbox electronically
Generat
Gene rator
or model
model . . . . . . GTS-DWG
GTS-DWG
8/5-2-ZE Degree
Degr ee of pr
prot
otec
ectition
on . . . IP 54
54 controlled
Dimensi
Dim ensions
ons . . . . . . . . . . 211x31
21 1x311x1
1x135
35 Generat
Generator
or fram
framee . . . . . . B3/
B3/two
two bear
bearings
ings
Generat
Gene rator
or type
type . . . . . . . Sync
Synchron
hronous,
ous,
Design . . . . . . . . . . . . . . Front panel
panel type
type Degre
Degreee of pro
prote
tect
ctio
ionn . . . IP 54
54
internal pole
Fusing
Fusing . . . . . . . . . . . . . . All pole
poless
Generat
Gene rator
or frame
frame . . . . . . B3/t
B3/two
wo beari
bearings
ngs
L1 . . . B16A Generator characteristics:
Degr
Degree
ee of pro
prote
tect
ctio
ionn . . . IP 54
54
L2 . . . B16A Extremely low dynamic internal resistance,
L3 . . . B16A same output voltage whether hot or cold,
Generator characteristics:
N . .. . lead
leadin
ingg N no dangerous overvoltage during dynamic
Extremely low dynamic internal resistance,
same output voltage whether hot or cold, overspeed, small reactive effect from non-
Insulation monitoring linear or very inductive equipment, trouble-
no dangerous overvoltage during dynamic
overspeed, small reactive effect from non- Model . . . . . . . . . . . . . . GMW-RI
Model GMW-RISO1.
SO1.00 free operation of equipment with phase
Controls
Controls . . . . . . . . . . . . . Red test
test button
button control, no dangerous overvoltage of the
linear or very inductive equipment, trouble-
Green reset unloaded phases, load current may have
free operation of equipment with phase
control, no dangerous overvoltage of the button significant DC components
unloaded phases, load current may have
Electronic evaluation system Power system
significant DC components
Integrated on ion
Speedd reduct
Spee the generator
reduction controller
. . . . . . Act
Activa
ivatio
tionn < 75W
75W (IEC
(IEC 38/50H
38/50Hz)
z) . . . . . . . . 400V/230V
3-phase AC
3-phase
Power system
This website stores data such as
(IEC
(IEC 38/50H
38/50Hz) z) . . . . . . . . 3-p
3-phase
hase AC Time
Time to
to speed
speed reduc
reductio
tionn 100 secon
secondsds
cookies to enable essential site 400V/230V Amplifi
Amplified
ed phas
phases
es . . . . . . 3
functionality, as well as marketing, Outputs
Output for speed reduction Nominal output (0.8 cap/ind)
personalization,
Amplif
Amp lified and
ied phas
phasesesanalytics.
. . . . . . 3 You
Potential-free make contact single-
single-phas
phasee . . . . . . . . . 7000
7000V VA
may change your settings at any time Switch
Switch vol
voltag
tage:e: . . . . . . . maxmax.. 250V
250V AC
AC
Nominal 3-phase
3-ph ase (sym
(sym)) . . . . . . . . 1300
13000V0VAA
or accept the output
default(0.8 cap/ind)
settings. max. 40V DC/1A Output current
single-
single-phas
phasee . . . . . . . . . 5000
5000V VA
Current
Current:: . . . . . . . . . . . . . max
max.. 6A single-
single-phas
phasee . . . . . . . . . 30.30.4A
4A
3-phase
3-ph ase (sym
(sym)) . . . . . . . . 8000
8000V VA
Nominal current Make-br
Mak e-break
eak capac
capacity ity . . . max
max.. 1500V
1500V AC 3-phase
3-ph ase . . . . . . . . . . . . . 18.
18.9A
9A
Privacy Policy
single-
single-phas
phasee . . . . . . . . . 21.6
21.6A A Startup
Startup cur
curren
rentt . . . . . . . 4.1 timtimes
es Irated
Admissible
Admissible load current
current . 5A/AC1 at 1x10
1x105 Operati
Oper ating
ng mode
mode . . . . . . S1, con contin
tinuous
uous
3-phase
3-ph ase (sym
(sym)) . . . . . . . . 11.5
1.5AA
switching cycles Protect
Protective
ive meas
measure ure . . . . EleElectr
ctrica
icall
Marketing
Startu
Sta rtupp curren
currentt . . . . . . . 4.1 tim
times
es Irated
Operati
Oper ating
ng mode
mode . . . . . . S1, cont continuo
inuousus 1A/24V DC L-R isolation, with
Personalization
Protect
Prot ective
ive measu
measure re . . . . Elec
Electri
trical
cal load at 2x105 equipotential
isolation, with switching cycles bonding
Analytics equipotential conductor in
accordance with
bonding
conductor in Range
Type .switch
. . . . . . . . . . . . . . 2 stage
stage swit
switch
ch VDE 0100.728
Save Accept All
accordance with Max. voltage at
VDE 0100.728 switch
switching
ing cont
contact
actss . . . . . 54V (DC)
(DC)
 43

11. Generator option

Coolant
Coolant . . . . . . . . . . . . . Air/ext
Air/externa
ernally
lly Measurement reference Min. speed for
ventilated with pote
potent
ntia
iall . . . . . . . . . . . . N nominal
nomi nal out
output
put . . . . . . . 3000 rpm
own fan, inde- Efficiency at nominal output
pendent of Generator data at 0.8
0.8 ind
ind . . . . . . . . . . . . 0.8
0.800
direction of Winding Colour Ins. class Resistance at 1.0
1.0 . . . . . . . . . . . . . . . 0.82
rotation (at 20°C)/ Ω
Permiss
Perm issibl
iblee speed
speed range 0 to 4000 rpm rpm Distortio
Distortionn factor
factor . . . . . . . < 5%
Speed for nominal output 3000 to 4000 rpm U-N brown-blue F 0.390 Weight
Wei ght . . . . . . . . . . . . . . 53 kg

Efficiency at nominal output V

W--NN w
blhaictek--bblluuee F
F 00..339900 Over
Overall
allll siz
Overa
Overall size
e th. . .. .. .. .. .. .. .. .. BG13
length
leng BG132 2
3577 mm
35
at 0.8
0.8 ind
ind . . . . . . . . . . . . 0.8
0.800 1/2 U-N yellow-blue 0.47
at 1.0
1.0 . . . . . . . . . . . . . . . 0.82 1/2 V-N yellow-blue 0.47 Generator regulator
1/2 W-N yellow-blue 0.47 Model . . . . . . . . . . . . . . WL
Model WLAx
Ax
Distortio
Distortionn factor
factor . . . . . . . < 5% 1F1-1F2 red-grey H 25.4 Connector assignment
Weight
Wei ght . . . . . . . . . . . . . . 64.44 kg
64. 8 pole Pin Colour Function
Overall
Over all siz
sizee . . . . . . . . . . BG1322
BG13 (All resistances measured using the 4-wire 1 red F1
Overa
Ove rallll leng
length
th . . . . . . . . 5088 mm
50 R method) 2 grey F2
3 not assigned
Generator regulator 4 yellow ZU
Model . . . . . . . . . . . . . .
Model LCAR
LCAR 3 BL 11.8
11.8 Technic
echnical
al characte
characteristics
ristics of 5 yellow ZV
Connector assignment 7 kV
kVA
A 110
110 V generator 6 yellow ZW
Pin Colour Function 7 brown L1
1 red F1 Generator
Generator model
model . . . . . . WG 7/5-2
7/5-2 8 blue N
2 grey F2 Generat
Generator
or type
type . . . . . . . Syn
Synchro
chronous
nous,,
3 violet 1/2 U internal pole, 4-pole 1 black switch contact
4 violet 1/2 V electronically 2 black switch contact
5 violet 1/2 W controlled 3 not assigned
Generat
Generator
or frame
frame . . . . . . B3/
B3/two
two beari
bearings
ngs 4 not assigned
Switchbox Degree
Degree of prot
protect
ection
ion . . . IP 54
Degreee of pro
Degre protetect
ctio
ionn . . . IP 54
54 Switchbox
Dimensions
Dimens ions . . . . . . . . . . 211x31
21 1x311x135
1x135 Generator characteristics: Degreee of pro
Degre protetect
ctio
ionn . . . IP 54
54
Design . . . . . . . . . . . . . . Front panel
panel type
type Extremely low dynamic internal resistance, Dimensions
Dimens ions . . . . . . . . . . 211x31
211x311x135
1x135
Fusing
Fusing . . . . . . . . . . . . . . All pole
poless same output voltage whether hot or cold, Design . . . . . . . . . . . . . . Front panel
panel type
type
L1 . . . B16A no dangerous overvoltage during dynamic Fusing
Fusing . . . . . . . . . . . . . . All pole
poless
L2 . . . B16A overspeed, small reactive effect from non- U1 . . . C32A
L3 . . . B16A linear or very inductive equipment, trouble- U2 . . . 2 x 16A
N . .. . lead
leadin
ingg N free operation of equipment with phase
control, no dangerous overvoltage of the Insulation monitoring
Insulation monitoring unloaded phases, load current may have Model . . . . . . . . . . . . . . GMW-RI
Model GMW-RISO1.
SO1.00
Model . . . . . . . . . . . . . . GMW-RI
Model GMW-RISO1.
SO1.00 significant DC components Controlss . . . . . . . . . . . . . Red test
Control test button
button
Controlss . . . . . . . . . . . . . Red test
Control test button
button Green reset
Green reset Power system button
button (IEC
(IEC 38/50Hz
38/50Hz)) . . . . . . . . 1-phase
1-phase AC
2 x 115V Areas of application
Electronic evaluation system engines difficult to get running, welding
Integrated
Speed
Spee on ion
d reduct
reduction the generator controller
. . . . . . Act
Activa
ivatio
tionn < 75W
75W Amplified
Amplif ied phase
phasess . . . . . . 3 devices (incl. inverters),
compressors, pumps,
tools, construction
This Ti
website
Time
me to stores
to speed
speed reduc data
reductio such as
tionn 100 secon
secondsds Nominal output machinery, illumination
cookies to enable essential site (0.88 cap/i
(0. cap/ind)
nd) . . . . . . . . .7000VA
7000V
functionality,
Outputs as well as marketing, Nomina
Nom inall current
current . . . . . . .32A + 2 x 16A Generator data
Output for speed
personalization, andreduction
analytics. You Startu
Sta rtupp curre
current
nt . . . . . . . 4.1 tim
times
es Irated Winding Colour Ins. class Resistance
Potential-free make contact Operati
Oper ating
ng mode
mode . . . . . . S1, con
contin
tinuous
uous (at 20°C)/ Ω
may Swit
change
Switch your
ch volta
voltage:ge: settings
. . . . . . .atmax
any
max. time
. 250V
250 V AC
AC Protec
Pro tectiv
tivee measure
measure . . . . Electri
Elec trical
cal
or accept the default settings. max. 40V DC/1A isolation, with U1-N brown-blue F 0.165
Current
Curr ent:: . . . . . . . . . . . . . max
max.. 6A equipotential U2-N black-blue F 0.165
Make-br
Mak e-break
eak capac
capacity ity . . . max
max.. 1500V
1500V AC bonding W-N black-blue F 0.28
Privacy Policy conductor in ZU-ZN yellow-yellow F 2.5
Admissible
Admiss ible load
load current
current . 5A/AC1 at 1x10 1x105 accordance with ZV-ZN yellow-yellow F 2.5
Marketing switching cycles VDE 0100.728 ZW-ZN yellow-yellow F 2.5
Coolant
Coolant . . . . . . . . . . . . . Air
Air/ex
/exter
ternal
nally
ly 1F1-1F2 red-grey H 22.1
1A/24V DC L-R
Personalization load at 2x105 ventilated with
own fan, inde- (All resistances measured using the 4-wire
switching cycles
Analytics pendent of R method)
direction of
Range
Type .switch
. . . . . . . . . . .Accept
. . . 2 stage
staAll
ge switc
switchh rotation
Save Nominal speed for
Max. voltage at
switch
switching
ing cont
contact
actss . . . . . 54V (DC)
(DC) nominal
nom inal fre
frequen
quency cy . . . . . 3000 rpm
 44

11. Generator option

11.9 Generator switchbox wiring diagram

diagra m 8 KVA and 12 KVA 400/230 V

PROTECTIVE ISOLATION WITH INSULATIO

INSULATION
N MONITORING
K = OPERATING CURRENT CIRCUIT BREAKER
AND FUSING/CIRCUIT BREAKING FOR ALL POLES
H =INSULATION FAULT INDICATOR LAMP
R = GMW/ISO INSULATION MONITOR
P = TEST BUTTON
    S
    S    R
    E    O       W      N
    R    L    A
    T       O      E 6-PIN CONNECTOR
    O    H       L      E
    T    S    R       L      R
    A    U    E       E      G CONTACTS VIEW
    R    R    N       Y
    E    B    E
    N     G
    E    R
    O    S
    G    F    U YELLOW/GREEN
    C    R    O
    I
    N    O    N
    O    T    O
    R    L
    T    A    H
    R     N    E
    L     K
    C
    C    U    C     O    U     A
    E    G    N     L
    L    E    Y     T    D     B
    E    R    S     T    O
    U
    B    M
    T    O
    S
    E    I
    S TO 4 POLE
    E    R
    R    O     N AMP PLUG
    F     E
    E MECHANICAL ON LCAR3-
OPTIONAL     R
    G
    / COUPLING TO F1 CONTROLLER VERSION 1.10
    N     W
    W     O     E
    O     L
    L     U
BROWN     R     E     L BROWN
    R     B     Y     B
    O
    T
    A WHITE
    R WHITE
    E
    N
    E BLACK
    G BLACK
    C
    I    R
    N    O
    O    T
    A
BLUE
    R
    T    L
    C    U CURRENTCONVERTER   BLUE
    E    G YELLOW/GREEN
    L    E ON LCAR3 CONTROLLER
    E    R

ATTENTION: POWER SUPPLY

TRIP-FREE RELEASING OF AUTOMATIC NO-LOAD OPERATION
OPTIONAL, EXTERNAL PE CONNECTION ALL CIRCUIT BREAKERS PRESSURE REDUCTION
COUPLED

    N
    E
    E SWITCHBOX
    R
    G
    /
    W TOTAL LENGTH OF
    O
    L
    L EQUIPMENT SUPPLY
    E
    Y CABLES

∑ < 250M

EXAMPLE:
CONNECTION WITH COMPR.
WIRING HARNESS LOAD PROTECTION
INSERTION SIDE VIEW CLASS I
(ALSO CLASS II/SEE
OPERATING MANUAL)
3PH
3PH Y L LO
LOAD
AD AC L LOAD
LOAD AC L LOAD
LOAD

Fig. 36

11.10 Generator switchbox wiring diagram

diagr am 7 KVA 110
110 V

PROTECTIVE ISOLATION WITH INSULATIO

INSULATION
N MONITORING
K = OPERATING CURRENT CIRCUIT BREAKER
AND FUSING/CIRCUIT BREAKING FOR ALL POLES
H =INSULATION FAULT INDICATOR LAMP
R = GMW/ISO INSULATION MONITOR
P = TEST BUTTON
      W      N
      O      E
      L      E 6-PIN CONNECTOR
      L      R
      E      G
      Y CONTACTS VIEW
YELLOW/GREEN

    K MODE SELECTOR SWITCH

    E     C
    N    L     A POSITION 1: OPEN
    O    U     L
    T    D     B POSITION 2: CLOSED
    T    O
    U
    B    M
    T    O     E
    E    I
    S    S     U
    L
    N     B TO 4 POLE
    E    R     E
    R    O     E AMP PLUG ON
    F     R
This website stores data such as     G
    /
    N     W
MECHANICAL
COUPLING TO F1
WLAX
    O
    W     L
cookies to enable essential site     O     L
    R     E
    B     Y
BROWN
functionality, as well as marketing,
personalization, and analytics. You
    C
    I    R    R
BLACK
    N    O    O
may change your settings at any time
    O
    R
    T    T
    A    A
    T    R    L
    C    E    U
CURRENTCONVERTER
ON WLAX CONTROLLER
    E    N    G
or accept the default settings.
    L    E    E
    E    G    R
BLUE

ATTENTION: POWER SUPPLY

      N
      E
TRIP-FREE RELEASING OF AUTOMATIC NO-LOAD OPERATION
      E ALL CIRCUIT BREAKERS
OPTIONAL, EXTERNAL PE CONNECTION       R PRESSUREREDUCTION
Privacy Policy       G
      /
      W
      O
COUPLED
      L
      L
      E
      Y

Marketing       N
      E
      E
      R
SWITCHBOX
      G
Personalization       /
      W
      O
      L
TOTAL LENGTH OF
      L EQUIPMENT SUPPLY
      E
      Y
CABLES
Analytics CONNECTION WITH COMPR.
∑ < 250M
WIRING HARNESS
INSERTION SIDE VIEW
EXAMPLE:

Save Accept All LOAD PROTECTION

CLASS I
(ALSO CLASS II/SEE
OPERATING MANUAL) AC-L-
AC-L-LOA
LOAD
D AC
AC-L-
-L-LOA
LOAD
D AC-
AC-L-L
L-LOAD
OAD

Fig. 37
 Fig. 37
45

11. Generator option

11.11 Troubleshooting

Sockets dead

Has insulation Unplug Press green Plug in devices Is insulation

monitor released? YES connected rese
resett bu
butt
tton
on one after the monitoring still YES
(indicator lamp lit) devices other enabled?

NO NO

Connected
devices are faulty

Unplug
Does fuse
Has fuse blown? YES connected YES
still blow?
devices

NO NO

Connected
devices are faulty
Contact customer
services or
take
take de
devi
vice
ce in fo
forr
checking

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 46

11. Generator option

Problem Possible cause(s) Correction

The generator supplies no or insufficient The generator circuit breaker has tripped Check electrical load output.
voltage. due to overload or is defective.
Check that all electrical terminals are
properly seated.

Check generator protective switch and

replace if required.
Check connected electrical loads for short
or earth contact.

Drive motor speed too low. Set to nominal speed, max. 3,100 rpm.

Mode switch in position 0. Position switch in position 1.

Generator circuit breaker not depressed. Press the protective switch.

Compressor operating pressure set too Re-adjust the operating pressure at the
high, engine overloaded, speed decreases. adjuster.

Coil of the "Speed increase" solenoid valve Check and replace solenoid valve if
defective. required.

Complete or significant voltage drop during Insufficient engine speed or speed control Have the nominal speed adjusted by the
operation under load. inoperative. engine after-sales service max. 3,100 rpm.

Check that all electrical terminals are

properly seated.

Check connected electrical loads for short

or earth contact.

The engine output has been reduced due Do not operate the generator at nominal
to climatic or other conditions. output, see the operating instructions for
the engine.

Compressor operating pressure set too high. Re-adjust.

Excessive generator voltage. Excessive engine speed. Have adjusted to nominal speed.

Voltage fluctuates in short intervals. Diesel engine operates irregularly. Have checked by the engine after-sales
service.
The engine speed control operates
irregularly or is defective. Check according
instructions to the
supplied by operating
the engine
This website stores data such as manufacturer.
cookies to enable essential site
functionality,
Generatorasheats
well up
as to
marketing,
unacceptable levels. Clogged cooling air supply. Ensure that the cooling air supply is not
personalization, and analytics. You restricted.
may change your settings at any time
Machine is dusted. Clean the machine and position in a way
or accept the default settings. that dust-free cooling air only will be taken
in. It is strictly recommended that the
cooling air is cleaned at regular intervals.
Privacy Policy
Output reduction due to set-up at too high Partial load operation possible only.
Marketing an altitude.

Personalization Ambient temperature too high. The generators are designed to ensure that
no danger exists at ambient temperatures
Analytics of up to 35 °C. In higher ambient
temperature environments, the generator
may be operated at partial load only.
Save Accept All
When additional problems occur, call for Attention
compressor service!
 Use genuine spare parts only!
47

12. Heat exchanger option

12.1
12.1 Safety
Safety regula
regulatio
tions
ns for the
the use
of the heat exchanger

Danger 

When operating the compressor

compressor,, please 
observe the general safety regulations 
laid forth in the compressor operating 
manual.
The heat exchanger operates fully 
automatically.. Operating errors at the 
automatically
heat exchanger are excluded.

12.2 Design and operation

System function diagram:

see page 21, fig. 5
* The compr
compress
essed
ed air
air is heate
heatedd up in
in a
heat exchanger by means of the engine
oil.
* The dies
diesel
el engine
engine is equip
equipped
ped with
with an
oil temperature regulator, which ensures
that the engine oil has the proper
minimum
operation temperature required the
and which bypasses for heat
exchanger at the diesel engine during
start-up and warm-up until the required
engine oil temperature has been
reached.
The second oil temperature regulator,
which is located in the oil line, for heating
up the compressed air ensures that the
compressed air may not be heated up
exceeding maximum specified
temperatures during summer operation.
This fully automatical uniform
temperature control ensures both the
proper temperature of the compressed air
and the proper engine oil temperature
irrespective of the ambient temperatures
which the installation will be operated in.

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12.3toMaintenance/Care
enable essential site
functionality, as well as marketing,
This systemand
personalization, is maintenance-free.
analytics. You
may change your settings
For information at any
on engine time see
oil change
or accept the default
the operating settings.
instructions of the engine.

Privacy
12.4Policy
Troubleshooting

Compressed
Marketingair temperature too low
Defective oil temperature regulator in
Personalization
the engine or in the oil line -> replace.
Compressed
Analytics air temperature too high

Defective
the
Saveoil lineoil
-> temperature
Acceptregulator
replace. All in
 48

13. Compressed air processing option (After cooler / Filter)

13.1
13.1 Safety
Safety regulati
regulations
ons for alternat
alternate
e In an air cooler (on the cooling air intake 13.3 Maintenance instructions
side), the compressed air is cooled down
compressed air processing
to a temperature close to the prevailing
Danger 
ambient air temperature downstream of the
Danger  pressure vessel. A condensate separator Prior to and when carrying out 
with continuous condensate discharge is maintenance and repair procedures,
When operating the compressor, please 
installed downstream the air-cooler. please do observe the general safety 
observe the general safety regulations 
laid forth in the compressor operating  regulations in chapter 3 of the 
manual. Attention compressor operating manual.
When there is a danger of freezing or
Attention
when the machine is switched off for a
13.2 Design and operation prolonged period, any remaining The filters have to be disposed of.
condensation must be drained from the
System function diagram: secondary cooler.
cooler. For doing this the The post cooling systems is mainte-
see page 21, fig. 5 bottom cover of the secondary cooler nance-free. For cleaning procedures,
must be opened and it must be emptied see 9.1 „General maintenance“ in the
utilising the pressure remaining in the compressor operating manual.
After cooler option machine.

3 Post option
1 Filter option (ZTV-ING Part 3 Sec. 4) Filter change is required at latest when
A residual oil contents in the compressed a diferential
f pressure of 400 mbar has
air of < 0.01 ppm is achieved by means of been reached or after approximately
filtering. The filter assembly consists of a 500 oper
operati
ating
ng hours
hours - dependi
depending
ng on the
the
4 fine filter and an extra-fine filter. Both filters degree of contamination.
are equipped
continuous with a collecting
condensate receiver
discharge. The with
separated or filtered liquids are brought
2 together to a common drain.
Fig. 38 Attention
1 Filter
The oil-containing condensate has to be
2 Heat
He at exc
excha
hang
nger
er
collected. Do not allow to enter into the
3 Afte
Af terr co
cool
oler
er
soil or into the drains!
4 Condens
Con densate
ate sep
separat
arator
or

13.4 Troubleshooting

Problem Possible cause(s) Correction

Increased air humidity of the compressed Contaminated air cooler. Clean

air
Aperture
separatororcollecting
silencer tank
in condensate
clogged. Replace or clean
This website stores data such as
cookies
Oil to enable essential
in discharge air line site See chapter 10 "Troubleshooting" in this
functionality, as well as marketing, manual.
personalization, and analytics. You
Aperture or silencer in filter collecting tanks Replace or clean
may change your settings at any time
clogged.
or accept the default settings.
Faulty filter cartridges. Replace

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 49

14. Breath
Breathing
ing air connect
connection
ion optio
optionn

14.1
14.1 Notes
Notes on
on safet
safety
y and
and
description of function

Danger 

See the separate instruction manual for 

the filter unit for notes on safety and 
description of function! 
System function diagram:
see page 20, fig. 5

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 50

15. Oil temperature controller option

15.1
15.1 Safety
Safety regula
regulatio
tions
ns for the
the use
of an oil temperature controller

Danger 

Please observe the general safety 

regulations in the compressor manual 
when operating the compressor.
Operation of the oil temperature 
controller is fully automatic. Mal- 
operation of the oil temperature 
controller itself is impossible.

15.2 Design and function

See page 21, fig. 5, for system function

diagram.
With the aid of the oil temperature
controller, the compressor oil circuit is kept
at an optimum service temperature.
The oil temperature controller regulations
the temperature of the oil within the set
temperature limits, and only feeds as much
oil to the cooler as is necessary to achieve
the desired oil temperature.

FROM
TO
COOLER
COMPRESSOR
(OUTLET)

FROM
PRESSURE
VESSEL
TO
COOLER
(INLET)

Figure 39stores data such as

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cookies to enable essential site
functionality, as well as marketing,
personalization, and analytics.
15.3 Maintenance / care You
may change your settings at any time
This system is maintenance-free.
or accept the default settings.

15.4 Troubleshooting
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Compressed air temperature too low
Marketing
Oil temperature controller in the oil line
is defective -> replace it.
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Analytics

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 51

16. Undercarriage

16.1 Introduction 16.3

16.3 KHV13
KHV13 height-a
height-adju
djusta
stable
ble 16.4 Braking system
towing system, model B 3.5.13
Attention Introduction
The adjustable joint between the drawbar * KNOTT
KNOTT over-r
over-run
un brake
brake syste
systems
ms consis
consistt
The user forfeits all rights to claim if and intermediate arm, and between the of over-run hitches and wheel brakes
parts other than those of the overrun system and intermediate arm, used in combination with KNOTT
manufacturer are used. consists of toothed heads or retainers with torsional thrust spring axles. They are
Hirth-type or radial serrations.
We reserve the right to modify design and The radial serrations are secured with approved in all countries of the EC and
in Switzerland.
performance without prior notice. Please
quote axle number, model and article fastening screws. The fastening nut must * With
With the KNOT
KNOTT T autore
autorevers
versee system
system
number when contacting us with queries or be tightened to the specified torque in order ‘Backmat’ there is no problem changing
ordering spare parts. to establish a no-play, torque transmitting the direction of travel from forward to
connection. The tightening torque depends reverse. The braking system is ready for
on the permitted gross weight of the trailer immediate operation again when
and the length of intermediate (swivelling) changing from reverse to forward travel.
16.2 Safety arm
* KNOTT
KNOTT torsio
torsional
nal thrus
thrustt spring
spring axles
axles as
* It is most
most impo
importa
rtant
nt that
that the
the wheel
wheel and well as rubber spring axles have superb
the hub are compatible dimensionally. Adjusting procedure springing and excellent dampening
This means that the P.C.D., wheel bolts characteristics. With the torsional thrust
and inset must all be compatible both After the spring-loaded plugs have been spring axles the spring elements with
with the hub and the rim. Particular released from the fastening nuts, the nuts their vulcanized rubber are pretensioned
attention must be paid to the can be loosened until the teeth are before being pressed into the axle
recommended torque figures for the exposed. The angle of the intermediate tubes. There is no squashing of the
wheel bolts. arm can then be adjusted. rubber during spring action. Instead the
* No weldin
weldingg is permi
permitte
ttedd on the
the AL-KO
AL-KO rubber is stretched in accordance with
axle. Danger  its characteristics.
Care must be taken without fail to  With the rubber spring axles theaxle
* Please
Please note
note the
the swing
swing arm move
movement
ment..
ensure that the overrun or towing  tube bears the axle by pretensioned
(See assembly instructions).
system is always aligned parallel with  rubber strings. The results of the
* The AL-
AL-KO
KO wheel
wheel brak
brakes
es are
are matche
matchedd the drawbar. stretching are exceptionally long life and
to the AL-KO overrun devices. zero maintenance.
The vehicle must not be driven unless 
Before using an overrun from another
the overrun system is parallel with the 
manufacturer, please check the Attention
drawbar! 
compatibility with our Technical
Department. After the coupling has been adjusted for * Use the
the jack
jack only
only under
under the
the fixin
fixing
g
height, the serrations should be locked brackets or at the chassis, never in
Attention together with the clamping nuts and the centre.
secured against working loose by means
Model details must not be obscured by * Towi
owing
ng eye
eye and ball
ball coupl
coupling
ing may
may
of the spring-loaded plugs.
paint now concealed by components. only be changed by specialists.
The radial serrations of the intermediary
* Use a new
new safet
safety
y nut eve
every
ry time
time one
one
piece and the drawbar are joined by union
of these items is changed.
bolts M28x1.5 and M36x1.5 respectively.

M28x1.5 T = 400 Nm * Use spec

specifi
ified
ed torqu
torque
e setti
setting:
ng:
This website stores data such as M36x1.5 T = 650 Nm Ball coupling
cookies to enable essential site M12 8.8: T = 77 Nm
The radial serrations of the intermediary
M14 10.9: T = 125 Nm
functionality, as well as marketing, piece and the run-up assembly are joined
personalization, and analytics. You by union bolts M20x1.5 and M28x1.5 Towing eyes
may change your settings at any time respectively. M12 10.9: T = 115 Nm
M14 10.9: T = 180 Nm
or accept the default settings. M20x1.5 T = 250 Nm
M28x1.5 T = 400 Nm * When usin
using g the ball coupl
coupling,
ing, plea
please
se
follow the instructions given.
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 52

16. Undercarriage

Over-run hitches 16.5.2 Preliminary requirements: When the brake is correctly adjusted, the
actuating travel of the control cable [11] will
KNOTT over-run hitches are available for * When
When carryin
carryingg out adjust
adjustment
ments,
s, alway
alwayss
be 5-8 mm.
both hydraulic and mechanical brakes. start with the wheel brakes.
Carry out the adjustment procedure,
Handbrake lever with power reservoir, * When
When carryin
carryingg out adjust
adjustment
ments,
s, turn
turn the
as described, on all the wheel brakes in
code „KH“ wheel only in the direction of forward
succession.
travel.
With the type “KH” the spring reservoir is

under torsion
handbrake at the centre
is applied, then point. If the
it works * Insert
warningthe security bolt [15] (see
plate)! 16.5.4
16.5.4 Adjusting
Adjusting the brake
brake
automatically and requires almost no force. compensating system
* Do not pre-tension the expanding
The system is designed so that when the
handbrake is applied, sufficient energy is locking mechanism in the brake. If
necessary, loosen the brake linkage [6]
stored within the spring. When transmitted
at the brake compensator [8].
through the brake rods this prevents the
brake shoes from slipping away from the * Check the expanding locking
brake drum. mechanism and control cable [11]
for ease of movement.

16.5 Adjusting the braking system Attention

16.5.1 Preparations * The comp

compress
ression
ion spri
spring
ng [7]
[7] may
may only
be lightly pre-tensioned and must not
* Ja
Jack
ck up the
the tra
traililer
er become fully compressed when
* Re
Rele
leas
asee the
the hand
handbr
brak
akee activated!

* Pull out the

the drawba
drawbarr [5] of
of the over
overrun
run-- * Bowden
Bowden cable
cable [14] must not acti
activate
vate
brake.
system as far as it will go * Never
Never readjus
readjustt the brak
braking
ing syste
systemm or
brakes by the brake linkage [6] or
turnbuckles (if fitted) in the linkage!

16.5.3 Adjusting the brake

Fig. 43 KNOTT transmission system for
tandem and single-axle chassis.
6 Brak
akee lin
linkkage
7 Comp
Compreress
ssio
ionn spr
sprin
ingg
8 Compens
Com pensatiating
ng bal
balanc
ancee ass
assemb
embly
ly
9 Compens
Com pensatiating
ng bal
balance
ance (ta
(tande
ndem)
m) or
Fig. 40: KNOTT overrun brake master compensator
10 Compens
Compensatingating balance
balance (single
(single axle)
axle)
1 Con
Contactact-b
t-break
reaking
ing cab
cable
le 11 Con
Contro
troll cab
cablele
2 Trai
Trailer
ler coupling
coupling ring (varies by type)type)
3 Ha
Handb
ndbrarake
ke le
leve
verr
4 Tran
ransmsmisissi
sion
on lever
lever
5 Dr
Drawawbar
bar and bebellllows
ows Fig. 42: KNOTT wheel brake
This website stores data such as
cookiesDanger 
to enable essential site 12 Adjus
Adjustiting
ng sc
scre
rew
w
functionality,
When any as disconnection
well as marketing, of the braking 
13 Ca
Cabl
blee entr
entryy
personalization,
system takes place, secureYou
and analytics. handbrake  Tighten the adjusting screw [12] (on the
may change
lever byyour settings
reinserting atsecurity
the any time bolt  outside of the brake plate, opposite the 14
[15] (see warning plate
or accept the default settings. [16]). cable entry [13]), turning clockwise until the
wheel can only be turned with difficulty or
not at all.
Wrench sizes for adjusting screws [12] Fig. 44 KNOTT transmission system for
Privacy Policy tandem and single-axle chassis.
Brake size Wrench size
Marketing 14 Bowden cable for handbrak
handbrakee
160x35 / 200x50 SW 17
Personalization 250x40 SW 19
300x60 SW 22 * Insert the security bolt [15] (see
16 warning plate)!
Analytics Ease off the adjusting screw [12] in the
15 * Rem
Remove
ove the bow
bowden
den cab
cable
le [14]
[14]..
anticlockwise direction (approx. 1/2 turn)
Save Accept All until the wheel turns freely. Slight rubbing * Preadjus
Preadjustt the lengt
lengthh of the brake
brake link
linkage
age
Fig. 41 noises, which do not effect the free turning [6] (slight play permitted).
of the wheel, are permitted.
15 securi
security
ty bolt * Ins
Insert
ert the bow
bowden
den cab
cable
le [14]
[14]..
 16 Warni
Warning
ng plate
53

16. Undercarriage

* Rem
Remove
ove the sec
securi
urity
ty bolt
bolt [15
[15].
]. Brake test * Check
Check tthe
tthe bowden
bowden cable
cable for
for slight
slight pla
playy
[14]; if neccessary, adjust the cable.
* Operate
Operate the
the handb
handbrake
rake lev
lever
er [3]
[3] and
and * Recheck
Recheck the play
play in
in the brak
brakee linkage
linkage [6]
[6]
check the position of the compensating and, if necessary, readjust the linkage * Check
Check the tensi
tension
on of the
the compr
compress
ession
ion
balances [9 and 10]. They should be at [6] for length free of play ( during spring [7]
right angles to the direction of towing. operating braking with empty trailer
should be used maximally 1/2 of the
* If necess
necessary
ary,, adjust
adjust the positi
position
on of the
overrun travel )
balance [10] and control cables [11]; in 16.7 Maintenance and care
the case of tandem trailers, also adjust
the master compensator [9] on the KNOTT – overrun systems
linkage [6]. 16.6 Readjusting the braking system
* The overru
overrunn system
system must
must be
be lubrica
lubricated
ted
* The compr
compress
ession
ion sprin
springg [7] may
may only
only be In general, readjusting the wheel brakes with lithium-soap grease by way of the
lightly pre-tensioned and must not adequately serves to readjust the braking grease nipples and at all the moving
become fully compressed when system, i.e. to compensate for brake lining parts.
activated! wear. To
To readjust the wheel brakes, a) ever
everyy 5000
5000 km
km (3000
(3000 mi mile
les)
s)
proceed as described under 'Adjusting the b) or ever
everyy 6 mon
month
thss
16.5.5 Adjusting the brake linkage [6] braking system'. Check the play in the c) or if th
they
ey be
beco
come
me st
stififff
linkage [6] and readjust if necessary.
Adjust the brake linkage [6] so that it is * Inspec
Inspectt the bello
bellows
ws for
for damage,
damage, replac
replacee
free of play longitudinally, without initial Attention if necessary
tension (reversing lever [4] free of play).
* Check
Check the
the expa
expandi
nding
ng lock
locking
ing * Replace
Replace the
the overr
overrun
un shock
shock abso
absorber
rber
mechanism and control cable [11] every 20,000 km (12,500 miles) or
Readjustment every 3 years at the latest.
* The expa
expandi
nding
ng lock
lock compen
compensat
sator
or
* Operate
Operate the hand
handbrak
brakee lever
lever [3] must not be pre-tensioned in the
* Check
Check the pla
playy at the
the coupli
coupling
ng point
point
powerfully several times in order to every 20,000 km (12,500 miles). If the
settle the braking system. brake. play exceeds 3 mm, replace the guide
* Do not
not attem
attempt
pt to comp
compens
ensate
ate for bearing or drawbar.
* Chec
Checkk the
the posit
position
ion of the
the brake
brake ease of movement caused by brake
compensating balances [9 and 10] lining wear by readjusting * Check
Check the tig
tighte
htenin
ningg torques
torques of the
the
which should be at right angles to the (shortening) the brake linkage [6], fastening screws at the guide bearing
direction of towing e.g. by way of the
t he linkage screw every 5000 km (3000 miles);
* Check
Check the the play
play in the
the linka
linkage
ge [6];
[6]; ifif fastenings Screws with grease nipple
necessary, adjust the linkage [6] again 50 +5 Nm
so that it is free of play, but without Readjustment Screws without grease nipple
initial tension 80 +5 Nm
* Operate
Operate the hand
handbra
brake
ke leve
leverr [3]
[3]
Slight play in the bowden cable [14] powerfully several times in order to * Check
Check the tig
tighte
htenin
ningg torques
torques at the
the
must persist. settle the braking system clamping block of the drawbar and
clamping socket (drawbar tube - axle
* Check
Check the
the positi
position
on of the hand
handbrak
brakee * Check
Check the
the posi
positio
tionn of the brak
brakee  joint) every 5000 km (3000 miles);
lever [3]; compensating balances [9 and 10]
(which should be at right angles to the M12 screws 80 +5 Nm
when checking the dead centre of the
lever, resistance starts 10-15 mm above direction of towing). M14 screws 90 +10 Nm
dead centre * Check
Check that
that the
the brakin
brakingg syste
system
m is
* Recheck
Recheck the playplay in
in the lin
linkag
kagee [6];
[6]; correctly adjusted every 5000 km
This *website
Checkk that
Chec tha t the data
stores wheels
wheels rotate
rotat
such ase freely
freely with
with if necessary, adjust the linkage [6] again (3000 miles).
the brake released. so that it is free of play, but without
cookies to enable essential site
functionality, as well as marketing, initial tension.
Vertically adjustable drawbars
Final check
personalization, and analytics. You * Check
Check the the positi
positions
ons of
of the hand
handbrak
brakee
lever [3], the play in the bowden cable Clean the faces of the tooth systems free
may *change
Checkk your
Chec fastening
fasten ingss for secur
settings se
atcurity
ity (secur
any (s ecuree
time of fretting rust or other contamination at
the hexagon locking
or accept the default settings. nuts of the screw and compression spring [7] (only light
initial tension); least once a year in order to maintain a
fastenings for the transmission system,
good fit.
control cables, brake compensators, * when
when checki
checking
ng the
the dead
dead centre
centre of the
the
turnbuckle, linkage, etc.). lever, resistance starts 10-15 mm above Lubricate the threaded bolts and joints
Privacy Policy once a year or at any time if they become
* Chec
Checkk the bowd
bowden en cable
cable for
for slight
slight play
play dead centre
stiff.
[14]; if neccessary, adjust the cable.
Marketing
* Chec
Checkk the compr
compressession
ion spri
spring
ng [7]
[7] for Final check Attention
Personalization
initial tension. * Check
Check the
the screw
screw fast
fasteni
enings
ngs for
for the
the Do not grease the tooth system!
Analytics transmission system (control cables,
Test run brake compensators, linkage, etc.).
* Save
If necess
necessary carryAccept
ary,, carry out 2-3 All e tests
2-3 brake
brak tests * during
during operat
operating
ing brak
braking
ing with
with empt
emptyy
trailer should be used maximally 1/2 of
the overrun travel
 54

16. Undercarriage

If desired, a lifting and adjusting system

can be installed between the drawbar
and the overrun system. The control arms
of the adjusting system permit swivelling
about an angle of -10° to +49° in six
positions. In every case, the overrun
system or drawgear always remains
horizontal.
An integral gas-filled strut automatically
generates lifting force which reduces the
force required by the user. If the strut
becomes damaged or develops a leak, it
must be replaced.

Information regarding dual-row angular bail

bearings:
* These
These bearin
bearings
gs are maint
maintenan
enance-
ce-fre
free,
e,
have been provided with a lifetime
lubrication. and have an extremely high
running performance.
* The beari
bearings
ngs have
have been
been fixe
fixedd in their
their
correct position using a safety flanged
nut. This flanged nut must be tightened
with a torque of 280 +/- 10 Nm.
* It is
is recom
recommend
mended
ed to
to check
check thi
thiss
tightening torque in the course of service
works.
* The flang
flanged
ed nut
nut can
can only
only be unsc
unscrewe
rewedd
and re-used once. Afterwards. a new nut
must be used. When releasing or
tightening the flanged nut, grease the
threads slightly, so as to avoid damage
to the fine thread.
* Due to the
the high
high durab
durabili
ility
ty and
and the
the
maintenance-free design of these dual-
row angular ball bearings, there will be
no damage at the bearings under
normal conditions.
* If. due
due to excepti
exceptional
onal circ
circums
umstan
tances
ces..
problems were to occur with these
bearings, completely
with pressed-in new circlips
bearings, brake drums
and
This website stores data such as
new locking nuts should be installed in
cookies principle.
to enable essential site
functionality, as well as marketing,
* Due to to the design
design chara
characte
cteris
ristic
ticss of the
personalization, and analytics. You
bearings, the brake drums and the
may change
wheels your
maysettings at any
have a slight time
axial and
or accept the play;
tilting default settings.
however, this is insignificant.

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 55

16. Undercarriage

16.8 Malfunctions and remedies

Malfunction Cause Remedy

Insufficient braking effect Excessive backlash in brake system Re-adjust brake system

Brake linings not "run in" Actuate hand-brake lever slightly;

drive 2-3 kilometers

Brake linings glazed, oily or damaged Replace brake shoes completely; clean
braking areas in the brake drums

Overrunning hitch hard to operate Grease overrunning hitch

Brake linkage is jammed or deformed Eliminate cause

Brake Bowden cables rusty or kinked Replace Bowden cables

Brake reacts by jerks Excessive backlash in brake system Re-adjust brake system

Shock absorber of overrunning hitch Replace shock absorber

defective

Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders

Trailer is braked unilaterally Wheel brakes are actuated unilaterally Re-adjust brake system
Causes: possibly specified under see above
"Insufficient braking effect"

Trailer is already braked when the Shock absorber of overrunning hitch Replace shock absorber
accelerator pedal is released defective

Reverse driving had to accomplish, or even Brake system adjusted too tightly Re-adjust brake system
impossible
Bowden cables pre-loaded Re-adjust brake system

Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
brake shoe holder shoe holders

Braking action of hand-brake insufficient Incorrect setting Re-adjust brake system

Actuate hand-brake lever as far as possible

Causes: possibly specified under idem

This website stores data such as "Insufficient braking effect"
cookies to enable essential site
functionality, as well as marketing, Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
personalization, and analytics. You brake shoe holder shoe holders
may change your settings at any time
Wheel brakes get hot Brake system incorrectly set Re-adjust brake system
or accept the default settings.
Causes: possibly specified under idem
"Insufficient braking effect"
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Backmat brake shoe is jammed in the Replace compl. brake shoes with brake
Marketing brake shoe holder shoe holders

Personalization Wheel brakes dirty Clean

Analytics Reversing lever of overrunning hitch is Remove reversing lever, clean it and
 jammed grease it with Molykote
Save Accept All Handbrake lever not or only partially Set handbrake lever into zero- position
released
 56

16. Undercarriage

Malfunction Cause Remedy

Ball coupling does not rest on ball Coupling dirty on the inside Clean and grease thoroughly

Ball of towing vehicle too big Check ball diameter:

According to DIN 74058, the ball on the car
must not exceed 50 mm in diameter when
new. If the ball diameter decreases to less
than 49.5 mm, the ball has to be replaced.
The ball must be perfectly spherical

Danger 
Works on the brake system may only be 
carried out in specialized workshops.
When replacing braking shoes, make 
sure that all brake shoes of the axle are 
replaced.
When working at the wheel brakes,
make sure that the springs, the brake 
shoes and the spreading lever are 
correctly installed; observe the correct 
sense of rotation.
When adjusting the wheel brakes, turn 
wheels in forward direction! 
Basically, a readjustment according to 
chapter 17.5 "Fitting of the braking 
system" must be effected whenever 
works are carried out at the brake 
system.
If the wheel brakes or the brake drum 
have got very hot, continue to drive 
carefully on, if possible, until they have 
somewhat cooled down.

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 57

17. Tool oiler option

* Check
Check the
the seal
seal of the
the scre
screw
w plug,
plug,
replace if required.
* Screw
Screw in the scr
screw
ew plug
plug with
with the
the seal
seal
and tighten.
* Check
Check for
for leaks
leaks after
after star
start-u
t-upp of the
the
screw compressor.

Fig. 45
Attention

Do not run the machine with an empty

oiler tank! The tank must always
always
contain a minimum of 0.2 l of tool oil.

Danger 
Only refill the tool oiler, when the screw 
compressor is out of operation and 
depressurized! 
Only screw off the oiler reservoir, when 
the screw compressor is out of 
operation and depressurized! 
Do not spill any oil! 
Watch out for leakage! 
The oil dosage is continuously variable at
the adjusting knob.
* Turnin
Turningg the adjus
adjustin
tingg knob cloc
clockwi
kwise
se
(symbol »–«) will reduce the oil flow up
to 0-quantity (i.e. no oil for tool
lubrication in the compressed air).
* Turnin
Turningg the adjustin
adjustingg knob counter
counterclo
clock-
ck-
wise (symbol »+«) will increase the oil
flow.

Check the oil level in the depressurized

tool oiler
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Fig.Marketing
46
* Shut downn the scr
dow
Personalization screw
ew compr
compress
essor
or and
and
wait until the compressor is
Analytics
depressurized.
* Unscr
Unscrew
ew the
the scr
screwew plug
plug..
* Save
The oil
oil must
must be visAccept
be visible theAll
ible in the oiler
oiler
reservoir; refill, if necessary (oil to be
used: CompAir AES 82).
 58

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CompAir Drucklufttechnik GmbH

Argenthaler Str. 11
55469 Simmern
Deutschland

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

Fax ++49 (0)6761 832-409

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